Sanipump ZPG 71 - Pump Sanibroyeur - Free user manual and instructions

USER MANUAL Sanipump ZPG 71 Sanibroyeur

ZPG 71 Installation and Maintenance Manual - Original operating instructions All rights reserved. The contents of this document must not be reproduced, modified or disclosed to third parties except upon written consent from the manufacturer. This document may be subject to change without notice. Status of the operating instructions: February 2020

Safety instructions for maintenance, inspection and assembly work . pg.5

8. MALFUNCTIONS, CAUSES AND

WARNING This device may be used by children who are at least 8 years old, by people with reduced physical, sensory or mental capacities or those without knowledge or experience, if they are properly supervised and if the instructions relating to using the device completely safely have been given to them and the associated risks have been understood. Children must not play with the device. Cleaning and maintenance undertaken by the user must not be carried out by unsupervised children. ELECTRICAL CONNECTIONS: The electrical installation must be done by a qualified electrical engineer. The device's power supply must be connected to ground (class I) and protect- ed by a high sensitivity differential circuit breaker (30 mA). Devices without plugs must be connected to a main switch on the power supply which discon- nects all poles (contact separation distance of at least 3 mm). The connection must be used exclusively to provide the power to the product. If the power cord is damaged, to prevent possible danger, it must be replaced by the manufacturer, customer service team or a similarly qualified individual. The operation manual at hand provides basic notes which have to be taken into account during assembly, opera-tion and maintenance works. Therefore, before assembly and com- missioning, this operation manual has to be read by the assembler as well as the responsi- ble personnel/operator at all costs. It always has to be available on site of operation of the machine/plant. The general safety notes listed under the main point safety are not the only notes to be taken into account. Please also observe the specific safety instructions, such as those for private use, listed under other main points.

1.1 Identifying the warning signs

Danger This term defines a high risk of danger, which can lead to death or seri- ous injury, if not avoided. Dangerous area This symbol characterises hazards that could lead to death or injury. Dangerous voltage This symbol characterises dangers associated with the voltage and provides information on voltage protection. Property damage This symbol, in combination with the keyword ATTENTION, characterises dangers to the machine and its proper operation.5 It is imperative to observe signs that are attached directly to the machine (for example, rotational direction arrow, sign for fluid connections) and must be kept fully legible.

1.2 Personnel qualications and training

The personnel responsible for operation, maintenance, inspection and assembly have to have the corresponding qualifications for those types of work. Area of responsibility, competence and the surveillance of the personnel have to be regulated precisely by the operator. If the personnel do not possess the necessary knowledge, they have to be trained and instructed. By order of the operator, the instruction and training, if necessary, can be carried out by the manufacturer/supplier. Furthermore the operator has to make sure that the personnel have completely understood the content of the operation manual.

1.3 Dangers from non-observance of the safety instructions

Non-observance of the safety instructions can result in danger to persons and damage to the environment and the machine. Non-observance of the safety instructions can lead to loss of any claims for damage compensation. In detail, non-observance can for instance involve the following hazards :

• Failure of important machine/system functions

• Failure of prescribed methods for maintenance and repairs

• Danger to persons through electrical, mechanical and chemical hazards

• Danger to the environment through leakage of harmful substances

1.4 Safety-awareness at work

The safety instructions described in this Operating Manual, the valid national regulations on accident prevention, and possible internal regulations of the customer on work, operation and safety are to be observed.

1.5 Safety instructions for the customer/operator

• Hot or cold machine components which could cause danger have to be secured against contact by the customer.

• Protective devices to prevent touching moving machinery (e.g. coupling) may not be removed from operating machines.

• Leakage (e.g. shaft seals) of dangerous conveyed products (e.g. explosive, poisonous, hot) has to be led off in such a way that there is no endangerment to persons or environment. Legal stipulations are to be maintained.

• Hazards through electric energy are to be eradicated (for details, see national regulations and those of the local power supply companies).

1.6 Safety instructions for maintenance, inspection and assembly

work The customer has to ensure that all maintenance, inspection and assembly work is carried out by authorised and qualified specialist personnel, who have been sufficiently informed through relevant and adequate study of the Operating Manual. Work on the machine is to be done on principle only when it is shut down. The procedure for shutting down the machine is described in the Operating Manual and is to be precisely adhered to. Pumps, or pump units that convey hazardous media have to be decontaminated. Immediately after finishing work, all safety and protective devices have to be re-attached and put into effect.6 Prior to initial (re-)start-up, you are to take heed of the points listed in the section Initial Operation.

1.7 Unauthorised re-equipping and spare-part production

Re-equipment and modification of the machine are only permitted after consultation with the manufacturer. Original spare parts and accessories authorised by the manufacturer are all part of the safety strategy. Use of other parts can eliminate liability for the consequences that ensue.

1.8 Unauthorised modes of operation

Operational safety of the delivered machine is only guaranteed when it is used appropriately according to Section 2 - General in the Operating Manual. The limit values specified in the data sheet may on no account be exceeded.

This operation manual is valid for the submersible greywater pumps SANIPUMP

ZPG 71. If the instructions of the operation manual – especially the safety instructions - are not observed, or in case of unauthorized modifications of the plant or the installa- tion of non-original spare parts, the guarantee expires automatically. The manu- facturer assumes no liability for damages resulting from such behaviour! Manufactured sizes: SANIPUMP

2.2 Queries and orders

Please send your queries and orders to your specialist dealer.

ZPG 71.1 S ZPG 71.1 T ZPG 71.2 T ZPG 71.3 T P1 [kW] 2.2 2.1 3.9 3.9 Rated power P

[kW] 1.6 1.7 1.7 3.2 Voltage U [V] 230 400 400 400 Frequency [Hz] 50 Rated current consumption I [A] 10.5 3.7 3.7 6.5 Drive n [min

/h] 43 43 43 43 Max. delivery height H max [m] 19 19 26 31 Max. media temperature t max [°C] 40 Pressure connection (optional) Flange DN50 Weight with cable [kg] 38 38 38 44 Duty ratio ED S1 - continuous operation (flooded), S3 - 40% (emerged) Minimum fluid level Bottom line of motor housing7 Materials Motor housing GG 20 Motor shaft 1.4021 Pump housing GG 20 Bearing flange GG 20 Impeller GG 20 Floating-ring type shaft seal SiC (silicon carbide

Auxiliary bearing flange St 37-2 Other seals NBR, FPM

2.4 Range of application

The submersible greywater pumps of the type series SANIPUMP

ZPG 71 are used for the drainage of wastewater in manholes. The use of this pump is not suitable for the disposal of waste water containing faeces (blackwater). The waste water must not contain any components which affect the materials of the pump or the manhole and its parts.

All pumps of the type series SANIPUMP

ZPG 71 are delivered with 10 m of cable and free cable end. Optional: - switching devices available as standard or special models with various level control systems; - a coupling device (stationary operation) for the installation of the pump.

ZPG 71 should be lifted and/or transported using the eyelets on top or the handlebar designed for that purpose. Under no circumstances is the pump to be lifted on the power supply cable! For temporary storage and conservation, it suffices if the pumps are stored in a cool, dry, frost-protected and dark place. In case of longer storage periods, please spin the impeller of the pump at least once per month to avoid the jamming of the mechanical seals.

ZPG 71 are equipped with an AC asynchronous induction motor or a three- phase asynchronous motor. In each of the 3 motor windings one temperature sensors (bi-metal) is integrated which work as temperature regu-lator respectively temperature limiters (opener). If the motor overheats for any reason, the bimetallic contacts respond to this and the motor is switched off.

The pump housing and the impeller are made of grey cast iron. The pumps are equipped with a flange DN 50.

4.3 Switching device

The pumps with 400 V three-phase motor are delivered without switchgear. The pumps with 230 V motor are delivered with a switchgear with capacitor and motor protection.8

- Disconnect the power supply before carrying out any kind of work on the plant! - The electrical connections are not to be exposed to humidity!

5.1 Electrical equipment

The AC-powered model of the pump must be operated with the supplied auxiliary switchgear. The pump is connected to an earthed wall socket with an earthed type plug by means of the cable which is con-nected to the switching device.

- The switching device has to be installed outside the flood- endangered area! - The floater for the protection against dry running has to be installed in such a way, so that a decline of the water level below the bottom line of the motor housing is not possible. Further electrical installation is not necessary. If required, the motor housing can additionally be earthed by means of the external earthing terminal intended for that. If an additional switching device is connected to the pump SANIPUMP

ZPG 71.1 S, it has to be connected as follows: 1~ 230 V/50 Hz 230 V50 Hz L1 N

Motorprotection Fuse MAINSMotorrelayMotor capacitorThermal windingprotectionGreen/YellowPE conductor Three phase model: The wires of the seven-wire connection cable of the pumps (three-phase model) are marked as follows: Green/Yellow PE Ground wire (earthing) 4 TB1 First contact control loop 1 U1 Three windings, star connection 5 TB2 Second contact control loop 2 V1 3 W19

- The switching device has to be installed outside the flood- endangered area! - The floater for the protection against dry running has to be installed in such a way, so that a decline of the water level below the bottom line of the motor housing is not possible. Wiring diagrams three phase AC motor: 3~ 400 V/50 Hz

Motorprotection Fuse MAINS MotorrelayThermal windingprotectionGreen/YellowPE conductor Connection of the thermal winding cover: Control loop: T1 and T2 must be connected in a switching device in such a way, that the following function is guaranteed: when the temperature sensors respond, the pump is switched off until the tempera-ture has dropped again. Now the pump is switched on again.

The waste water pump must be protected effectively against the suction of air. Installation with supporting ring: - Mount supporting ring to intake flange of the pump and install pump. Ensure stability of the pump. - Connect pressure side by means of flange DN 50. - If a hose is to be laid on the pressure side, kinks are to be avoided. - Avoid kinks during the laying of the supply cable. Lay supply cable without tensile loading and without causing chafe marks. Installation for shaft fitting: - Position pipe clamp on inner rim of the shaft and loosely fix it with two screws.10 - Sound out position of guide pipe frame for coupling pedestal, adjust coupling pedestal on shaft bottom and mount it with the heavy-duty dowels which are included in the delivery. - Install pressure pipe and valves in a tension-free manner. - Slip the guide pipe on the coupling pedestal, shorten it to correct length, slip on pipe clamp and tighten it for good. - Mount coupling element and lowering chain to the pump, lower pump with the chain (insert guide pipe into coupling element) and couple it, hang the chain up on the pipe clamp so that it is ready to hand. - Lay supply cable. Avoid kinks and lay supply cable without tensile loading and without causing chafe marks.

5.3 Level control system

ZPG 71 have to be controlled by means of a level control in such a way, that a decline of the water level beneath the minimum allowable level (bottom line of motor housing) is avoided at all costs. The level control can be effected by means of a floating switch, electropneumatically (press switch) or by means of other applicable methods. The switching point of the pump should be set in such a way, that the pump is entirely submersed under water.

Check all connections for correct assembly, set gate valve on passage and check level control system for proper operation. During the initial test run, check pipes for tightness and reseal them, if necessary.

Disconnect the power supply before carrying out any kind of work on the plant! After an operation time of six to twelve months, the oil storage inside the seal carrier always has to be controlled as follows: - put the pump on its side on a clean surface and position it in such a way that the oil filling screw faces upwards, - take out the screw and check the oil level. If only a small quantity of oil is lacking, the oil storage can be filled up without any problems. If a considerable quantity of oil is lacking, or if the oil is mingled with water, the customer department has to be informed. All other maintenance works on the pump and on the electrical equipment should be carried out by the manufacturer or an authorised qualified company in intervals of six to twelve months (or also in shorter intervals, according to case of operation). Please immediately inform the customer department in case of damage to the pump and/or the electrical equipment.

8. MALFUNCTIONS, CAUSES AND TROUBLESHOOTING

Disconnect the power supply before carrying out any kind of work on the plant!11 Malfunction Cause Elimination

rotating - absence of line voltage or improper line voltage - check voltage supply - incorrect connection - correct the connection - defective power cable - replacement (customer service) - defective/wrong capacitor - replacement (customer service) - impeller/cutting knife blocked - cleaning - activated motor protection (overheating, blocking, improper voltage or other malfunction) - inspection, inform customer service - control malfunction/defective floating switch - inspection, inform customer service - motor defective - replacement (customer service)

2. Motor rotates but

does not convey - impeller blocked or worn out - cleaning/replacement - check valve blocked - cleaning - gate valve blocked/closed - cleaning/opening gate valve - pressure pipe blocked/hose buckled - cleaning/eliminating kinks - intake socket blocked - cleaning - incorrect rotating direction - correction - water deficiency inside the shaft - switch off/inform customer service

3. Motor switches off

during start-up - voltage improper or unsteady - correction/customer service - thermal protection laid out incorrectly - inspection/customer service - current consumption too high - customer service

switch off - control malfunction - customer service - wrong/defective floating switch - replacement/customer service

As the manufacturer, we provide a warranty of 24 months on these pumps from date of purchase. Your sales receipt will act as a proof of warranty. During that warranty period, we gratuitously remedy all deficiencies which are attributed to material or fabrication defects by either repairing the plant, or by replacing the defective parts (to our choice). Defects which are attributed to misuse or wear are excluded from warranty. We will assume no res- ponsibility for consequential damages that are caused by a breakdown of the plant. In case of a war- ranty claim, please contact your specialist retailer.

10. TECHNICAL MODIFICATIONS

We reserve all rights for technical modifications in terms of further development.12 Appendix A: Characteristic curves Appendix B: Pump dimensions Fixed installation Portable installation13 Appendix C: Sectional drawing and list of spare parts Pos. Art. Nr. Designation 1 Designation 2 Quantity 10 17842 Motor complete SANIPUMP