KSB CK pumping station installation instructions

Safety sign according to DIN 4844 – W9,

for warning of electrical current:

Safety sign according to DIN 4844 – W8

For safety advice, which could cause damage to the machine and its functioning if not observed, the word ATTENTION is inserted.

Advice marked directly on the machine, for example:

Direction of rotation arrow
Symbol for fluid connection
Must be observed, and maintained in a completely legible state.

2.2 Personnel qualification and training.

Service, maintenance, inspection and installation personnel must all have the corresponding qualifications for the work.  Areas of responsibility and supervision must be precisely set out by the user. If the personnel do not have the necessary knowledge, then they must be trained. This can, if the manufacturer/ supplier, of the contract with the machine user/owner carry out necessary.   Furthermore, the user should ensure that personnel have fully understood the content of the operating instructions.

2.3 Dangers of not observing the safety advice
Failure to observe the safety advice can endanger personnel, the machine and the environment.  Failure to observe safety advice leads to the invalidation of any compensation claim.

In particular, non-observance of the examples of dangers following can lead to:
- Failure of important functions of the machine/ system
- Failure of prescribed methods for maintenance
- Endangering of persons through electrical, mechanical and chemical effects.
- Endangering the environment through leakage of dangerous materials

2.4 Safety conscious working
The safety advice described in the operating instructions, which comprise national regulations for the prevention of accidents as well relevant internal working, operating and safety regulations, are to be observed.

2.5 Safety advice for the user
If hot or cold machine components are dangerous, they must be protected from being touched by the customers.
Guards around moving parts (e.g. coupling) may not be removed from machines, which are in service.
Leakage (e.g. the shaft seal) of dangerous pumped products (e.g. explosive, poisonous, hot) must be channeled so that no dangers to persons and the environment ensue.  Legal requirements are to be observed.
Danger from electrical energy must be eliminated. (For details of this see the specific regulations of the country and the regulations of the local energy supply business).

2.6 Safety advice for maintenance, inspection and assembly

The user should ensure that all maintenance, inspection and assembly work is carried out by authorised specialists, who have informed themselves sufficiently through careful study of the operating instructions

All safety and protective devices must be reactivated immediately after completion of the work.  Before putting back into service, the points described in the start up paragraph should be observed.

2.7  Unauthorised modification and manufacture of spare parts
Modifications or alterations to the machine are only permissible with the agreement of the manufacturer.  Original spare parts and accessories authorised by the manufacturer promote safety.  Use of others parts can invalidate liability for any resulting consequences.

2.8 Improper operation
The operational safety of the pump supplied is only guaranteed for use within specified parameters.  The limiting values given in the data sheets may not be exceeded under any circumstances.

2.9 Safety requirements (on explosion protection)
For installations in Zone 1 [danger of explosion] areas, (our submersible pump motor sets Amarex…/Y are built for these zones), the regulations of the PTB test certificate must be adhered to.  The PTB test certificate must be kept at site (e.g. caretaker’s office, etc).

3.  Transport
Inland delivery to inland to private house/ installation site excluding off-loading.  A sufficiently firm, all weather access with HGV turning facility must be guaranteed.  Should the vehicle become stuck, additional costs must be borne by the customer.
The system is delivered in component form for assembly at site:
1 pallet with complete CK tank, fitted with duckfoot bends, gate valve, non return valve, pipework, (including mounted clamps) and float switches
1 pallet with:
1 cover plate with seat ring
1 box per pump
1 claw per pump
1 chain per pump
1 box with switch gear




1) With Ama-Porter 2) with Amarex
Check for transit damage before assembly and installation of pump components.
4.  Description
4.1 General description
The description and instructions in these operating instructions relate to standard design with original KSB control devices.  Additional switchgear from other manufacturers is not covered.
The use of devices from other manufacturers invalidates the guarantee and product liability for these parts of the pumping station.
     
The CK Pumping Station is designed for domestic sewage disposal.  It can be positioned in stable ground on a firm base without any concrete work.
Systems with submersible pump types Amarex S and Ama-Porter S (macerator pumps) are designed for handling sewage. 
Submersible pump types Amarex F and Ama-Porter (vortex pumps) are for handling fluids with particles and stringy waste.
The pump type series Ama-Porter are not explosion proof                                                                                                            
Please refer to DIN 1986, part 5.
The following, among others, must not be allowed to enter the chamber:
Hard solids, fibrous matter, tar, sand, cement, ash, cardboard, refuse butchery waste, grease, oil and sewage containing chemicals.
For installations to handle sewage containing grease, a grease trap must be incorporated in the drainage layout
4.2 Designation (off the shelf program)

5.1          Excavation of the foundations
The foundations should be excavated according to the regulations of DIN 4124/ IN 18 3000 and VOB
A minimum working space of 50 cm should be maintained on all sides at the base of the foundation. 
The foundations must be dry during building work.
5.2 Installation of the Plastic Tank
A 15 cm depth of sand should be laid in the bottom of the excavation and compressed. 
Lower the tank into the foundation with appropriate lifting gear (digger or crane) see fig. 1 and align.
Install the ready to use tank so that the tank cover is level with the ground. With tank extension (available as accessory) and/ or max. 3 industrial leveling rings DIN 4034-AR 625 x 100 can increase installation depth up to max. 2.5m  (see 9.1 installation).
5.3 Connection of the pipework
Attention!
When connecting inlet & outlet pipework, avoid passing on pipework stress to the tank.  The pipework should be laid in a frost-free environment.  See also paragraph 9.
5.3.1       Discharge pipe

5.3.2       Inlet pipe DN 150 for uPVC pipe.
Variable connection options are available through 6 height settings of inlet sockets DN 150 and DN 100.  All inlet sockets are closed when the plastic tank is delivered. The chosen inlet connection must be cut open.
Clean inlet pipe.
Push the round sealing ring on to the connecting end of the inlet pipe. Then push the inlet pipe carefully into the inlet socket until the round sealing rings connects.  The pipe end should stick into the tank by about 50mm.

5.3.3 Venting connection DN 100 for uPVC Pipe
Cut open the chosen DN 100 ventilation socket.
Connect the ventilation pipe with appropriate connecting parts and put in place in the tank at a slight gradient.  This also functions as the cable duct for motor and control cables (if required).
Attention
A 30º bend makes it easier to pull the draw wire.
5.4  Backfill of the foundations
Attention!
The concrete ring (part no. 89-9) should be installed on the tank before back-filling the foundations.
Back-fill the foundations according to DIN 4124/ DIN 18 300 and VOB.
A backfill layer of sand of about 300mm should be used for the protection of the plastic tank.  Use sand with a maximum particle size of 8mm.
Attention
Carefully fill the space round the contours of the tank with a spade or similar, and compress by hand.
The rest of the foundations can be back filled with the excavated material, provided this does not contain any sharp particles, pebbles or rocks.
The backfill should be layered in levels of up to 30 cm and compressed at each level.  Compress with a light tamper according to DIN 4033.
Attention
Pressure on one side of the plastic tank is to be avoided, if necessary, to prevent this fill the tank with water before hand in order to rectify any misshape.
Remove any earth, gravel or sand from inside the tank. 
Carry out work according to DIN 18 300, Page 10, 3.11.
Attention
In areas with high ground water levels, or where there is high clay content, we recommend the tank be layered from outside with concrete (min 1 m3).
Where a groundwater lowering system is installed, this should not be switched off until after the foundations have been refilled and compressed.


5.5          Level Control by Float Switches
                The float switch type level controls are supplied ready installed in the tank and simply require pulling through the cable duct and connecting to the control panel (by a qualified electrician)
5.6          Protective Multiple Earthing
In areas with explosion risk, PME bonding is required in order to avoid inflammable sparks:
·         On the pipework, according to VDE 01656 with 6 mm2 cable
The Connection clamp (Fig 2) should be connected to the site PME bonding with 6 mm2 single wire
·         On the pump according to EN 50 014 or VDE 0170/0171 with 4 mm2 Cu cable.
·         The PME bonding cable should be checked for continuity.

For pump connection see Amarex operating instructions.

5.7    Electrical connections
5.7.1       General
Electrical work should only be carried out by a professional tradesman in accordance with the site regulations.
VDE 0100 is recommended, and VDE 0165 for explosion protection.


See also installation example 9.3.

5.8 Installation of the pump/s
Place the pumps over the upper guide wire holder and lower slowly.  After lowering, the pump fixes itself to the duckfoot, and is thereby attached to the discharge pipework ready for operation.
It should be ensured that enough free cable length is left in the pump tank, so that the pumps can be safely pulled out for maintenance work making sure that this is secured at the top of the chamber and cannot be drawn into the pump suction.
6    Start up/ Shut down

For the start up/ shut down of the pump, refer to the pump operating instructions

These are the only components included and should additionally be found in the document pack CK pump station operating instructions.

6.1    Limits of operation

6.1.1 Operation pressure.

The maximum pressure of the system may not exceed 4 bar.

6.1.2       Pumped product temperature and external temperature

Amarex… Type Y with explosion protection          40 ºC
Ama-Porter…       without explosion protection     40 ºC