KBS mini-Compacta, Installation & Operating Manual

Page 1: ...Floodable Sewage Lifting Unit mini Compacta From Series S Y 1 From series 2013w01 Installation Operating Manual...

Page 2: ...s provided herein must neither be distributed copied reproduced edited or processed for any other purpose nor otherwise transmitted published or made available to a third party without the manufacture...

Page 3: ...nspection and installation work 9 2 9 Unauthorised modes of operation 9 3 Transport Temporary Storage Disposal 10 3 1 Checking the condition upon delivery 10 3 2 Transport 10 3 3 Storage preservation...

Page 4: ...system 45 8 4 Reassembly 47 8 5 Fitting the level sensor 49 8 6 Fitting the repair kit and check valve 49 8 7 Tightening torques 50 8 8 Disposal recycling of the lifting unit 50 8 9 Checklist for com...

Page 5: ...gs and sites Flood level Maximum backflow level of waste water in a drainage system EN 12050 1 European Standard for sewage lifting units which are used to dispose of sewage with faeces occurring belo...

Page 6: ...rtly completed machinery To install partly completed machinery supplied by KSB refer to the sub sections under Servicing Maintenance 1 3 Target group This operating manual is aimed at the target group...

Page 7: ...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...

Page 8: ...ded by sufficiently trained specialist personnel If required the operator can commission the manufacturer supplier to train the personnel Training on the lifting unit must always be supervised by tech...

Page 9: ...y 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 mus...

Page 10: ...S2 100D US2 100E 56 67 UZ1 150D UZ1 150E 100 111 UZS1 150D UZS1 150E 116 127 The lifting unit has been checked for in transit damage 1 Use suitable transport equipment in acc with weights table 2 Tran...

Page 11: ...d blown through with anhydrous inert gas to ensure drying 4 Always complete and enclose a certificate of decontamination when returning the lifting unit Section 14 Page 84 Always indicate any safety a...

Page 12: ...control and monitoring unit for either one or two pumps 4 2 Designation Example mini Compacta UZS X 1 150 D C Table 5 Key to the designation Code Description mini Small package unit Compacta Type ser...

Page 13: ...al Made in Germany EN 12050 1 mini Compacta U1 100 D 26 5 11 9 Q H max max m h m 2014w07 0197 07 DoP2317 1 01 54 kg 4 6 7 8 1 5 2 3 Fig 2 Tank name plate example 1 Type series size 2 Maximum flow rate...

Page 14: ...Shaft seal ring A grease fill is provided between the impeller end and drive end shaft seals mini Compacta US UZS and variant C Impeller end Mechanical seal Drive end Shaft seal ring An oil reservoir...

Page 15: ...horizontal vertical inlet nozzles 1 and is collected in a gas odour and water tight plastic tank 10 Controlled by a level sensor 2 and control unit either one or two pumps 3 are started up automatical...

Page 16: ...vel sensor 0 5 V DOL starting 2 3 1 Fig 5 Type Basic Compact BC 1 Control panel 2 Master switch optional 3 Manual 0 automatic switch LevelControl Basic 2 Type Basic Control Cabinet BS Pump control and...

Page 17: ...le on request Table 7 Electrical data of the LevelControl Basic 2 control unit Characteristic Value Rated operating voltage 3 400 V AC 10 15 1 230 V AC 10 15 Mains frequency 50 Hz 2 Enclosure 400 V IP...

Page 18: ...g to DIN 1986 3 the following fluids can be discharged into sewer systems Water contaminated by domestic use human and as far as required and permitted animal faeces together with the necessary flushi...

Page 19: ...aracteristics The sound pressure level depends on the local conditions and the duty point and is in the region of 70 dB A 4 10 Scope of supply Depending on the model the following items are included i...

Page 20: ...Max current A Size HxWxD mm kg 14 760 x 600 x 210 19 18 760 x 600 x 210 19 23 760 x 600 x 210 19 25 760 x 600 x 210 19 40 760 x 600 x 210 24 63 760 x 600 x 210 26 4 Description 20 of 86 mini Compacta...

Page 21: ...llation WARNING Installation on mounting surfaces which are unsecured and cannot support the load Personal injury and damage to property Use a concrete of compressive strength class C12 15 which meets...

Page 22: ...el sensor has been fitted with a transport lock which must be removed prior to commissioning see Fig Fig 7 Removing the transport lock 5 4 Connecting the piping DANGER Impermissible loads acting on th...

Page 23: ...highest point must be above the locally defined flood level e g street level A gate valve must be installed downstream of the check valve NOTE Check valves of DN 80 are equipped with a lifting device...

Page 24: ...onnection nozzles will be used 2 Open the nozzles required by sawing off the nozzle faces A approx 10 mm A A Fig 10 Opening the nozzles NOTE On mini Compacta UZS1 150 the inlet nozzle arranged at 180...

Page 25: ...ng unit Install a swing check valve 5 6 Electrical connection DANGER Electrical connection work by unqualified personnel Danger of death from electric shock Always have the electrical connections inst...

Page 26: ...ree phase 3 400 V D models the direction of rotation must be checked during commissioning and every time the product is returned to service Section 6 1 Page 27 5 Installation at Site 26 of 86 mini Com...

Page 27: ...y all means Observe the following parameters and values during operation Parameter Value Maximum permissible fluid temperature 40 C for max 5 minutes up to 65 C Max ambient temperature 40 C air Operat...

Page 28: ...ion and leak free operation Setting the unit to the lowest inlet nozzle used The switching frequency can be reduced by setting the unit to the lowest inlet nozzle used A switch for this setting is pro...

Page 29: ...ion of rotation is indicated on the name plate Function and leak testing NOTE A sensor fault may be displayed when the lifting unit has not been filled yet It will disappear after the lifting unit has...

Page 30: ...ump OFF Off Off Pump running Steady green Contact 11 14 closed On TCB Excessive motor temperature TCB fault unacknowledged Flashing red Contact 11 12 closed Off Interval tone TCB fault acknowledged St...

Page 31: ...ower failure Power failure Contact 11 12 closed Off Interval tone NOTE If battery voltage drops below 5 3 V Basic 1 or 10 6 V Basic 2 the control units automatically switch off the mains independent a...

Page 32: ...250 2 320 3 700 4 Vertical 5 Connecting the rechargeable battery DANGER Live voltage Danger to life Only open the device after it has been de energised To enable the mains independent alert connect th...

Page 33: ...9 Page 50 6 3 2 1 Using additional functions 6 3 2 1 1 Functional check run For pumps with long idle periods a functional check run can be activated at parameter 3 7 1 The functional check run is carr...

Page 34: ...m pump 5 After long idle periods Remove and clean rotating assembly 01 44 Spray the hydraulic section with oil for preservation 6 Unscrew hand hole cover 160 7 Clean the tank WARNING Fluids handled an...

Page 35: ...e pump is operated in the same way pump specific steps shall only be carried out once in this case The control unit can be operated via Control panel Manual 0 automatic selector switch Service interfa...

Page 36: ...ter alert is output the red LED lights up The pumps are started with high priority except if sensor of ATEX compliant models is defective Alerts with a higher priority overwrite the high water alert 7...

Page 37: ...o call up the measured value parameters 2 Use the arrow keys to select the required parameter number The relevant measured value is displayed automatically after 1 5 seconds 3 Use the arrow keys to se...

Page 38: ...meter number 3 Confirm the parameter number with OK The parameter value is displayed immediately 4 Set the parameter value using the arrow keys In multi digit entries the digit to be entered flashes T...

Page 39: ...y For instance alert A1 has a higher priority than alert A2 Fig 25 Acknowledging alerts and warnings Alert indications On the display e g A09 As long as a parameter value is displayed this will not be...

Page 40: ...pumps OFF can be changed via ServiceTool A11 11 Alert Auto Sensor fault No changes A12 12 Warning Auto Incorrect rotary field of mains supply phase sequence No changes A13 13 Warning Auto Undervoltag...

Page 41: ...unit 3 Disconnect the battery 4 Undo the battery clamp 5 Replace the batteries 6 Reattach the battery clamp 7 Re establish the connections for the battery 8 Close the device properly 9 Reconnect the...

Page 42: ...lifting unit to cool down to ambient temperature WARNING Fluids handled and supplies posing a health hazard Hazard to persons and the environment Decontaminate lifting units which handle fluids posing...

Page 43: ...ust be overhauled For this purpose always contact KSB s service centres 8 2 3 Unblocking the cutter mini Compacta US UZS If the water level in the tank rises and the alert is triggered without the pum...

Page 44: ...rise inside the pump as oil fill heats up Mechanical seal failure Fill in the correct oil quantity Section 8 2 4 1 Page 44 8 2 4 1 Oil quantity quality Fill the oil reservoir with 0 7 litres of oil We...

Page 45: ...100 UZ150 1 Remove hexagon socket head cap screws 914 04 2 Lift rotating assembly 01 44 out of tank 591 3 Take O rings 412 11 and 412 12 off casing cover 161 4 Undo hex nut 920 02 and remove disc 550...

Page 46: ...R C3 and 321 02 6205 LLU C3 L45 8 3 3 Removing the pump plate assembly mini Compacta US100 UZS150 1 Separate pump plate assembly 10 5 from the discharge line 2 Undo hexagon socket head cap screws 914...

Page 47: ...and 321 02 6305 2RS1 JC3 8 4 Reassembly 8 4 1 General instructions Observe the following points for reassembly The pump shall be reassembled in accordance with the general rules of sound engineering...

Page 48: ...g to ensure trouble free operation of the mechanical seal The protective wrapping of the contact faces shall only be removed immediately before assembly takes place Extreme care and cleanliness during...

Page 49: ...Section 8 7 Page 50 4 Secure nuts 920 03 with Loctite 5 After mounting the rotating assembly on the plate turn the impeller to check for rubbing noises 6 Fit rotating assembly 01 44 into casing 100 8...

Page 50: ...can be separately recycled Plastic components are marked in accordance with ISO 11 469 8 9 Checklist for commissioning inspection and maintenance Table 20 Checklist Actions Required during Read the op...

Page 51: ...1986 100 a grease separator must be installed upstream of the lifting unit Check cover 160 for leakage Check fuses Size characteristics three poles interlocking device Replace the fuses after two yea...

Page 52: ...not completely vented Check the vent lines of lifting unit pumps Pump intake clogged by deposits Clean the intake pump components and collecting tank Inlet lines or impeller clogged Remove deposits in...

Page 53: ...in the collecting tank Clean the collecting tank in case of greasy deposits fit a grease separator Check valve does not close tightly Clean the check valve screw the lifting screw back as far as it wi...

Page 54: ...bly drawing exploded view and list of components 10 1 1 mini Compacta U60 U100 UZ150 Rotating assembly UG 1088985 Bl 1 Fig 33 General assembly drawing of mini Compacta U60 U100 Rotating assembly 10 Re...

Page 55: ...otor unit 550 03 Support disc 411 01 Joint ring 920 02 Hexagon nut 412 01 O ring 932 Circlip 811 Motor housing 99 20 02 Small parts repair kit 81 59 Stator 411 01 Joint ring 824 Cable 412 01 11 12 O r...

Page 56: ...330 Bearing bracket 411 02 Joint ring 412 01 02 O ring 421 01 Lip seal 412 11 12 O ring 433 Mechanical seal 433 Mechanical seal 550 01 Disc 80 1 Motor unit 550 02 Disc 411 01 Joint ring 550 03 Suppor...

Page 57: ...Hex nut 932 01 02 Circlip B5 Vent 10 1 3 mini Compacta U60 U100 Collecting tank Fig 36 Exploded view of mini Compacta U60 U100 Collecting tank Part No Part No Description Part No Part No Description...

Page 58: ...1 Joint ring 747 Check valve 412 21 23 O ring 100 Body 746 Valve disc 132 Intermediate piece 99 3 1 Set of installation accessories 411 21 Joint ring 400 Gasket 412 21 23 O ring 550 04 Disc 531 Lockin...

Page 59: ...2 O ring 550 31 Disc 550 05 Disc 81 45 Level sensor 551 Spacer disc 914 31 Hexagon socket head cap screw 591 Tank 81 99 Rechargeable battery 71 11 Y pipe set 82 16 Control unit 400 Gasket 90 3 Set of...

Page 60: ...Spacer disc 100 Body 901 04 Hexagon head bolt 132 Intermediate piece 920 04 Hexagon nut 411 21 Joint ring 99 3 2 Set of pads 412 21 23 O ring B5 Vent 531 Locking sleeve 550 21 Disc 746 Valve disc 900...

Page 61: ...9 Exploded view US100 UZS150 Rotating assembly Part No Part No Description Part No Part No Description 01 44 Rotating assembly 920 Nut 10 5 Pump plate assembly 922 Impeller nut 10 Related Documents mi...

Page 62: ...n 932 01 02 Circlip 719 03 04 Hose 99 20 02 Small parts repair kit 72 1 Flanged bend 411 01 02 Joint ring 733 03 04 Hose clip 412 01 05 O ring 80 1 Motor unit 550 Set of spacer discs 411 01 Joint ring...

Page 63: ...Cover 91 99 Rechargeable battery 412 31 41 O ring 82 16 Control unit 550 05 Disc 90 3 Set of mounting elements 591 Tank 901 05 Hex head bolt 719 01 02 05 Hose 99 3 2 Set of pads 732 Bracket 5B Vent 7...

Page 64: ...0 Cover 81 99 Rechargeable battery 412 31 41 O ring 92 16 Control unit 550 05 Disc 90 3 Set of mounting elements 591 Tank 901 05 Hex head bolt 719 01 02 05 Hose 99 3 2 Set of pads 732 Bracket 5B Vent...

Page 65: ...taining lifting units shall be of sufficient size to give a working space of at least 60 cm around and above all parts to be operated or serviced 1 1 a b Fig 42 Connection example a mini Compacta U60...

Page 66: ...ng lifting units shall be of sufficient size to give a working space of at least 60 cm around and above all parts to be operated or serviced 1 Fig 43 Connection example mini Compacta UZ150 UZS150 1 Fl...

Page 67: ...10 3 Dimensions 10 3 1 mini Compacta U60 and U100 1 1 a b Fig 44 Dimensions a mini Compacta U60 and b U100 1 With gate valve 745 mm 10 Related Documents mini Compacta 67 of 86...

Page 68: ...10 3 2 mini Compacta US100 and UZ150 1 a b Fig 45 Dimensions a mini Compacta US100 and b UZ150 1 With gate valve 1005 mm 10 Related Documents 68 of 86 mini Compacta...

Page 69: ...shut off elements 10 3 4 1 Inlet line U60 U100 US100 JL 1 DN 100 DN 150 PVC 1 DN 100 DN 150 Fig 46 Dimensions of inlet line with cast iron and PVC gate valve mini Compacta U60 U100 US100 1 Tank connec...

Page 70: ...ig 47 Dimensions of inlet line with cast iron and PVC gate valve mini Compacta UZ150 UZS150 1 Tank connection 10 3 4 3 Discharge line U60 U100 US100 a b Fig 48 Dimensions of the discharge line a mini...

Page 71: ...10 3 4 4 Discharge line UZ150 UZS150 a b Fig 49 Dimensions of the discharge line a mini Compacta UZ150 and b UZS150 10 Related Documents mini Compacta 71 of 86...

Page 72: ...100 Inlet DN 150 100 Inlet DN 100 50 Inlet DN 150 100 Inlet DN 50 6 Inlet DN 150 100 Drain DN 40 Drain DN 40 Vent DN 50 Vent DN 70 Discharge line DN 80 100 Discharge line DN 80 100 6 To prevent backf...

Page 73: ...DN 150 100 Inlet DN 150 100 Inlet DN 150 100 Inlet DN 150 100 DN 40 drainage nozzle DN 40 drainage nozzle Vent DN 70 Vent DN 70 Discharge line DN 50 DN 32 Discharge line DN 80 100 10 4 3 mini Compacta...

Page 74: ...Compacta U1 60 U2 100 US2 100 Connection to floor mounted toilet bowl mini Compacta U1 60 Connection to wall mounted toilet bowl mini Compacta U2 100 US2 100 Connection to wall mounted toilet bowl mi...

Page 75: ...e phase motor L3 5 6 3 Z2 WSK 230 V C1 25 F 40 F Excessive motor temperature RD WH T1 1 4 High water ext fault T2 2 5 PE PE S1 A 0 H Acknowledgement acoustic alarm ok MAN RD WH 1a Pump ON 1 K1 A2 A1 A...

Page 76: ...ve motor temperature RD WH T1 1 4 High water ext fault T2 2 5 PE PE S1 A 0 H Acknowledgement acoustic alarm ok MAN RD WH 1a Pump ON 1 K1 A2 A1 AUT 1b 24 V Option Moisture monitor Three wire connection...

Page 77: ...2 M 1 1a 1 Motor sensors Standard 209 3 4 1 1 109 2 U2 U1 Z1 Z2 222 5 6 3 3 122 3 PE P1 X1 PE PE 221 PE 121 21 220 4 120 20 5 X11 P2 M1 P1 Q1 A2 A1 1 1 P2 Q1 1 2 M 1 1 R1 3 4 2 2 2 U2 U1 Z1 Z2 5 6 3 3...

Page 78: ...1 P E S X1 PE P E P E P E PE P E P1 M1 P1 X1 1 M 1 1 2 109 2 U2 U1 Z1 Z2 3 122 3 PE PE P E PE 121 21 4 120 20 5 X11 A2 A1 1 1 R1 2 2 3 3 4 4 001 002 B1 Level sensor V 6 30 V DC Signal 0 3 4 7 V BK 24...

Page 79: ...PE P2 X1 1 M 1 222 1 X11 4 2 2 U2 U1 Z1 Z2 3 221 3 3 P1 Q1 A1 A2 2 220 PE P E PE 1 R1 4 5 X21 4 3 001 P2 Q1 A1 A2 2 002 1 R1 B1 Level sensor V 6 30 V DC Signal 0 3 4 7 V B K 24 V 1 024 PE BN Signal 2...

Page 80: ...r sensors Standard 1 2 2 P1 M1 1 2 P1 Q1 1 2 M 3 U1 V1 W1 PE 1 2 1a 1 209 3 4 1 1 109 2 222 5 6 3 3 122 3 PE 121 121 21 220 4 120 20 5 X11 P1 Q1 A2 A1 1 1 P2 M1 1 3 P2 Q1 1 2 M 3 U1 V1 W1 PE 1 3 1 R1...

Page 81: ...lowing harmonised international standards have been applied ISO 12100 EN 809 A1 EN 60034 1 EN 60034 5 A1 EN 60204 1 EN 61000 6 2 EN 61000 6 3 EN 12050 1 Certified by T V Rheinland LGA Products GmbH 01...

Page 82: ...specification Effectiveness EN 12050 1 2001 Handling of solids Passed Pipe connections Passed Ventilation Passed Minimum flow velocity 0 7 m s Minimum cross section of the system 40 mm Minimum cross s...

Page 83: ...hnical specification Effectiveness EN 12050 1 2001 Handling of solids Passed Pipe connections Passed Ventilation Passed Minimum flow velocity 0 7 m s Minimum cross section of the system Passed Minimum...

Page 84: ...cleaned In cases of containment shroud leakage the outer rotor bearing bracket lantern leakage barrier and bearing bracket or intermediate piece have also been cleaned For canned motor pumps the roto...

Page 85: ...medies 52 Flow velocity 12 Fluids handled 18 H High water alert 36 I Insulation resistance 43 Intended use 7 M Maintenance 42 Manual 0 automatic selector switch 37 Misuse 8 N Navigation keys 36 O Oper...

Page 86: ...2317 886 05 EN 01442639 KSB Aktiengesellschaft 67225 Frankenthal Johann Klein Str 9 67227 Frankenthal Germany Tel 49 6233 86 0 Fax 49 6233 86 3401 www ksb com...