KSB mini-Compacta 2013w01 Series Installation & Operating Manual Download Page 1

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Floodable Sewage Lifting Unit

mini-Compacta

From Series S-Y/1
From Series 2013w01

Installation/Operating Manual

Summary of Contents for mini-Compacta 2013w01 Series

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

Page 2: ...tents 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 manufac...

Page 3: ...13 3 4 Return to supplier 13 3 5 Disposal 14 4 Description 15 4 1 General description 15 4 2 Designation 15 4 3 Name plates 17 4 4 Design details 18 4 5 Configuration and function 19 4 6 Technical da...

Page 4: ...ly 52 8 3 4 Removing the rotating assembly 53 8 3 5 Dismantling the motor section 53 8 4 Reassembly 54 8 4 1 General instructions 54 8 4 2 Installing the bearing assembly shaft seal 54 8 4 3 Fitting t...

Page 5: ...ase 1 93 10 6 2 LevelControl Basic 1 three phase 3 94 10 6 3 LevelControl Basic 2 Type BC dual pump unit up to 1 5 kW 1 95 10 6 4 LevelControl Basic 2 Type BC single pump unit with cutter up to 1 5 kW...

Page 6: ...s and sites EN 12050 1 European Standard for sewage lifting units which are used to dispose of sewage with faeces occurring below the flood level of buildings and land It defines general requirements...

Page 7: ...rget group of trained and qualified specialist technical personnel Section 2 3 Page 9 1 4 Other applicable documents Table 1 Overview of other applicable documents Document Contents Sub supplier produ...

Page 8: ...es in accordance with EU Directive 2014 34 EU ATEX 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 Elect...

Page 9: ...eres 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 Do not operate p...

Page 10: ...ions 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 protectiv...

Page 11: ...vices Before returning the product to service observe all instructions on commissioning Make sure the lifting unit cannot be accessed by unauthorised persons e g children 2 8 Unauthorised modes of ope...

Page 12: ...nts Never suspend the lifting unit by its power cable Use suitable and permitted transport equipment e g crane forklift or pallet truck Table 4 Weight Sizes Weight1 kg US1 40D US1 40E 37 37 U1 60D U1...

Page 13: ...cap screws 914 04 2 Remove rotating assembly 01 44 from plate 185 01 using two forcing screws M8 3 Lift rotating assembly 01 44 out of collecting tank 591 4 Preserve rotating assembly 01 44 with oil 5...

Page 14: ...he waste water lifting unit 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 Dispos...

Page 15: ...otor D Three phase asynchronous motor E Single phase AC motor C Material C Variant for aggressive fluids 2 Standard variant for domestic waste water and faeces Control unit Example BC 2 400 D V N A 10...

Page 16: ...EX functions A Installation variants O Standard A With rechargeable battery M With motor protection switch if not included in standard version N With rechargeable battery and motor protection switch i...

Page 17: ...50 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 Johann Klein Stra e 9 Deutschland 67227 Frankenthal KSB SE Co KGaA Fig 2 Tank name plate exam...

Page 18: ...peller type Free flow impeller Cutter Bearings Grease packed maintenance free rolling element bearings Shaft seal mini Compacta US 40 litres U 60 litres U 100 litres UZ 150 litres Impeller end 1 shaft...

Page 19: ...be handled flows into the waste water lifting unit through the selected horizontal or vertical inlet nozzle 1 and is collected in a gas tight odour tight and water tight collecting tank 10 The liftin...

Page 20: ...control and monitoring unit in compact plastic housing For either one or two pumps With display Level detection via Level sensor 0 5 V DOL starting 2 3 1 Fig 6 Type Basic Compact BC 1 Master switch 2...

Page 21: ...V AC 10 10 1 230 V AC 10 10 Mains frequency 50 Hz 2 Enclosure 400 V IP54 230 V IP54 Insulation voltage 500 V AC Nominal motor current 10 A 4 6 1 1 Sensors LevelControl Basic 1 Analog level sensor Inpu...

Page 22: ...4 A 18 A 23 A 25 A 40 A 63 A 4 6 2 1 Sensors LevelControl Basic 2 Analog level sensor Input voltage 0 5 V Motor protection Thermal circuit breaker bimetal 24 V Inputs 1 external alarm input via volt f...

Page 23: ...ater a grease separator to DIN 4040 1 must be fitted Variant C for aggressive fluids Additional permissible fluids In addition to the fluids approved for the standard variant this lifting unit is also...

Page 24: ...ensor Level dependent control unit 4 11 Dimensions and weights available For dimensions and weights please refer to the outline drawing of the lifting unit Control unit Table 11 Dimensions and weights...

Page 25: ...es A failure of the lifting unit can cause damage to property by flooding due to the risk of backflow from the sewage system Fit operator supplied mains independent alarm equipment e g alarm switchgea...

Page 26: ...roved fluid Section 4 7 Page 23 The installation room is frost proof All structural work required has been prepared in accordance with the dimensions stated in the connection example and in EN 12056 T...

Page 27: ...t them without transmitting any stresses or strains Observe the permissible forces and moments at the lifting unit Section 8 7 Page 59 Take appropriate measures to compensate thermal expansion of the...

Page 28: ...rainage Under normal operating conditions the valve closes if the stem has been screwed out as far as it will go NOTE mini Compacta U UZ are fitted with an integrated check valve of DN 80 For UZ dual...

Page 29: ...sure that the connection is smell proof If changes of direction are unavoidable the pipe should be laid with a minimum gradient of 1 50 Drainage nozzle for hand diaphragm pump NOTE To fully drain the...

Page 30: ...0100 534 IEC 60364 5 53 2001 A2 2015 modified Whenever modifications are made to existing installations retrofitting a surge protective device SPD in accordance with VDE is mandatory A maximum cable...

Page 31: ...ipment 5 7 Checking the direction of rotation WARNING Hands or objects inside the tank Risk of personal injury Damage to the lifting unit Never insert your hands or any other objects into the tank Che...

Page 32: ...peration against a closed shut off valve Never exceed the temperatures indicated in the product literature and on the name plate Prevent dry running Observe the following parameters and values during...

Page 33: ...All relevant VDE standards and country specific regulations are complied with The safety regulations are complied with and the technical data of the sewage lifting unit is suitable for the unit s inte...

Page 34: ...60 D Horizontal 100 mm DN 50 OFF OFF OFF OFF Horizontal 180 mm OFF OFF OFF OFF Vertical ON OFF OFF OFF U1 100 E U1 100 D U2 100 E U2 100 D Horizontal 180 mm OFF ON OFF OFF Horizontal 250 mm ON ON OFF...

Page 35: ...he sewage lifting unit is unfilled a sensor fault may be output This fault is cleared as soon as the unit is filled Functional test Test run the lifting unit for several fill and pump off cycles and c...

Page 36: ...2 closed Off Interval tone TCB fault acknowledged Steady red Contact 11 12 closed Off Off TCB fault gone unacknowledged Flashing red Contact 11 14 closed Depending on filling level Interval tone TCB f...

Page 37: ...Basic 2 Settings for the collecting tank To reduce the frequency of starts the lowest open inlet nozzle can be selected at the control unit 1 Press the ESC key until the level is displayed 2 Press the...

Page 38: ...the unit to the power supply No fault message Correct connection Alarm A12 Reverse the rotary field of the power supply inside the control unit 2 Check the direction of rotation of the pump set at the...

Page 39: ...be connected to the Ack terminals 6 3 2 1 5 Output for horn or signal light A horn or signal light 12 V DC max 200 mA can be connected 6 4 Shutdown 1 Pump off the tank contents 2 Shut off the inlet a...

Page 40: ...l instructions refer to both the pump sets For single pump lifting units the steps only have to be carried out for one pump set Operation via Manual 0 automatic selector switch Section 7 2 Page 42 Con...

Page 41: ...set is OFF manual 0 automatic selector switch set to 0 Flashing yellow Pump set is in manual mode manual 0 automatic selector switch set to manual Red Pump set is locked when an alarm is active or no...

Page 42: ...h 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 The pump is switched off Switch l...

Page 43: ...are displayed Table 23 Displaying and adjusting parameters and parameter values Esc OK Step 1 Activating the setting mode 1 Press and hold the ESC key and press the OK key P 3 3 2 is displayed Step 2...

Page 44: ...parameter value has not been confirmed 1 To cancel the changed value press the ESC key The parameter value remains unchanged The display shows the selected parameter Esc Step 6 Leaving the setting mod...

Page 45: ...uto acknowledgement Automatic deactivation and acknowledgement as soon as the cause or the fault has been rectified Manual acknowledgement is possible Table 25 Displaying and acknowledging fault messa...

Page 46: ...0 V No action Auto A15 15 Flat battery No action Auto A16 16 Service interval system No action deactivated by default can be set via the KSB ServiceTool Auto 7 3 4 Displaying the alerts list The alert...

Page 47: ...o ensure that the device operates reliably in battery mode Use original KSB spare parts only 1 Switch off the power supply 2 Open the control unit 3 Disconnect the battery 4 Undo the battery clamp 5 R...

Page 48: ...a health hazard 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 he...

Page 49: ...he insulation resistance at the cable ends with an insulation resistance measuring device The insulation resistance must be 2 M Measuring voltage at 3 400 V AC 1000 V DC Measuring voltage at 1 230 V A...

Page 50: ...ee Fig 903 02 411 03 Fig 24 Filling the oil reservoir 7 Fit screw plug 903 2 together with joint ring 411 03 Table 29 Condition of oil Condition of oil Action Oil emulsion yellowish to white Oil can b...

Page 51: ...pump to Automatic This pump will now be started and stopped automatically via the level sensor 7 Open the inlet side and discharge side gate valves CAUTION Excessive inflow Flooding of installation r...

Page 52: ...le object e g a cylinder diam 15 x 15 mm against the face of shaft 210 and use the screw plug to press the shaft out of motor housing 811 4 Remove O ring 412 01 and circlip 932 from the casing cover 5...

Page 53: ...10 6 Take off cutter 23 14 7 Prise off impeller 230 by inserting a screwdriver into the grooves in the impeller shroud and casing cover 161 respectively 8 Remove key 940 9 Remove circlip 932 02 and su...

Page 54: ...original spare parts Make sure that the sealing surfaces are clean and that O rings are properly seated We recommend using new O rings gaskets whenever the pump is reassembled CAUTION O rings do not...

Page 55: ...d 3 Fill the grease reservoir with multi purpose grease 99 15 DIN 51 825 4 Slide deep groove ball bearings 321 01 6201 2RSR C3 and 321 02 6305 2RS1 JC3 onto shaft 210 Section 8 2 4 Page 49 5 Guide sha...

Page 56: ...210 through bearing end shield 360 Fasten it above the bearing seat with circlip 932 5 Insert O ring 412 01 6 Fit motor unit 80 1 on rotor 818 with bearing end shield 360 Fasten it with hexagon socke...

Page 57: ...olt hexagon socket head cap screw 914 03 NOTE Cutter and impeller must be easy to rotate by hand Rubbing contact is not permissible Otherwise check the impeller clearance and the tightening torques of...

Page 58: ...rotating assembly 01 44 in casing 100 8 5 Installing the float switch A residual fill level of approx 50 mm is available in the collecting tank Top it up if necessary 1 Install float switch 81 45 incl...

Page 59: ...ni Compacta US40 Connection Tightening torque Nm Float switch 81 45 collecting tank 2 Bearing end shield 360 or pump assembly collecting tank 6 Motor unit 80 1 bearing end shield 360 6 Screw plug 903...

Page 60: ...rials that can be separately recycled Plastic components are marked in accordance with ISO 11 469 8 9 Checklist for commissioning inspection and maintenance Table 32 Checklist Actions Required during...

Page 61: ...IN 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 y...

Page 62: ...e Pump is running in the off design range Check the pump s operating data Pump or piping are not completely vented Check the vent lines of lifting unit pumps Pump intake clogged by deposits Clean the...

Page 63: ...efective radial bearing in the motor Contact the manufacturer Cutter is blocked on US UZS Excessive solids content Impermissible solids Unblock the cutter Section 8 2 3 Page 49 Deposits in the collect...

Page 64: ...10 1 1 mini Compacta U60 U100 UZ150 Rotating assembly UG 1088985 Bl 1 903 01 411 01 80 1 811 81 59 412 01 826 824 412 11 932 321 02 161 412 12 230 01 44 210 321 01 02 821 932 550 01 321 01 818 6x 914...

Page 65: ...r 99 20 01 Bearing repair kit 230 Impeller 321 01 02 Deep groove ball bearing 412 01 O ring 421 01 02 Lip seal 412 11 12 O ring 550 01 02 Disc 80 1 Motor unit 550 03 Support disc 411 01 Joint ring 920...

Page 66: ...Part No Description 01 44 Rotating assembly 99 20 01 Bearing shaft seal repair kit 161 Casing cover 321 01 Deep groove ball bearing 230 Impeller 321 02 Deep groove ball bearing 330 Bearing bracket 41...

Page 67: ...o Description 210 Shaft 550 02 Disc 321 01 02 Deep groove ball bearing 550 03 08 Support disc 821 Rotor core pack 550 04 Disc 932 01 Circlip 903 01 02 Screw plug 99 15 Lubricating oil 914 01 Hexagon s...

Page 68: ...on Part No Part No Description 160 Cover 81 45 Level sensor 400 Gasket 412 31 O ring 412 31 O ring 550 31 Disc 412 41 O ring 81 45 Level sensor 550 05 Disc 914 31 Hexagon socket head cap screw 551 Spa...

Page 69: ...9 of 104 mini Compacta 2317 886 16 EN Part No Part No Description Part No Part No Description 746 Valve disc 920 04 Hexagon nut 900 21 Screw 99 3 2 Set of pads 903 21 Screw plug B5 Vent 914 21 Hexagon...

Page 70: ...04 733 03 81 45 99 3 2 722 B5 Fig 38 Exploded view of mini Compacta UZ150 Collecting tank Part No Part No Description Part No Part No Description 160 Cover 81 45 Level sensor 400 Gasket 412 31 O ring...

Page 71: ...accessories 732 Bracket 400 Gasket 733 01 02 03 05 Hose clip 550 04 Disc 747 Check valve 551 Spacer disc 100 Body 901 04 Hexagon head bolt 132 Intermediate piece 920 04 Hexagon nut 411 21 Joint ring...

Page 72: ...824 811 81 59 903 01 411 01 421 01 321 02 932 412 02 360 6x 914 01 6x 550 01 8x 914 02 8x 550 02 99 15 23 14 500 421 02 210 321 01 02 821 932 818 321 01 550 06 55 2 551 102 411 02 400 742 914 05 550...

Page 73: ...mbly Part No Part No Description Part No Part No Description 01 44 Rotating assembly 99 20 01 Bearing shaft seal ring repair kit 102 Volute casing with elbow 321 01 02 Deep groove ball bearing 23 14 C...

Page 74: ...int ring 55 2 Support disc 412 01 O ring 903 01 Screw plug 811 Motor housing 550 03 04 05 Disc 81 59 Stator 914 03 04 05 Hexagon socket head cap screw 824 Cable 99 20 03 Screws repair kit 826 Cable gl...

Page 75: ...2x 550 03 B5 433 343 330 8x 914 04 8x 550 04 161 321 02 421 01 818 932 01 821 321 01 025 210 321 01 932 01 2x 914 07 2x 550 07 903 02 411 02 99 15 72 1 412 06 412 05 14x 914 06 14x 550 06 185 920 80 1...

Page 76: ...3 14 562 920 230 412 04 330 321 02 932 01 932 02 550 02 433 421 01 940 412 02 903 02 411 02 161 818 8x 914 04 8x 550 04 210 321 01 02 821 932 01 321 01 Fig 42 Exploded view US100 UZS150 Rotating assem...

Page 77: ...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 550 01 03 07 Disc 412 01 O ring 550 02...

Page 78: ...732 2x 901 05 2x 90 3 Fig 43 Exploded view of mini Compacta US40 collecting tank Part No Part No Description Part No Part No Description 160 Cover 81 99 Rechargeable battery 412 31 41 O ring 82 16 Co...

Page 79: ...0 05 90 3 Fig 44 Exploded view of mini Compacta US100 collecting tank Part No Part No Description Part No Part No Description 160 Cover 81 99 Rechargeable battery 412 31 41 O ring 82 16 Control unit 5...

Page 80: ...2 99 3 2 732 Fig 45 Exploded view of mini Compacta UZS150 collecting tank Part No Part No Description Part No Part No Description 160 Cover 81 99 Rechargeable battery 412 31 41 O ring 92 16 Control u...

Page 81: ...ctions for servicing work 1 1 b c 1 a DN 50 690 35 240 DN 100 DN 150 500 240 95 225 86 DN 50 DN 100 300 500 DN 40 DN 32 DN 100 500 300 500 300 DN 50 DN 50 DN 100 500 DN 40 DN 100 DN 50 DN 80 DN 100 DN...

Page 82: ...f 104 mini Compacta 2317 886 16 EN 10 2 2 mini Compacta UZ150 UZS150 NOTE Provide sufficient clearance at least 600 mm in all directions for servicing work 1 Fig 47 Connection example mini Compacta UZ...

Page 83: ...0 x 600 mm as a minimum The opening can be covered with either a removable panel or a door 600 400 400 2 1 Fig 48 Installation concealed in a pre wall system 1 Provide an opening of 400 x 600 mm or la...

Page 84: ...and U60 1 a b 180 255 90 240 180 240 310 75 100 72 320 310 86 650 100 180 300 340 400 405 370 355 50 A A 65 85 315 540 155 80 65 230 510 20 510 180 100 50 340 455 225 DN 40 130 DN 50 450 DN 100 DN 80...

Page 85: ...10 Related Documents 85 of 104 mini Compacta 2317 886 16 EN 10 3 2 mini Compacta U100 and US100 1 a b Fig 50 mini Compacta a U100 and b US100 dimensions 1 With gate valve 745 mm...

Page 86: ...10 Related Documents 86 of 104 mini Compacta 2317 886 16 EN 10 3 3 mini Compacta UZ150 and UZS150 1 a b Fig 51 mini Compacta a UZ150 and b UZS150 dimensions 1 With gate valve 1005 mm...

Page 87: ...10 90 60 60 300 450 DN 100 DN 150 Fig 52 Dimensions of the inlet line with grey cast iron and PVC gate valve mini Compacta US40 U60 U100 US100 1 Tank connection 10 3 4 2 Inlet line UZ150 UZS150 JL PVC...

Page 88: ...20 max 40 min 20 max 40 108 400 DN 32 135 82 175 DN 32 DN 50 DN 50 DN 32 DN 50 DN 32 DN 50 330 340 250 60 90 45 160 Fig 54 Dimensions of the discharge line of mini Compacta a US40 b U60 U100 and c US1...

Page 89: ...Number Connection for Inlet DN 100 Inlet DN 100 Inlet DN 100 Inlet DN 100 Inlet DN 100 50 Inlet DN 100 50 Inlet DN 50 Inlet DN 50 8 Drain DN 40 Drain DN 40 Vent DN 50 Vent DN 50 Discharge line G 1 1...

Page 90: ...d b US100 Table 36 Connections of mini Compacta U100 and US100 Number Connection for Number Connection for Inlet DN 150 100 Inlet DN 150 100 Inlet DN 150 100 Inlet DN 150 100 Inlet DN 150 100 Inlet DN...

Page 91: ...ble 37 Connections of mini Compacta UZ150 and UZS150 Number Connection for Number Connection for Inlet DN 150 100 Inlet DN 100 50 Inlet DN 100 50 Inlet DN 150 100 Inlet DN 150 100 Inlet DN 150 100 Inl...

Page 92: ...s of connection mini Compacta US40 U60 U100 US100 Connection to a floor mounted toilet bowl mini Compacta US40 U60 Connection to wall mounted toilet bowl mini Compacta U100 US100 Connection to wall mo...

Page 93: ...PE Rotary field indicator L2 N 3 4 2 U2 Single phase motor L3 5 6 3 Z2 WSK 230V 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 acousti...

Page 94: ...dicator L2 N 3 4 2 V1 Three phase motor L3 5 6 3 W1 WSK 230V 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...

Page 95: ...3 PE PE PE PE PE P2 S1 H 0 A PE PE 1b X22 P1 M1 1 2 2 P1 Q1 1 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...

Page 96: ...e sensor Motor sensors Standard motor 1 Power supply Max back up fuse 16 A Max connection cross section 2 5 mm 2 General fault message Standard Reviewed by Created on Created by Name Date Amended Orig...

Page 97: ...PE PE L2 122 4 N N N L3 121 5 120 PE PE PE X1 PE PE PE PE P2 M1 209 PE 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 PE PE 1 R1 4 5 X21 4 3 001 P2 Q1 A1 A2 2 002 1 R1 B1 Le...

Page 98: ...N N BU 3 3 PE PE PE PE P2 S1 GN YE H 0 A PE PE 1b X22 Motor 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...

Page 99: ...use of certain hazardous substances in electrical and electronic equipment RoHS 2014 30 EU Electromagnetic Compatibility EMC The manufacturer also declares that the following harmonised international...

Page 100: ...Not relevant Table 38 9 Declared performance Essential characteristics Performance Harmonised technical specification Effectiveness EN 12050 1 2001 Handling of solids Passed Pipe connections Passed V...

Page 101: ...ssment Not relevant Table 39 9 Declared performance Essential characteristics Performance Harmonised technical specification Effectiveness EN 12050 1 2001 Handling of solids Passed Pipe connections Pa...

Page 102: ...over bearing ring carrier 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 bearin...

Page 103: ...es 62 Fluids handled 23 H High water alert 41 I Impeller type 18 Installation at site 26 Insulation resistance 49 Intended use 9 K Key to safety symbols markings 7 L LED display 40 Lubrication Oil qua...

Page 104: ...KSB SE Co KGaA Johann Klein Stra e 9 67227 Frankenthal Germany Tel 49 6233 86 0 www ksb com 2317 886 16 EN 01442639...

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KSB mini-Compacta 2013w01 Series, Installation & Operating Manual

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