Kessel Pumpfix F Comfort, Pumpfix F Standard Nstructions For Assembly, Operation And Maintenance

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Page 1

INSTRUCTIONS FOR ASSEMBLY, OPERATION AND MAINTENANCE

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KESSEL - backwater pumping station

Pumpfix

for wastewater with and without sewage

F Standard/Comfort

Product advantages

For wastewater with and without sewage

Backwater flap and draining pump

Simple installation in through pipes

Plug & play control unit

Control unit with self-diagnosis system

(SDS) with integrated battery back-up

Fig. shows:

Pumpfix®F

Comfort for installation in the ground plate

Fig. shows:

Pumpfix®F

Standard for installation in an exposed pipe

Straightforward replacement of wearing

parts

Simple tool-free servicing

Additional advantages of the Komfort

version:

Control unit with display

Motor-driven locking of the backwater

flap

Integrated drain function for surface

water drainage

The installation and service of this unit should be carried out by a licensed professional servicer

Name/Sign Date Town

Stand 04/2011

Stamp

Subject to technical amendments

ID-Number 010-843EN

Page 2

Table of contents

1. Safety instructions

2. General points

3. Installation

4. Service and maintenance

........................................................................................................... Page 2

2.1 Use ..................................................................................................... Page 3

2.2 Scope of supply .................................................................................. Page 3

2.3 Installation procedure ......................................................................... Page 3

2.4 General instructions about the installation of backwater valves ......... Page 3

3.1 Installation in the ground plate............................................................ Page 4

3.2 Recessed installation in the ground plate ........................................... Page 4

3.3 Ventilation connection ........................................................................ Page 4

3.4 Installation in an exposed wastewater pipe ........................................ Page 5

3.5 Installation in water load..................................................................... Page 5

3.6 Special features of

3.7 Set-up................................................................................................. Page 5

4.1

Service ..................................................................................................... Page 6

4.2 Maintenance............................................................................................. Page 6

4.2.1 Mounting the two covers........................................................................... Page 6

4.3 Test ......................................................................................................... Page 6

4.3.1 Test Standard ........................................................................................... Page 6

4.3.2 Test Comfort ............................................................................................. Page 6

4.4 Pump removal .......................................................................................... Page 7

4.5 Motor installation ...................................................................................... Page 7

4.6 Removing motor ground installation......................................................... Page 7

4.7 How the emergency valve works.............................................................. Page 8

4.7.1 Standard................................................................................................... Page 8

4.7.2 Comfort..................................................................................................... Page 8

4.8 Servicing the ventilation ........................................................................... Page 8

Pumpfix®F

Comfort ............................................. Page 5

5. Spare parts

6. Warranty

7. Commissioning protocol for the installer

8. Commissioning protocol for the installation company

5.1 Standard............................................................................................. Page 9

5.2 Comfort............................................................................................... Page 10

......................................................................................... ................. Page 11

........................................................................................................... Page 12

1. Safety instructions

Dear customer, Before you put your backwater pumping station Pumpfix®F into operation, please read through the installation instructions carefully and follow them.

Check first whether the system has arrived undamaged. In the event of transport damage, please follow the instructions in chapter 6 “Warranty”.

1. Safety instructions: During installation, operation, maintenance or repair of the system, the regulations for the prevention of accidents, the pertinent DIN and VDE standards and directives, as well as the directives of the local power supply industry must be heeded. Before putting the device into operation, make sure through professional examination that the necessary protective features are available. Grounding, neutral, residual current-operated protective circuit etc. must correspond to the requirements of the local power supply industry. The system must not be operated in po-

tentially explosive areas. The system contains electric charges and controls rotating mechanical system components. Non-compliance with the operating instructions may result in considerable damage to property, personal injuries or even fatal accidents.

The system must be disconnected from the mains or made currentless before any work is carried out on it.

It must be ensured that the electric cables as well as all other electrical system equipment are in a faultless condition. In case of damage, the system may on no account be put into operation or must be stopped immediately. The system must be inspected and serviced according to DIN 1986 to maintain its operational ability. We recommend that you conclude a servicing contract with your installation company.

...................................................................................... Page 14

No repairs or maintenance work may be carried out during a backwater situation or if a backwater situation is imminent. The backwater flaps and the locking lever always have to be able to be moved freely.

Note:

No system components may be installed in protection zone 0 or 1 in accordance with DIN VDE 0100 701. In the case of flush-to-floor showers, zone 1 is defined as with a radius of 1.20 m (projected area on the floor) around the water intake point. Deviating local regulations must be taken into account. The regulations set out by the directives VDE 0100, VDE 01107, IEC or by the local power supply industry must be heeded. The control unit must not be installed in rooms where there is an explosion hazard. For the operation of this system, these instructions and instructions no. 010-846 must be used together!

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2. General

2.1 Use

The KESSEL backwater pumping station Pumpfix®F has been designed for through

astewater pipes that have soiled water

w pipes as well as toilets and urinals connected to them. This guarantees the safe draining of draining spots below the backwater level even during backwater. The pump only

orks during backwater and pumps the soi-

w led water into the sewage channel against the backwater. During backwater-free operation, the soiled water is discharged into the sewage channel through the natural gradient.

Pumpfix

does not provide protection against rats! If there is a rat hazard, the system must be protected from damage onsite. A rat protection flap is available as an option and prevents damage caused by gnawing to a large extent (Standard only).

Important:

Pre-condition for trouble-free operation is

•

Sufficient gradient in the draining pipes (note: there is a gradient of 9 mm between feed and drain with Pumpfix® F)

•

A high share oSufficient gradient in the draining pipes (note: there is a gradient of 9 mm between feed and drain with Pumpfix® F)

•

A high share of water in the wastewater to optimise the self-cleaning effect

•

Correct routing and ventilation of the feed pipe in accordance with DIN EN 12056 / DIN 1986-100

•

Use with greasy wastewater only possible with increased maintenance and cleaning efforts

•

Rain surfaces up to max. 20 m

2.2 Scope of supply

The scope of supply of the KESSEL backwater pumping station Pumpfix®F is

ade up of the drain body with pump and

m backwater valve and the electric packages. The electric packages are made up of:

Standard

. The optical probe

2. A control unit (mains connection 230 V, 50 Hz, protective rating IP 54) with battery back-up (2 x 9V) for alarm message in the event of a power failure.

3. An installation and operating manual

Comfort

1. Two optical probes and the drive motor

2. One control unit with display (mains

connection 230 V, 50 Hz, protective rating IP54) with battery back-up (2 x 9V) for alarm message in the event of a power supply.

3. An installation and operating manual

2.3 Installation procedure

During the construction phase only the drain body is installed and connected in accordance with chapter 3. Usually, the power connection (chapter 4) and subsequent initial operation (chapter 5) cannot be carried out directly. Please connect the electric system components (pump, probes, motor and control unit, depending on the variant) when you put the KESSEL backwater pumping station Pumpfix® F into operation. Until this point, the enclosed electric package and the control unit must be kept stored in a clean and dry place. Only remove the plug end plates when the system is put into operation. Care must be taken that the system is always sealed with an upper cover section and cover or protective hood when set up as

a free-standing device in order to prevent soiling of the system.

aution: The pump is secured by a trans-

C portation safety tape that has to be removed before initial operation.

2.4 General instructions about the intallation of backwater valves

According to DIN EN 12056 backwater valves may not be used to protect all the draining points of a building - including those above the backwater level (street level) - because if the backwater valve is closed, the wastewater from above can no longer be drained into the sewage pipe but will - according to the principle of communicating pipes - escape from the drainage points furthest below the backwater level first (usually basement rooms) and thus flood the basement.

Only draining points below the backwater level may be protected against backwater. All draining points above the backwater level must be discharged into the sewage pipe with free gradient past the backwater valve.

Consequence: separate pipe routing. Domestic wastewater above the backwater level can thus rise up to a maximum of street level inside the downpipe without flooding the basement. Rainwater must never be discharged via backwater valves.

Installation of a backwater valve in the right place

Right!

Backwater protection

Backwater level

Installation of a backwater valve in the wrong place

Wrong!

Backwater level

Backwater protection

Page 4

3. Installation

Please note:

IN EN 12056 must always be heeded when

D routing the base pipes. Downpipes must always be introduced downstream from the Pumpfix® F (about 1m). In addition, a stilling section must be observed upstream and downstream of the FKA (at least 1 m). During installation of the backwater valve, care must be taken that there is a sufficient gap to the wall for maintenance work to be carried out. The KG pipe must not be connected directly to the drain body but only to the muff.

Caution: During installation pay attention to the direction of flow arrows on the product.

3.1 Kessel backwater pumping station

Pumpfix

ground plate

DThe drain body of the KESSEL-Pumpfix® F must be aligned horizontally (see Fig. 1). For connection of the electric cables of probe and pump, a cable conduit (at least DN 50, Kessel recommends 2 x 45° bends) must be provided. A second probe cable and motor connection cable must be connected for the Komfort variant. For this, a cable conduit (at least DN 70, Kessel recommends 2 x 45° bends) must be planned. To do this, lay the cable conduit to at least finished flooring height (see Fig. 2) and insert in the cable duct in the adapter of the KESSEL Pumpfix® F (cable conduit should protrude about 2 cm into the interior - tightness (Fig. 5). Changes of direction must be laid with bends of max. 45°. To guarantee proper aerating and venting of the pump chamber, the cable conduit must not be sealed airtight. Insert the enclosed profile lip seal into the adapter groove and grease this. Then mount the upper cover section (see Fig. 3). Thanks to the telescopic design of the upper cover section, the KESSEL-Pumpfix® F can be adapted exactly to the prevailing installation depth. Ground slopes of up to 5° can be compensated. The upper cover section can also be turned to align the cover to the tile pattern, for example (see Fig. 4). The seal must be checked for a good fit after adjustment.

CAUTION: The upper cover section must be shortened to the necessary size to achieve minimum installation depth. If necessary, recesses must be cut out of the upper cover section near the cable conduit and the ventilation pipe. Maximum groundwater resistance is 2 m. Following final alignment of the upper cover section, a recess may have to be introduced near the cable duct to enable the cable to be pulled out again during later inspections (see Fig. 5).

The lip seal must be fitted in the cover plate. Care must be taken that the sealing lip and

F for installation in the

centring lug are facing upwards during installation. The centring lug must be placed in the recess (see Fig. 6). During installation, make sure that the function of units in the chamber is not impaired by construction material.

Installation of covers with a choice of finishes (tile height max. 15 mm).

With the covers with a choice of finishes, tiles or natural stone can be inserted in the cover on site, so that they can be matched to the roomʼs flooring. Products e.g. from PCI, Schomburg, Deitermann are suitable for tile laying. To achieve straightforward processing and adhesion, we recommend the following procedure:

Tile laying: a) aPrime the cover plate e.g. with PCI primer

303. Following the respective flash-off time, lay the tiles with silicone. This type of laying is particularly suitable for thinner tiles since the base can be filled up to the required height.

b) Laying the tiles e.g. using PCI Silcoferm S

(self-adhesive silicone). This allows a thin adhesive bed to be used, particularly good for thicker tiles.

Laying natural stone:

(marble, granite, agglo-marble): a) Prime the cover plate e.g. with PCI primer

303. Lay the natural stone panels using e.g. PCI-Carralit..

b) Laying the natural stone panels using e.g.

PCI-Carraferm (special silicone for natural stone). Areas of application analogue to “Laying tiles”.

3.2 Recessed installation in the ground plate

(order no. 83071). Chapter 3.4 must be heeded for installation in water load. Depending on the installation depth, one or max. two extension pieces can be used between the upper cover section and the adapter. The respective seals must be greased accordingly. Please note that with recessed installation you still have to be able to reach down to the drain body for maintenance purposes.

3.3. Ventilation connection

Pumpfix® F is fitted as standard with a ventilation valve with activated carbon filter. Alternatively, ventilation according to standard can be connected. For this, the ventilation valve can be removed and connected directly to a ventilation pipe (to the roof).

ig. 1

fig. 2

Fig. 3

Fig. 4

fig. 5

Fig. 6

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3. Einbau

BWS

Fliesen Estrich Dämmung Betonboden

BWS

Unterbeton

Fliesen Estrich Dämmung Betonboden Schutzbeton Abdichtung

3.4 Installation in an exposed wastewaer pipe

The version for free-standing set-up is delivered with a protective hood to prevent damage to the components following commissioning. Fig. 7 shows the cable ducts – 1 or 2 (depending on the variant).

3.5 Installation in water load

(Seal set art. no. 83023

Fig. 7

If the valve is to be installed in water load, the flange serves as the necessary sealing level for a white or black tub (see Figure). For this purpose, seal sheeting is clamped between the plastic counterflange and the compression seal flange integrated on the drain body, and screwed together using the enclosed screws. The sheeting used on site can be used as seal sheeting. For installation in a waterproof white tub, KESSEL also has matching seal sheeting available made of natural rubber NK/SBR, where the bore holes for the screws have already been cut out (see Fig.

8).

If it is necessary to perforate the waterproof concrete tub to connect feed pipes, cable conduits etc., these holes must also be set up waterproof. Maximum groundwater resistance is 2 m.

nstallation with extension (order no.

83071).

Use of the extension allows the flange height to be individually adjusted. The

ttachment must be shortened to the re-

a quired height if necessary.

Special features of Pumpfix®F

Comfort

Pumpfix F Komfort has an integrated drai-

ing function for surface water drainage.

3.7 Set-up

Connection of the draining function to the feed cover is via the enclosed draining connection. Insert the draining connection into the prescribed opening and lock using the one-handed quick-action closure. Depending on installation depth (installation depth of the upper cover section), the draining connection must be shortened to the respective length (see Fig. 9) or extended using HT-pipe DN 70 if recessed installation using extension (art. no. 83071) is used.

Fig 9

Seal seat (83023)

• Counterflange • Sealing sheet

Pressdichtungsflansch

Fig. 8

Pumpfix®F Comfort

Installation example “black tub”

Tiles Screed Insulation Concrete floor Protective concrete Sealing Underfloor

➀ KESSEL-Pumpfix® F, Staufix® FKA, Staufix® SWA, Controlfix ➁ Compression seal flange with seal set art. no. 83023 ➂ Extension art. no. 83071 ➃ Adapter DN 100 with compression seal flange made of stainless

steel art. no. 27198

Installation example “white tub”

➄ Elastomer sealing sheet art. no. 27159 ➅ Upper cover section with plastic cover plate ➆ Control unit ➇ Locking lever

Tiles Screed Insulation Concrete floor

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WU-Beton

Page 6

4. Service and maintenance

.1 Service

The system must be checked once every month by the operator through observation of the switching routine for operational

bility and leaks.

• Close emergency valve or with Komfort:

press test key to carry out functional test on backwater valve -> valve closes

• Allow water to flow in

Wait until level-LED + pump trigger.

•

• Switch off water feed

• Switch off level-LED and wait for pump

• Open hand lever (vertical position OPEN)

-> Standard

Komfort: Please note that the backwater valve must be open after the inspection has been completed. The pump should be checked at regular intervals. If operational noises increase, pumping capacity decreases or there are vibrations in the pipeline system, the pump housing and impeller must be checked for any stubborn soiling or wear.

4.2 Maintenance (at least every six

months)

CAUTION: Disconnect the unit from the mains during all servicing work! Heed safety instructions! No warranty will be granted in the event of insufficient maintenance! All the servicing and maintenance work described below may only be carried out by authorised qualified personnel. Repairs may only be carried out by the manufacturer.

tandard Comfort

a) Pull the insertable part out b) Clean all the parts c) Check the seals d) Apply lubricant (e.g. fittings grease)

to the outside of the seals of the insertable parts as well as the guide parts of the flap valves

We recommend these jobs after longer periods of standstill or intermediate storage, too, as well as after longer or frequent occurrences of backwater. If problems should occur that cannot be eliminated, please contact the specialist company who carried out the installation (see stamp on cover sheet) if in doubt.

4.2.1 Mounting the two covers (see Fig. 12, 13, 14)

Insert the covers on one side, push the other side down and lock in place using the locking levers. During installation of the overflow cover the red flap lever or the motor flap position must always be “CLOSED”

e) Insert the insertable part exactly f) Make sure the attachment clips are in

place properly! g) Heed cover installation 4.2.1 h) Carry out functional test in accordan-

ce with instruction manual 010-846.

Abb. 12

DIN 1986, part 3, must be heeded during maintenance work on systems. Maintenance work must be carried out at least every six months by authorised qualified staff. The following tasks have to be carried out:

• Visual inspection of the complete system

• Thorough cleaning of the complete system and the pump

• Check on the complete system and pump housing for external damage and visible wear

• Check on the pump for free movement, wear and deposits

• Check the connection cables for mechanical damage and wear

• Check the seal connections for leaks and any recognisable wear

• Insulation test on the pump motor

• Check the control unit for damage and soiling

• Check and clean the ventilation valve

• Clean the optical probe

4.3 Test

4.3.1 Test Standard

1. Hold the pump probe into the water "On" level Level-LED lit Pump starts Pump-LED lit

4.3.2 Test Comfort

1. Hold the motor probe into the water Flap closes Backwater-LED flashes

Flap-LED flashes

Flap closed Backwater-LED flashes

Flap-LED lit

2. Hold the pump probe into the water Pump starts Pump-LED lit

Page 7

4. Service and maintenance

4.4 Pump removal:

T To do this, turn both pump removal levers

hrough 180°. This makes them fold out-

t wards to the side so that the pump can be lifted out.

he pump can be removed individually.

Fig. 13 shows the Comfort variant

Locking lever muff

Pump removal lever

Fig. 14

Pump removal lever

Lock both sides!

Locking lever muff

4.5 Motor installation:

The levelled drive shaft of the motor must be in a vertical position (state on delivery). Move the locking lever of the operating valve on the locking cover to the “CLOSED” position, insert the drive motor into the drive groove from above, and screw in place using the four M5 x 12 screws (TX25) on the locking cover (Fig.

16).

4.6 Removing motor ground installation

Fig. 15 Probe test

Fig. 16 Motor installation











In this case, the outlet cover must be dismantled to remove the motor. To do this, open the locking lever and take the out-

let muff out. Loosen levers ②and ③and

remove the bypass muff, to do this tilt

pump connection muff ④away or remo-

ve the pump if necessary.After removing

the two cover locking levers ⑤the outlet

cover can be removed. Now the motor can be screwed off.

Page 8

4. Service and maintenance

4.7 How the emergency valve works

4.7.1 Standard

Locking position (Fig. 17, emergency

alve completely closed): The hand lever

v of the emergency valve must be put in the respective CLOSED position. The backwater flap works as a pipe barrier. This function is only considered as protection

rom backwater during longer periods of

f absence (e.g. holidays).

Connected draining points are still drained. The emergency valve must be released again for normal operation.

Abb. 17

Fig. 17 Bleeder

Emergency flap can be locked by hand

4.7.2 Komfort

Locking position: The backwater flap is closed by pressing the TEST key (flap). The backwater flap works as a pipe barrier. This function is only considered as protection from backwater during longer periods of absence (e.g. holidays). Connected draining points are still drained.

After return, the emergency valve must be released again for normal operation: by pressing the TEST key

(flap) again. Make sure that there is no backwater when this takes place.

Fig. 18 Activated carbon filter

The bleeder(Fig. 17 from right to left) comprises seal, drain body, float ball, seal, bayonet locking cap, activated carbon filter and cover.

Pull the cover off (Fig. 19) by tilting it slightly to the side. Then turn bayonet locking

cap (Fig. 20) ➀ and pull it up and off ②.

Removesealand floatballand clean everything. Re-assembly takes place in reverse order.

Fig. 19 Cover









4.8 Servicing the ventilation

The ventilation (see spare parts section 6) must be cleaned regularly and the activated carbonfilter (Fig. 18) must be changed annually or as required.

The ventilation must be cleaned and checked after every pump failure.

Fig. 20 Bayonet locking cap

Page 9

5. Spare parts

5.1 Standard

umpfix

All spare parts can be purchased from a specialist company.

for installation in an exposed wastewater pipe

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esignation Art. no.



Pumpfix®F

) Additional board for potential-free contact 80072

) Remove signal generator 20 m 20162

c) Battery 9V (2 units required) 197-081



Optical probe IP 68 (5 m, inc. adapters) 80888



Cover pump feed side (without outlet function) 28052



Pumpfix®F



Pumpfix®F



Ventilation complete 28060

a) Activated carbon filter 28061



Mechanical flap 80033



Insertion part for mechanical flap 80034



Hood 80031

햻

Transition piece 83032

Seal set II 70319

Pumpfix®F

control unit Standard IP 54 28073

-cover Standard outlet side 28053

-pump IP 68 (5m, inc. plug) 28351

for installation in the ground plate

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햳

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햷

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햵

a,b,c



All spare parts can be purchased from a specialist company.

Designation Art. no.



Pumpfix®F

a) Additional board for potential-free contact 80072

b) Remove signal generator 20 m 20162

c) Battery 9V (2 units required) 197-081



Optical probe IP 68 (5 m, inc. adapters) 80888



Cover pump feed side (without outlet function) 28052



Pumpfix®F



Pumpfix®F



Ventilation complete 28060

6a) Activated carbon filter 28061



Mechanical flap 80033



Insertion part for mechanical flap 80034

Seal set II 70319

-control unit Standard IP 54 28073

-cover Standard outlet side 28053

-pump IP 68 (5m, inc. plug) 28351







햹

햷



a,b,c

햵

햸

Page 10

5.2 Comfort

5. Spare parts

Pumpfix®F

All spare parts can be purchased from a specialist company.

Designation Art. no.



Pumpfix®F

a) Additional board for potential-free contact 80072

b) Remove signal generator 20 m 20162

c) Battery 9V (2 units required) 197-081



Optical probe IP 68 (5 m, inc. adapters) 80888



Cover pump feed side (without outlet function) 28052



Pumpfix®F



Pumpfix®F



Ventilation complete 28060

a) Activated carbon filter 28061



Motor-driven flap 80038



Insertion part for motor-driven flap 80039



Hood 83031

햻

Transition piece 83032

햽

Drive motor IP 68 (5m cable) 80076

Seal set II 70319

for installation in an exposed wastewater pipe

-control unit Komfort IP 54 28071

-cover Komfort outlet side 28056

-pump IP 68 (5m, inc. plug) 28351

햳

햴

햻

햶

햽

햹

햷

햳

햺

햵



,b,c



Pumpfix®F

All spare parts can be purchased from a specialist company.

Designation Art. no.



Pumpfix®F

a) Additional board for potential-free contact 80072

b) Remove signal generator 20 m 20162

c) Battery 9V (2 units required) 197-081



Optical probe IP 68 (5 m, inc. adapters) 80888



Cover pump feed side (with outlet function) 28054



Pumpfix®F



Pumpfix®F



Ventilation complete 28060

6a) Activated carbon filter 28061



Motor-driven flap 80038



Insertion part for motor-driven flap 80039

햺

Drive motor IP 68 (5m cable) 80076

Seal set II 70319

for installation in the ground plate

-control unit Komfort IP 54 28071

-cover Komfort outlet side 28056

-pump IP 68 (5m, inc. plug) 28351







햹

햺



햷



a,b,c

햵

햸

Page 11

6. Warranty

1. In the case that a KESSEL product is defective, KESSEL has the option of repairing or replacing the product. If the product remains defective after the second attempt to repair or replace the product or it is economically unfeasible to repair or replace the product, the customer has

he right to cancel the order / contract or

t reduce payment accordingly. KESSEL must be notified immediately in writing of defects in a product. In the case that the defect is not visible or difficult to detect, KESSEL must be notified immediately in writing of the defect as soon as it is discovered. If the product is repaired or re-

laced, the newly repaired or replaced

p product shall receive a new warranty identical to that which the original (defective) product was granted. The term defective product refers only to the product

or part needing repair or replacement and not necessarily to the entire product or unit. KESSEL products are warranted for a period of 24 month. This warranty period begins on the day the product is shipped form KESSEL to its customer. The warranty only applies to newly ma-

ufactured products. Additional informa-

n tion can be found in section 377 of the HGB. In addition to the standard warranty, KESSEL offers an additional 20 year warranty on the polymer bodies of class I / II fuel separators, grease separators, inspection chambers, wastewater treat-

ent systems and rainwater storage

m tanks. This additional warranty applies to the watertightness, usability and structural soundness of the product.

A requirement of this additional warranty is that the product is properly installed and operated in accordance with the valid installation and user's manual as well as the corresponding norms / regulations.

2. Wear and tear on a product will not be onsidered a defect. Problems with pro-

c ducts resulting from improper installation, handling or maintenance will also be considered a defect.

Note: Only the manufacturer may open sealed components or screw connections. Otherwise, the warranty may beco-

e null and void

01.06.2010

Page 12

7. Commissioning Protocol for installer

Separator Type: __________________________________________________________

Day / Hour __________________________________________________________

roject description /Building services supervisor __________________________________________________________

Address __________________________________________________________