S-ZPK 30 KS - Water pump Zehnder Pumpen - Free user manual and instructions

USER MANUAL S-ZPK 30 KS Zehnder Pumpen

Technical cross-sectional diagram of a mechanical device with numbered components for identification.

ZPK 30 A / ZPK 35 A

Technical cross-sectional diagram of a mechanical device with numbered components for identification.

ZPK 40 A

© 2012 by Zehnder GmbH

Nur für EU-Länder

Table of contents 13

Declaration of conformity....13

1. General....14

1.1 Introduction ...... 14

1.2 Enquiries and orders.... 14

1.3 Technical data.... 14

1.4 Range of application 15

1.5 Accessories 15

1. Safety 15

2.1 Marking of the notes contained in the operation manual 15

2.2 Personnel development and training 15

2.3 Dangers in case of non-observance of the safety notes 16

2.4 Safety-conscious way of working 16

2.5 Safety notes for the operator/user 16

2.6 Safety notes concerning maintenance, inspection and assembly works ..... 16

2.7 Unauthorised modification and fabrication of spare parts 16

2.8 Unauthorised modes of operation 17

1. Description.... 17

2. Installation and Commissioning.... 17

3. Maintenance 18

4. Malfunctions; causes and elimination 18

5. Warranty....18

6. Technical modifications .... 19

7. Characteristics....19

8. Example of installation – stationary installation .... 19

9. Sectional drawing and spare parts list ZPK 30 A / ZPK 35 A 20

10. Sectional drawing and spare parts list ZPK 40 A 22

Declaration of conformity

that the submersible motor pumps of the type series ZPK

conform to the following relevant regulations in the respectively valid versions:

- EC low voltage directive 2014/35 EU

- EMC directive 2014/30 EU

- Machinery directive 2006/42/EC

Applied harmonised standards, particularly

EN 60335-1:2012/A11:2014

EN 60335-2-41:2003/A2:2010

EN 809:1998/AC:2010

EN 55014-1:2006/A2:2011, EN 55014-2:1997/A2:2008

EN 61000-3-2:2014, EN 61000-3-3:2013

EN 61000-6-1:2007, EN 61000-6-2:2005, EN 61000-6-3/A1:2011, EN 61000-6-4/A1:2011

Grünhain, 28/10/2016

Matthas Kotte

Product development

OM: ZPK English

State: 2011

1. General

1.1 Introduction

This operation manual is valid for the submersible pumps of the type series ZPK.

If the instructions of the operation manual – especially the safety instructions - are not observed, or in case of unauthorized modifications of the device or the installation of non-original spare parts, the guarantee expires automatically. The manufacturer assumes no liability for damages resulting from such behaviour!

Such as any other electrical device, this product may fail due to absence of mains voltage or a technical failure. If damage could occur, an emergency power supply, a second plant and/or an off-grid alarm device should be provided according to the application. We as manufacturer are at your disposal for consultation also after the purchase. In case of failures or damages, please contact your retailer.

Manufacturer: ZEHNDER Pumpen GmbH

Zwönitzer Straße 19

Date of manufacture: The date of manufacture of the pump is engraved on the top of the housing.

Manufactured sizes: Drainage pump ZPK 30 / ZPK 35 / ZPK 40

Design A with floating_switch, design KS with compact floater

State of the operation manual: 2011

1.2 Enquiries and orders

In case of enquiries or orders, address yourself to your retailer and/or specialist retailer.

1.3 Technical data

	ZPK 30	ZPK 35	ZPK 40
Pressure connection	G 114 “ AG
max. particle size	10 mm	10 mm	30 mm
Voltage	230 V
Frequency	50 Hz
Rated input P1	300 W	850 W	850 W
Nominal output P2	130 W	430 W	430 W
Power input	1.3 A	3.7 A	3.7 A
Rotational speed	2800 min^-1
Mains connection line	10 m, 3 x 1 mm ^2
Floating switch	yes	yes	yes
max. discharge flow	7,000 l/h	11,000 l/h	10,000 l/h
max. discharge height	7.5 m	11 m	10 m
Weight with cable	4.4 kg	6.6 kg	6.6 kg
Diameter	150 mm
Total height	270 mm	300 mm	345 mm
max. submersion depth	5 m	5 m	5 m

Materials:

Pump housing: Polypropylene (PP) Running wheel: PA 6

Motor recept. housing: Polypropylene (PP) Floating switch: Polypropylene (PP)

Bottom filter: Polyethylene (PE) Screws: Stainless steel 1.4301

Motor housing:

Stainless steel 1.4301

Mechanical seal:

Carbon/Ceramics

The submersible pumps of the type series ZPK are applicable up to a liquid temperature of 40 °C , short-term up to 70 °C .

1.4 Range of application

The pumps of the type series ZPK are adapted for the discharge of slightly polluted liquids with suspended solids (no stones) from private homes, in the industrial sector and agriculture.

The dimension of the suspended solids must not exceed the maximum grit size as mentioned in point

1.3. The pumps must not be used for the discharge of sewages containing excrements.

1.5 Accessories

The pumps of the type series ZPK are delivered with an outlet bend with a nut connector (1¼"), to which a hose (1" in case of ZPK 30, 1¼" in case of ZPK 35 and ZPK 40) may be connected.

As optional accessory (not included in scope of delivery) a retrofit kit, outlet bend with non-return valve, with the article number 17016 is available. This is preassembled and consists of:

Bend 90° 1 1/4" IG/AG, non-return valve 1 1/4", straight hose nozzle 1 1/4" with seal for a hose diameter of 25 and 32 mm.

Furthermore, the pumps market with "A" are equipped with a floating switch and the pumps marked with "KS" are equipped with a compact floating switch for confined spaces.

2. Safety

(from: "VDMA sheet 24 292")

The operation manual at hand provides basic notes which must be taken into account during assembly, operation and maintenance works. Therefore, before assembly and commissioning, this operation manual must be read by the assembler as well as by the responsible personnel/operator at all costs. It always must be available on site of operation of the device.

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.

2.1 Marking of the notes contained in the operation manual

The safety notes contained in this operation manual which can cause danger to persons are specifically marked by the following general danger symbol

Safety sign according to DIN 4844 - W 9

The following symbol warns against dangers caused by voltage

Safety sign according to DIN 4844 - W 8

In case of safety notes the non-observance of which can cause danger to the device and its functioning, the word ATTENTION! is inserted.

Notes that are directly attached to the device, such as - Arrow indicating the direction of rotation - Characteristics of liquid connections

must be observed and kept in completely readable condition at all costs.

2.2 Personnel development and training

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

2.3 Dangers in case of non-observance of the safety notes

The non-observance of the safety notes can cause dangers to persons as well as to the environment and the machine. If the safety notes are not observed, this can result in the loss of all compensation claims.

In detail, non-observance can for instance result in the following damages as an example:

• Failure of important functions of the pump
• Failure of the prescribed methods for maintenance and repair
• Endangerment of persons through electrical, mechanical and chemical influences
• Endangerment of the environment through leakage of hazardous substances

2.4 Safety-conscious way of working

The safety notes listed in this operation manual, the existent national regulations on accident prevention as well as possible internal working, operating, and safety instructions of the operator must be observed.

2.5 Safety notes for the operator/user

• Hot or cold device components which could cause danger must be secured against contact by the customer.
• The pumps are equipped with a thermal winding cover, if the motor cools down, the pump starts automatically. Due to this fact, the device must be disconnected from mains during repair or maintenance works!
• Protection against contact with moving parts (e.g. coupling) must not be removed while the machine is operating.
• Leakages (e.g. of the shaft sealing) of hazardous materials to be conveyed (e.g. explosive, toxic, hot) must be discharged in such a way that no danger arises for persons or the environment. The legal requirements must be observed.
• Endangerments through electric power must be eliminated (details concerning this, see e.g. the regulations of the VDE (German Association for Electrical, Electronic and Information Technology) and the local energy suppliers).

2.6 Safety notes concerning maintenance, inspection, and assembly works

The operator must make sure that all maintenance, inspection, and assembly works are carried out by authorised, skilled, and qualified personnel which are adequately informed by having thoroughly studied the operation manual.

Only use original spare parts.

Generally, works on the machine are only to be carried out when the pump is turned off. The proceeding prescribed in the operation manual in order to stop the pump must be respected at all costs.

Pumps or pump units conveying media dangerous to health must be decontaminated. Immediately after finalising the works, all safety and protection installations must be reinstalled and/or activated.

Before restart, the points listed in the chapter commissioning must be taken into consideration.

2.7 Unauthorised modification and fabrication of spare parts

Retrofitting and modifications of the switching device are permitted only after having consulted the manufacturer. Original spare parts and accessories authorised by the manufacturer ensure the safety. The use of other parts can lead to the removal of liability for the resulting damages.

2.8 Unauthorised modes of operation

The operational reliability of the machine is only guaranteed, if it is used as intended according to chapter 1 – General. The limit values stated in the data sheet must not be exceeded.

Attention

Also a device operating automatically such as a submersible pump must not be operated without supervision for a longer time period.

3. Description

The pumps of the type series ZPK are equipped with a sturdy alternating current motor; the sealing of the pump housing to the motor is executed using a mechanical seal. The current is connected using the 10 m long connecting cable with 230 V-50 Hz alternating current.

- The pump must be connected to a socket with earthing.

- Never carry the pump on the cable, never low it on cable into the water; never pull it on cable out of the water.

- If the power is not supplied obligatory via an earth leakage circuit breaker with maximum measured residual current 30 mA, the pump must be connected via a separate earth leakage circuit breaker to the socket

The use of the pump at swimming pools and garden ponds and within their protection zones is only permitted if the plants located there are installed according to DIN VDE 0100/part 702. It is forbidden to take a bath in the pool during operation of the pump. Ask your professional electrician.

4. Installation and commissioning

Before commissioning of the pump, check it for possible external damages (e.g. transport damages), in order to prevent accidents with electrical power.

In order to ensure an excellent working of the pump, the following minimum water levels are required:

ZPK 30: 120 mm (discharges to 25 mm)

ZPK 35: 160 mm (discharges to 25 mm)

ZPK 40: 200 mm (discharges to 45 mm)

If the pump shall be used in a cavity or a shaft the shaft/cavity must have a minimum dimension of 450 x 450 x 450 mm. The suction basket must not be blocked by sludge and/or media containing fibres. The floating switch attached to the pump (pumps marked with A or KS) must be freely moveable. . If the water level raises, the floater floats, switches the pump on and discharges the water until the water level is low that the floater switches the pump off. The switching- on and switching-off height of the floater can be varied by displacing the floater cable inside of the mounting eye or, in case of a KS floater, by displacing the float body. The function of the floater can be checked by lifting and lowering. In case of pumps without floating switch, the pumping process starts with connecting the plug to the socket. The water leakage between the two parts of the housing is normal, due to the fact that there is pump ventilation.

- In order to prevent damage to the mechanical seal, the pump must not run dry.

5. Maintenance

Disconnect the power supply before carrying out any kind of work on the pump and protect it against unauthorised reconnection!

Maintenance contains an inspection and a cleaning of the pump housing. For this purpose loosen the four cross-head screws (pos. 24 of the sectional drawing), remove and clean the inlet filter (pos. 3) and the base plate (pos. 4). Subsequently, reassemble all parts in the right order.

ATTENTION In case of a worn running wheel (e.g. due to abrasive media) a wear of the mechanical seal is also possible. The inspection of the mechanical seal and the motor as well as the replacement of the electric connecting cable should be effected by authorised after-sales services or by manufacturing factory only.

6. Malfunctions; causes and elimination

- Disconnect the power supply before carrying out any kind of work on the ejection unit!

Failure	Cause	Removal
1. No motor rotation	- Mains voltage missing or faulty	- Check power supply
	- Incorrect connection	- Correct the connection
	- Defective current cable	- Replacement (after-sales-service)
	- Running wheel is blocked	- Cleaning
	- Activated motor protection (over-heating, blockage, voltage failure or other defect)	Check, inform the after-sales-service
	- Floater got stuck	- Position the pump in such a way that the floater can work freely
	- Motor is defective	- Replacement (after-sales-service)
2. Motor rotates but does not con-vey	- Running wheel is blocked or worn	- Cleaning/Replacement
	- Pressure pipe is blocked/hose is bended	- Clean/remove kinks
	- Intake socket is blocked	- Clean
3. Discharge flow is too low	- Pump is not properly bled (air bubble inside of the housing)	- Bleed the pressure pipe during initial commissioning of the pipe, so that water reaches the pump hous-ing
4. Discharge flow is too low	- Too small dimension of the pressure pipe	- min. diameter 25 mm (1“)

7. Warranty

As manufacturer, for all pumps of the type series ZPK we provide a warranty of 24 months from date of purchase. Your sales receipt passes for verification. During that warranty period, we gratuitously remedy all deficiencies which are attributed to material or fabrication defects by either repairing or replacing the pump (to our choice).

Defects which are attributed to misuse or wear (running wheel and shaft seal) are excluded from warranty.

Furthermore, the warranty claim expires if works (excepting those under point 5) are effected on the pump. We will assume no responsibility for consequential damages that are caused by a breakdown of the pump.

8. Technical modifications

Technical modifications are reserved for the purpose of further development.

9. Characteristics

10. Example of installation – stationary installation

Ein On Marchel einstellbar adjustable- adjustable Aus Off Arrêt min. 450×450 mm min. 450×450 mm

11. Sectional drawing and spare parts list ZPK 30 A / ZPK 35 A

Technical cross-sectional diagram of a mechanical device with numbered components for identification.

ZPK 30 A / ZPK 35 A

Pos.	Designation	Quantity	Order number
1	Pump housing 207/00 yellow	1	272091.2
2	Motor reception housing 1-hole (without floater)	1	270002.1
2	Motor reception housing 2-hole (with floater)	1	270002.2
3	Bottom filter	1	272093.4
4	Base plate	1	272094
5	Running wheel d = 90 mm (ZPK 30)	1	272405.R
5	Running wheel d = 100 mm (ZPK 35)	1	272905.R
11	Condenser 5 μF (ZPK 30)	1	900134
11	Condenser 8 μF (ZPK 35)	1	279911
12	Fixation piece	1	270012
13	Plastic sleeve	2	270013
14	Bend relief	2	270014
15	E-cable with plug L = 10 m	1	270015
16	Floating switch L = 0.5 m (design A)	1	270016.G
16 A	Compact floating switch (design KS)	1	550.041
21	Mechanical seal	1	270021+270921
22	O-ring 95x7	1	270022
24	Sheet metal screw 4.2 x 19	6	270024
24	Sheet metal screw 4.2 x 19 for base plate	4	270024
25	Sheet metal screw 3.9 x 19	3	270025
27	Terminal block 5-pole	1	270027
30	Oil filling 0.01 l	1	117123
31	Hose connection piece R 1 1⁄4" -1" for ZPK 30	1	129011
31	Hose connection piece R 1 1⁄4" - 1 1⁄4" for ZPK 35	1	129012
32	Connecting nut (contained in pos. 34)	1	129910
	Motor unit for ZPK 30 A (incl. pos. 5; 21; 30)	1	207068
	Motor unit for S-ZPK 30 A (incl. pos. 5; 21; 30)	1	272499.1
	Motor unit for ZPK 35 A (incl. pos. 5; 21; 30)	1	207069
	Motor unit for S-ZPK 30 A (incl. pos. 5; 21; 30)	1	272999.1

12. Sectional drawing and spare parts list ZPK 40 A

Technical cross-sectional diagram of a mechanical device with numbered components for identification.

ZPK 40 A

Pos.	Designation	Quantity	Order number
1	Pump housing 207/00 yellow	1	272091.2
2	Motor reception housing 1-hole (without floater)	1	270002.1
2	Motor reception housing 2-hole (with floater)	1	270002.2
3	Base plate with support bracket	1	272094
5	Running wheel d = 105 mm	1	272905.R
11	Condenser 8 μF	1	279911
12	Fixation piece	1	270012
13	Plastic sleeve	2	270013
14	Bend relief	2	270014
15	E-cable with plug L = 10 m	1	270015
16	Floating switch L = 0.5 m	1	270016.G
16 A	Compact floating switch (design KS)	1	550.041
21	Mechanical seal	1	270021+270921
22	O-ring 95x7	1	270022
24	Sheet metal screw 4.2 x 19	6	270024
24	Sheet metal screw 4.2 x 19 for base plate	4	270024
25	Sheet metal screw 3.9 x 19	3	270025
27	Terminal block 5-pole	1	270027
30	Oil filling 0.01 l	1	117123
31	Hose connection piece R 1 1⁄4“ – 1 1⁄4“	1	129012
32	Connecting nut (contained in pos. 34)	1	129910
	Motor unit (incl. pos. 5; 21; 30)	1	207047

© 2011 by Zehnder GmbH

Only for EU countries

Do not put the pump into the household waste!

According to the European Directive 2002/96/EC on Waste Electrical and Electronic Equipment and transposition into national law, wasted electronic tools must be collected separately and must be recycled in an environmentally compatible manner.

Sommaire:

Page

Sommaire 24

- Directive 2006/42/EG relative aux machines

Technical cross-sectional diagram of a mechanical device with numbered components for identification.

Technical cross-sectional diagram of a mechanical device with numbered components for identification.

ZPK 40 A

© 2011 by Zehnder GmbH