KSB Ama-Drainer-Box Operating Manual

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Automatic Waste Water Lifting Unit

Ama-Drainer-Box

Installation/Operating Manual

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Legal information/Copyright

Installation/Operating Manual Ama-Drainer-Box Original operating manual

KSB Aktiengesellschaft Frankenthal

All rights reserved. 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 KSB´s express written consent.

Subject to technical modification without prior notice.

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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 these operating instructions

...................................................................................................... 8

2.5 Safety awareness ............................................................................................. 8

2.6 Safety instructions for the operator/user ...................................................... 8

2.7 Safety instructions for maintenance, inspection and installation work ...... 8

2.8 Unauthorised modes of operation ................................................................. 9

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

5.4 Installing the above-floor lifting unit .......................................................... 26

Contents

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5.5 Installing the submersible motor pump(s) ................................................... 30

5.6 Fitting the cover plate/cover ........................................................................ 38

5.7 Venting device with activated carbon filter (accessories) .......................... 40

6 Commissioning/Start-up/Shutdown ................................................. 41

6.1 Commissioning/start-up ................................................................................ 41

6.2 Shutdown/storage/preservation ................................................................... 41

6.3 Returning to service ...................................................................................... 42

7 Servicing/Maintenance ...................................................................... 43

7.1 Safety regulations ......................................................................................... 43

7.2 Servicing/inspection ...................................................................................... 43

7.3 Drainage/cleaning ......................................................................................... 44

7.4 Recommended spare parts stock .................................................................. 44

8 Trouble-shooting ............................................................................... 45

9 Related Documents ........................................................................... 46

9.1 General assembly drawing with list of components ................................... 46

9.2 Dimensions .................................................................................................... 52

9.3 Installation example ...................................................................................... 56

10 EC Declaration of Conformity .......................................................... 58

11 Certificate of Decontamination ....................................................... 59

Index .................................................................................................. 60

Contents

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Glossary

Above-floor box

Automatic waste water lifting unit for abovefloor installation

Backflow loop

The section of the discharge pipe of a waste water lifting unit that is located above the flood level

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 pump (set) 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.

Dual-pump unit

Waste water lifting unit containing a duplicate pumping device which starts up automatically as necessary.

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 land. It defines general requirements as well as principles of construction and testing.

Inlet line

Pipe used for draining waste water from sanitary installations into the lifting unit

Noise characteristics

The noise emission to be expected, indicated as sound pressure level LpA 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, closecoupled 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.

Underfloor box

Automatic waste water lifting unit for underfloor installation in substructures and foundations.

Waste water

Faecal-free waste water (grey water) from washbasins, showers, washing machines, etc.

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

White tank

Waterproof concrete structure. Waterimpermeable concrete is used to produce a waterproof "tank".

Glossary

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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/size, the main operating data and the order number. The series/serial number uniquely identifies the lifting unit and serves as identification for all further business processes.

In the event of damage, immediately contact your nearest KSB service centre to maintain the right to claim under warranty. Noise characteristics

1.2 Installation of partly completed machinery

To install partly completed machinery supplied by KSB, please refer to the subsections under Servicing/Maintenance.

1.3 Target group

This manual is aimed at the target group of trained and qualified specialist technical personnel.

1.4 Other applicable documents

Table 1: 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

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 General

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2 Safety

All the information contained in this section refers to hazardous situations.

2.1 Key to safety symbols/markings

Table 3: Definition of safety symbols/markings

Symbol Description

DANGER

DANGER indicates a high-risk hazard which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a medium-risk hazard which, if not avoided, could result in death or serious injury.

CAUTION

CAUTION 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 indicates a hazard which will or could result in death or serious injury.

Electrical hazard identifies information about protection against electrical voltage.

In conjunction with the signal word CAUTION, this symbol indicates a hazard for the machine and its functions.

2.2 General

This manual contains general installation, operating and maintenance instructions that must be observed to ensure safe operation of the lifting unit and prevent injury and damage to property.

The safety information in all sections of this manual must be complied with.

This manual must be read and completely understood by the specialist personnel/ operators responsible prior to installation and commissioning.

The contents of this manual must be available to the specialist personnel at the site at all times.

Instructions attached directly to the lifting unit must always be complied with and be 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 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.

DANGER

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Training on the lifting unit must always be supervised by technical specialist personnel.

2.4 Consequences and risks caused by non-compliance with these operating instructions

▪ 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 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 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 while the pump is running. ▪ 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 instructions for maintenance, inspection and installation work

▪ 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 all maintenance, inspection and installation work 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.

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▪ As soon as the work is complete, re-install and/or re-activate any safety-relevant

and protective devices. Before returning the product to service, observe all instructions on commissioning. (⇨ Section 6.1 Page 41)

▪ 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. 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.

2.9 Intended use

The lifting unit must only be operated within the operating limits described in the other applicable documents.

▪ The lifting unit must only be operated when in perfect technical condition. ▪ Do not operate partially assembled lifting units. ▪ The lifting unit must only 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 information on minimum flow rates specified in the product

literature (to prevent overheating, bearing damage, etc).

▪ Observe the information on maximum flow rates specified in the product

literature (to prevent overheating, mechanical seal damage, cavitation damage, bearing damage, etc).

▪ Do not throttle the flow rate on the suction side of the lifting unit (to prevent

cavitation damage).

▪ Consult the manufacturer about any other modes of operation not described in

the product literature.

Preve n t ion of f oresee a b le mis u s e

▪ Never exceed the permissible operating limits (pressure, temperature, etc.)

specified in the product literature.

▪ Observe all safety information and instructions in this manual.

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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.

In the event of in-transit damage, assess the exact damage, document it and notify KSB or the supplying dealer (as applicable) 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 storing the waste water lifting unit:

CAUTION

Damage during storage by frost, humidity, dirt, UV radiation or vermin Corrosion/contamination of the waste water lifting unit!

▷ Store the waste water lifting unit in a frost-proof room. Do not store the unit

outdoors.

CAUTION

Wet, contaminated or damaged openings and connections Leakage or damage of the waste water lifting unit!

▷ Only open the openings of the waste water lifting unit at the time of

installation.

Store the waste water 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 per operating instructions.

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 fluids handled leave residues which might lead to corrosion when coming into contact with atmospheric humidity, or which might ignite when coming into contact with oxygen, the lifting system must also be neutralised and blown through with anhydrous inert gas for drying purposes.

4. Always complete and enclose a certificate of decontamination when returning the lifting unit. Always indicate any safety and decontamination measures taken.

NOTE

If required, a blank certificate of decontamination can be downloaded from the KSB web site at: www.ksb.com/certificate_of_decontamination

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3.5 Disposal

WARNING

Fluids posing a health hazard and/or hot fluids Hazard to persons and the environment!

▷ Collect and properly dispose of flushing liquid and any residues of the fluid

handled.

▷ Wear safety clothing and a protective mask, if required. ▷ Observe all legal regulations on the disposal of fluids posing a health hazard.

1. Dismantle the lifting unit. Collect greases and other lubricants during dismantling.

Separate and sort the pump materials, e.g. by:

- Metals

- Plastics

- Electronic waste

- Greases and other lubricants

3. Dispose of materials in accordance with local regulations or in another controlled manner.

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4 Description

4.1 General description

▪ Automatic waste water lifting unit

Lifting unit for the collection and automatic lifting of unpressurised, faecal-free domestic waste water and stormwater above the flood level.

4.2 Designation

Examp l e : Ama- D r ainer- B o x Z2 U 3 0 1

Table 4: Key to the designation

Code Description Ama-Drainer-Box Type series Z Dual-pump unit

No code = single-pump unit

2 200 litres total collecting tank volume

1 = 100 litres

U Underfloor installation

B = above-floor installation

301 Pump code number

e.g. 301 = Ama-Drainer N 301

4.3 Name plate

Ama-Drainer-Box Z2 U

FO001998 Made by KSB

EN 12 050-2

S - Y

1 2

Fig. 1: Name plate (example)

1 Type series, design 2 Series number 3 Principles of construction and

testing

Key t o the se r i es num b e r

Calendar year 2011 2012 2013 2014 1st half of the year S-Y S-A S-C S-E 2nd half of the year S-Z S-B S-D S-F

4.4 Design details

Desig n

Under f l oor bo x U

▪ Collecting tank made of impact-resistant plastic, for installation in substructures

and foundations. Cover with level-adjusting extension, cover plate with floor drain and siphon trap.

▪ Single-pump or dual-pump units ▪ 100 or 200 litres tank volume ▪ To EN 12050-2

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Above - f loor b o x B

▪ Collecting tank made of impact-resistant plastic, for above-floor installation.

Closed with odour-proof cover.

▪ Single-pump or dual-pump units ▪ 100 or 200 litres tank volume ▪ To EN 12050-2

Type o f insta l l ation

▪ Stationary installation

Conne c t ions

Single-pump units Box 1 U and Box 1 B

▪ Inlet: DN 50 / DN 70 / DN 100 ▪ Discharge: DN 40 / G 1 1/

Dual-pump units Box Z2 U / Box Z2 B

▪ Inlet: DN 50 / DN 70 / DN 100 / DN 150 ▪ Discharge: DN 50 / G 2

Drive

▪ Single-phase a.c. motor ▪ Three-phase motor ▪ Integrated temperature switch

Impel l e r type

▪ Open multi-vane impeller, free passage of 10/11 mm ▪ Free-flow impeller, free passage of 35 mm

4.5 Configuration and function

Fig. 2: Sectional drawing

1 Collecting tank 2 Inlet-side connection 3 Float 4 Discharge-side connection 5 Submersible motor pump

The lifting unit consists of a stable collecting tank (1) with integrated submersible motor pump (5), an inlet-side connection (2) and a discharge-side connection (4).

The fluid to be handled flows into the lifting unit through an inlet-side connection (2) and is collected in a gas-, odour- and water-tight plastic tank (1). When a specified fluid level is reached, the float (3) triggers the automatic start of the submersible motor pump (5). The fluid handled is then pumped to above the flood level and discharged into the public sewer via the discharge-side connection.

Design

Function

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4.6 Fluids handled

WARNING

Pumping of impermissible fluids Hazardous to persons and the environment!

▷ Only discharge permissible fluids into the public sewer system. ▷ Check the suitability of pump/system materials.

CAUTION

Unsuitable fluids Damage to the pump!

▷ Never use the pump to handle corrosive, combustible or explosive fluids. ▷ Never use the pump to transport waste water from toilets and urinal systems. ▷ Do not use the pump for foodstuff applications.

Stand a r d vari a n t Suitable for handling chemically neutral, slightly contaminated waste water as well

as wash water. Varia n t C for a ggress i v e wate r Suitable for handling the above fluids and, in addition:

▪ Seawater and water containing salt ▪ Swimming pool water and brackish water ▪ Aggressive waste water

Varia n t R for w ater c o n tainin g o il an d o il em u l s ions Suitable for handling the above fluids and, in addition:

▪ Oil emulsions and cutting oils ▪ Waste water containing oil

4.7 Scope of supply

The off-the-shelf range includes entire, ready-to-connect waste water lifting units identified by one material number. For configurable range models, the individual components are selected to configure the waste water lifting unit. The lifting unit (off-the-shelf and configurable range) is delivered unassembled in the form of subassemblies and must be assembled on site. Ama-Drainer-Box waste water lifting units meet the requirements of EN 12050-2.

Under f l oor bo x 1 U – s i ngle-p u m p unit Collecting tank made of impact-resistant plastic, 100 litres, for installation in

substructures and foundations. Cover with level-adjusting extension, cover plate with floor drain and siphon trap. Delivered in three parts:

Tank with extension and cover plate.

2. Submersible waste water pump which starts and stops automatically, with 3 m or 10 m cable (depending on pump size) and shockproof plug or CEE plug (for models with three-phase motor).

3. Connection set with full set of installation parts and swing check valve (AmaDrainer N 301, N 302 and N 303 have an integrated swing check valve).

Under f l oor bo x Z2 U – d ual-pu m p unit Collecting tank made of impact-resistant plastic, 200 litres, for installation in

substructures and foundations. Cover with level-adjusting extension, cover plate with floor drain and siphon trap. Delivered in four parts:

Tank with extension and cover plate.

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2. Two submersible waste water pumps with 10 m cable and shockproof plug, or free cable end for models with three-phase motor.

Connection set with full set of installation parts, swing check valve (Ama-Drainer N 301, N 302 and N 303 have an integrated swing check valve) and two float switches with 10 m cable.

4. LevelControl Basic 2 control unit for dual-pump units with automatic alternate, peak-load and stand-by operation function.

Above - f loor b o x 1 B – s ingle- p u m p uni t

Collecting tank made of impact-resistant plastic, 100 litres, for floor mounting. Closed with odour-proof cover and taper lock ring. Delivered in three parts:

Tank with cover and taper lock ring.

2. Submersible waste water pump which starts and stops automatically, with 3 m or 10 m cable (depending on pump size) and shockproof plug or CEE plug (for models with three-phase motor).

3. Connection set with full set of installation parts and swing check valve (AmaDrainer N 301, N 302 and N 303 have an integrated swing check valve).

Above - f loor b o x Z2 B – dual-p u m p unit

Collecting tank made of impact-resistant plastic, 200 litres, for floor mounting. Closed with odour-proof, bolted cover. Delivered in four parts:

Tank with cover.

2. Two submersible waste water pumps with 10 m cable and shockproof plug, or free cable end (for models with three-phase motor).

3. Connection set with full set of installation parts, swing check valve (Ama-Drainer N 301, N 302 and N 303 have an integrated swing check valve) and two float switches with 10 m cable.

4. LevelControl Basic 2 control unit for dual-pump units with automatic alternate, peak-load and stand-by operation function.

Acces s o ries

Depending on the variant, the following parts may be included in the supply: Pipe adapter for connection of inlet and vent pipes of different outside diameters Socket gate valve CuZn

Socket ball valve 1.4408 Sealing collar for connection to site-supplied sealing sheet (underfloor box only) Puddle flange for protection against water under hydrostatic pressure (underfloor

box only) Level-adjusting piece H = 300 mm (underfloor box Z2 U only) Venting device with activated carbon filter

NOTE

Prevent damage by using a mains-independent alarm switchgear or a washing machine interrupter.

If the supply of mains voltage is interrupted or the submersible motor pump is defective, there is a risk of flooding damage.

The AS 0, AS 2, AS 4 or AS 5 alarm switchgears in combination with an alarm contactor trigger an alarm if the permissible fluid level in the collecting tank is exceeded.

The KSB washing machine interrupter triggers an alarm and stops the washing machine before the collecting tank overflows.

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4.8 Dimensions and weights

For the dimensions refer to the outline drawing of the lifting unit. (⇨ Section 9.2 Page 52)

Table 5: Lifting unit weights (off-the-shelf range) in kg

Single-pump units Dual-pump units

Underfloor 1 U Above-floor 1 B Underfloor Z2UAbove-floor Z2

[kg] [kg] [kg] [kg] Total weight 21.2 to 30.9 14.2 to 23.9 53.4 to 69.6 46.9 to 65.3 Collecting tank

weight

15.7 8.7 31.3 29.9

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5 Installation at Site

NOTE

All lifting units are supplied unassembled in the form of subassemblies. The following sections describe the conditions which must be met to assemble the individual subassemblies to form the complete waste water lifting unit in accordance with the instructions and without compromising health and safety.

5.1 Safety regulations

DANGER

Power supply not disconnected Danger to life!

▷ Pull the mains plug and secure the pump against unintentional start-up.

DANGER

Electrical connection work by unqualified personnel Risk of fatal injury due to electric shock!

▷ Always have the electrical connections installed by a trained and qualified

electrician.

▷ Observe IEC 60364 (DIN VDE 0100) requirements.

DANGER

Unsuitable electrical installation Danger to life!

▷ Make sure the electrical installation meets the VDE 0100 installation rules (i.e.

sockets with earthing terminals).

▷ Make sure the electric mains is equipped with a residual current device of

maximum 30 mA.

▷ Always have the electrical connections installed by a trained and qualified

electrician.

DANGER

Improper use Danger of death from electric shock!

▷ Any extension cords must match the quality of the power cable supplied with

the pump.

▷ Do not expose electrical connections or devices to moisture.

5.2 Checks to be carried out prior to installation

Before installing the lifting unit make sure that the following requirements are met:

▪ Check the data on the name plate of the lifting unit to make sure it can be

operated on the available mains.

▪ The fluid to be handled matches the description of suitable fluids. ▪ The above safety instructions have been complied with. ▪ The place of installation is frost-proof.

NOTE

Observe the provisions of EN 12056 Gravity Drainage Systems in Buildings" when installing the unit at site.

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NOTE

Waste water lifting units are to be vented through the roof if they are sealed so as to be odour-proof.

NOTE

Other operating manuals that describe components of this lifting unit must also be observed. Any transport locks that might have been provided have to be removed prior to assembly and installation.

NOTE

Lifting units should not be installed next to sleeping or living quarters.

5.3 Installing the lifting unit

5.3.1 Installing the underfloor box The collecting tank is installed in substructures or foundations. Make sure it is

installed in a frost-proof area. The underfloor box is not trafficable. The following drawing can be used for reference.

Fig. 3: Installation example

1 Flooring 2 Screed 3 Insulation 4 Concrete 5 Pipe backfill 6 Tank backfill (sidefill) 7 Bedding 8 Cover plate 9 Level-adjustable extension 10 Sealing collar (accessory) 11 Puddle flange (accessory)

CAUTION

Groundwater under hydrostatic pressure Water ingress!

▷ Observe special measures against water under hydrostatic pressure. (⇨ Section

5.3.5 Page 25)

NOTE

Humidity control in wet areas. (⇨ Section 5.3.4 Page 23)

NOTE

A level-adjusting piece (accessory) for installation at lower depths (H = 300 mm) is available for Box Z2 U dual-pump units.

(⇨ Section 9.2.3 Page 54)

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1. Excavate the construction pit. The construction pit must be dry during

construction.

Fill the level pit floor with a horizontal bedding layer of approximately 200 mm and compact the bedding.

3. Remove cover plate 68-3 with extension 13-21 from collecting tank 591.

4. Remove the parts located in the tank and keep them in a safe place.

5. Put on provisional cover 185 to protect the collecting tank.

6. Place collecting tank into the construction pit, level it and backfill around the

base.

5.3.2 Connect the underfloor box piping

CAUTION

Stresses and strains at the piping Impermissible load acting on the collecting tank!

▷ Connect the piping without transmitting any stresses or strains; make sure that

no forces and moments act on the collecting tank. Protect the piping against frost.

Connections

▪ Support the piping weights on site. ▪ All tank nozzles are closed.

5.3.2.1 Inlet and vent line ▪ Open the inlet and vent nozzles selected using a saw or angle grinder and debur

the cut edges (▼A).

▪ Connect the inlet and vent line using commercial connection elements, e.g. PVC-

KG socket or parts without sockets (SML).

Fig. 5: Connecting the piping

1 Provisional cover 185 2 Inlet line 3 Vent line 4 Optional emergency drainage

The vent line can also be used as a cable duct for the pump power and control cables. Alternatively, free connection nozzles (and an additional PG 36 cable gland on Box 1 U) are available to connect a separate conduit.

CAUTION

Line too angled Feeding in a draw wire (fish tape) is too difficult or impossible!

▷ Lay pipes with maximum angles of 30°.

Fig. 4: Opening the nozzles

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5.3.2.2 Connecting the discharge line

CAUTION

Incorrect installation of discharge line Risk of leaks!

▷ Run the discharge line above the flood level before leading it into the sewer. ▷ Do not connect the discharge line to the waste water downpipe. ▷ Do not connect any additional sanitary installations to the discharge line.

NOTE

To prevent any backflow from the collecting main, run the discharge line in the form of a pipe loop whose invert at its highest point must be above the locally defined flood level (e.g. street level).

NOTE

All waste water lifting units are equipped with check valves.

NOTE

We recommend installing a gate valve in close proximity to the system. After installation, subject the discharge line to a pressure test.

Lay discharge line with a slightly rising slope. Disch a r ge lin e of sin g l e-pump u n its 1 U - DN 4 0 G 1 1/2 thread or non-threaded pipe end produced by removing the threaded section

(glued nozzle), outside diameter 50 mm.

✓ Spigot and socket connection 720.04 has been fitted at the factory.

Fit discharge pipe 710.01. If the discharge line is connected via a glued joint, remove the threaded section of the discharge pipe in the area marked Ⓐ using a saw or angle grinder; debur the pipe end.

2. Slide the discharge pipe into the spigot and socket connection from the outside. Apply a sufficient amount of lubricant to the pipe end before inserting it.

3. Align the discharge pipe and observe the installation dimension.

4. Connect the on-site discharge line.

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710.01

720.04

Ⓐ

Fig. 6: Fitting the discharge line; setting the installation dimension; dimensions given in mm

1 Fitting direction

CAUTION

Discharge pipe not aligned, installation dimension not complied with Risk of fracture due to impermissible stresses and strains at the connections! Submersible motor pump cannot be installed in the collecting tank!

▷ Observe the alignment of the discharge pipe and the installation dimension.

Disch a r ge lin e of dua l - pump u n i t s Z2 U - DN 5 0 G 2 thread or non-threaded pipe end produced by removing the threaded section

(glued nozzle), outside diameter 63 mm.

✓ Profile joint 410.01 has been fitted at the factory.

Fit Y-pipe 715. If the discharge line is connected via a glued joint, remove the threaded section of the Y-pipe in the area marked Ⓐ using a saw or angle grinder; debur the pipe end.

2. Slide Y-pipe into the profile joint from the inside. Apply a sufficient amount of lubricant to the pipe end before inserting it.

3. Align the Y-pipe horizontally and observe the installation dimension.

4. Connect the on-site discharge line.

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715

410.01

591

Ⓐ

Fig. 7: Fitting the Y-pipe; setting the installation dimension; dimensions given in mm

1 Fitting direction

CAUTION

Y-pipe not aligned, installation dimension not complied with Risk of fracture due to impermissible stresses and strains at the connections! Submersible motor pump cannot be installed in the collecting tank!

▷ Observe the alignment of the Y-pipe and the installation dimension.

5.3.3 Backfilling around the tank

✓ The piping has been connected. ✓ The collecting tank has been levelled and backfilled around its base.

1. Provide proper bedding and backfilling of piping.

2. Place backfill around the collecting tank (sidefill); use sand as backfill material.

NOTE

Carefully compact backfill directly at the tank contour to prevent voids. Never use stones, shingle or coarse gravel as backfill material directly at the tank.

Continuously check the tank for any deformations and other signs of uneven loads and installation errors.

Fig. 8: Backfilling around the collecting tank

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Encase collecting tank in concrete so that its upper edge is flush with the floor plate.

NOTE

Provide sufficient clearance at the circumference of the tank neck in the area of provisional cover 185 for fitting profile joint 410.02.

Fig. 9: Encasing the collecting tank in concrete

NOTE

Secure the collecting tank against floating when setting it in concrete.

Prior to floor construction (insulation, screed, flooring) position level-adjustable extension 13-21 and profile joint 410.02 (the sealing lips must point inwards) and adjust to match the intended height of the floor. Apply a sufficient amount of lubricant to the end of the extension and fit the extension.

The telescopic extension allows flexible height adjustment to match the floor level.

NOTE

Insert cover plate 68-3 into the extension to protect the tank interior against dirt.

Fig. 10: Installed underfloor box (example)

5.3.4 Fitting the sealing collar DF 40 0 and DF 6 30

Moisture barrier, e.g. by polymer sealing sheets, for wet areas without water under hydrostatic pressure.

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DF 40 0 sealin g collar

1. Place the sealing collar 3 with O-ring 7 onto the tank neck 8 and level it.

The sealing collar is encased in concrete so that its upper edge is flush with the floor plate 4. Take care to backfill any voids under the sealing collar.

3. Roll out the sealing sheet 2, cut it to length in the area of the tank edge and put it into place.

4. Glue the sealing collar and sealing sheet together using a permanently elastic adhesive bonding and sealing compound.

Fig. 11: Configuration with DF 400 sealing collar

1 Insulation 2 Sealing sheet 3 Sealing collar 4 Floor plate 5 Profile joint 6 Extension 7 O-ring 8 Collecting tank

DF 63 0 sealin g collar

1. Affix the sealing cord 5 (self-adhesive on one side) flush onto the tank or the level-adjusting piece 7 outside the threaded inserts. Cut the sealing cord to length.

Fit the sealing collar 4 and fasten crosswise with the enclosed bolts/washers 2.

3. The sealing collar is encased in concrete so that its upper edge is flush with the floor plate 9. Take care to backfill any voids under the sealing collar.

4. Roll out the sealing sheet 3, cut it to length in the area of the tank edge and put it into place.

5. Glue the sealing collar and sealing sheet together using a permanently elastic adhesive bonding and sealing compound.

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Fig. 12: Configuration with DF 630 sealing collar

1 Insulation 2 Bolt/washer (12) 3 Sealing sheet 4 Sealing collar 5 Sealing cord 6 Profile joint 7 Tank or level-adjusting piece 8 Extension 9 Floor plate

5.3.5 Fitting MK 400 and MK 630 puddle flanges (accessories)

Seali n g again s t water u nder h y d r ostat i c press u r e Special measures are required for installation. Manufacture the base from

waterproof concrete ("white tank"). Use a puddle flange to seal the area where the collecting tank passes through the "white tank" (waterproof concrete tanking).

Installation of the MK 630 puddle flange additionally requires the level-adjusting piece (H = 300 mm). The level-adjusting piece is included in the accessories for the MK 630 puddle flange.

NOTE

Measures required to ensure pressure-sealed pipe entry through the baseplate need to be taken on site.

NOTE

If the level of groundwater under hydrostatic pressure is >3 m, the white tank must be equipped with a hermetically sealed waterproof concrete substructure in the area of the lifting unit. Formwork is required.

✓ Smooth, non-porous and clean surface. ✓ Concrete cover of at least 50 mm. ✓ Use of waterproof concrete.

Slide on the puddle flange 2 by hand.

2. Position puddle flange in the centre of the floor plate 1.

3. Tighten the straps 3.

Box 1 U

Box 2 ZU

Installation

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Fig. 13: Fitting the puddle flange

1 Floor plate 2 Puddle flange 3 Strap 4 Collecting tank (Box 1 U) or level-

adjusting piece (Box Z2 U)

5.4 Installing the above-floor lifting unit

5.4.1 Installing the above-floor box

1. Box 1 B Open taper lock ring 515 and remove with cover 160. Box Z2 B Undo 12 pan head screws 900.01 and remove cover 160 with O-ring 412.01.

Remove the parts located in the collecting tank 591 and keep them in a safe place.

3. Glue pads 592 to the tank bottom.

4. Place the tank on a level floor and level it with the help of a spirit level.

5. Use the float protection fixtures supplied to secure the tank firmly to the floor.

1 2 3

Installing the collecting tank of Box 1 Installing the collecting tank of Box Z2

1 Collecting tank 591 2 Set of pads 99-32 3 Set of fasteners 99-31

5.4.2 Connect the above-floor box piping

CAUTION

Stresses and strains at the piping Impermissible load acting on the collecting tank!

▷ Connect the piping without transmitting any stresses or strains; make sure that

no forces and moments act on the collecting tank. Protect the piping against frost.

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Connections

▪ Support the piping weights on site. ▪ All tank nozzles are closed.

5.4.2.1 Inlet and vent line ▪ Open the inlet and vent nozzles selected using a saw or angle grinder and debur

the cut edges (▼A).

▪ Connect the inlet and vent line using commercial connection elements, e.g. PVC-

KG socket or parts without sockets (SML).

NOTE

The collecting tanks are equipped with cable entries for pump power and control cables. Connections

(⇨ Section 5.5.1.3 Page 33) (⇨ Section 5.5.2.3 Page 37) As an option, the vent line or a free connection nozzle with separate conduit can be used as a cable duct.

5.4.2.2 Connecting the discharge line

CAUTION

Incorrect installation of discharge line Leaks and flooding of installation room!

NOTE

All waste water lifting units are equipped with check valves.

NOTE

We recommend installing a gate valve in close proximity to the system. After installation, subject the discharge line to a pressure test.

Disch a r ge lin e Options: Discharge position vertical (Y) or horizontal on the right (X) or on the left

(Z), including flexible hose connection and hose clips.

✓ The discharge line 700 has been pre-assembled at the factory.

1. Position the discharge line as required (X, Y, Z).

2. Connect the discharge line (pipe outside diameter 50 mm) with hose 719.02 and

hose clips 733.11.

Fig. 14: Opening the nozzles

Single-pump units 1 B

DN 40

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2 3

min. 10 max. 20

Fig. 15: Connecting the discharge line, dimensions given in mm

1 Mains discharge line 2 Hose 719.02 3 Hose clip 733.11 4 Discharge pipe 700

Horizontal discharge, including flexible hose connection and hose clips.

✓ Profile joint 410.01 has been fitted at the factory.

Remove the threaded section of the Y-pipe 715 in the area marked Ⓐ using a saw or angle grinder (see Fig.); debur the pipe end.

2. Slide Y-pipe into the profile joint from the inside. Apply a sufficient amount of

lubricant to the pipe end before inserting it.

3. Align the Y-pipe horizontally and observe dimension X.

4. Connect the Y-pipe (pipe outside diameter 63 mm) with hose 719.02 and hose

clips 733.01 to the discharge line.

715

410.01

591

Ⓐ

Fig. 16: Connecting the discharge line; setting the installation dimension; dimensions given in mm

1 Fitting direction

Dual-pump units Z2 B

DN 50

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CAUTION

▷ Observe the alignment of the Y-pipe and the installation dimension.

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5.5 Installing the submersible motor pump(s)

5.5.1 Single-pump units

5.5.1.1 Single-pump units – Fitting the discharge pipe

Ama-Drainer N 301 SE, N 302 SE, N 303 SE

733.02

719.01

733.12

720.01

719.01 Hose

720.01 Hose nozzle

733.12 Hose clip

733.02 Hose clip

For Ama-Drainer N 302 SE, N 303 SE shorten hose 719.01 by 38 mm.

Ama-Drainer N 358 SE/NE

733.12

719.01

720.03

03-40

747

731.02

74-4

03-40 Check valve body

719.01 Hose

720.03 Hexagon reducing nipple

731.02 Pipe union

733.12 Hose clip (2) 74-4 Float 747 Swing check valve

NOTE

Replace float 74-4 of the pump with the float included in the connection set (take out of package 40991680 supplied with the lifting unit).

Ama-Drainer 4../10 SE, SD

733.12

720.02

719.01

854

720.03

719.01 Hose

720.02 Hose nozzle with union nut

720.03 Hexagon reducing nipple

733.12 Hose clip (2) 854 Check valve

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Ama-Drainer 4../35 SE, SD

733.12

03-40

719.01

747

720.03

13-16

13-16 Protective casing 03-40 Check valve body

719.01 Hose

720.03 Hexagon reducing nipple

733.12 Hose clip (2) 747 Swing check valve

NOTE

The protective casing 13-16 of the submersible motor pump must be permanently removed for connection to the discharge pipe.

Ama-Drainer 5../10 K SE, SD

733.12

719.01

733.12

720.02

854

719.01 Hose

720.02 Hose nozzle with union nut

733.12 Hose clip (2) 854 Check valve

5.5.1.2 Single-pump units – Fitting the float switch Ama-D r a iner N 3 01 SE, N 302 S E , N 303 S E and N 3 58 SE / N E Snap on the float, screw on the knurled nut and tighten lightly by hand.

Fig. 17: Cut-in/Cut-out levels

Table 6: Limits of the float levels

Type series b min b max

[mm] [mm] Ama-Drainer N 301 SE ~ 70 ~ 295 Ama-Drainer N 302 SE ~ 110 ~ 315 Ama-Drainer N 303 SE ~ 110 ~ 315 Ama-Drainer N 358 SE/NE ~ 165 ~ 395

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Fig. 18: Adjusting the cut-in level control

Insert a screwdriver into the screw at the float and hold it in this position. Do not turn the screw.

2. Push the float up or down to adjust it to the required cut-in level.

3. Pull the screwdriver back out again.

4. Check the cut-in level by moving the float up and down. You should be able to

hear a "click" each time the float is lifted up to the cut-in level.

Ama-D r a iner 4 . . /10 SE , SD and 4 . ./35 S E , SD A

ma-Dr a i ner 5. . / 10 K S E , SD

Fit the bracket and float switch.

1. Undo cap nut 920 and disc 550 on pump 81-53; see drawing below.

576

920

550

732 81-53

81-45

Fig. 19: Fitting the bracket

Remove handle 576.

3. Remove bracket 732 from the connection set.

4. Position bracket and handle via the stay bolts and tighten cap nuts.

5. Fix float switch cable 81-45 in clamp 81-39.

See the drawing below for the required clearance.

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732

81-39

81-45

Fig. 20: Fitting the float switch

732

81-39

81-45

Fig. 21: Clearance L = 180 mm

5.5.1.3 Single-pump units – Fitting the pump

✓ The discharge pipe has been fitted. ✓ The float switch has been fitted.

Place the pump into the collecting tank.

2. Connect the hose to the discharge pipe.

3. Align the pump.

4. Slide anti-rotation device 710.00 into the opposite guide grooves and place it

onto the pump handle.

5. Secure the pump and the anti-rotation device using the two cable ties 81-73.

6. Lay the power cables.

Ama-Drainer N 301 SE, N 302 SE, N 303 SE and N 358 SE/NE with integrated magnetic float switch

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3 m motor power cable for N 301 to N 303 SE 10 m motor power cable for N 358 SE/NE and variant C With shockproof plug

Ama-Drainer 4../10 SE, 4.../35 SE, 5../10 K SE 10 m motor power cable (float switch directly connected to the motor) With shockproof plug

Ama-Drainer 4../10 SD, 4.../35 SD, 5../10 K SD 10 m motor power cable 10 m connection cable for float switch With CEE motor protection plug, type Hyper

Under f l oor bo x

✓ The plug has been removed prior to introducing the cables into the conduit.

Route the pump power cable and the cable of the float switch, if any, to the power supply through the vent line or a separate conduit using a draw wire (fish tape).

Above - f loor b o x

Pull shockproof plug through the drilled hole of the cable entry. Remove CEE plug (on models with three-phase motor).

1 1 1 2

Fig. 22: Cable grommet

For Ama-Drainer N 301 SE, N 302 SE, N 303 SE 1 cable entry for motor power cable

For Ama-Drainer N 301 SE/NE, N 302 SE/NE, N 303 SE/NE, variant C, Ama-Drainer N 358 SE/NE, Ama-Drainer 4../10 SE, 4../35 SE, 5../10 K SE 1 cable entry for motor power cable

For Ama-Drainer 4../10 SD, 4../35 SD, 5../10 K SD 1 cable entry for motor power cable 2 cable entries for float switch

NOTE

In order to ensure tight sealing of the cable entry, carefully open the nubs of the cable grommets using an awl. Do not use a knife to open them.

DANGER

Electrical connection work by unqualified personnel Danger of death from electric shock!

▷ Have a new shockproof plug (not included in the scope of supply) fitted by a

trained electrician only.

NOTE

Make sure that enough free cable length remains in the collecting tank which allows the pump to be pulled out for service work.

Cable grommet A

Cable grommet B

Cable grommet C

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5.5.2 Dual-pump units

5.5.2.1 Dual-pump units – Fitting the discharge pipe

Ama-Drainer N 301 SE/NE, N 302 SE/NE, N 303 SE/NE

715

412.02

700

412.02 O-ring (2)

700 Discharge line (2)

715 Y-pipe

NOTE

Install the locking disc for the float.

Ama-Drainer N 358 SE/NE

715

411

700

747

720

731.02

411 Joint ring (2)

700 Discharge line (2)

715 Y-pipe

720 Hexagon reducing nipple (2)

731.02 Pipe union (2)

747 Swing check valve

NOTE

Install the locking disc for the float.

Ama-Drainer 4../10 NE, ND

715

854

700

700 Discharge line (2)

715 Y-pipe

854 Check valve (2)

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Ama-Drainer 4../35 NE, ND

700

715

747

411

720

13-16

13-16 Protective casing (2)

411 Joint ring (2)

700 Discharge line (2)

715 Y-pipe

720 Hexagon reducing nipple (2)

747 Swing check valve (2)

NOTE

The protective casing 13-16 of the submersible motor pump must be permanently removed for connection to the discharge pipe.

Ama-Drainer 5../10 K NE, ND

715

854

700

411

411 Joint ring (2)

700 Discharge line (2)

715 Y-pipe

854 Check valve (2)

Ama-Drainer 5../11 ND

715

854

700

700 Discharge line (2)

715 Y-pipe

854 Check valve (2)

5.5.2.2 Dual-pump units – Fitting the float switch LevelControl Basic 2 control unit for dual-pump units with automatic alternate, peak-

load and stand-by operation function.

Two float switches for pump ON/OFF Three float switches for pump ON/OFF and high water alert

Fit the bracket 2 at the centre of cross-beam 1.

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2. Fix the cables of the float switches 3, 4, 5 in the clamps 6. See the drawing below for the dimensions. Fit the float switches for base load 4 and peak load 5 with upper float position in the direction of the tank wall. Fit the float switch for alarm 3 in the direction of the centre of the tank between the two pumps.

110

230

Fig. 23: Fitting the float switches, dimensions given in mm

A Length of float switch 180 mm for

all floats

1 Cross-beam

2 Bracket 3 Alarm (optional) 4 Base load ON

Pumps OFF

5 Peak load ON

6 Clamp

3. Place the pre-assembled bracket with float switches onto the Y-pipe 715 using clamps 733.04 (⇨ Section 9.1.2 Page 49). Make sure it is properly fixed on the Ypipe.

NOTE

Make sure the float switches can float freely; test their function.

5.5.2.3 Dual-pump units – Fitting the pumps

✓ The discharge pipe has been fitted. ✓ The float switches have been fitted.

Place the pumps with the pre-assembled discharge line into the collecting tank.

2. Align the pumps.

3. Connect the pumps to the Y-pipe.

4. Lay the power cables.

Under f l oor bo x

✓ The shockproof plug (230 V 1~) has been removed.

Route the pump power cables and the float switch cables to the power supply through the vent line or a separate conduit using a draw wire (fish tape).

Above - f loor b o x

✓ The shockproof plug (230 V 1~) has been removed.

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1. Feed the power cables through the cable grommet 916.

Fig. 24: Cable grommet

1 Cable entries for motor power cables

NOTE

In order to ensure tight sealing of the cable entry, carefully open the nubs of the cable grommets using an awl. Do not use a knife to open them.

2. Route the power cables of the float switches out of the tank connector panel through the cable glands 731 (set of cable glands, comprising 5 M 20 cable glands - drill to Ø 20 mm).

DANGER

Electrical connection work by unqualified personnel Danger of death from electric shock!

▷ Have a new shockproof plug (not included in the scope of supply) fitted by a

trained electrician only.

NOTE

Make sure that enough free cable length remains in the collecting tank which allows the pump to be pulled out for service work.

5.6 Fitting the cover plate/cover

Use the following drawings as a reference for installation.

Under f l oor bo x of sin g l e-pump u n it 1 U a nd du a l - pump u n i t Z2 U

914

550

68-3

139

400

13-21

90-1

Fig. 25: Fitting the cover plate

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13-21 Extension 139 Siphon trap 400 Gasket 550 Disc (4) 68-3 Cover plate 90-1 Plug 914 Socket head cap screw (4)

NOTE

The plug 90-1 included in the scope of supply of the underfloor box can be used instead of the siphon trap 139 to close the cover plate 68-3 so as to be odour-proof.

Above - f loor b o x 1 B – s ingle- p u m p uni t

160

515

591

Fig. 26: Fitting the cover

160 Cover with sealing element 515 Taper lock ring 591 Tank

Above - f loor b o x Z2 B – dual-p u m p unit

900.01

550.01

160

412.01

591

Fig. 27: Fitting the cover

160 Cover 412.01 O-ring

550.01 Disc (12) 591 Tank

900.01 Screw (12)

Tighten the screws 900.01 crosswise.

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5.7 Venting device with activated carbon filter (accessories)

If it is not possible to run a vent pipe out of the roof, e.g. in refurbished buildings or because of other site conditions, a venting device with an impregnated activated carbon filter can be used.

Make sure that the following requirements have been met prior to installation:

▪ The venting device must always be installed above the level of the highest

sanitary appliance.

▪ Do not install venting devices in rooms subject to high hygienic requirements. ▪ Install venting devices so that they are easy to access at any time (filter

replacement).

▪ Provide a sufficient supply of air.

NOTE

Replace the filter element after two years at the latest – or sooner if odour is detected (mat. No. 01315572).

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6 Commissioning/Start-up/Shutdown

6.1 Commissioning/start-up

6.1.1 Prerequisites for commissioning/start-up Before commissioning/start-up of the lifting unit make sure that the following

requirements are met:

▪ The pump set is properly connected to the power supply. ▪ All safety regulations are observed. ▪ The operating voltage has been checked. ▪ All relevant VDE standards and/or regulations applicable in the country of use are

complied with.

▪ A functional test has been performed. ▪ All connections and pipes have been checked for tightness and re-sealed, if

required.

▪ Observe the operating instructions for the submersible motor pump and, if

applicable, the control unit.

6.1.2 Starting up/stopping the pump set The pump (set) must have been properly connected to the electric power supply. The pump's control system will automatically cut in or out when the respective

specified levels are reached.

6.1.3 Operating limits Table 7: Operating limits

Characteristic Ama-Drainer-Box

Single-pump unit Dual-pump unit Flow rate 35 m3/h max. 46 m3/h max. Head 21 m max. 24 m max. Fluid temperature Up to 40°C in continuous operation

Up to 90°C (for 3 minutes max.) Max. particle size ≤ 10 mm, 11 or 35 mm Noise level < 70 dB(A)

6.2 Shutdown/storage/preservation

6.2.1 Measures to be taken for shutdown

WARNING

Inadvertent start-up of the waste water lifting unit Risk of injury by moving parts!

▷ Only carry out work on the waste water lifting unit after the electrical

connections have been disconnected.

▷ Make sure that the waste water lifting unit cannot be started up accidentally.

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WARNING

Fluids handled posing a health hazard Hazard to persons and the environment!

▷ Decontaminate lifting units which handle fluids posing a health hazard.

Wear safety clothing and a protective mask, if required.

▷ Observe all legal regulations on the disposal of fluids posing a health hazard.

1. Disconnect the lifting unit from the power supply and secure it against

unintentional start-up.

Remove the lifting unit as per operating instructions.

3. Flush the lifting unit as per operating instructions.

4. Leave the lifting unit to dry.

Special preservation measures are not required.

6.3 Returning to service

Observe the sections on commissioning/start-up (⇨ Section 6.1 Page 41) and the operating limits to return the lifting unit to service.

In addition, carry out all servicing/maintenance operations before returning the lifting unit to service. (⇨ Section 7 Page 43)

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7 Servicing/Maintenance

7.1 Safety regulations

DANGER

Failure to interrupt power supply Danger to life!

▷ Pull the mains plug or disconnect all electrical connections and secure against

unintentional start-up.

DANGER

Work on the lifting unit by unqualified personnel Danger of death from electric shock!

▷ Have system components modified and dismantled by authorised personnel

only.

WARNING

Insufficient stability Risk of crushing hands and feet!

▷ During assembly/dismantling, secure the pump (set)/pump parts to prevent

tipping or falling over.

7.2 Servicing/inspection

DANGER

Vent opening clogged Gas accumulation! Explosion hazard!

▷ Regularly check the vent line. The opening must never be clogged.

NOTE

A regular maintenance schedule will help avoid expensive repairs and contribute to trouble-free, reliable operation with a minimum of maintenance expenditure and work.

NOTE

For all inspection and servicing work to be carried out at regular intervals we recommend taking out the maintenance contract offered by KSB.

Operating reliability will be improved if proper functioning of the pump station is checked and verified at regular intervals. Check the lifting unit interior for deposits, mainly in the area of the float switch. Clean it, if required.

KSB recommends the following servicing/maintenance schedule:

▪ Every 3 months for lifting units installed in industrial businesses ▪ Every 6 months for lifting units installed in multiple dwelling buildings ▪ Every 12 months for lifting units installed in single-family houses

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7.3 Drainage/cleaning

WARNING

Fluids posing a health hazard and/or hot fluids Hazard to persons and the environment!

▷ Collect and properly dispose of flushing liquid and any residues of the fluid

handled.

▷ Wear safety clothing and a protective mask, if required. ▷ Observe all legal regulations on the disposal of fluids posing a health hazard.

1. Any fluid inside the discharge line will flow back into the tank.

Lift the pump set out of the tank.

⇨ The pump set will be automatically drained when it is taken out of the fluid

handled.

3. Always flush the system if it has been used for handling noxious, hot or other

hazardous fluids. Always flush and clean the lifting unit thoroughly before transporting it to the workshop.

7.4 Recommended spare parts stock

It is not necessary to keep spare parts on stock.

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8 Trouble-shooting

NOTE

Before performing any work on the pump's internal parts during the warranty period please always consult the manufacturer. Our after-sales service will be at your disposal. Non-compliance will lead to forfeiture of any and all rights to claims for damages.

NOTE

If problems or malfunctions develop, also consult and observe the pump operating manual(s) supplied.

Pump is running but does not deliver Pump delivers insufficient flow rate Excessive current/power consumption Insufficient discharge head Vibrations and noise during pump operation

A B C D E Possible cause

Remedy

✘ ✘ Pump is running in the off-design range (low

flow/overload).

Check the pump's operating data.

✘ ✘ Pump intake clogged by deposits. Clean the intake, pump components and non-

return valve. ✘ ✘ ✘ Inlet line or impeller clogged Remove deposits in the pump and/or piping. ✘ ✘ Dirt/fibres in the clearance between the

casing wall and impeller; sluggish rotor

Check whether the impeller can be easily rotated;

clean the hydraulic system, if required. ✘ ✘ ✘ ✘ Wear of internal parts Replace worn parts by new ones.

✘ ✘ ✘ Defective riser (pipe and sealing elements). Fit new riser pipes. Fit new sealing elements.

✘ ✘ ✘ Wrong direction of rotation (three-phase

units)

Check electrical connections.

✘ ✘ Pump clogged by sand, dirt in the tank,

insufficient inflow

Clean the intake, strainer, pump components and

check valve; drain and clean the tank.

✘ The temperature control device for

monitoring the winding has tripped due to excessive winding temperature (on singlephase models).

The motor will restart automatically once it has

cooled down. If the motor trips repeatedly, check

the lifting unit.

✘ ✘ Deposits in the collecting tank Clean the collecting tank; in case of greasy

deposits, fit a grease separator. ✘ Check valve does not shut off tightly. Clean the check valve.

✘ Defective CE plug / incorrect connection in the

control cabinet

Check the CE plug / electrical connection, see

operating instructions of the pump or switchgear.

✘ Defective float switch; float blocked by dirt or

fluff

Check the float switch. Clean the float.

B C

Release pump pressure and let the parts cool down before attempting to remedy faults on pressure-retaining parts. Interrupt power supply and secure against unintentional start-up.

8 Trouble-shooting

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9 Related Documents

9.1 General assembly drawing with list of components

9.1.1 Single-pump units – Underfloor box 1 U / above-floor box 1 B

Underfloor box 1 U

(914)

(550)

(68-3)

400

139

13-21

68-3

90-1

(826)

410.02

720.04

591

710.01

Above-floor box 1 B

160

515

591

733.11719.02

733.11

99-3.1

(901)

(733.03)

(90-3)

916

720.04

700

99-3.2

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719.01

(81-73)

710.2

733.12

733.02

720.01

[747]

655

733.12

719.01

720.03

03-40

747

731.02

74-4

(81-73)

710.2

Ama-Drainer N 301 - N 303 Ama-Drainer N 358

719.01

733.12

720.02

854

655

720.03

(81-73)

710.2

(81-73)

710.2

732

81-39

[81-45]

719.01

733.12

03-40

747

655

720.03

732

81-39

[81-45]

732

(81-73)

710.2

719.01

733.12

720.02

854

655

[81-45]

Ama-Drainer 4.. /10 Ama-Drainer 4.. /35 Ama-Drainer 5.. /10 K

Table 8: List of components

Part No. Includes: Description Quantity

Underfloor box 1 U Above-floor box 1

B 03-40 Swing check valve assembly 1 1 13-21 Extension 1 139 Siphon trap 1 160 Cover with sealing element - 1 400 Gasket 1 -

410.02 Profile joint 1 515 Taper lock ring - 1 591 Collecting tank 1 1 655 Pump 1 1 68-3 Cover plate 1 -

139 Siphon trap 1 400 Gasket 1 550 Disc (4) 68-3 Cover plate 1 90-1 Plug (4) 914 Hexagon socket head cap screw 1 -

700 Discharge line - 1

710.01 Discharge pipe 1 -

710.02 Anti-rotation device 1 1

9 Related Documents

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Part No. Includes: Description Quantity

Underfloor box 1 U Above-floor box 1

719.01 Hose 1 1

719.02 Hose - 1

720.01 Hose nozzle 1 1

720.02 Hose nozzle with union nut 1 1

720.03 Hexagon reducing nipple 1 1

720.04 Spigot and socket connection 1 1

731.02 Pipe union 1 1 732 Bracket 1 1

732 Bracket (1) (1) 81-39 Clamp (1) (1)

733.11 Hose clip - 2

733.12 Hose clip 1 / 2 1 / 2

733.02 Hose clip 1 1 74-4 Float 1 1 747 Swing check valve [1] / 1 [1] / 1 81-73 Cable tie (2) (2) 81-45 Float switch [1] [1] 826 Cable gland (1) 854 Check valve 1 1 90-1 Plug 1 916 Set of cable grommets - 1

916.1 Cable grommet A - (1)

916.2 Cable grommet B - (1)

916.3 Cable grommet C - (1)

99-3.1 Set of fasteners - 1

733.03 Pipe clamp - (2) 90-3 Anchor bolt - (4) 901 Hexagon head bolt - (4)

99-3.2 Set of pads - 1

( ) Not available as individual spare part [ ] See Ama-Drainer spare parts programme

9 Related Documents

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9.1.2 Dual-pump units – Underfloor box Z2 U / above-floor box Z2 B

Underfloor box Z2 U

(914.01)

(550.01)

(68-3)

139

400

68-3

13-21

410.02

90-1

(57-3) (914.02) (733.04) (732)

(81-39)

732

(900.02) (920)

81-45.03

591

715

81-45.01/.02

410.01

Above-floor box Z2 B

(900.01)

(550.01)

(160)

412.01

160

715

81-45.01/.02

719.02 410.01

733.01

99-3.2

(57-3) (914.02) (733.04) (732)

(81-39)

732

(900.02) (920)

81-45.03

731

916

591

(901) (550.02) (90-3)

99-3.1

9 Related Documents

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Page 50

715

(412.02)

700

655

715

(412.02)

700

655

715

(411)

700

655

715

854

700

655

747

720

731.02

[747]

Ama-Drainer N 301 SE/NE Ama-Drainer N 302 SE/NE,

N 303 SE/NE

Ama-Drainer N 358 SE/NE Ama-Drainer 4.. /10 NE/ND

715

412.02

700

655

715

411

700

655

715

854

700

655

747

720

731.02

715

(411)

700

655

715

854

700

655

715

854

700

655

747

720

411

Ama-Drainer 4../35 NE/ND Ama-Drainer 5../10 K NE/ND Ama-Drainer 5../11 ND

Table 9: List of components

Part No. Includes: Description Quantity

Underfloor box Z2UAbove-floor box Z2

B 13-21 Extension 1 139 Siphon trap 1 160 Cover - -

160 Cover - 1 412 O-ring - 1

550.01 Disc - (12)

900.01 Bolt/screw - (12)

400 Gasket 1 -

410.01 Profile joint 1 1

410.02 Profile joint 1 411 Joint ring (2) (2)

412.01 O-ring - 1

412.02 O-ring (2) (2) 591 Collecting tank 1 1 655 Pump 2 2 68-3 Cover plate 1 -

139 Siphon trap 1 400 Gasket 1 -

550.01 Disc (4) 68-3 Cover plate 1 90-1 Plug 1 -

914.01 Hexagon socket head cap screw (4) 700 Discharge line 2 2 715 Y-pipe 1 1

9 Related Documents

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Part No. Includes: Description Quantity

Underfloor box Z2UAbove-floor box Z2

719.02 Hose - 1 720 Hexagon reducing nipple 2 2

731.01 Set of cable glands - 1

734 Cable gland - (5)

731.02 Pipe union 2 2 732 Bracket 1 1

57-3 Cross-beam (1) (1) 732 Bracket (1) (1)

733.04 Pipe clamp (2) (2)

81-39 Clamp (3) (3)

900.02 Oval head screw (3) (3)

914.02 Socket head cap screw (3) (3)

920 Hexagon nut (3) (3)

733.01 Hose clip - 2 747 Swing check valve [2] / 2 [2] / 2 81-45 Float switch, 10 m - -

81-45.01 Base load ON 1 1 81-45.02 Peak load ON 1 1

81-45.03 Alert Option Option 854 Check valve 2 2 90-1 Plug 1 916 Cable grommet - 1 99-3.1 Set of fasteners - 1

550.02 Disc - (2)

90-3 Anchor bolt - (2)

901 Hexagon head bolt - (2) 99-32 Set of pads - 1

( ) Not available as individual spare part [ ] See Ama-Drainer spare parts programme

9 Related Documents

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9.2 Dimensions

9.2.1 Underfloor box of single-pump unit 1 U

Connections Dimensions

420

700

G1

/2 / Ø 50

160

240

320

480

355

380

158

835

min. 910

max. 1110

ET = Installation depth

Table 10: Connections

Ama-Drainer-Box 1 U Connection Description Inlet

Connection nozzles

Horizontal 1 2x DN 50/DN 70 graded nozzles opposite each other, outside diameter

50/78 mm

2 2x DN 70/DN 100 graded nozzles opposite each other, outside diameter

78/110 mm

Discharge 3 Horizontal DN 40

G 1 1/2 thread, alternatively non-threaded pipe end (glued nozzle), outside

diameter 50 mm Venting 1 + 2 Option: free DN 50/DN 70/DN 100 connection nozzle Auxiliary connections Cable entry 1 + 2 Options: free DN 50/DN 70/DN 100 connection nozzle or vent nozzle

4 PG 36 cable gland for cable duct with inside diameter of 24 mm (for

single-phase alternating current only) Emergency drainage 5 Horizontal

2x DN 40 nozzles opposite each other, outside diameter 49 mm Floor drain 6 DN 50

9 Related Documents

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9.2.2 Above-floor box of single-pump unit 1 B

Connections Dimensions

485

Ø 50

355

465

940

485

325

245

165

700

815

650

380

Table 11: Connections

Ama-Drainer-Box 1 B Connection Description Inlet

Connection nozzles

Horizontal 1 2x DN 50/DN 70 graded nozzles opposite each other, outside

diameter 50/78 mm

2 2x DN 70/DN 100 graded nozzles opposite each other, outside

diameter 78/110 mm

Discharge 3 Options: vertical (Y) or horizontal on the right (X) or on the left (Z),

DN 40, flexible hose connection, hose inside diameter 50 mm Venting 1 + 2 Option: free DN 50/DN 70/DN 100 connection nozzle Auxiliary connections Cable entry 4 Cable grommet A, B or C, depending on cable diameter Emergency drainage 5 Horizontal

2x DN 40 nozzles opposite each other, outside diameter 49 mm

9 Related Documents

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9.2.3 Underfloor box of dual-pump unit Z2 U

Connections Dimensions Standard With level-adjusting piece

590

590

530

900

1200

min. 1270

max. 1470

min. 970

max. 1170

265

405

810

710

590

530

900

G 2 / Ø63

Table 12: Connections

Ama-Drainer-Box Z2 U Connection Description Inlet

Connection nozzles

Horizontal 1 1x DN 100/DN 150 graded nozzle, outside diameter 110/159 mm 2 2x DN 50/DN 70 graded nozzles opposite each other, outside

diameter 58/78 mm

3 1x DN 70/DN 100 graded nozzle, outside diameter 78/110 mm

Discharge 4 Horizontal DN 50

G 2 thread, alternatively non-threaded pipe end (glued nozzle),

outside diameter 63 mm Venting 1 - 3 Option: free DN 50/DN 70/DN 100/DN 150 connection nozzle Auxiliary connections Cable entry 1 - 3 Option: free DN 50/DN 70/DN 100/DN 150 connection nozzle Emergency drainage 5 Horizontal

2x DN 40 nozzles opposite each other, outside diameter 49 mm Floor drain 6 DN 50

9 Related Documents

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9.2.4 Above-floor box of dual-pump unit Z2 B

Connections Dimensions

935

530

710

890

810

405

265

590

G 2 / Ø63

Table 13: Connections

Ama-Drainer-Box Z2 B Connection Description Inlet

Connection nozzles

Horizontal 1 1x DN 100/DN 150 graded nozzle, outside diameter 110/159 mm 2 2x DN 50/DN 70 graded nozzles opposite each other, outside

diameter 58/78 mm

3 1x DN 70/DN 100 graded nozzle, outside diameter 78/110 mm

Discharge 4 Horizontal DN 50

including flexible hose connection, hose inside diameter 63 mm Venting 1 - 3 Option: free DN 50/DN 70/DN 100/DN 150 connection nozzle Auxiliary connections Cable entry 5 Cable grommet for 2 motor power cables Connector panel 6 For cable glands for float switches 5 x M20 (drill to Ø 20 mm) Emergency drainage 7 Horizontal

2x DN 40 nozzles opposite each other, outside diameter 49 mm

9 Related Documents

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9.3 Installation example

9.3.1 Underfloor box 1 U

1 2

1 Inlet 2 Waste water lifting unit 3 Puddle flange 4 Sealing collar 5 Discharge line 6 Socket gate valve 7 Flood level 8 Vent line

9.3.2 Above-floor box 1 B

1 Inlet 2 Waste water lifting unit 3 Discharge line 4 Socket gate valve 5 Flood level 6 Vent line

9 Related Documents

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9.3.3 Underfloor box Z2 U

1 Inlet 2 Waste water lifting unit 3 Puddle flange 4 Sealing collar 5 Floor drain 6 Discharge line 7 Socket gate valve 8 Flood level 9 Vent line

9.3.4 Above-floor box Z2 B

1 Inlet 2 Waste water lifting unit 3 Discharge line 4 Socket gate valve 5 Flood level 6 Vent line

9 Related Documents

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10 EC Declaration of Conformity

Manufacturer: KSB Aktiengesellschaft

Johann-Klein-Straße 9

67227 Frankenthal (Germany)

The manufacturer herewith declares that the product:

Ama-Drainer-Box

▪ is in conformity with the provisions of the following Directives as amended from time to time:

–

Construction Products Directive 89/106/EEC

▪ Applied harmonised standards

– EN 12050-2

Certified by TÜV Rheinland LGA Products GmbH (0197)

The EC Declaration of Conformity was issued in/on:

Frankenthal, 1 March 2011

Thomas Heng

Head of Product Development

Submersible Pumps

KSB Aktiengesellschaft

Johann-Klein-Straße 9

67227 Frankenthal (Germany)

10 EC Declaration of Conformity

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11 Certificate of Decontamination

Type ................................................................................................................................

Order number/ ................................................................................................................................

Order item number

................................................................................................................................

Delivery date ................................................................................................................................

Field of application: ................................................................................................................................

Fluid handled2):

................................................................................................................................

Please check where applicable2):

   

Radioactive Explosive Corrosive Toxic

   

Harmful Bio-hazardous Highly flammable Safe

Reason for return2):

................................................................................................................................

Comments: ................................................................................................................................

................................................................................................................................

The system/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/placing at your disposal.

 No special safety precautions are required for further handling.  The following safety precautions are required for flushing fluids, fluid residues and disposal:

...............................................................................................................................................................

We confirm that the above data and information are correct and complete and that dispatch is effected in accordance with the relevant legal provisions.

.................................................................... ....................................................... .......................................................

Place, date and signature Address Company stamp

Required fields

11 Certificate of Decontamination

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Index

Certificate of decontamination 59 Commissioning 41

Disposal 11

Impeller type 13 Intended use 9

Operating limits 9 Other applicable documents 6

Return to supplier 10 Returning to service 42

Safety 7 Safety awareness 8 Shutdown 42 Start-up 41 Stopping 41

Index

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KSB Aktiengesellschaft

67225 Frankenthal • Johann-Klein-Str. 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 • Fax +49 6233 86-3401 www.ksb.com

2336.81/02-EN

KSB Ama-Drainer-Box Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual