KSB Ama-Drainer-Box Installation & Operating Manual
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KSB Ama-Drainer-Box Installation & Operating Manual

KSB Ama-Drainer-Box Installation & Operating Manual

Automatic waste water lifting unit
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Automatic Waste Water Lifting Unit
Ama-Drainer-Box
Installation/Operating Manual

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  • Page 1 Automatic Waste Water Lifting Unit Ama-Drainer-Box 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 01/10/2019...

  • Page 3: Table Of Contents

    Installing the above-floor box...................... 32 5.4.2 Above-floor box: Connecting the piping .................. 33 Installing the pump set .......................... 36 5.5.1 Single-pump lifting units: Installing the pump set ................ 36 5.5.2 Dual-pump lifting units: Installing the pump set................ 41 Electrical connection ............................ 44 Ama-Drainer-Box 3 of 76...
  • Page 4 9.3.1 Underfloor box: installation example.................... 67 9.3.2 Above-floor box: Installation example ..................... 68 EU Declaration of Conformity ...................... 70 Declaration of Performance as per Regulation (EU) No. 305/2011, Annex III........ 71 Certificate of Decontamination...................... 72 Index .............................. 73 Ama-Drainer-Box 4 of 76...

  • Page 5: Glossary

    Submersible motor pumps are floodable, close- coupled 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. Ama-Drainer-Box 5 of 76...

  • 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 facility 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: Key To Safety Symbols/Markings

    In conjunction with one of the signal words this symbol indicates a hazard involving electrical voltage and identifies information about protection against electrical voltage. Machine damage In conjunction with the signal word CAUTION this symbol indicates a hazard for the machine and its functions. Ama-Drainer-Box 7 of 76...

  • Page 8: Safety

    ▪ Never exceed the permissible application and operating limits specified in the data sheet or product literature regarding pressure, temperature, etc. ▪ Never open the discharge-side shut-off elements further than permitted. – The maximum flow rates specified in the product literature or data sheet would be exceeded. Ama-Drainer-Box 8 of 76...

  • Page 9: Personnel Qualification And Training

    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.) Ama-Drainer-Box 9 of 76...

  • Page 10: Safety Information For Maintenance, Inspection And Installation

    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. (ð Section 2.2, Page 8) Ama-Drainer-Box 10 of 76...

  • Page 11: 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 12: Return To Supplier

    Contact your local waste disposal partner for returns. If the used electrical or electronic equipment contains personal data, the operator is responsible for deleting it before the equipment is returned. Ama-Drainer-Box 12 of 76...

  • Page 13: Description

    ▪ Waste water containing oil 4.2 Product information as per Regulation No. 1907/2006 (REACH) For information as per chemicals Regulation (EC) No. 1907/2006 (REACH), see http:// www.ksb.com/reach. 4.3 Designation Example: Ama-Drainer-Box Z2 U 301 Table 4: Designation key Code Description Ama-Drainer-Box Type series...

  • Page 14: Name Plate

    4 Description 4.4 Name plate KSB SE & Co. KGaA 0197 Johann-Klein-Straße 9 DoP2336.1-01 67227 Frankenthal Deutschland Ama-Drainer-Box Z2 B EN 12 050-2 2019w10 FO001999 Made in Germany Fig. 1: Name plate (example) 1 Type series, size 4 Reference number of the declaration...

  • Page 15: Configuration And Function

    (6). The fluid handled is pumped through the discharge- side connection (5) to a level above the flood level and discharged into the public sewer. 4.7 Noise characteristics Sound pressure level < 70 dB(A) Ama-Drainer-Box 15 of 76...

  • Page 16: Scope Of Supply

    Waste water lifting units from both the off-the- shelf range and the configurable range are supplied in several parts for assembly on site. Ama-Drainer-Box waste water lifting units meet the requirements of EN 12050-2. Underfloor box 1 U – single-pump unit ▪...

  • Page 17: Dimensions And Weights

    In combination with one of the alarm switchgears (AS 0, AS 2, AS 4 or AS 5) the M1 alarm contact triggers 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.

  • Page 18: Installation At Site

    If the supply of mains voltage is interrupted or the submersible motor pump is defective, there is a risk of flooding damage. Prevent damage by using a mains- independent alarm switchgear or a KSB washing machine interrupter. Ama-Drainer-Box 18 of 76...

  • Page 19: Checks To Be Carried Out Prior To Installation

    (ð Section 4.4, Page 14) ▪ The pump (power) is suitable for the operating conditions and losses in the discharge-side piping applicable to Ama-Drainer-Box. ▪ The fluid handled is a permissible fluid. (ð Section 6.2.2.1, Page 52) ▪ The above safety instructions have been complied with.
  • Page 20 8. Connect the inlet line and vent line. (ð Section 5.3.2.2, Page 24) 9. Fit the level-adjusting piece / puddle flange with level-adjusting piece (not included in the scope of supply). (ð Section 5.3.3, Page 26) 10. Backfill around the collecting tank. Pour concrete around the top of the collecting tank. (ð Section 5.3.4, Page 28) Ama-Drainer-Box 20 of 76...

  • Page 21: Underfloor Box: Connecting The Piping

    All waste water lifting units are equipped with check valves. NOTE Installing a gate valve in the discharge line close to the lifting unit is recommended. After the installation, subject the discharge line to a pressure test. Ama-Drainer-Box 21 of 76...
  • Page 22 Apply a sufficient amount of lubricant to the pipe end before inserting it. 4. Align the discharge pipe and observe the installation dimension. 5. Connect the discharge line provided at the site. Solvent-free and plasticiser-free, e.g. R+F Optiline. Ama-Drainer-Box 22 of 76...
  • Page 23 3. Insert the y-pipe into the profile seal from the inside. Apply a sufficient amount of lubricant to the pipe end before inserting it. 4. Align the y-pipe horizontally and observe the installation dimension. 5. Connect the discharge line provided at the site. Ama-Drainer-Box 23 of 76...
  • Page 24 2. Connect the inlet line and vent line using connection elements (e.g. PVC sewer pipe socket part or SML pipes). Fig. 7: Connecting the piping 1 Provisional cover 185 3 Vent line 2 Inlet line 4 Emergency drain (optional) Ama-Drainer-Box 24 of 76...
  • Page 25 1. Cut the auxiliary connection (4) open at the marking with a 48 mm diameter hole saw. 2. Debur the hole. 3. Insert supplied cable gland 826 with a joint ring into the hole. Fasten it from the inside with the nut. Ama-Drainer-Box 25 of 76...

  • Page 26: Underfloor Box: Fitting The Level-Adjusting Piece / Puddle Flange With Level-Adjusting Piece (Not Included In The Scope Of Supply)

    3. Fit bolts 900.01 with discs 550.01. Tighten the bolts crosswise. 4. Fit profile seal 410.02. Verify that it is seated correctly. 5. Fit extension piece 13-21. Only one level-adjusting piece can be used. Ama-Drainer-Box 26 of 76...
  • Page 27 ü The concrete layer will measure 50 mm as a minimum. 1. Fit strap (3). 2. Slide on puddle flange (2) by hand. 3. Fit strap (3). 4. Position the puddle flange in the centre of floor plate (1). 5. Tighten straps (3). Ama-Drainer-Box 27 of 76...

  • Page 28: Underfloor Box: Backfilling Around The Collecting Tank And Pouring Concrete Around The Top

    Protect the collecting tank against hydrostatic uplift. Fig. 12: Pouring concrete around the top of the collecting tank 5. Prior to floor construction (insulation, screed, flooring) position level-adjustable extension 13-21 and profile seal 410.02. Make sure that the sealing lips point inwards. Ama-Drainer-Box 28 of 76...
  • Page 29 7. Insert cover plate 68-3 into the extension piece. 8. Adjust the level-adjustable extension to the floor level by inserting it further into the collecting tank. For Ama-Drainer-Box Z2 U only Solvent-free and plasticiser-free, e.g. R+F Optiline. Ama-Drainer-Box 29 of 76...

  • Page 30: Underfloor Box: Fitting The Sealing Collar

    3. Roll out 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. 5. Install the pump set. (ð Section 5.5, Page 36) Ama-Drainer-Box 30 of 76...
  • Page 31 4. Roll out 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. 6. Install the pump set. (ð Section 5.5, Page 36) Ama-Drainer-Box 31 of 76...

  • Page 32: Installing The Above-Floor Box

    4. Place the collecting tank on a level floor. Align it with a spirit level. 5. Use the float protection fixtures supplied to secure the lifting unit firmly to the floor. 6. Connect the piping (ð Section 5.4.2, Page 33) Ama-Drainer-Box 32 of 76...

  • Page 33: Above-Floor Box: Connecting The Piping

    All waste water lifting units are equipped with check valves. NOTE Installing a gate valve in the discharge line close to the lifting unit is recommended. After the installation, subject the discharge line to a pressure test. Ama-Drainer-Box 33 of 76...
  • Page 34 5. Connect the discharge pipe (pipe outside diameter 50 mm) with flexible tube 719.02 and pipe clamps 733.11 to the discharge line provided on site. ð Distance between the pipe ends: 10 to 20 mm. Solvent-free and plasticiser-free, e.g. R+F Optiline. Ama-Drainer-Box 34 of 76...
  • Page 35 (e.g. saw) and debur them (A). Fig. 21: Marking for opening the nozzles 2. Connect the inlet line and vent line using connection elements (e.g. PVC sewer pipe socket part or SML pipes). Solvent-free and plasticiser-free, e.g. R+F Optiline. Ama-Drainer-Box 35 of 76...

  • Page 36: Installing The Pump Set

    74-4 733.12 719.01 733.12 03-40 720.03 731.02 Fig. 24: Fitting the discharge pipe 03-40 Check valve body 733.12 Pipe clamp (2x) 719.01 Flexible tube 74-4 Float switch 720.03 Hexagon reducing nipple Swing check valve 731.02 Pipe union Ama-Drainer-Box 36 of 76...
  • Page 37 719.01 Flexible tube Swing check valve 1. Insert a suitable tool no more than 2 mm into the recesses provided for this purpose in protective casing 13-16. Lever up and remove the protective casing. Fig. 28: Removing the protective casing Ama-Drainer-Box 37 of 76...
  • Page 38 Cut-out level b Cut-in level c Cut-out level b Cut-in level c [mm] [mm] [mm] [mm] Ama-Drainer N 301 SE/SE Ama-Drainer N 302 SE/SE Ama-Drainer N 303 SE/SE Ama-Drainer N 358 SE/SE Minimum values for automatic operation Ama-Drainer-Box 38 of 76...
  • Page 39 Ama-Drainer 522 SD/11 81-39 81-45 81-53 81-45 Fig. 32: Fitting the bracket 1. Undo cap nut 920 and disc 550 on pump 81-53 (see illustration). 2. Remove handle 576. 3. Remove bracket 732 from the connection set. Ama-Drainer-Box 39 of 76...
  • Page 40 3. Align the pump set. 4. Slide anti-rotation device 710.02 into the opposite guide grooves and place it onto the pump handle. 5. Secure the pump set and the anti-rotation device with cable ties 81-73. 6. Lay the power cables. Ama-Drainer-Box 40 of 76...

  • Page 41: Dual-Pump Lifting Units: Installing The Pump Set

    731.02 Pipe union (2×) Y-pipe Swing check valve 1. Fit the locking disc for the float switch. Ama-Drainer 4../10 NE, ND Ama-Drainer 4../10 ND Fig. 36: Fitting the discharge pipe Discharge line (2×) Check valve (2×) Y-pipe Ama-Drainer-Box 41 of 76...
  • Page 42 Ama-Drainer 5../10 K NE Ama-Drainer 5../10 K ND Fig. 39: Fitting the discharge pipe Joint ring (2×) Y-pipe Discharge line (2×) Check valve (2×) Ama-Drainer 5../11 ND Fig. 40: Fitting the discharge pipe Discharge line (2×) Check valve (2×) Y-pipe Ama-Drainer-Box 42 of 76...
  • Page 43 733.04. Check that it is securely fastened to the y-pipe. (ð Section 9.1.2, Page 60) 4. Lay the power cables of the float switches so they are not too tight. Check that the float switches can move freely. Ama-Drainer-Box 43 of 76...

  • Page 44: Electrical Connection

    SPD. ▪ The associated lightning protection concept must be provided by the operator or by a suitable provider commissioned by the operator. Surge protective devices can be offered for the control units on request. Ama-Drainer-Box 44 of 76...

  • Page 45: Underfloor Box: Electrical Connection

    Ama-Drainer N 302 NE Ama-Drainer N 303 SE A, B Ama-Drainer N 303 NE Ama-Drainer N 358 SE/NE Ama-Drainer 4../10 SE Ama-Drainer 4../10 SD Ama-Drainer 4.../35 SE Ama-Drainer 4.../35 SD Ama-Drainer 5../10 K SE Ama-Drainer 5../10 K SD Ama-Drainer-Box 45 of 76...
  • Page 46 1. Feed the power cables through the openings of cable grommet 916. 2. Fit cable grommet 916. 3. Install the CEE motor protection plug, type Hyper, or a new shockproof plug (1~ 230 V, not included in the scope of supply). Ama-Drainer-Box 46 of 76...

  • Page 47: Fitting The Cover Plate / Cover

    5.7.1 Underfloor box: Fitting the cover plate 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. Ama-Drainer-Box 47 of 76...
  • Page 48 ▪ Anti-slip properties – Slip-resistant tiles with anti-slip properties rated R11 ▪ Building material classification by combustibility (to DIN 4102-1) – B2 normally flammable (The cover is made of polyurethane (PUR).) Ama-Drainer-Box 48 of 76...

  • Page 49: Above-Floor Box: Fitting The Cover

    1. Fit O-ring 412.01. Verify that it is seated correctly. 2. Position cover 160. Verify that the drilled holes are aligned. 3. Fit bolts 900.01 with discs 550.01. Tighten the bolts crosswise. 4. If applicable, fit the venting device with activated carbon filter. (ð Section 5.8, Page 50) Ama-Drainer-Box 49 of 76...

  • Page 50: Venting Device With Activated Carbon Filter (Accessory)

    ▪ Install venting devices so that they are easy to access at any time (filter replacement). ▪ Provide a sufficient supply of air for the venting device. NOTE Replace the filter element at least every two years or sooner if odour is detected (Mat. No. 01315572). Ama-Drainer-Box 50 of 76...

  • Page 51: Commissioning/Start-Up/Shutdown

    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. Ama-Drainer-Box 51 of 76...

  • Page 52: Free Passage

    Table 11: Permissible flow rate Permissible flow rate Single-pump lifting unit Dual-pump lifting unit Maximum 35 m 46 m Swimming pool water (0.4 to 1.4 mg/l free chlorine, max. 0.6 mg/l combined chlorine, pH 6.9 to 7.7, water hardness 10 to 30 °dH, max. salt content 7 g/l) Ama-Drainer-Box 52 of 76...

  • Page 53: Shutdown/Storage/Preservation

    In addition, carry out all servicing/maintenance operations before returning the waste water lifting unit to service. (ð Section 7, Page 54) Up to a maximum of 3 minutes for waste water from the hot water cycle of washing machines and dishwashers for non- industrial use Ama-Drainer-Box 53 of 76...

  • Page 54: Servicing/Maintenance

    Check the inside of the waste water lifting unit for any deposits, especially in the area of the float switch. Clean it if required. KSB recommends regular maintenance in accordance with the following plan: ▪ Every of a year for lifting units installed in industrial businesses ▪...

  • Page 55: 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 55 of 76...

  • Page 56: 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 service is required. A Pump is running, but does not deliver B Insufficient flow rate...

  • Page 57: Related Documents

    9.1 Exploded view and list of components 9.1.1 Single-pump lifting units: underfloor box / above-floor box 410.02 (826) (914) (550) (68-3) 68-3 90-1 720.04 710.01 13-21 Fig. 48: Underfloor box 1 U 719.02 733.11 733.11 720.04 (901) 99-3.1 (733.03) (90-3) 99-3.2 Fig. 49: Above-floor box 1 B Ama-Drainer-Box 57 of 76...
  • Page 58 Quantity Underfloor box 1 U Above-floor box 1 03-40 Check valve body assembly 13-21 Extension Siphon trap Cover with sealing element Gasket 410.02 Profile seal Locking ring Collecting tank Pump 68-3 Cover plate Siphon trap Gasket Washer Ama-Drainer-Box 58 of 76...
  • Page 59 90-1 Plug Set of cable grommets 916.1 Cable grommet A 916.2 Cable grommet B 916.3 Cable grommet C 99-3.1 Set of mounting elements 733.03 Pipe clamp 90-3 Anchor bolt Hexagon head bolt 99-3.2 Set of pads Ama-Drainer-Box 59 of 76...

  • Page 60: Dual-Pump Lifting Units: Underfloor Box / Above-Floor Box

    (914.01) (550.01) 68-3 (68-3) 90-1 13-21 410.01 410.02 Fig. 50: Underfloor box Z2 U (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 Fig. 51: Above-floor box Z2 B Ama-Drainer-Box 60 of 76...
  • Page 61 Above-floor box Z2 13-21 Extension Siphon trap Cover Cover O-ring 550.01 Disc (12) 900.01 Bolt/screw (12) Gasket 410.01 Profile seal 410.02 Profile seal Joint ring 412.01 O-ring 412.02 O-ring Collecting tank Pump 68-3 Cover plate Siphon trap Ama-Drainer-Box 61 of 76...
  • Page 62 81-45.03 Alert Option Option Check valve 90-1 Plug Cable grommet 99-3.1 Set of mounting elements 550.02 Disc 90-3 Anchor bolt Hexagon head bolt 99-32 Set of pads 99-9 Set of sealing elements Joint ring 412.02 O-ring Ama-Drainer-Box 62 of 76...

  • Page 63: Dimensions And Connections

    / smooth pipe end (glued nozzle), outside diameter 50 mm Cable gland PG 36 for conduit Inside diameter 24 mm (for single-phase AC motor only) Emergency drainage 2× DN 40 horizontal, opposite each other Outside diameter 49 mm Floor drain DN 50 Ama-Drainer-Box 63 of 76...
  • Page 64 Free connection nozzle DN 50 / DN 70 / DN 100 / DN 150 Discharge-side connection DN 50 horizontal, threaded connection G 2 / smooth pipe end (glued nozzle) Outside diameter 63 mm Emergency drainage 2× DN 40 horizontal, opposite each other Outside diameter 49 mm Floor drain DN 50 Ama-Drainer-Box 64 of 76...

  • Page 65: Above-Floor Box: Dimensions And Connections

    Discharge-side connection DN 40, horizontal on the left, with flexible hose connection Inside hose diameter 50 mm Cable entry Cable grommet A/B/C, depending on the cable diameter (ð Section 5.6.2, Page 45) Emergency drainage 2× DN 40 horizontal, opposite each other Outside diameter 49 mm Ama-Drainer-Box 65 of 76...
  • Page 66 Inside hose diameter 63 mm Cable entry Grommet for two motor power cables Connector panel For cable glands of float switches 5 × M20 (drill diameter 20 mm) Emergency drainage 2× DN 40 horizontal, opposite each other Outside diameter 49 mm Ama-Drainer-Box 66 of 76...

  • Page 67: Installation Example

    8 Vent line Dual-pump lifting unit Fig. 57: Installation example 1 Inlet 2 Lifting unit 3 Puddle flange 4 Sealing collar 5 Floor drain 6 Discharge line 7 Socket gate valve 8 Flood level 9 Vent line Ama-Drainer-Box 67 of 76...

  • Page 68: Above-Floor Box: Installation Example

    3 Discharge line 4 Socket gate valve 5 Flood level 6 Vent line Dual-pump lifting unit Fig. 59: Installation example 1 Inlet 2 Lifting unit 3 Discharge line 4 Socket gate valve 5 Flood level 6 Vent line Ama-Drainer-Box 68 of 76...
  • Page 69 9 Related Documents Ama-Drainer-Box 69 of 76...

  • Page 70: Eu Declaration Of Conformity

    10 EU Declaration of Conformity 10 EU Declaration of Conformity Manufacturer: KSB SE & Co. KGaA 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 Regulations as amended from time to time: –...
  • Page 71 Waste water lifting units for waste water without faeces to EN 12050-2 Serial number See name plate Intended use For collecting and automatically lifting waste water 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 72: 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 72 of 76...

  • Page 73: Index

    Causes and remedies 56 Impeller type 14 Installation 14 Intended use 8 Key to safety symbols/markings 7 Name plate 14 Operating limits 8 Other applicable documents 6 Partly completed machinery 6 Preservation 11 Product description 13 Return to supplier 12 Returning to service 53 Safety 8 Safety awareness 9 Shutdown 53 Start-up 51 Stopping 53 Storage 11 Ama-Drainer-Box 73 of 76...
  • Page 76 KSB SE & Co. KGaA Johann-Klein-Straße 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 www.ksb.com...

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