Operating Instructions Submersible sump pump
Contents
1. detach slots between foot strainer and pump casing and lever down the foot strainer To ensure the suction of the pump the hose must be emptied before each pumping sequence and the lowest water level must be 40 mm 1 6 inch The built in level control of the U 3 KS Niro is not working in the low level pumping mode Whirl system To keep the bottom of the sump in the suction area of the pump largely free of sediments a small modification is necessary The pump performance will be reduced to 6 m h and 6 0 meters of head Take off the foot strainer as described under shallow pumping Unscrew the 6 grooved sheet metal screws part No 08552 out of the wear plate and take it of Drill 3 holes with 5 mm into the wear plate as shown on picture 5 remove the burr from the holes and assemble the pump again The new holes must not be covered from a web of the foot strainer Picture 8 whirl system 4 27825 00 Checking of pump unit Worn out impellers can have sharp edges Inspect and adjust the impeller depending on the frequency of operation and the medium being pumped but not later than half yearly At reduced pump performances or increased operational noises the impeller and the pump casing must be checked and replaced if necessary by qualified experts Torque ratio Ma for screw material for M 6 Ma 8 Nm 0 8 kom for M 8 Ma 20 Nm 2 0 kom for M 10 Ma 40 Nm 4 0 kpm for M 12 Ma 70Nm 7 0 kpm2. Always use the shackle to carry the AN pump never lift it at the cable or the hose To lower the pump in a deep tank use a rope or a chain Stay clear of suspended loads Take out the main fuses to isolate the mains supply both control unit and pump before any works and make sure it cannot be energized again Make sure the pump cannot roll or fall over and injure people or damage property In some installations the water and the pump can be hot Bear in mind the risk of burn injuries Before installation please check the visible parts of the pump and the installation sluice and reflux valves the oil level in the oil chamber if the impeller moves freely direction of rotation The pump should be installed correspondingly to picture 3 4 5 or 6 Under DIN EN 12056 2 the pressure tube must be taken in a loop over the local back up level and secured with a reflux valve Observe the min flow speed of 0 7 m s in the pipe work To ensure the proper installation consider the dimensions of the installation The sump has to be cleaned from all sediments before any installation or repair works The minimum height between the lifting hook and the floor shall be sufficient to lift the pump out of the sump The lifting equipment shall be able to hoist the pump straight up and down in the sump preferably without the need for resetting the lifting hook Oversized lifting equipment could cause damages if the pump should stick whe
3. and safety codes and any other service and safety instructions issued by the plant operator shall be complied with page 2 Safety instructions relevant for operation lf hot or cold machine components involve hazards they must be guarded against accidental contact Guards for moving parts e g coupling must not be removed form the machine while in operation Any leakage of hazardous e g explosive toxic hot fluids e g from the shaft seal must be drained away so as to prevent any risk to persons or the environment Statutory regulations are to be complied with The pumping station must be kept tidy and in good condition Hazards resulting from electricity are to be prevented see for example the national specifications or the regulations of your local electricity supply company Safety instructions relevant for maintenance inspections and assembly work It shall be the plant operator s responsibility to ensure that all maintenance inspection and assembly work is performed by authorized and qualified personnel who have adequately familiarized themselves with the subject matter by studying this manual in detail Any work on the machine shall only be performed when it is at a stand still it being imperative that the procedure for shutting down the machine described in this manual be followed Pumps and pump units which convey hazardous media must be decontaminated All waste emissions such as used oil must be appropriatel
4. for M 16 Ma 160 Nm 16 0 kpm page 10 Malfunctions Pump does not run cause missing mains supply remedy check supply voltage cause faulty fuse maybe too low remedy check fuse and change if necessary cause damaged supply cable remedy changing of the cable gland only by qualified personnel Pump runs but doesn t deliver water cause trapped air in the spiral housing remedy drain off the pressure tube or hose to ensure the opening of the reflux valve to deaerate the spiral housing and ensure the correct operation of the pump Blockage of impeller cause solid or fibrous admixtures blocking the impeller remedy check impeller as explained under adjustment of impeller or cleaning Reduced performance curve cause clogged impeller remedy clean impeller and spiral housing cause worn out impeller and or wear plate remedy change impeller and or spiral housing At replacing the impeller prevent the bearings against being pushed out of their position by supporting the upper edge of the motor shaft when pressing on the impeller Jung Pumpen GmbH amp Co Industriestra e 4 6 33803 Steinhagen XX EN 12050 2 Abwasserhebeanlage fur fakalienfreies Abwasser DN 32 Hebewirkung siehe technische Daten Gerauschemissionswert lt 70GB A Die beiden ersten Ziffern der Pumpen Nr bezeichnen das Produktionsjahr Operating Instructions Picture 9 sectional drawing
5. page 11 Operating Instructions Pos eodewo Descipion o 1 08219 micro switch with leads 1 2 16318 capacitor 6uF 400 V DB 1 1 3 20538 screw Amtec 5 0 x 20 4 4 4 16325 O ring 86 x 6 1 1 5 16687 quarter elbow 11 1 1 6 27183 spiral housing 1 1 7 27186 strainer base 1 1 8 07162 float 1 9 26211 impeller 1 1 10 27187 camshaft 1 11 16327 sheet metal screw 4 8 x 32 1 12 03990 rotary shaft seal 12 x 24 x 4 5 1 13 27226 operating cam 1 14 16936 reflux valve compl 1 1 Replacement kits 27227 spiral housing completely including 27186 27230 terminal completely U 3 K spezial including 16318 27231 terminal cover completely U 3 KS spezial with 3 0 m cable including 03990 08219 16318 27187 27226 27399 motor unit completely including 26211 By ordering spare parts indicate type of the pump and the part number page 12
6. Operating Instructions General Safety Instructions Application Electrical Connection Installation Maintenance Submersible sump pump You have bought a Jung Pumpen product and therefore purchased quality and performance Guarantee this achievement by an installation according to the operating instructions so that our product can meet your demands to your full satisfaction Please note that damages as a result of poor installation will affect the guarantee For this reason please follow the advice of the operating instructions Like any other electrical appliance the operation of this product can fail by electrical failure or technical faults It is wise to always consider standby pumps emergency generator and a control unit fitted with mains independent alarm U 3 K spezial ID No 09562 02 U 3 KS spezial ID No 09563 02 2 611 1 1 0304 page 1 Operating Instructions General Safety Instruction This operation manual gives basic instructions that should be followed carefully during installation operation and maintenance It is essential that this manual is carefully read by the responsible personnel operator before assembly and commissioning It is always to be kept available at the installation site Identification of safety instructions in the operating manual Safety instructions given in this manual non available with which would affect safety are identified by the following symbol General danger for person
7. ances Electrical connection Following works should only be done by qualified and authorized electricians Jung Pumpen disclaims all responsibility for A work done by untrained or and unauthorized personnel Heed operating voltage see name plate and additional labels Take out the main fuses to isolate the mains supply from the control unit before repairs or any other works and make sure it cannot be energized again If the pump is equipped with automatic level control there is a risk of sudden restart Before starting check the efficiency of the protective arrangements of the pump and the monitoring equipment Failure to heed this warning may cause a lethal accident Do not put the lead ends into water Irruption of water may cause malfunctions If persons are likely to come into physical contact with pump or pumped media the earthed grounded socket must have an additional connection to an earth ground fault protection device GFI When pumping near a lake a jetty a pond etc a safety distance of at least 20 m between the person and the pump is applicable Do not place the pump directly in a pool Observe the special safety regulations if used in connection with swimming pools Use the pump only in accordance to the data stated on the pump s plate resp in the technical data on page 4 Special rules apply to installation in A N explosive atmosphere Intrinsically safe circuits Exi are normally req
8. ase of repairs or maintenance pull main plug Check the cable on mechanical or chemical damages The foot strainer prevents blockages in the pump it has to be cleaned regularly as well as the float switch to guarantee the trouble free operation with full performance In case of blockages take off the wear plate see whirl system and remove blocking parts Other works are not necessary page 9 Cleaning Regularly cleaning of the impeller and the level control sensors or float switches secures the maximum pumping capacity and operational reliability Installation of flap trap The enclosed rubber flap must be screwed into the discharge branch of the pump casing by using the grooved sheet metal screw see pic 7 If the pump is used in sumps that can dry out replace the flap trap by a separate reflux valve e g Jung Pumpen swing type check valve No 9739 The reflux valve should be mounted above the screw fitting To ensure the correct deaeration of the spiral housing drill a 6 mm hole into the enclosed quarter elbow part No 16687 at the marked position In contrast to the U 3 KS Niro with built in level control the switching points of the U 3 K Niro can be variated if separate float switches are used Picture 7 deaeration hole 4 27883 00 Operating Instructions Low level pumping Flooded basements roofs etc can easily be drained down to a level of 5 mm with the U 3 K Niro Put 2 screwdrivers into the
9. d storage o Sale PRECAUTIONS eriein a page 5 MASTAMAUON onran a a a a S page 6 8 Electrical connection Mobile an stationary installation amp Mantenan E sier aaa page 9 10 Cleaning Low level pumping Whirl system Maintenance Sectional AWG aenea EAA E E page 11 gt opale OIS S enaa T a ad page 12 page 3 Operating Instructions Technical Data U 3 K special U 3 KS special Supply voltage V 1 x 230 Power input P1 kW 0 32 Nominal current A 1 40 ee eosphi gs 3 50 max switch frequenc max water temperature protective system Description Application This manual applies to a Jung Pumpen submersible The U3 K KS pump is designed for usual domestic sump pump U 3 K special or U 3 KS special with vortex waste water It must not be used for pumping impeller and mounted on level control sewage water from lavatories In some countries sumps with a connection to the public sewer are an B ai explosion hazardous location For this application Picture 1 dimensions the explosion proof UFK series is necessary for further information ask your distributor Only Ex approved pumps may be used at different operating conditions in explosion hazardous locations Please ask the industrial and trade supervision the building inspection or the employer s liability insurance association for such an application Allowed temperature of pumped medium Continuous operation 35 C S1
10. mp The lifting equipment shall be able to hoist the pump straight up and down in the sump preferably without the need for resetting the lifting hook Oversized lifting equipment could cause damages if the pump should stick when it is lifted The lifting equipment has to be securely anchored Operating Instructions Picture 3 single installation example device Single unit with built in level control Sump dimensions min 40 x 40 cm If a covering plate is installed intend a sump ventilation Picture 5 duplex installation example peak load ON ALARM basic load ON Loewen S N N min min L min SNS SIN Z Notice of min distance 3 27827 00 Sump dimensions min 50 x 50 cm If a covering plate is installed intend a sump ventilation page Picture 4 stationary single installation example 4 27826 00 Single unit with guide rail system GR 32 and built in level control Sump dimensions min 40 x 50 cm If a covering plate is installed intend a sump ventilation Picture 6 stationary duplex installation example SN i 1 Se peak load ge ON ney z Pd P 4 cee Ne N Y MN N Notice of min distance Pumps with GR 32 1 shown turned at 90 3 28110 00 Duplex unit with guide rail system GR 32 and built in level control Sump dimensions min 50x 50 cm If a covering plate is installed intend a sump ventilation Operating Instructions
11. n it is lifted The lifting equipment has to be securely anchored Stationary installation To remove the pump easily we recommend our guide rail systems alternatively a flexible connection min DN 32 114 in the pressure tube near the pump is conceivable Adjust the duck foot bend drill the holes through the base of the duck foot bend and install the coupling unit the guide tubes and the guide bracket with the enclosed screws and plugs Install the pipe work including a ball reflux valve or a swing type check valve and a stop valve Mount the guide rail claw on the pump fasten the chain at the shackle and lower the pump via guide tube into the sump A fastening device for a hoist simplifies the pump installation WARNING Observe the measurements of the level sensors as shown in the pictures 3 4 5 and 6 The sensors must not be installed below the inlet In contrast to the U 6 Niro ES DS with built in level control the switching points of the U 6 K Niro E D can be variated if separate float switches are used The control unit must be installed in well ventilated room above the back pressure level page 8 Mobile operation deaeration For mobile operation and retrofitting of existing sumps a pump base installation is uncomplicated and easy to maintain Mount a 90 elbow to the discharge install the pressure pipe fasten the chain at the shackle and lower the pump into the sump A fastening device for a hoist
12. nel Dangerous voltage Danger for machine and function P It is imperative that signs affixed to the machine e g rotation arrow fluid connection symbols data approval plate be observed and kept legible Qualification of personnel An authorized certified electrician and mechanic shall carry out all work Scope of responsibility and supervision of the personnel must be exactly defined by the plant operator If the staff does not have the necessary knowledge they must be trained and instructed which may be performed by the machine manufacturer or supplier on behalf of the plant operator moreover the plant operator is to make sure that the contents of the operating manual are fully understood by the personnel Hazards in the event of non compliance with the safety instructions Non compliance with the safety instructions may produce a risk to the personnel as well as to the environment and the machine and results in a loss of any right to claim damages or compensation For example non compliance may involve the following hazards Failure of important functions of the machine plant Failure of specified procedures of maintenance and repair Exposure of people to electrical mechanical and chemical hazards Endangering the environment owing to hazardous substances being released Safety regulations for owner operator All safety instructions contained in this manual all relevant national and local health
13. operation Intermittent operation 60 C S3 operation 40 4 min operation 6 min stand by The pumps can be used for pumping waste water from dish washers and washing machines If kept dry the pump can be stored down to a minimum temperature of 20 C The flooded pump must not freeze Without any additional accessories a low level pumping in flooded basements on flat roofs etc down to 5 mm water level is possible see low level pumping a CN N LA On _ Transportation and storage The pump can be transported and stored in vertical or horizontal position 280 270 Always use the handle to carry the pump never lift it at the cable Make sure the pump cannot roll or fall over and injure people or with special float damage property code No 174 amp 24 If kept dry the pump can be stored down to a minimum 4 27818 00 temperature of 20 C The flooded pump must not freeze For longer periods of storage the pump must be protected against moisture and heat The impeller should be rotated occasionally to prevent the seals from sticking together After a long period of storage the pump should be inspected before it is taken into operation Pay special attention to the seals and the cable gland Follow the instructions of Operation page 4 Operating Instructions Please pay attention to the following A N regulations at installing the pump s or ask your qualified electrician distributor
14. ordered as a special version They need a special PTC thermistor for motor protection and a tripping unit with a conformity certificate e g PTB 3 53 PTC A Use frequency converters only for deceleration If three phase current pumps are operated through a frequency converter the r o m change proportional to the input frequency Frequency converters have a setting range between nearly 0 Hz and more than 50 Hz Because of physically reasons the pumps must not be operated with higher frequencies than indicated on the name plate If the frequency rises beyond the rated value the absorbed power escalates to the overload of the motor To recognize pumps with a PTC thermistor please check the name plate The last letter in the field of the motor type must be a K Example motor type D 160 4 200 K has a PTC thermistor and can be operated through a frequency converter Pumps without this mark cannot be operated through a frequency converter Example motor type D 112 4 200 Additionally the pumps have a label at the lead end to point out the possible frequency converter operation Supply voltage of the PTC thermistor max 2 5 V Installation To ensure the proper installation consider the dimensions of the installation The sump has to be cleaned from all sediments before any installation or repair works The minimum height between the lifting hook and the floor shall be sufficient to lift the pump out of the su
15. regulations for electrical installations in Germany VDE 0100 VDE 0165 VDE 0100 Teil 701 bathrooms VDE 0100 Teil 704 building ground VDE 0100 Teil 737 damp rooms regulations for prevention of accidents in sewage technical installations in Germany GUV 7 4 GUV 17 6 guidelines for explosion protection in Germany GUV 19 8 electrical installations in explosion hazardous areas in Germany Elex V Safety precautions In order to minimize the risk of accidents in connection with the service and installation work the following rules should be followed Never work alone Use a lifting harness safety line and a respirator as required Do not ignore the risk of drowning Make sure there are no poisonous gases within the work area Check the explosion risk before welding or using electric hand tools Do not ignore health hazards Observe strict cleanliness Bear in mind the risk of electrical accidents Make sure that the lifting equipment is in good condition Provide a suitable barrier around the work area e g guard rail Make sure you have a clear path of retreat Use safety helmet safety goggles and protective shoes All personnel who work with sewage systems must be vaccinated against diseases to which they may be exposed A first aid kit must be close at hand Note that special rules apply to installation in explosive atmosphere Follow all other health and safety rules and local codes and ordin
16. simplifies the pump installation WARNING The level sensors must not be installed below the inlet The control unit must be installed in well ventilated room above the back pressure level Climbing pressure pipe work has to be installed frost protected If a flexible hose is connected to the pump no reflux valve must be installed and the hose must have a gradient to ensure a completely drained off hose when the pump stops working When the pump is submerged again water in the hose will prevent the deaeration of the spiral housing and therewith the correct operation of the pump For the same reason the pump may not operate properly when it is submerged in switched on condition In sumps that can dry out ensure the correct deaeration of the spiral housing by drilling a 6mm hole into the enclosed quarter elbow part No 16687 at the marked position In case of a damage at the pump a slight quantity of the oil chamber filling can leak into the pumping medium Operating Instructions Maintenance Take out the main fuses to isolate the mains supply of both control unit and pump before any works and make sure it cannot be energized again Check the cable on mechanical or chemical damages At using a chain to lift the pump please pay AN attention to the rules for prevention of accidents Chains have to be inspected regularly by qualified personal Only authorised workshops or the manufacturer are permitted to carry ou
17. t repairs effecting the electrical security In case of repairs defective parts must be replaced by genuine spare parts Jung Pumpen disclaims all responsibility for work done by untrained unauthorized personnel General safety clean the pump thoroughly beware of the risk of infection follow local safety regulations The pump is designed for use in liquids which can be dangerous to health When working on the pump prevent injuries to the eyes and skin by wearing goggles and rubber gloves cleaning the pump before any works cleaning the parts after dismantling hold a cloth over the drain plug to prevent splatter when opening the oil chamber In case of contact with dangerous liquids eye contact rinse your eyes immediately in running water for 15 min Hold your eyelids apart with your fingers Contact an eye specialist skin contact remove contaminated clothes wash your skin with soap and water seek medical attention if necessary To keep the reliability of operation servicing should be made after every 300 working hours but not later than once a year If the pump delivers water with abrasive additions servicing should be carried out at adequate shorter intervals At decreasing flow rates or ascending noises the impeller has to be checked on wear and if necessary it has to be changed In case of a damage at the pump a slight quantity of the oil chamber filling can leak into the pumping medium Maintenance In c
18. uired for the automatic level control system by level regulators A Jung Pumpen control unit gives you the certainty of design under safety regulations and an acceptance of work without any problems Level sensors must be used at low voltage For further details please see data sheet o m Local rules may specify otherwise To prevent the pump from blocking after long rest periods an additional daily trial run unit can be installed Connection only to a mains supply installed in accordance to the local regulations For fusing use only 10 A slow fuses or automatic circuit breaker with C or D characteristic former G and K Because the motor s nominal voltage is measured at the terminal board of the pump please consider the voltage drop of long supply cables The motors of the three phase a c pumps must be protected by a suitable overcurrent release Adjustment as following direct start 10 of the nominal current Star delta start nominal current x 0 58 10 If the protective arrangement has trigged eliminate the trouble Replace the cable if the cable jacket is damaged Do not pinch the cable or pull it around sharp bends Always install the control unit in a dry and well ventilated room above the backpressure level Never install the control unit in the sump Earthing For safety reasons the earth conductor should be appr 50 mm 2 inch longer than the phase conductors If the motor cable is jerked loose b
19. y disposed of oil spills must be cleaned up and emissions to the environment must be reported On completion of work all safety and protective facilities must be reinstalled and made operative again Prior to restarting the machine the instructions listed under Electrical Connection and Installation are to be observed Unauthorized alterations and production of spare parts Any modification may be made to the machine only after consultation with the manufacturer Using spare parts and accessories authorised by the manufacturer is in the interest of safety Use of other parts may exempt the manufacturer from any warranty or compensation claims Unauthorized modes of operation The reliability of the machine delivered will be only guaranteed if it is used in the manner intended in accordance with clause 1 of this manual The limit values specified in the data sheet must under no circumstances be exceeded Warranty claim Jung Pumpen pumps are long living high quality products with expected reliable operation However should the need arise for a warranty claim please contact your Jung Pumpen distributor Operating Instructions List of contents e General Safety INStrUCTIONS ccccccececssesssseeeeeececceanensnsceesceneeeesanansaseseseeness page 2 St OnCOl te IS sorsa n a E E page 3 Extent OMOCIIVONY eisses hextadaceessaadedzeeiaccadnasssycamsed shadeaanateedunecadses page 4 Application Transportation an
20. y mistake the earth conductor should be at last conductor to come loose from its terminal This applies to both ends of cable Ensure the correct earthing of the pump and the control unit page 5 Operating Instructions Electrical connection Picture 2 wiring diagram wer 1 230V 50Hz 0 L X Pump without float switch with bridge Model with float switch UB type U Pumps E ES arrangement plug in connection Oise identification 4 07422 Winding thermostat Because of the built in thermostat an additional motor protection is not necessary Inadmissible high temperatures and operation times will release the thermostat If so pull out the plug before repairs to prevent automatically pump restarts AN Sense of rotation only three phase models Before installation you have to check the sense of rotation At correct rotating field the start bump of the pump is into the opposite direction to the arrow on the top of the pump In case of wrong direction of rotation change two of the three phases of the mains supply Heed operating voltage see name plate Do not put the plug into water Irruption of water may cause malfunctions Watch out for the start bump which can be powerful page 6 Operation through frequency converter If you want to operate pumps through a frequency converter please contact your distributor If the technical feasibility is already checked the pumps have to be
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