KSB Ama-Drainer-Box Operating Manual
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KSB Ama-Drainer-Box Operating Manual

KSB Ama-Drainer-Box Operating Manual

Automatic waste water lifting unit
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Automatic Waste Water Lifting Unit
Ama-Drainer-Box
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Summary of Contents for KSB Ama-Drainer-Box

  • Page 1 Automatic Waste Water Lifting Unit Ama-Drainer-Box Installation/Operating Manual...
  • Page 2 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.

  • Page 3: Table Of Contents

    Dimensions and weights ................16 Installation at Site ................17 Safety regulations ..................17 Checks to be carried out prior to installation ..........17 Installing the lifting unit ................18 Installing the above-floor lifting unit ............26 Ama-Drainer-Box 3 of 62...
  • Page 4 Trouble-shooting ................45 Related Documents ................46 General assembly drawing with list of components ........46 Dimensions ....................52 Installation example ..................56 EC Declaration of Conformity ............58 Certificate of Decontamination ............59 Index ....................60 Ama-Drainer-Box 4 of 62...

  • Page 5: Glossary

    "tank". buildings and land. It defines general requirements as well as principles of construction and testing. Ama-Drainer-Box 5 of 62...

  • Page 6: General

    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...

  • Page 7: Safety

    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. Ama-Drainer-Box 7 of 62...

  • Page 8: Consequences And Risks Caused By Non-Compliance With These Operating Instructions

    ▪ 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. Ama-Drainer-Box 8 of 62...

  • Page 9: Unauthorised Modes Of Operation

    P r e v e n t i o n o f f o r e s e e a b l e m i s 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. Ama-Drainer-Box 9 of 62...

  • Page 10: Transport/Temporary Storage/Disposal

    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 Ama-Drainer-Box...

  • Page 11: Disposal

    Collect greases and other lubricants during dismantling. 2. 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. Ama-Drainer-Box 11 of 62...

  • Page 12: Description

    1 = 100 litres Underfloor installation B = above-floor installation Pump code number e.g. 301 = Ama-Drainer N 301 4.3 Name plate Ama-Drainer-Box Z2 U S - Y EN 12 050-2 FO001998 Made by KSB Fig. 1: Name plate (example)

  • Page 13: Configuration And Function

    (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. Ama-Drainer-Box 13 of 62...

  • Page 14: Fluids Handled

    Ama-Drainer-Box waste water lifting units meet the requirements of EN 12050-2. U n d e r f l o o r b o x 1 U – s i n g l e - p u m p u n i t Collecting tank made of impact-resistant plastic, 100 litres, for installation in substructures and foundations.
  • Page 15 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. Ama-Drainer-Box...

  • Page 16: Dimensions And Weights

    Dual-pump units Underfloor 1 U Above-floor 1 B Underfloor Z2 Above-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 15.7 31.3 29.9 weight Ama-Drainer-Box 16 of 62...

  • Page 17: Installation At Site

    ▪ 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. Ama-Drainer-Box 17 of 62...

  • Page 18: Installing The Lifting Unit

    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) Ama-Drainer-Box 18 of 62...
  • Page 19 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°. Ama-Drainer-Box 19 of 62...
  • Page 20 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. Ama-Drainer-Box 20 of 62...
  • Page 21 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. Ama-Drainer-Box 21 of 62...
  • Page 22 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 Ama-Drainer-Box 22 of 62...
  • Page 23 Fig. 10: Installed underfloor box (example) 5.3.4 Fitting the sealing collar D F 4 0 0 a n d D F 6 3 0 Moisture barrier, e.g. by polymer sealing sheets, for wet areas without water under hydrostatic pressure. Ama-Drainer-Box 23 of 62...
  • Page 24 Roll out the sealing sheet 3, cut it to length in the area of the tank edge and put it into place. Glue the sealing collar and sealing sheet together using a permanently elastic adhesive bonding and sealing compound. Ama-Drainer-Box 24 of 62...
  • Page 25 ✓ Concrete cover of at least 50 mm. ✓ Use of waterproof concrete. 1. 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. Ama-Drainer-Box 25 of 62...

  • Page 26: Installing The Above-Floor Lifting Unit

    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. Ama-Drainer-Box 26 of 62...
  • Page 27 ✓ 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. Ama-Drainer-Box 27 of 62...
  • Page 28 4. Connect the Y-pipe (pipe outside diameter 63 mm) with hose 719.02 and hose clips 733.01 to the discharge line. Ⓐ 410.01 Fig. 16: Connecting the discharge line; setting the installation dimension; dimensions given in mm Fitting direction Ama-Drainer-Box 28 of 62...
  • Page 29 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. Ama-Drainer-Box 29 of 62...

  • Page 30: Installing The Submersible Motor Pump(S)

    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 719.01 Hose 720.02 Hose nozzle with union nut 720.03 Hexagon reducing nipple 733.12 733.12 Hose clip (2) 719.01 Check valve 733.12 720.02 720.03 Ama-Drainer-Box 30 of 62...
  • Page 31 [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 Ama-Drainer-Box 31 of 62...
  • Page 32 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. Ama-Drainer-Box 32 of 62...
  • Page 33 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 Ama-Drainer-Box 33 of 62...
  • Page 34 ▷ 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. Ama-Drainer-Box 34 of 62...
  • Page 35 Joint ring (2) Discharge line (2) Y-pipe Hexagon reducing nipple (2) 731.02 Pipe union (2) Swing check valve 731.02 NOTE Install the locking disc for the float. Ama-Drainer 4../10 NE, ND Discharge line (2) Y-pipe Check valve (2) Ama-Drainer-Box 35 of 62...
  • Page 36 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. Ama-Drainer-Box 36 of 62...
  • Page 37 (fish tape). A b o v e - f l o o r b o x ✓ The shockproof plug (230 V 1~) has been removed. Ama-Drainer-Box 37 of 62...

  • Page 38: Fitting The Cover Plate/Cover

    U n d e r f l o o r b o x o f s i n g l e - p u m p u n i t 1 U a n d d u a l - p u m p u n i t Z 2 U 68-3 90-1 13-21 Fig. 25: Fitting the cover plate Ama-Drainer-Box 38 of 62...
  • Page 39 A b o v e - f l o o r b o x Z 2 B – d u a l - p u m p u n i t 900.01 550.01 412.01 Fig. 27: Fitting the cover Cover 412.01 O-ring 550.01 Disc (12) Tank 900.01 Screw (12) Tighten the screws 900.01 crosswise. Ama-Drainer-Box 39 of 62...

  • Page 40: Venting Device With Activated Carbon Filter (Accessories)

    ▪ 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). Ama-Drainer-Box 40 of 62...

  • Page 41: Commissioning/Start-Up/Shutdown

    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 m /h max.

  • Page 42: 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) Ama-Drainer-Box 42 of 62...

  • Page 43: Servicing/Maintenance

    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.

  • Page 44: Drainage/Cleaning

    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. Ama-Drainer-Box 44 of 62...

  • Page 45: Trouble-Shooting

    Defective float switch; float blocked by dirt or Check the float switch. Clean the float. fluff 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. Ama-Drainer-Box 45 of 62...

  • Page 46: Related Documents

    9.1.1 Single-pump units – Underfloor box 1 U / above-floor box 1 B Underfloor box 1 U 410.02 (826) (914) (550) (68-3) 68-3 90-1 720.04 710.01 13-21 Above-floor box 1 B 719.02 733.11 733.11 720.04 (901) 99-3.1 (733.03) (90-3) 99-3.2 Ama-Drainer-Box 46 of 62...
  • Page 47 Cover with sealing element Gasket 410.02 Profile joint Taper lock ring Collecting tank Pump 68-3 Cover plate Siphon trap Gasket Disc 68-3 Cover plate 90-1 Plug Hexagon socket head cap screw Discharge line 710.01 Discharge pipe 710.02 Anti-rotation device Ama-Drainer-Box 47 of 62...
  • Page 48 916.3 Cable grommet C 99-3.1 Set of fasteners 733.03 Pipe clamp 90-3 Anchor bolt Hexagon head bolt 99-3.2 Set of pads ( ) Not available as individual spare part [ ] See Ama-Drainer spare parts programme Ama-Drainer-Box 48 of 62...
  • Page 49 81-45.01/.02 (920) 81-45.03 (914.01) (550.01) 68-3 (68-3) 90-1 13-21 410.01 410.02 Above-floor box Z2 B (900.01) (550.01) (160) 412.01 (57-3) (914.02) (733.04) (732) (81-39) (900.02) 81-45.01/.02 (920) 81-45.03 719.02 410.01 733.01 (901) 99-3.1 (550.02) (90-3) 99-3.2 Ama-Drainer-Box 49 of 62...
  • Page 50 Profile joint 410.02 Profile joint Joint ring 412.01 O-ring 412.02 O-ring Collecting tank Pump 68-3 Cover plate Siphon trap Gasket 550.01 Disc 68-3 Cover plate 90-1 Plug 914.01 Hexagon socket head cap screw Discharge line Y-pipe Ama-Drainer-Box 50 of 62...
  • Page 51 Check valve 90-1 Plug Cable grommet 99-3.1 Set of fasteners 550.02 Disc 90-3 Anchor bolt Hexagon head bolt 99-32 Set of pads ( ) Not available as individual spare part [ ] See Ama-Drainer spare parts programme Ama-Drainer-Box 51 of 62...

  • Page 52: Dimensions

    Connections Dimensions ⃞420 G 1 / Ø 50 ET = Installation depth Table 10: Connections Ama-Drainer-Box 1 U Connection Description Inlet Horizontal Connection nozzles 2x DN 50/DN 70 graded nozzles opposite each other, outside diameter 50/78 mm 2x DN 70/DN 100 graded nozzles opposite each other, outside diameter...
  • Page 53 9 Related Documents 9.2.2 Above-floor box of single-pump unit 1 B Connections Dimensions Table 11: Connections Ama-Drainer-Box 1 B Connection Description Inlet Horizontal Connection nozzles 2x DN 50/DN 70 graded nozzles opposite each other, outside diameter 50/78 mm 2x DN 70/DN 100 graded nozzles opposite each other, outside...
  • Page 54 Connections Dimensions Standard With level-adjusting piece ⃞590 ⃞590 Table 12: Connections Ama-Drainer-Box Z2 U Connection Description Inlet Horizontal Connection nozzles 1x DN 100/DN 150 graded nozzle, outside diameter 110/159 mm 2x DN 50/DN 70 graded nozzles opposite each other, outside...
  • Page 55 9 Related Documents 9.2.4 Above-floor box of dual-pump unit Z2 B Connections Dimensions Table 13: Connections Ama-Drainer-Box Z2 B Connection Description Inlet Horizontal Connection nozzles 1x DN 100/DN 150 graded nozzle, outside diameter 110/159 mm 2x DN 50/DN 70 graded nozzles opposite each other, outside...

  • Page 56: Installation Example

    Waste water lifting unit Puddle flange Sealing collar Discharge line Socket gate valve Flood level Vent line 9.3.2 Above-floor box 1 B Inlet Waste water lifting unit Discharge line Socket gate valve Flood level Vent line Ama-Drainer-Box 56 of 62...
  • Page 57 Waste water lifting unit Puddle flange Sealing collar Floor drain Discharge line Socket gate valve Flood level Vent line 9.3.4 Above-floor box Z2 B Inlet Waste water lifting unit Discharge line Socket gate valve Flood level Vent line Ama-Drainer-Box 57 of 62...

  • Page 58: Ec Declaration Of Conformity

    10 EC Declaration of Conformity 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: –...

  • Page 59: Certificate Of Decontamination

    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 Ama-Drainer-Box 59 of 62...

  • Page 60: Index

    Return to supplier 10 Commissioning 41 Returning to service 42 Disposal 11 Safety 7 Safety awareness 8 Shutdown 42 Start-up 41 Stopping 41 Impeller type 13 Intended use 9 Operating limits 9 Other applicable documents 6 Ama-Drainer-Box 60 of 62...
  • Page 62 KSB Aktiengesellschaft 67225 Frankenthal • Johann-Klein-Str. 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 • Fax +49 6233 86-3401 www.ksb.com...

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