KSB Evamatic-Box N 200 I Installation & Operating Manual Download Page 1

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Automatic Waste Water Pump Station

Evamatic-Box N

Installation/Operating Manual

Summary of Contents for Evamatic-Box N 200 I

Page 1: ...Automatic Waste Water Pump Station Evamatic Box N Installation Operating Manual ...

Page 2: ...ents 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 S A S Sequedin Lille France 14 03 2019 ...

Page 3: ...nfiguration and function 15 4 6 Scope of supply 17 4 7 Dimensions and weights 18 4 8 Accessories 19 5 Installation at Site 21 5 1 Safety regulations 21 5 2 Checks to be carried out prior to installation 21 5 3 Preparing the collecting tank 22 5 3 1 Inlet nozzles and vent nozzles 22 5 3 2 Discharge side connection 23 5 3 3 Drain 24 5 3 4 Fitting the profile joint for the discharge line 25 5 3 5 Fit...

Page 4: ... 49 6 3 Returning to service 49 7 Servicing Maintenance 50 7 1 Safety regulations 50 7 2 Servicing inspection 51 7 3 Drainage disposal 51 7 4 Recommended spare parts stock 51 8 Trouble shooting 52 9 Related Documents 53 9 1 General assembly drawings 53 9 1 1 Evamatic Box N 200 l transportable version with Ama Porter 53 9 1 2 Evamatic Box N 200 l stationary version with Ama Porter 54 9 1 3 Evamatic...

Page 5: ... back from the discharge line into the lifting unit Domestic waste water Faecal free waste water grey water from washbasins showers washing machines etc 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 sites It defines general requirements as well as principles of construction and testin...

Page 6: ...rtly 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 of trained and qualified specialist technical personnel ð Section 2 2 Page 8 1 4 Other applicable documents Table 1 Overview of other applicable documents Document Contents Sub supplier product literature Operating manuals and other prod...

Page 7: ...ON CAUTION This signal word 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 this symbol indicates a hazard which will or could result in death or serious injury Electrical hazard In conjunction with one of the signal words this symbol indicates a hazard involving electrical voltage and identi...

Page 8: ...ate The operator is responsible for ensuring compliance with all local regulations not taken into account 2 2 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 mus...

Page 9: ...e use of other parts can invalidate any liability of the manufacturer for resulting damage The operator ensures that maintenance inspection and installation are 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 ha...

Page 10: ...maximum flow rate indicated in the data sheet or product literature to prevent overheating mechanical seal damage cavitation damage bearing damage etc Do not throttle the flow rate on the inlet side of the lifting unit to prevent cavitation damage Consult the manufacturer about any use or mode of operation not described in the data sheet or product literature Never exceed the permissible applicati...

Page 11: ...he corresponding weight has been selected and is on hand ð Section 4 7 Page 18 1 Check for any in transit damage 2 Transport the waste water pump station to the place of installation 3 Carefully place down the waste water pump station at the site of installation 3 3 Storage preservation CAUTION Damage during storage due to frost humidity dirt UV radiation or vermin Corrosion contamination of the l...

Page 12: ...te www ksb com certificate_of_decontamination 3 5 Disposal WARNING Fluids handled consumables and supplies which are hot and or pose a health hazard Hazard to persons and the environment Collect and properly dispose of flushing fluid and any fluid residues Wear safety clothing and a protective mask if required Observe all legal regulations on the disposal of fluids posing a health hazard 1 Dismant...

Page 13: ...marex NS 32 5 Ama Porter 6 Ama Porter E Motor version E Single phase AC motor D Three phase asynchronous motor 1 Start capacitor 1 Without start capacitor B With start capacitor P Installation type P Transportable mounted on 3 pump feet S Stationary mounted on flanged bend M As delivered condition M Collecting tank fully assembled K Collecting tank as assembly kit 4 3 Name plate The pump station i...

Page 14: ...ture switch Three phase asynchronous motor 50 Hz 400 V DOL starting Enclosure IP68 permanently submerged to EN 60529 IEC 529 Thermal class F Shaft seal Drive end Shaft seal ring Pump end 1 bi rotational mechanical seal with oil reservoir filled with environmentally friendly oil Impeller type Various application oriented impeller types Bearings Grease packed bearings sealed for life Automation KSB ...

Page 15: ...motor pump 6 an inlet nozzle 2 and a vent nozzle 2 8 options available for selection as well as a discharge line 5 Function The fluid handled flows into the pump station through the inlet nozzle 2 and is collected in a gas odour and water tight tank 1 made of polyethylene As soon as the float switch 3 detects a defined fill level the submersible motor pump 6 is started up automatically The fluid h...

Page 16: ... as well as two discharge lines 5 Function The fluid handled flows into the pump station through the inlet nozzle 2 or 3 and is collected in a gas odour and water tight tank 1 made of polyethylene As soon as the float switch 9 detects a defined fill level the first submersible motor pump 6 is started up automatically The fluid handled is pumped off through the discharge line to a level above the f...

Page 17: ... line fully assembled Ama Porter pump with single phase motor and float switch or Amarex N S 32 pump with three phase motor and float switch foot mounted Power cable Cable grommet or PG cable gland Lifting chain made of stainless steel 1 4401 The cover is mounted temporarily fastened with 2 screws the remaining 10 screws are in a bag inside the collecting tank 8 nozzle options for inlet and ventin...

Page 18: ...s the remaining 10 screws are in a bag inside the collecting tank 12 nozzle options for inlet and venting from DN 50 to DN 150 for cutting open DN 40 drain nozzle for cutting open 4 7 Dimensions and weights Dimensions For the dimensions refer to the outline drawings of the station Weights Table 5 Approximate weights for Evamatic Box N Size kg 132 U D S 61 1500 E P 1503 E P 54 1601 E P 1603 E P 64 ...

Page 19: ...asing adapters or reducing adapters Level adjusting piece height 300 mm Fig 3 Level adjusting piece Part No Description Quantity 412 O ring 1 513 21 Level adjusting piece 1 550 Disc 12 900 Bolt screw 12 IP68 cable connectors Fig 4 Cable connectors for fitting at the cover For connecting the power cables of the pump sets and float switches inside the collecting tanks Scope of supply cable support t...

Page 20: ...ox N Self adhesive noise reduction pads made of natural rubber Fig 5 Noise reduction pads for fitting on the floor of the collecting tank Noise reduction pads for reducing noise emission and vibrations during operation inside buildings ...

Page 21: ...esidual 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 DANGER Insufficient preparation of work Risk of injury Wear personal pr...

Page 22: ...on proof pumps for handling water containing faeces this system must not be used for this specific fluid 5 3 Preparing the collecting tank 5 3 1 Inlet nozzles and vent nozzles The collecting tanks are fitted with a selection of inlet and vent nozzles of various sizes and alignments DANGER No vent line fitted Explosion hazard from gas accumulation Always make sure that a vent line is fitted Evamati...

Page 23: ...ecting tank cannot be used Always provide openings in the correct places at the correct distance with the correct diameter Evamatic Box N 200 litres 1 Cut an opening with a suitable hole saw Height 663 mm from the floor Recess number 3 Diameter Ø 67 1 for pipe DN 50 PVC pipe diameter Ø 63 Ø 79 1 for pipe DN 65 PVC pipe diameter Ø 75 ...

Page 24: ...67 1 for pipe DN 50 PVC pipe diameter Ø 63 Ø 79 1 for pipe DN 65 PVC pipe diameter Ø 75 5 3 3 Drain The 200 litre pump station is fitted with two opposite closed DN 40 drain nozzles in its lower part The 500 litre pump station is fitted with one closed DN 40 drain nozzle in its lower part One nozzle can be opened and connected to a manual pump to facilitate draining of the fluid for maintenance or...

Page 25: ...e discharge line at the collecting tank 4 Remove any sealant residues from the collecting tank 5 3 5 Fitting the O ring for the tank cover 1 Thoroughly clean the seal groove on the tank 2 Generously cover the bottom of the groove with sealant This is of particular importance when installing pump stations in buildings to ensure the pump station is odour proof 3 Thoroughly press the O ring into the ...

Page 26: ...ipe anywhere else in the piping system NOTE Use special glue suitable for PVC for fitting and sealing the cylindrical parts 1 Seal the pipe unions with Teflon tape or sealant 2 Fit the parts and make sure they are correctly seated Check that the lift check valve is fitted for the correct direction of flow Observe the alignment of the discharge line protruding from the collecting tank alignment of ...

Page 27: ...the lift check valve is fitted for the correct direction of flow 5 Seal threaded socket 731 and screw it to lift check valve 742 6 Check that the joint ring has been fitted in the discharge nozzle Fasten the pre assembled piping with screws 901 2 discs 550 and nuts 920 to the pump 7 Fasten elbow 13 18 to pipe 710 2 and secure it with glue 8 Fasten pipe adapter 730 to pipe 710 2 and secure it with ...

Page 28: ...hreaded socket 731 15 Move outlet pipe 710 1 back by approx 50 mm 16 Fasten the pre assembled piping consisting of elbow 13 18 pipe 710 2 and pipe adapters 730 to outlet pipe 710 3 Align and secure with glue 17 Quickly press outlet pipe 710 1 into pipe adapter 730 and secure the connection with glue Hold the entire piping tightly in position for this step 18 Move the pump back as far as possible t...

Page 29: ...w 144 and screw it to flanged bend 72 1 4 Seal male threaded fitting 720 and screw it to elbow 144 5 Seal lift check valve 742 and screw it to male threaded fitting 720 Check that the lift check valve is fitted for the correct direction of flow 6 Seal threaded socket 731 and screw it to lift check valve 742 7 Fasten outlet pipe 710 1 to the collecting tank ð Section 5 5 2 Page 37 8 Position the ba...

Page 30: ...ameter of 75 mm 11 Shorten pipe 710 3 to match the calculated length X 12 Glue pipe 710 3 to threaded socket 731 13 Move outlet pipe 710 1 back by approx 50 mm 14 Fasten elbow 13 18 to pipe 710 3 align it and secure it with glue 15 Quickly press outlet pipe 710 1 into pipe adapter 730 and secure the connection with glue Hold the entire piping tightly in position for this step ...

Page 31: ...bow 144 and screw it to flanged bend 72 1 4 Seal male threaded fitting 720 and screw it to elbow 144 5 Seal lift check valve 742 and screw it to male threaded fitting 720 Check that the lift check valve is fitted for the correct direction of flow 6 Seal threaded socket 731 and screw it to lift check valve 742 7 Fasten outlet pipe 710 1 to the collecting tank ð Section 5 5 2 Page 37 8 Position the ...

Page 32: ...ameter of 75 mm 11 Shorten pipe 710 3 to match the calculated length X 12 Glue pipe 710 3 to threaded socket 731 13 Move outlet pipe 710 1 back by approx 50 mm 14 Fasten elbow 13 18 to pipe 710 3 align it and secure it with glue 15 Quickly press outlet pipe 710 1 into pipe adapter 730 and secure the connection with glue Hold the entire piping tightly in position for this step ...

Page 33: ...571 into the grooves provided for this purpose in flanged bend 72 1 2 Fasten flanged bend 72 1 with screws 901 2 discs 550 and nuts 920 to baseplate 890 Move the flanged bend as far as possible towards the discharge side and install it in this position to allow the float switches to move freely 3 Seal male threaded fitting 720 and screw it to flanged bend 72 1 4 Seal elbow 144 and screw it to male...

Page 34: ...is purpose ð Section 5 5 2 Page 37 11 Fasten the assembly consisting of elbow 13 18 lift check valve 742 and sockets 731 and 731 1 to pipe 710 1 without using glue 12 Accurately measure dimension A Fig 13 Calculating length X ð The length of pipe 710 3 equals X A 2 38 for an outside diameter of 63 mm X A 2 44 for an outside diameter of 75 mm 13 Shorten pipe 710 3 to match the calculated length X 1...

Page 35: ...rved An incorrect pipe alignment would lead to impermissible tension and leakage at the connections and sockets 5 Seal first threaded socket 731 and screw it to elbow 144 6 Guide pipe 710 3 into threaded socket 731 until it will not go any further Secure it with glue 7 Seal second threaded socket 731 and screw it to lift check valve 742 8 Guide the assembly unit consisting of the lift check valve ...

Page 36: ... clamp holder 81 73 to the tank with the screw supplied for this purpose A protrusion for inserting the screw is provided on the outside of the tank Use this precise position when fitting the clamp holder 4 Fasten the clamp to clamp holder 81 73 and tighten it 5 Attach hook 59 18 to the clamp 6 Fasten the shackle and chain 885 to the pump handle 7 Lower the submersible motor pump with the fitted p...

Page 37: ...not alter the original condition of the cable grommet seat 3 Fasten clamp holder 81 73 to the tank with the screw supplied for this purpose A protrusion for inserting the screw is provided on the outside of the tank Use this precise position when fitting the clamp holder 4 Fasten the clamp to clamp holder 81 73 and tighten it 5 Attach hook 59 18 to the clamp 6 Fasten the shackle and chain 885 to t...

Page 38: ...er 25 1 mm for fitting PG cable gland 45 3 for the power cable of the pump 7 1 5 mm Use the marking in a central position of the tank provided for drilling the hole Alternatively for tanks installed underfloor the power cable of the pump can be guided through the vent nozzle In this case do not drill any holes for the PG cable glands NOTE For fitting PG cable glands 45 3 gasket 400 must be fitted ...

Page 39: ...uide the claw into the hoop and slowly lower the pump into the tank 6 Fit the three supplied clamp holders for fastening the power cable in the tank 7 Fasten the power cable Protrusions for inserting the screws are provided on the outside of the tank Use these precise positions when fitting the clamp holders 8 Pull the float switch cable through cable grommet 916 Press the cable grommet into its s...

Page 40: ...400 must be fitted on the outside of the tank 2 Fasten the two clamp holders 81 73 to the tank with the screws supplied for this purpose Two protrusions for inserting the screws are provided on the outside of the tank Use these precise positions when fitting the clamp holders 3 Fasten the clamps to clamp holders 81 73 and tighten them 4 Attach the two hooks 59 18 to the clamps 5 Fasten the shackle...

Page 41: ... tank Use these precise positions when fitting the clamp holders NOTE KSB supplies optional cable connectors for connecting the power cables for pumps and float switches inside the tanks When cable connectors are used the power cables do not need to be disconnected in the control cabinet and pulled out through the PG cable glands of the tank or the vent line for removing the submersible motor pump...

Page 42: ...e pre assembled piping of the first pump into the tank and position the baseplate on the protrusion provided for this purpose see arrow A ð Section 5 4 4 Page 33 7 Adjust the pipe position by moving the foot 72 1 along baseplate 890 8 Move outlet pipe 710 1 into socket 731 until it will not go any further Secure it with glue 9 Attach chain 885 to hook 59 18 10 Install the second piping assembly as...

Page 43: ... from any traces of sealant 6 Mount the cover and fasten it with screws 900 and discs 550 7 Tighten the screws in the order shown below see illustration to a torque of 2 Nm 5 7 Installing the pump station DANGER No vent line fitted Explosion hazard from gas accumulation Always make sure that a vent line is fitted CAUTION Danger of frost Damage to pipelines and pump Observe the frost protection mea...

Page 44: ...e sure that all preparatory and connection work at pump and piping has been completed NOTE KSB recommends connecting the piping with commercially available System J spigot and socket connections This system allows for PVC sockets to be fitted and glued in NOTE Guide the power cable s through the vent nozzle Do not alter the original condition of the cable grommet seat Do not drill any holes for th...

Page 45: ...ith extreme climatic conditions the use of a second level adjusting piece is permitted as long as the pump in the tank is mounted on a foot Never fit more than 2 level adjusting pieces 7 If the sump floor is made of concrete fasten the collecting tank to the sump floor at the two anchor points with composite anchor bolts 8 Fill the collecting tank with water 9 Fill the sump with sand Compact the s...

Page 46: ...es 4 Fasten the collecting tank to the floor at the two anchor points with composite anchor bolts CAUTION Transport lock not removed Damage to the machinery Prior to commissioning a pump station which has been supplied completely assembled always remove the transport lock of the pump NOTE As an option KSB offers a set of eight noise reduction pads made of natural rubber which can be stuck to the b...

Page 47: ...ed Every time the existing installation is modified retrospectively overvoltage protection to VDE must be retrofitted The maximum cable length between the surge arrester usually type 1 internal lightning protection at the point where electricity enters the building and the device to be protected should not exceed 10 m For longer cables additional surge arresters type 2 must be fitted in the upstre...

Page 48: ...ghtness and re sealed if required The operating manual of the pump set has been taken into account The transport lock of the pump in the collecting tank has been removed 6 1 2 Starting up switching off the pump set The pump set has been properly connected to the electric power supply The pump s automatic control system will automatically cut in or out when the respective specified levels are reach...

Page 49: ...e fluids posing a health hazard must be decontaminated 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 system from the power supply and protect it against inadvertent start up 2 Pull the pump s out of the system 3 Flush the system as per operating instructions 4 Leave the system to dry Special pr...

Page 50: ... DANGER Insufficient preparation of work Risk of injury Wear personal protective equipment PPE for all work WARNING Insufficient stability Risk of crushing hands and feet During assembly dismantling secure the pump set pump parts to prevent tilting or tipping over The operator ensures that maintenance inspection and installation are performed by authorised qualified specialist personnel who are th...

Page 51: ...r lifting units installed in industrial businesses Every 1 2 year for lifting units in multiple dwelling buildings Every year for lifting units installed in single family houses 7 3 Drainage disposal WARNING Fluids handled consumables and supplies which are hot and or pose a health hazard Hazard to persons and the environment Collect and properly dispose of flushing fluid and any fluid residues We...

Page 52: ...he 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 components Replace worn components by new ones Defective riser pipe and sealing element Fit new riser pipes Fit new sealing elements Wrong direction of rotation three phase drive Check the electrical connection Pump clogged by san...

Page 53: ...59 18 885 410 655 156 591 916 550 900 550 900 160 74 4 Fig 28 Exploded view of the transportable version Part No Description Part No Description 156 Discharge nozzle 591 Collecting tank 160 Cover 655 Pump 410 Profile seal 74 4 Float switch 412 O ring 81 73 Cable support 513 21 Level adjusting piece 1 x O ring 412 optional 885 Chain 550 Disc 900 Bolt screw 59 18 Hook 916 Cable grommet ...

Page 54: ...0 732 72 1 890 571 Fig 29 Exploded view of the stationary version Part No Description Part No Description 156 Discharge nozzle 591 Collecting tank 160 Cover 655 Pump 410 Profile seal 72 1 Flanged bend 412 O ring 81 73 Cable support 513 21 Level adjusting piece 1 x O ring 412 optional 885 Chain 550 Disc 890 Baseplate 571 Guide hoop 900 Bolt screw 59 18 Hook 916 Cable grommet ...

Page 55: ...74 4 Fig 30 Exploded view of the stationary version Part No Description Part No Description 156 Discharge nozzle 591 Collecting tank 160 Cover 655 Pump 45 3 Wall stuffing box 72 1 Flanged bend 410 Profile seal 74 4 Float switch 412 O ring 81 73 Cable support 513 21 Level adjusting piece 1 x O ring 412 optional 885 Chain 550 Disc 890 Baseplate 571 Guide hoop 900 Bolt screw 59 18 Hook 916 Cable grom...

Page 56: ...versions with horizontal and vertical discharge outlet Part No Description Part No Description A Version with horizontal discharge outlet 59 18 Hook B Version with vertical discharge outlet 591 Collecting tank 156 Discharge nozzle 655 Pump 160 Cover 72 1 Flanged bend 410 Profile seal 81 45 Float switch 45 3 Wall stuffing box 81 73 Cable support 412 O ring 885 Chain 513 21 Level adjusting piece 1 x...

Page 57: ... N 16 663 Ø 650 Ø 630 890 90 50 X X X X 620 Ø 710 DN50 DN70 DN70 DN100 DN70 DN50 DN100 DN150 Ø 110 Ø 78 Ø 78 Ø 58 420 420 60 70 70 60 50 70 470 410 100 80 Ø 78 Ø 58 Ø110 Ø 159 DN40 DN40 Y Y Y Y Ø 49 55 350 700 12 931 530 40 48 A B Evamatic Box N 132 U Ø 63 Evamatic Box N 15 Fig 32 Outline drawing of Evamatic Box N 200 l A Transportable version B Stationary version ...

Page 58: ...975 DN40 DN100 DN150 DN50 DN70 DN100 DN70 DN70 DN50 170 Y Y 170 580 280 Ø 78 DN50 DN70 DN70 DN100 Ø 58 Ø 110 Ø 78 967 730 70 730 967 70 Ø 880 Ø 960 840 12 473 Ø 630 998 845 730 Ø 49 55 48 Ø 58 Ø 78 Ø 78 Ø 110 X X 70 70 1090 280 Ø 58 Ø 78 80 70 Ø 159 Ø 110 A B Fig 33 Outline drawing Evamatic Box N 500 l stationary installation A Discharge line outlet horizontal B Discharge line outlet vertical ...

Page 59: ...tallation 1 Vent line 2 Inlet line 3 Discharge line 4 Public sewer system Installation underfloor 1 3 5 2 4 6 Fig 35 Installation drawing for underfloor installation 1 Inlet line 2 Vent line 3 Discharge line 4 Evamatic Box N collecting tank 5 Sand or gravel compact thoroughly prior to installing the tank 6 Sand compact evenly while filling the sump ...

Page 60: ... is in conformity with the provisions of the following Regulations as amended from time to time Construction Products Regulation 305 2011 EU Applied harmonised standards EN 12050 1 Certified by TÜV Rheinland LGA Products GmbH 0197 The EU Declaration of Conformity was issued in on Frankenthal 1 February 2018 Thomas Heng Head of Product Development Series Pumps KSB SE Co KGaA Johann Klein Straße 9 6...

Page 61: ...arrier plain bearing inner rotor has been removed from the pump and 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 rotor and plain bearing have been removed from the pump for cleaning In cases of leakage at the stator can the stator space has been exam...

Page 62: ...E Event of damage 6 F Faults Causes and remedies 52 I Impeller type 14 Installation 14 Intended use 9 K Key to safety symbols markings 7 O Operating limits 9 Other applicable documents 6 P Partly completed machinery 6 Product description 13 R Return to supplier 12 Returning to service 49 S Safety 8 Safety awareness 9 Scope of supply 17 Shaft seal 14 Shutdown 48 49 Start up 48 W Warnings 7 Warranty...

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Page 64: ...KSB S A S 128 rue Carnot 59320 Sequedin France Tél 33 3 2022 7000 Fax 33 3 2022 7099 www ksb com 2321 83 04 EN ...

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KSB Evamatic-Box N 200 I, Installation & Operating Manual

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