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Summary of Contents for KSB Compacta UZ10.450D
- Page 1 Sewage Lifting Unit Compacta UZ, ZF, ZK UZ - with Amarex N/KRT ZF, ZK - with Sewabloc From series S-V/1 From series 2013w01 Installation/Operating Manual...
- Page 2 All rights reserved. The contents provided herein must neither be distributed, copied, reproduced, edited or processed for any other purpose, nor otherwise transmitted, published or made available to a third party without the manufacturer's express written consent. Subject to technical modification without prior notice. © KSB SE & Co. KGaA, Frankenthal 23/07/2018...
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Page 3: Table Of Contents
Contents Contents Glossary .............................. 5 General.............................. 6 Principles ................................ 6 Installation of partly completed machinery.................... 6 Target group.............................. 6 Other applicable documents.......................... 6 Symbols ................................ 6 Safety .............................. 7 Key to safety symbols/markings........................ 7 General................................ 7 Intended use .............................. 8 Personnel qualification and training....................... 8 Consequences and risks caused by non-compliance with this manual ............ 8 Safety awareness .............................. 8 Safety instructions for the operator/user...................... 9 Safety information for maintenance, inspection and installation .............. 9... - Page 4 Contents 6.2.1 Operating limits per operating mode .................... 27 6.2.2 Supply voltage............................ 28 Commissioning/start-up of control unit ...................... 28 6.3.1 Lifting unit with LevelControl Basic 2.................... 29 Shutdown................................ 30 Operation.............................. 32 Control panel .............................. 32 7.1.1 Indicators ............................ 32 7.1.2 Display .............................. 33 7.1.3 Navigation keys.......................... 33 Manual-0-automatic selector switch ...................... 34 Control panel .............................. 34 7.3.1 Displaying measured value parameters.................... 34...
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Page 5: Glossary
Glossary Glossary Certificate of decontamination Stormwater A certificate of decontamination is enclosed by the Water from natural precipitation which has not customer when returning the product to the been contaminated by any form of use manufacturer to certify that the product has been properly drained to eliminate any environmental Vent line and health hazards arising from components in... -
Page 6: General
The serial number uniquely describes the product and is used as identification in all further business processes. In the event of damage, immediately contact your nearest KSB Service centre to maintain the right to claim under warranty. 1.2 Installation of partly completed machinery To install partly completed machinery supplied by KSB refer to the sub-sections under Servicing/Maintenance. -
Page 7: Safety
2 Safety 2 Safety All the information contained in this section refers to hazardous situations. DANGER In addition to the present general safety information the action-related safety information given in the other sections must be observed. 2.1 Key to safety symbols/markings Table 3: Definition of safety symbols/markings Symbol Description... -
Page 8: Intended Use
2 Safety 2.3 Intended use ▪ The lifting unit must not be used in potentially explosive atmospheres. ▪ The lifting unit must only be operated within the operating limits described in the other applicable documents. ▪ Only operate lifting units which are in perfect technical condition. ▪... -
Page 9: Safety Instructions For The Operator/User
2 Safety 2.7 Safety instructions for the operator/user ▪ Fit protective equipment (e.g. contact guards) supplied by the operator for hot, cold or moving parts, and check that the equipment functions properly. ▪ Do not remove any protective equipment (e.g. contact guards) during operation. ▪... -
Page 10: Transport/Temporary Storage/Disposal
1. On transfer of goods, check each packaging unit for damage. 2. In the event of in-transit damage, assess the exact damage, document it and notify KSB or the supplying dealer and the insurer about the damage in writing immediately. - Page 11 3 Transport/Temporary Storage/Disposal Sizes Weight Per pump Lifting unit UZ28.450D UZ28.900D UZ29.450D UZ29.900D Table 5: Weight Compacta ZF - Sewabloc [kg] Sizes Weight Per pump Lifting unit ZF30.450D ZF30.900D ZF31.450D ZF31.900D ZF32.450D ZF32.900D ZF33.450D ZF33.900D ZF34.450D ZF34.900D ZF35.450D ZF35.900D ZF36.450D ZF36.900D ZF40.450D ZF40.900D ZF41.450D...
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Page 12: Storage/Preservation
3 Transport/Temporary Storage/Disposal Sizes Weight Per pump Lifting unit ZK52.450D ZK52.900D ZK53.450D ZK53.900D ZK54.450D ZK54.900D ZK55.450D ZK55.900D ZK56.450D ZK56.900D ü The lifting unit has been checked for in-transit damage. 1. Select suitable transport equipment (in acc. with weights table). 2. Transport the tank/pump to the place of installation. 3. -
Page 13: Return To Supplier
Always indicate any safety and decontamination measures taken. NOTE If required, a blank certificate of decontamination can be downloaded from the following web site: www.ksb.com/certificate_of_decontamination 3.5 Disposal WARNING Fluids handled, consumables and supplies which are hot and/or pose a health... -
Page 14: Description
4 Description 4 Description 4.1 General description Floodable sewage lifting unit ▪ The sewage lifting unit consists of either one or two collecting tanks, two pump sets and the unit control system. NOTE The flow velocity in the discharge line must not be less than 0.7 m/s and not higher than 2.3 m/s. -
Page 15: Name Plates
Country-specific version 4.3 Name plates Examples: Pump For the pump name plate refer to the installation/operating manual of the waste water pump. Tank KSB SE & Co. KGaA Johann-Klein-Straße 9 67227 Frankenthal Deutschland Type series, size Serial No. Maximum flow rate... -
Page 16: Configuration And Function
▪ Frequency 50 Hz ▪ DOL starting (from 5.5 kW star-delta starting) Compacta UZ: ▪ Submersible motor made by KSB, IP68 enclosure ▪ Monitoring by temperature switches in the winding Compacta ZF, ZK: ▪ Standardised motor made by KSB, IP55 enclosure ▪... - Page 17 4 Description Design The lifting unit is provided with several horizontal inlet nozzles (1). The pump (4) pumps the fluid handled into the vertical discharge line (8). Function The fluid to be handled flows into the lifting unit through horizontal inlet nozzles (1) and is collected in a gas-, odour- and water-tight plastic tank (7). When the level sensor detects a defined fill level, the fluid is automatically pumped off to a level above the flood level and towards the public sewer by either one or two pumps (4).
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Page 18: Technical Data Of The Control Unit
4 Description Fig. 5: Type Basic Control Cabinet (BS) Master switch Control panel Manual-0-automatic switch NOTE The control units are not explosion-proof, and therefore must only be operated outside potentially explosive atmospheres. The control unit is always located outside the potentially explosive atmosphere and may only be installed in a flood-proof room. -
Page 19: Fluids Handled
4 Description Process outputs ▪ 1 x volt-free signalling output (250 V, 1 A, changeover contact) ▪ 1 x signalling output (12.6 to 13.2 V), e.g. for connecting a horn, alarm combination or alarm strobe light (12 V connection) Rechargeable battery Connection for rechargeable battery, for mains-independent power supply of: ▪... -
Page 20: Noise Characteristics
4 Description 4.9 Noise characteristics The sound pressure level depends on the local conditions and the duty point. It is ≤ 70 dB(A). 4.10 Scope of supply Depending on the model, the following items are included in the scope of supply: Sewage lifting unit consisting of: ▪... -
Page 21: Installation At Site
5 Installation at Site 5 Installation at Site The "Installation at Site" section describes the conditions which must be fulfilled for assembling the complete sewage lifting unit in accordance with the instructions and without compromising the safety and health of persons. 5.1 Safety regulations DANGER Improper installation... -
Page 22: Installing The Lifting Unit
5 Installation at Site 5.3 Installing the lifting unit 5.3.1 Setting up the tank(s) NOTE Lifting units should not be installed next to sleeping or living quarters. WARNING Insufficient ventilation Personal injury and damage to property! ▷ Provide proper aeration and ventilation. ▷... -
Page 23: Connecting The Piping
5 Installation at Site NOTE In battery design (two tanks), each pump is assigned to a tank. 5.4 Connecting the piping DANGER Impermissible loads acting on the system nozzles Danger to life from leakage of hot, toxic, corrosive or flammable fluids! ▷... -
Page 24: Cellar Drainage
5 Installation at Site Fig. 6: Opening the nozzles Vent line for the collecting tank Sewage lifting units to EN 12050-1 must be vented through the roof. The vent line must not be connected to the inlet-side vent line of a grease separator. Connect the DN 70 vent line to the vertical vent nozzle by means of the flexible hose connection, making sure that the connection is odour-proof. -
Page 25: Connection To Power Supply
5 Installation at Site CAUTION Discharge line for cellar drainage connected to the discharge line of the lifting unit Flooding of installation room! ▷ Run the separate discharge line for cellar drainage above the flood level before leading it into the sewer. ▷... -
Page 26: Checking The Direction Of Rotation
5 Installation at Site 5.7 Checking the direction of rotation WARNING Hands or objects inside the pump casing / inside the lifting unit Risk of injuries, damage to the pump / lifting unit! ▷ Never hold your hands or any other objects into the pump. ▷... -
Page 27: Commissioning/Start-Up/Shutdown
6 Commissioning/Start-up/Shutdown 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 lifting unit has been properly connected to the electric power supply and is equipped with all protection devices. ▪... -
Page 28: Supply Voltage
6 Commissioning/Start-up/Shutdown Table 12: Frequency of starts Motor rating Maximum No. of starts per pump [kW] [Starts/hour] 3,7 - 7,5 > 7,5 6.2.1.2 Application limits for S1 duty Compacta ZF, ZK - Hydraulics code 30 to 56 ▪ Continuous duty S1 Table 13: Frequency of starts Motor rating Maximum No. -
Page 29: Lifting Unit With Levelcontrol Basic 2
6 Commissioning/Start-up/Shutdown 6.3.1 Lifting unit with LevelControl Basic 2 DANGER Live voltage Danger to life! ▷ Only open the device after it has been de-energised. Setting the motor protection switch Set the motor protection switch to the rated motor current indicated on the pump name plate and switch on the motor protection switch. -
Page 30: Shutdown
6 Commissioning/Start-up/Shutdown NOTE A sensor fault may be displayed when the lifting unit has not been filled yet. It will disappear after the lifting unit has been filled. The manual-0-automatic switch must be set to "Automatic". 6.3.1.1 Using additional functions 6.3.1.1.1 Functional check run For pumps with long idle periods, a functional check run can be activated at parameter 3-7-1. - Page 31 6 Commissioning/Start-up/Shutdown WARNING Fluids handled and supplies 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. Compacta UZ, ZF, ZK 31 of 64...
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Page 32: Operation
7 Operation 7 Operation DANGER Unintentional starting of pumps Risk of injury: Limbs can be pulled into or crushed by machinery! ▷ Make sure that nobody is within the immediate, hazardous vicinity of the pumps. ▷ Make sure that all piping is properly installed and that the fluid handled cannot escape. - Page 33 7 Operation Table 14: Traffic light LEDs Description Green Readiness for operation Yellow Warning (one or more warnings) Alert (one or more alerts) LED for pump operating status This LED indicates the operating status of the pumps: Table 15: LED for pump operating status Description Green Pump ready for operation...
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Page 34: Manual-0-Automatic Selector Switch
7 Operation 7.2 Manual-0-automatic selector switch Each pump can be operated as follows by means of a manual-0-automatic selector switch: Table 17: Switch positions of manual-0-automatic selector switch Switch position Function Function allowing the pump to be operated manually for a short period Switch locks in place. -
Page 35: Setting Parameters
7 Operation 7.3.2 Setting parameters NOTE The parameters that you can call up depend on the operating mode and measurement method. Only parameters that are relevant to the current operating mode and measurement method are displayed. Fig. 13: Setting parameters 1. Press and hold the ESC key and press OK. ð... -
Page 36: Acknowledging Alerts And Warnings
7 Operation Parameter Description 3.3.4.1 Pumps OFF Level Pumps OFF [mm] 3.3.4.2 Base Load ON Level Base Load ON [mm] 3.3.4.3 Peak Load ON Level Peak Load ON [mm] 3.3.4.4 High Water Level High Water [mm] 3.3.5.3 Stop Delay Setting the stop delay [ 4.1.1 Firmware version Firmware version... -
Page 37: Displaying The Alerts List
No changes by default) NOTE The service interval is deactivated by default and can be set via the KSB Service Tool. 7.3.4 Displaying the alerts list Alerts that have been acknowledged but are still present are stored in the alerts list (2-1-1) and can be called up. -
Page 38: Servicing/Maintenance
8 Servicing/Maintenance 8 Servicing/Maintenance 8.1 General information/Safety regulations WARNING Improper lifting/moving of heavy assemblies or components Personal injury and damage to property! ▷ Use suitable transport devices, lifting equipment and lifting tackle to move heavy assemblies or components. WARNING Work on the lifting unit by unqualified personnel Risk of personal injury! ▷... -
Page 39: Inspection Contract
8.2.1 Inspection contract For all inspection and servicing work to be carried out at regular intervals we recommend taking out the inspection contract offered by KSB. Contact your Service Partner for details. Checklist for commissioning/start-up, checklist for inspection (ð Section 8.7, Page 41) -
Page 40: Dismantling The Pump
8 Servicing/Maintenance DANGER Failure to support the discharge line Risk of injury! ▷ Take suitable steps to support the weight of the discharge line. Remove the screws from plug fixings 90-3 at foot 182. Remove flexible connection 719.6 between the tank and hose elbow 72-1.2. Use suitable lifting equipment to remove the pump from the lifting unit. -
Page 41: Pump Reassembly
8 Servicing/Maintenance CAUTION O-rings do not seal properly Damage to the lifting unit! ▷ Use original O-rings. ▷ Do not use O-rings that have been made by cutting an O-ring cord to size and gluing the ends together. Reassembly is effected in reverse order to dismantling. Use the general assembly drawing and the list of components for orientation. - Page 42 8 Servicing/Maintenance Actions Required during Check the switching mechanism. ➀ ➁ Remove the level sensor; check for jamming/incrustations; clean, if necessary. Check the switchover time from star to delta (required = approx. 3 seconds) ➀ ➁ Check fuses. ➀ ➁ Size, characteristics, three poles/interlocking device Replace the fuses every two years of operation (cartridges).
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Page 43: Trouble-Shooting
Non-compliance will lead to forfeiture of any and all rights to claims for damages. If problems occur that are not described in the following table, consultation with the KSB customer service is required. A Pump is running, but does not deliver B Insufficient flow rate... - Page 44 ✘ Manual-0-automatic selector switch set to Set manual-0-automatic selector switch to "0". "Automatic". ✘ ✘ Motor winding or electric cable are defective. Replace by new original KSB parts or contact KSB. ✘ - Water level in the tank too low during Check level sensor.
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Page 45: Related Documents
10 Related Documents 10 Related Documents 10.1 General assembly drawing/exploded view and list of components 10.1.1 General assembly drawing of the lifting unit Part No. Description 160.1/.2 Cover 17-5 Baffle, cpl. Foot Plate 400.03 Gasket 412.08/.31/.41 O-ring 550.04/.21 Disc Strip Tank Pump 70-1... - Page 46 10 Related Documents Part No. Description 99-3.2 Set of accessories (pads) 5B.1 Vent connection Compacta UZ, ZF, ZK 46 of 64...
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Page 47: Exploded View Of Collecting Tank
10 Related Documents 10.1.2 Exploded view of collecting tank Part No. Description 160.1 Cover Plate 412.08/.31/.41 O-ring Strip Tank 710.1/.2 Pipe 719.1/.2/.5/.6 Flexible tube 733.1/.21/.55/.5 Hose clip 81-45 Level sensor 90-3 Set of mounting elements 920.4 99-3.2 Set of accessories (pads) 5B.2 Vent connection Compacta UZ, ZF, ZK... -
Page 48: Connection Examples
10 Related Documents 10.2 Connection examples 10.2.1 Compacta UZ10.450 - UZ15.450 NOTE Rooms containing 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. Flood level Compacta UZ 10. -
Page 49: Compacta Uz10.900 - Uz15.900
10 Related Documents 10.2.2 Compacta UZ10.900 - UZ15.900 NOTE Rooms containing 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. Flood level Compacta UZ 10. -
Page 50: Compacta Uz20.450 - Zk56.450
10 Related Documents 10.2.3 Compacta UZ20.450 - ZK56.450 NOTE Rooms containing 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. Fig. 15: Installation dimensions Compacta UZ, ZF, ZK .. 450 D [mm] Flood level Pump Hydraulics code... - Page 51 10 Related Documents Fig. 16: Installation dimensions Compacta UZ, ZF, ZK .. 900 D [mm] Flood level Pump Hydraulics code Amarex KRT F 80-250 20-26 Amarex KRT F 100-240 27-29 Sewabloc F 80-315 30-36 Sewabloc K 80-250 50-53 Sewabloc F 100-250/251 40-49 Sewabloc K 100-250 54-56...
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Page 52: Dimensions
10 Related Documents 10.3 Dimensions Alert Peak load Pump ON Pump OFF Compacta UZ, ZF, ZK 52 of 64... -
Page 53: Wiring Diagrams
10 Related Documents 10.4 Wiring diagrams 10.4.1 LevelControl Basic 2 Type BC - dual-pump unit - DOL starting - up to 4 kW - with motor protection switch - for Compacta UZ Compacta UZ, ZF, ZK 53 of 64... -
Page 54: Levelcontrol Basic 2 Type Bs - Dual-Pump Unit - Dol Starting - 5.5 Kw And Above - With Motor Protection Switch - For Compacta Uz
10 Related Documents 10.4.2 LevelControl Basic 2 Type BS - dual-pump unit - DOL starting - 5.5 kW and above - with motor protection switch - for Compacta UZ Compacta UZ, ZF, ZK 54 of 64... -
Page 55: Levelcontrol Basic 2 Type Bs - Dual-Pump Unit - Star/Delta Starting - 5.5 Kw And Above - With Motor Protection Switch - For Compacta Uz
10 Related Documents 10.4.3 LevelControl Basic 2 Type BS - dual-pump unit - star/delta starting - 5.5 kW and above - with motor protection switch - for Compacta UZ Compacta UZ, ZF, ZK 55 of 64... -
Page 56: Levelcontrol Basic 2 Type Bs - For Compacta Zf And Compacta Zk
10 Related Documents 10.4.4 LevelControl Basic 2 Type BS - for Compacta ZF and Compacta ZK NOTE For the electrical connection between LevelControl Basic 2 and Compacta ZF or Compacta ZK refer to the circuit wiring diagram supplied with the delivery and the operating manual supplied with the pump. Compacta UZ, ZF, ZK 56 of 64... -
Page 57: Eu Declaration Of Conformity
11 EU Declaration of Conformity 11 EU Declaration of Conformity Manufacturer: KSB SE & Co. KGaA Johann-Klein-Straße 9 67227 Frankenthal (Germany) The manufacturer herewith declares that the product:: Compacta-Amarex N Compacta-Amarex KRT ▪ is in conformity with the provisions of the following Regulations as amended from time to time: –... -
Page 58: Declaration Of Performance As Per Regulation (Eu) No. 305/2011, Annex Iii
Serial number See name plate Intended use For collecting and automatically lifting waste water with or without faeces above the flood level. Manufacturer KSB SE & Co. KGaA 67225 Frankenthal (Germany) Authorised representative Not applicable System of assessment and System 3... -
Page 59: Certificate Of Decontamination
13 Certificate of Decontamination 13 Certificate of Decontamination Type: ..........................Order number/ Order item number ..........................Delivery date: ..........................Field of application: ..........................Fluid handled ..........................Please tick where applicable ⃞ ⃞ ⃞ ⃞ Radioactive Explosive Corrosive Toxic ⃞ ⃞ ⃞... -
Page 60: Index
Index Index Alerts and warnings Operating limits 8 Acknowledgement 36 Other applicable documents 6 Alerts list Display 37 Parameter Settings 35 Bearings 16 Partly completed machinery 6 Cellar drainage 24 Rechargeable battery Certificate of decontamination 59 Inserting/replacing 37 Commissioning/start-up 27 Return to supplier 13 Control panel 32 Safety 7 Design 15 Safety awareness 8 Designation 14 Scope of supply 20 Dimensions 20 Shaft seal 16 Display 33... - Page 64 KSB SE & Co. KGaA Johann-Klein-Straße 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 www.ksb.com...
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