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9 Trouble-shooting

WARNING

Improper work to remedy faults
Risk of injury!

▷

For any work to remedy faults observe the relevant information in this manual
or in the relevant accessory manufacturer's product literature.

NOTE

Before performing any work on the pump's internal parts during the warranty

period please always consult the manufacturer. Our after-sales service will be at

your disposal. 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

KSB’s customer service is required.
Pump is running but does not deliver
Insufficient discharge head
Excessive current/power consumption
Insufficient discharge head
Vibrations and noise during pump operation
Lifting unit frequently switches to fault mode

Table 21: Trouble-shooting

A B C D E F Possible cause

Remedy

5)

-

✘ ✘

-

-

✘

Pump delivers against an excessively high
pressure.

Lifting unit is too small for the prevailing
operating conditions.

-

✘

-

-

-

✘

Gate valve in the discharge line is not fully
open.

Fully open the gate valve.

-

-

✘

-

✘ ✘

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 intake, pump components and
collecting tank.

-

✘

-

✘ ✘ ✘

Inlet lines or impeller clogged

Remove deposits in the pump and/or piping.

-

-

✘

-

✘ ✘

Dirt/fibres in the 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.

-

✘

-

✘ ✘ ✘

Impermissible air or gas content in the fluid
handled

Contact KSB.

-

-

✘

-

-

- Operating voltage is too low.

Check mains voltage;
check electrical cable connections

✘

-

-

-

-

- Motor is not running because of lack of

voltage.

Check electrical installation (and fuses).

-

✘ ✘ ✘ ✘ ✘

Wrong direction of rotation (three-phase
units)

Reverse two phases of power cable or motor
supply cable. (

Section 5.7 Page 25)

✘ ✘

-

✘

-

✘

Motor is running on two phases only (three-
phase units).

Check conductor voltages.
If necessary, replace defective fuse.
Check cable connections.

✘

-

-

-

-

✘

Manual-0-automatic selector switch set to
"0".

Set manual-0-automatic selector switch to
"Automatic".

✘

-

-

-

-

✘

Motor winding or electric cable are defective. Replace by new original KSB parts or contact

KSB.

A

B
C

D

E

F

5)

The pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.
Disconnect the pump from the power supply!

9 Trouble-shooting

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Содержание mini-Compacta

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

Страница 2: ...s 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 manufacture...

Страница 3: ...nspection and installation work 9 2 9 Unauthorised modes of operation 9 3 Transport Temporary Storage Disposal 10 3 1 Checking the condition upon delivery 10 3 2 Transport 10 3 3 Storage preservation...

Страница 4: ...system 45 8 4 Reassembly 47 8 5 Fitting the level sensor 49 8 6 Fitting the repair kit and check valve 49 8 7 Tightening torques 50 8 8 Disposal recycling of the lifting unit 50 8 9 Checklist for com...

Страница 5: ...gs and sites Flood level Maximum backflow level of waste water in a drainage system EN 12050 1 European Standard for sewage lifting units which are used to dispose of sewage with faeces occurring belo...

Страница 6: ...rtly completed machinery To install partly 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...

Страница 7: ...indicates a hazard for the machine and its functions 2 2 General This manual contains general installation operating and maintenance instructions that must be observed to ensure safe operation of the...

Страница 8: ...ded by sufficiently trained specialist personnel If required the operator can commission the manufacturer supplier to train the personnel Training on the lifting unit must always be supervised by tech...

Страница 9: ...y 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 have been released and the pump mus...

Страница 10: ...S2 100D US2 100E 56 67 UZ1 150D UZ1 150E 100 111 UZS1 150D UZS1 150E 116 127 The lifting unit has been checked for in transit damage 1 Use suitable transport equipment in acc with weights table 2 Tran...

Страница 11: ...d blown through with anhydrous inert gas to ensure drying 4 Always complete and enclose a certificate of decontamination when returning the lifting unit Section 14 Page 84 Always indicate any safety a...

Страница 12: ...control and monitoring unit for either one or two pumps 4 2 Designation Example mini Compacta UZS X 1 150 D C Table 5 Key to the designation Code Description mini Small package unit Compacta Type ser...

Страница 13: ...al Made in Germany EN 12050 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 Fig 2 Tank name plate example 1 Type series size 2 Maximum flow rate...

Страница 14: ...Shaft seal ring A grease fill is provided between the impeller end and drive end shaft seals mini Compacta US UZS and variant C Impeller end Mechanical seal Drive end Shaft seal ring An oil reservoir...

Страница 15: ...horizontal vertical inlet nozzles 1 and is collected in a gas odour and water tight plastic tank 10 Controlled by a level sensor 2 and control unit either one or two pumps 3 are started up automatical...

Страница 16: ...vel sensor 0 5 V DOL starting 2 3 1 Fig 5 Type Basic Compact BC 1 Control panel 2 Master switch optional 3 Manual 0 automatic switch LevelControl Basic 2 Type Basic Control Cabinet BS Pump control and...

Страница 17: ...le on request Table 7 Electrical data of the LevelControl Basic 2 control unit Characteristic Value Rated operating voltage 3 400 V AC 10 15 1 230 V AC 10 15 Mains frequency 50 Hz 2 Enclosure 400 V IP...

Страница 18: ...g to DIN 1986 3 the following fluids can be discharged into sewer systems Water contaminated by domestic use human and as far as required and permitted animal faeces together with the necessary flushi...

Страница 19: ...aracteristics The sound pressure level depends on the local conditions and the duty point and is in the region of 70 dB A 4 10 Scope of supply Depending on the model the following items are included i...

Страница 20: ...Max current A Size HxWxD mm kg 14 760 x 600 x 210 19 18 760 x 600 x 210 19 23 760 x 600 x 210 19 25 760 x 600 x 210 19 40 760 x 600 x 210 24 63 760 x 600 x 210 26 4 Description 20 of 86 mini Compacta...

Страница 21: ...llation WARNING Installation on mounting surfaces which are unsecured and cannot support the load Personal injury and damage to property Use a concrete of compressive strength class C12 15 which meets...

Страница 22: ...el sensor has been fitted with a transport lock which must be removed prior to commissioning see Fig Fig 7 Removing the transport lock 5 4 Connecting the piping DANGER Impermissible loads acting on th...

Страница 23: ...highest point must be above the locally defined flood level e g street level A gate valve must be installed downstream of the check valve NOTE Check valves of DN 80 are equipped with a lifting device...

Страница 24: ...onnection nozzles will be used 2 Open the nozzles required by sawing off the nozzle faces A approx 10 mm A A Fig 10 Opening the nozzles NOTE On mini Compacta UZS1 150 the inlet nozzle arranged at 180...

Страница 25: ...ng unit Install a swing check valve 5 6 Electrical connection DANGER Electrical connection work by unqualified personnel Danger of death from electric shock Always have the electrical connections inst...

Страница 26: ...ree phase 3 400 V D models the direction of rotation must be checked during commissioning and every time the product is returned to service Section 6 1 Page 27 5 Installation at Site 26 of 86 mini Com...

Страница 27: ...y all means Observe the following parameters and values during operation Parameter Value Maximum permissible fluid temperature 40 C for max 5 minutes up to 65 C Max ambient temperature 40 C air Operat...

Страница 28: ...ion and leak free operation Setting the unit to the lowest inlet nozzle used The switching frequency can be reduced by setting the unit to the lowest inlet nozzle used A switch for this setting is pro...

Страница 29: ...ion of rotation is indicated on the name plate Function and leak testing NOTE A sensor fault may be displayed when the lifting unit has not been filled yet It will disappear after the lifting unit has...

Страница 30: ...ump OFF Off Off Pump running Steady green Contact 11 14 closed On TCB Excessive motor temperature TCB fault unacknowledged Flashing red Contact 11 12 closed Off Interval tone TCB fault acknowledged St...

Страница 31: ...ower failure Power failure Contact 11 12 closed Off Interval tone NOTE If battery voltage drops below 5 3 V Basic 1 or 10 6 V Basic 2 the control units automatically switch off the mains independent a...

Страница 32: ...250 2 320 3 700 4 Vertical 5 Connecting the rechargeable battery DANGER Live voltage Danger to life Only open the device after it has been de energised To enable the mains independent alert connect th...

Страница 33: ...9 Page 50 6 3 2 1 Using additional functions 6 3 2 1 1 Functional check run For pumps with long idle periods a functional check run can be activated at parameter 3 7 1 The functional check run is carr...

Страница 34: ...m pump 5 After long idle periods Remove and clean rotating assembly 01 44 Spray the hydraulic section with oil for preservation 6 Unscrew hand hole cover 160 7 Clean the tank WARNING Fluids handled an...

Страница 35: ...e pump is operated in the same way pump specific steps shall only be carried out once in this case The control unit can be operated via Control panel Manual 0 automatic selector switch Service interfa...

Страница 36: ...ter alert is output the red LED lights up The pumps are started with high priority except if sensor of ATEX compliant models is defective Alerts with a higher priority overwrite the high water alert 7...

Страница 37: ...o call up the measured value parameters 2 Use the arrow keys to select the required parameter number The relevant measured value is displayed automatically after 1 5 seconds 3 Use the arrow keys to se...

Страница 38: ...meter number 3 Confirm the parameter number with OK The parameter value is displayed immediately 4 Set the parameter value using the arrow keys In multi digit entries the digit to be entered flashes T...

Страница 39: ...y For instance alert A1 has a higher priority than alert A2 Fig 25 Acknowledging alerts and warnings Alert indications On the display e g A09 As long as a parameter value is displayed this will not be...

Страница 40: ...pumps OFF can be changed via ServiceTool A11 11 Alert Auto Sensor fault No changes A12 12 Warning Auto Incorrect rotary field of mains supply phase sequence No changes A13 13 Warning Auto Undervoltag...

Страница 41: ...unit 3 Disconnect the battery 4 Undo the battery clamp 5 Replace the batteries 6 Reattach the battery clamp 7 Re establish the connections for the battery 8 Close the device properly 9 Reconnect the...

Страница 42: ...lifting unit to cool down to ambient temperature WARNING Fluids handled and supplies posing a health hazard Hazard to persons and the environment Decontaminate lifting units which handle fluids posing...

Страница 43: ...ust be overhauled For this purpose always contact KSB s service centres 8 2 3 Unblocking the cutter mini Compacta US UZS If the water level in the tank rises and the alert is triggered without the pum...

Страница 44: ...rise inside the pump as oil fill heats up Mechanical seal failure Fill in the correct oil quantity Section 8 2 4 1 Page 44 8 2 4 1 Oil quantity quality Fill the oil reservoir with 0 7 litres of oil We...

Страница 45: ...100 UZ150 1 Remove hexagon socket head cap screws 914 04 2 Lift rotating assembly 01 44 out of tank 591 3 Take O rings 412 11 and 412 12 off casing cover 161 4 Undo hex nut 920 02 and remove disc 550...

Страница 46: ...R C3 and 321 02 6205 LLU C3 L45 8 3 3 Removing the pump plate assembly mini Compacta US100 UZS150 1 Separate pump plate assembly 10 5 from the discharge line 2 Undo hexagon socket head cap screws 914...

Страница 47: ...and 321 02 6305 2RS1 JC3 8 4 Reassembly 8 4 1 General instructions Observe the following points for reassembly The pump shall be reassembled in accordance with the general rules of sound engineering...

Страница 48: ...g to ensure trouble free operation of the mechanical seal The protective wrapping of the contact faces shall only be removed immediately before assembly takes place Extreme care and cleanliness during...

Страница 49: ...Section 8 7 Page 50 4 Secure nuts 920 03 with Loctite 5 After mounting the rotating assembly on the plate turn the impeller to check for rubbing noises 6 Fit rotating assembly 01 44 into casing 100 8...

Страница 50: ...can be separately recycled Plastic components are marked in accordance with ISO 11 469 8 9 Checklist for commissioning inspection and maintenance Table 20 Checklist Actions Required during Read the op...

Страница 51: ...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 yea...

Страница 52: ...not completely vented Check the vent lines of lifting unit pumps Pump intake clogged by deposits Clean the intake pump components and collecting tank Inlet lines or impeller clogged Remove deposits in...

Страница 53: ...in the collecting tank Clean the collecting tank in case of greasy deposits fit a grease separator Check valve does not close tightly Clean the check valve screw the lifting screw back as far as it wi...

Страница 54: ...bly drawing exploded view and list of components 10 1 1 mini Compacta U60 U100 UZ150 Rotating assembly UG 1088985 Bl 1 Fig 33 General assembly drawing of mini Compacta U60 U100 Rotating assembly 10 Re...

Страница 55: ...otor unit 550 03 Support disc 411 01 Joint ring 920 02 Hexagon nut 412 01 O ring 932 Circlip 811 Motor housing 99 20 02 Small parts repair kit 81 59 Stator 411 01 Joint ring 824 Cable 412 01 11 12 O r...

Страница 56: ...330 Bearing bracket 411 02 Joint ring 412 01 02 O ring 421 01 Lip seal 412 11 12 O ring 433 Mechanical seal 433 Mechanical seal 550 01 Disc 80 1 Motor unit 550 02 Disc 411 01 Joint ring 550 03 Suppor...

Страница 57: ...Hex nut 932 01 02 Circlip B5 Vent 10 1 3 mini Compacta U60 U100 Collecting tank Fig 36 Exploded view of mini Compacta U60 U100 Collecting tank Part No Part No Description Part No Part No Description...

Страница 58: ...1 Joint ring 747 Check valve 412 21 23 O ring 100 Body 746 Valve disc 132 Intermediate piece 99 3 1 Set of installation accessories 411 21 Joint ring 400 Gasket 412 21 23 O ring 550 04 Disc 531 Lockin...

Страница 59: ...2 O ring 550 31 Disc 550 05 Disc 81 45 Level sensor 551 Spacer disc 914 31 Hexagon socket head cap screw 591 Tank 81 99 Rechargeable battery 71 11 Y pipe set 82 16 Control unit 400 Gasket 90 3 Set of...

Страница 60: ...Spacer disc 100 Body 901 04 Hexagon head bolt 132 Intermediate piece 920 04 Hexagon nut 411 21 Joint ring 99 3 2 Set of pads 412 21 23 O ring B5 Vent 531 Locking sleeve 550 21 Disc 746 Valve disc 900...

Страница 61: ...9 Exploded view US100 UZS150 Rotating assembly Part No Part No Description Part No Part No Description 01 44 Rotating assembly 920 Nut 10 5 Pump plate assembly 922 Impeller nut 10 Related Documents mi...

Страница 62: ...n 932 01 02 Circlip 719 03 04 Hose 99 20 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...

Страница 63: ...Cover 91 99 Rechargeable battery 412 31 41 O ring 82 16 Control unit 550 05 Disc 90 3 Set of mounting elements 591 Tank 901 05 Hex head bolt 719 01 02 05 Hose 99 3 2 Set of pads 732 Bracket 5B Vent 7...

Страница 64: ...0 Cover 81 99 Rechargeable battery 412 31 41 O ring 92 16 Control unit 550 05 Disc 90 3 Set of mounting elements 591 Tank 901 05 Hex head bolt 719 01 02 05 Hose 99 3 2 Set of pads 732 Bracket 5B Vent...

Страница 65: ...taining 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 1 1 a b Fig 42 Connection example a mini Compacta U60...

Страница 66: ...ng 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 1 Fig 43 Connection example mini Compacta UZ150 UZS150 1 Fl...

Страница 67: ...10 3 Dimensions 10 3 1 mini Compacta U60 and U100 1 1 a b Fig 44 Dimensions a mini Compacta U60 and b U100 1 With gate valve 745 mm 10 Related Documents mini Compacta 67 of 86...

Страница 68: ...10 3 2 mini Compacta US100 and UZ150 1 a b Fig 45 Dimensions a mini Compacta US100 and b UZ150 1 With gate valve 1005 mm 10 Related Documents 68 of 86 mini Compacta...

Страница 69: ...shut off elements 10 3 4 1 Inlet line U60 U100 US100 JL 1 DN 100 DN 150 PVC 1 DN 100 DN 150 Fig 46 Dimensions of inlet line with cast iron and PVC gate valve mini Compacta U60 U100 US100 1 Tank connec...

Страница 70: ...ig 47 Dimensions of inlet line with cast iron and PVC gate valve mini Compacta UZ150 UZS150 1 Tank connection 10 3 4 3 Discharge line U60 U100 US100 a b Fig 48 Dimensions of the discharge line a mini...

Страница 71: ...10 3 4 4 Discharge line UZ150 UZS150 a b Fig 49 Dimensions of the discharge line a mini Compacta UZ150 and b UZS150 10 Related Documents mini Compacta 71 of 86...

Страница 72: ...100 Inlet DN 150 100 Inlet DN 100 50 Inlet DN 150 100 Inlet DN 50 6 Inlet DN 150 100 Drain DN 40 Drain DN 40 Vent DN 50 Vent DN 70 Discharge line DN 80 100 Discharge line DN 80 100 6 To prevent backf...

Страница 73: ...DN 150 100 Inlet DN 150 100 Inlet DN 150 100 Inlet DN 150 100 DN 40 drainage nozzle DN 40 drainage nozzle Vent DN 70 Vent DN 70 Discharge line DN 50 DN 32 Discharge line DN 80 100 10 4 3 mini Compacta...

Страница 74: ...Compacta U1 60 U2 100 US2 100 Connection to floor mounted toilet bowl mini Compacta U1 60 Connection to wall mounted toilet bowl mini Compacta U2 100 US2 100 Connection to wall mounted toilet bowl mi...

Страница 75: ...e phase motor L3 5 6 3 Z2 WSK 230 V 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 acoustic alarm ok MAN RD WH 1a Pump ON 1 K1 A2 A1 A...

Страница 76: ...ve 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 1 K1 A2 A1 AUT 1b 24 V Option Moisture monitor Three wire connection...

Страница 77: ...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 Q1 A2 A1 1 1 P2 Q1 1 2 M 1 1 R1 3 4 2 2 2 U2 U1 Z1 Z2 5 6 3 3...

Страница 78: ...1 P E S X1 PE P E P E P E PE P E P1 M1 P1 X1 1 M 1 1 2 109 2 U2 U1 Z1 Z2 3 122 3 PE PE P E PE 121 21 4 120 20 5 X11 A2 A1 1 1 R1 2 2 3 3 4 4 001 002 B1 Level sensor V 6 30 V DC Signal 0 3 4 7 V BK 24...

Страница 79: ...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 P E PE 1 R1 4 5 X21 4 3 001 P2 Q1 A1 A2 2 002 1 R1 B1 Level sensor V 6 30 V DC Signal 0 3 4 7 V B K 24 V 1 024 PE BN Signal 2...

Страница 80: ...r 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 Q1 A2 A1 1 1 P2 M1 1 3 P2 Q1 1 2 M 3 U1 V1 W1 PE 1 3 1 R1...

Страница 81: ...lowing harmonised international standards have been applied ISO 12100 EN 809 A1 EN 60034 1 EN 60034 5 A1 EN 60204 1 EN 61000 6 2 EN 61000 6 3 EN 12050 1 Certified by T V Rheinland LGA Products GmbH 01...

Страница 82: ...specification Effectiveness EN 12050 1 2001 Handling of solids Passed Pipe connections Passed Ventilation Passed Minimum flow velocity 0 7 m s Minimum cross section of the system 40 mm Minimum cross s...

Страница 83: ...hnical specification Effectiveness EN 12050 1 2001 Handling of solids Passed Pipe connections Passed Ventilation Passed Minimum flow velocity 0 7 m s Minimum cross section of the system Passed Minimum...

Страница 84: ...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 roto...

Страница 85: ...medies 52 Flow velocity 12 Fluids handled 18 H High water alert 36 I Insulation resistance 43 Intended use 7 M Maintenance 42 Manual 0 automatic selector switch 37 Misuse 8 N Navigation keys 36 O Oper...

Страница 86: ...2317 886 05 EN 01442639 KSB Aktiengesellschaft 67225 Frankenthal Johann Klein Str 9 67227 Frankenthal Germany Tel 49 6233 86 0 Fax 49 6233 86 3401 www ksb com...

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