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KESSEL - backwater pumping station Pumpfix® F Standard/Comfort

1. All spare parts can be purchased from a specialist company Designation Art no Pumpfix F control unit Standard IP 54 28073 a Additional board for potential free contact 80072 b Remove signal generator 20 m 20162 c Battery 9V 2 units required 197 081 2 Optical probe IP 68 5 m inc adapters 80888 Cover pump feed side without outlet function 28052 Pumpfix F cover Standard outlet side 28053 Pumpfix F pump IP 68 5m inc plug 28351 Ventilation complete 28060 a Activated carbon filter 28061 Mechanical flap 80033 Insertion part for mechanical flap 80034 Hood 80031 Transition piece 83032 Seal set Il 70319 Pumpfix F for installation in the ground plate All spare parts can be purchased from a specialist company Designation Art no Pumpfix F control unit Standard IP 54 28073 a Additional board for potential free contact 80072 b Remove signal generator 20 m 20162 c Battery 9V 2 units required 197 081 2 Optical probe IP 68 5 m inc adapters 80888 Cover pump feed side without outlet function 28052 Pumpfix F cover Standard outlet side 28053 Pumpfix F pump IP 68 5m inc plug 28351 Ventilation complete 28060 6a Activated carbon filter 28061 Mechanical flap 80033 Insertion part for mechanical flap 80034 Seal set Il 70319 ae TT eT re er ie a ia sinik See a A Ai a e ee A a
2. Pre condition for trouble free operation is Sufficient gradient in the draining pipes note there is a gradient of 9 mm bet ween feed and drain with Pumpfix F Ahigh share oSufficient gradient in the draining pipes note there is a gradient of 9 mm between feed and drain with Pumpfix F e A high share of water in the wastewa ter to optimise the self cleaning effect e Correct routing and ventilation of the feed pipe in accordance with DIN EN 12056 DIN 1986 100 e Use with greasy wastewater only pos sible with increased maintenance and cleaning efforts e Rain surfaces up to max 20 m Installation of a backwater valve in the right place Ba 2 2 Scope of supply The scope of supply of the KESSEL back water pumping station Pumpfix F is made up of the drain body with pump and backwater valve and the electric packa ges The electric packages are made up of Standard 1 The optical probe 2 Acontrol unit mains connection 230 V 50 Hz protective rating IP 54 with bat tery back up 2 x 9V for alarm messa ge in the event of a power failure 3 An installation and operating manual Comfort 1 Two optical probes and the drive motor 2 One control unit with display mains connection 230 V 50 Hz protective rating IP54 with battery back up 2 x 9V for alarm message in the event of a power supply 3 An installation and operating manual 2 3 Installation procedure During the construction pha
3. sement Only draining points below the backwater level may be protected against backwater All draining points above the backwater level must be discharged into the sewage pipe with free gradient past the backwater valve Consequence separate pipe routing Domestic wastewater above the backwater level can thus rise up to a maximum of stre et level inside the downpipe without flooding the basement Rainwater must never be discharged via backwater valves Installation of a backwater valve in the wrong place Backwater level iki KESSEL 3 Installation Please note DIN EN 12056 must always be heeded when routing the base pipes Downpipes must al ways be introduced downstream from the Pumpfix F about 1m In addition a stilling section must be observed upstream and do wnstream of the FKA at least 1 m During in stallation of the backwater valve care must be taken that there is a sufficient gap to the wall for maintenance work to be carried out The KG pipe must not be connected directly to the drain body but only to the muff Caution During installation pay attention to the direction of flow arrows on the pro duct 3 1 Kessel backwater pumping station Pumpfix F for installation in the ground plate DThe drain body of the KESSEL Pumpfix F must be aligned horizontally see Fig 1 For connection of the electric cables of probe and pump a cable conduit at least DN 50 Kessel recommends 2 x 45 ben
4. newly ma nufactured products Additional informa tion can be found in section 377 of the HGB In addition to the standard warranty KESSEL offers an additional 20 year war ranty on the polymer bodies of class Il fuel separators grease separators in spection chambers wastewater treat ment systems and rainwater storage tanks This additional warranty applies to the watertightness usability and structu ral soundness of the product 11 A requirement of this additional warranty is that the product is properly installed and operated in accordance with the valid installation and user s manual as well as the corresponding norms regulations 2 Wear and tear on a product will not be considered a defect Problems with pro ducts resulting from improper installation handling or maintenance will also be con sidered a defect Note Only the manufacturer may open sealed components or screw connec tions Otherwise the warranty may beco me null and void 01 06 2010 IX KESSEL 7 Commissioning Protocol for installer Separator Type Day Hour Project description Building services supervisor Address Telephone Fax Builder Address Telephone Fax Planner Address Telephone Fax Contracted plumbing company Address Telephone Fax KESSEL Commissions no System operator owner Address Telephone Fax User Address Telephone Fax Person of delivery Other remarks The syst
5. of the ins ertable parts as well as the guide parts of the flap valves b C d We recommend these jobs after longer peri ods of standstill or intermediate storage too as well as after longer or frequent occurren ces of backwater If problems should occur that cannot be eliminated please contact the specialist company who carried out the installation see stamp on cover sheet if in doubt 4 2 1 Mounting the two covers see Fig 12 13 14 Insert the covers on one side push the other side down and lock in place using the locking levers During installation of the overflow cover the red flap lever or the motor flap po sition must always be CLOSED 4 3 Test 4 3 1 Test Standard 1 Hold the pump probe into the water On level Pump starts Comfort e Insert the insertable part exactly f Make sure the attachment clips are in place properly g Heed cover installation 4 2 1 h Carry out functional test in accordan ce with instruction manual 010 846 Level LED lit Pump LED lit 4 3 2 Test Comfort 1 Hold the motor probe into the water Flap closes Backwater LED flashes Flap LED flashes Flap closed Backwater LED flashes Flap LED lit 2 Hold the pump probe into the water Pump starts Pump LED lit 4 Service and maintenance 4 4 Pump removal The pump can be removed individually To do this turn both pump removal levers through 180 This makes them fold out wards to the
6. side so that the pump can be lifted out Fig 13 shows the Comfort variant Lock both sides Locking lever Locking lever 4 5 Motor installation The levelled drive shaft of the motor must be in a vertical position state on deli very Move the locking lever of the ope rating valve on the locking cover to the CLOSED position insert the drive motor into the drive groove from above and screw in place using the four M5 x 12 screws TX25 on the locking cover Fig 16 Pump remo val lever fe 4 6 Removing motor ground installation In this case the outlet cover must be dis mantled to remove the motor To do this open the locking lever and take the out let muff out Loosen levers 2 and and remove the bypass muff to do this tilt pump connection muff 4 away or remo ve the pump if necessary After removing the two cover locking levers the outlet cover can be removed Now the motor Motor installation Can be screwed off ur KESSEL 4 Service and maintenance 4 7 How the emergency valve works 4 7 1 Standard Locking position Fig 17 emergency valve completely closed The hand lever of the emergency valve must be put in the respective CLOSED position The back water flap works as a pipe barrier This function is only considered as protection from backwater during longer periods of absence e g holidays Connected draining points are still drai ned The emergency valv
7. te A sl ee a ae as A E q E a a A To a Ha mz Br 2 A ei a an IX KESSEL 5 Spare parts 5 2 Comfort Pumpfix F for installation in an exposed wastewater pipe All spare parts can be purchased from a specialist company Designation Art no Pumpfix F control unit Komfort IP 54 28071 a Additional board for potential free contact 80072 b Remove signal generator 20 m 20162 c Battery 9V 2 units required 197 081 2 Optical probe IP 68 5 m inc adapters 80888 Cover pump feed side without outlet function 28052 Pumpfix F cover Komfort outlet side 28056 Pumpfix F pump IP 68 5m inc plug 28351 6 Ventilation complete 28060 a Activated carbon filter 28061 Motor driven flap 80038 Insertion part for motor driven flap 80039 Hood 83031 Transition piece 83032 Drive motor IP 68 5m cable 80076 Seal set II 70319 Pumpfix F for installation in the ground plate All spare parts can be purchased from a specialist company Designation Art no Pumpfix F control unit Komfort IP 54 28071 a Additional board for potential free contact 80072 b Remove signal generator 20 m 20162 c Battery 9V 2 units required 197 081 2 Optical probe IP 68 5 m inc adapters 80888 Cover pump feed side with outlet function 28054 Pumpfix F cover Komfort outlet side 28056 Pumpfix F pump IP 68 5m inc plug 28351 Vent
8. INSTRUCTIONS FOR ASSEMBLY OPERATION AND MAINTENANCE KESSEL backwater pumping station Pumpfix F Standard Comfort for wastewater with and without sewage Product advantages For wastewater with and without sewage m Backwater flap and draining pump m Simple installation in through pipes Plug amp play control unit Control unit with self diagnosis system SDS with integrated battery back up Straightforward replacement of wearing parts Simple tool free servicing Additional advantages of the Komfort version Control unit with display Motor driven locking of the backwater flap Integrated drain function for surface water drainage Fig shows Pumpfix F Standard for installation in an exposed pipe The installation and service of this unit should be carried out by a licensed professional servicer Subject to technical amendments Name Sign Stand 04 2011 ix K FSS E ID Number 010 843EN Table of contents 1 Safety instructions 5 Spare parts 2 General points 2 2 2 2 3 Installation 3 3 3 3 3 3 3 4 Service and maintenance 4 4 4 4 4 4 4 4 4 4 4 4 4 5 5 6 Warranty 7 Commissioning protocol for the installer 8 Commissioning protocol for the installation company ROM NOOR Wh _ N ONNNDOORWWWPP 4 N A SCOPE Of Supply ccccccccccccccccccccccncnnnnno Installation procedure oocccccccccccooo General
9. ds must be provided A second probe cable and motor connection cable must be connected for the Komfort variant For this a cable conduit at least DN 70 Kessel recommends 2 x 45 bends must be planned To do this lay the cable conduit to at least finished flooring height see Fig 2 and insert in the cable duct in the adapter of the KESSEL Pumpfix F cable conduit should protrude about 2 cm into the in terior tightness Fig 5 Changes of direction must be laid with bends of max 45 To gua rantee proper aerating and venting of the pump chamber the cable conduit must not be sealed airtight Insert the enclosed profile lip seal into the adapter groove and grease this Then mount the upper cover section see Fig 3 Thanks to the telescopic design of the upper cover section the KESSEL Pumpfix F can be adapted exactly to the prevailing installation depth Ground slopes of up to 5 can be com pensated The upper cover section can also be turned to align the cover to the tile pattern for example see Fig 4 The seal must be checked for a good fit after adjustment CAUTION The upper cover section must be shorte ned to the necessary size to achieve mi nimum installation depth If necessary recesses must be cut out of the upper cover section near the cable conduit and the ventilation pipe Maximum ground water resistance is 2 m Following final alignment of the upper cover section a recess may have to be introduced
10. e must be re leased again for normal operation Abb 17 U AAA Emergency flap can be locked by hand 4 7 2 Komfort Locking position The backwater flap is closed by pressing the TEST key flap The backwater flap works as a pipe bar rier This function is only considered as protection from backwater during longer periods of absence e g holidays Connected draining points are still drai ned After return the emergency valve must be released again for normal operation by pressing the TEST key flap again Make sure that there is no backwater when this takes place 4 8 Servicing the ventilation The ventilation see spare parts section 6 must be cleaned regularly and the activa ted carbon filter Fig 18 must be changed annually or as required The ventilation must be cleaned and checked after every pump failure IX KESSEL A A Fig 18 Activated carbon filter The bleeder Fig 17 from right to left com prises seal drain body float ball seal bayonet locking cap activated carbon fil ter and cover Pull the cover off Fig 19 by tilting it slight ly to the side Then turn bayonet locking cap Fig 20 and pull it up and off Remove seal and float ball and clean ever ything Re assembly takes place in rever se order Fig 19 Cover Fig 20 Bayonet locking cap 5 1 Standard 5 Spare parts Pumpfix Ffor installation in an exposed wastewater pipe
11. em operator and those responsible were present during the commissioning of this system Place and date Signature owner Signature user IX KESSEL 12 RR RR O RA A A AA AA AAA A AO ARAS IX KESSEL 8 Commissioning Protocol for installation company Handover certificate copy for the company carrying out the installation d The initial operation and instruction was carried out in the presence of the person authorised to perform the ac ceptance and the system operator E The system operator person authorised to perform the acceptance was informed about the obligation to service the product according to the enclosed operating instructions m Initial operation and instruction were not carried out The client person responsible for initial operation was handed the following components and or product components Initial operation and instruction is being carried out by company address contact phone The exact coordination of the dates for initial operation instruction is being carried out by the system operator and person responsible for initial operation Place date Signature of person Signature of system operator Signature of the company authorised to perform acceptance carrying out the installation work IX KESSEL 14 QKl IX KESSEL d Back
12. ent DIN and VDE standards and direc tives as well as the directives of the local power supply industry must be heeded Before putting the device into operation make sure through professional examina tion that the necessary protective features are available Grounding neutral residu al current operated protective circuit etc must correspond to the requirements of the local power supply industry The system must not be operated in po IX KESSEL 1 Safety instructions tentially explosive areas The system contains electric charges and controls rotating mechanical system com ponents Non compliance with the opera ting instructions may result in considera ble damage to property personal injuries or even fatal accidents The system must be disconnec ted from the mains or made cur rentless before any work is car ried out on it gt It must be ensured that the electric cables as well as all other electrical system equipment are in a faultless condition In case of damage the system may on no account be put into operation or must be stopped immediately The system must be inspected and servi ced according to DIN 1986 to maintain its operational ability We recommend that you conclude a ser vicing contract with your installation com pany No repairs or maintenance work may be carried out during a backwater situation or if a backwater situation is imminent The backwater flaps and the locking lever al
13. essdichtungsflansch Pumpfix F Comfort 2a Tiles Screed Insulation Concrete floor Protective concrete Sealing 2 Underfloor y Y 2 5 Te O Kar Wer ra NTON Y a ZRA A os 4 Tits Ze Zr ee AR AL Va ETT TITS TT oe A m e e EE E OSOS 3 nae EEBRBAEE ARAS OS ASAS SNS ESE ES ee ETA RARA ARA a es oo a a KESSEL Pumpfix F Staufix FKA Staufix SWA Controlfix 2 Compression seal flange with seal set art no 83023 3 Extension art no 83071 4 Adapter DN 100 with compression seal flange made of stainless steel art no 27198 Control unit Locking lever Elastomer sealing sheet art no 27159 Upper cover section with plastic cover plate IX KESSEL 4 Service and maintenance 4 1 Service The system must be checked once every month by the operator through observati on of the switching routine for operational ability and leaks e Close emergency valve or with Komfort press test key to carry out functional test on backwater valve gt valve closes e Allow water to flow in e Wait until level LED pump trigger e Switch off water feed e Switch off level LED and wait for pump e Open hand lever vertical position OPEN gt Standard Komfort Please note that the backwater valve must be open after the inspection has been completed The pump should be checked at regular in tervals If operational noises increa
14. ilation complete 28060 6a Activated carbon filter 28061 Motor driven flap 80038 Insertion part for motor driven flap 80039 Drive motor IP 68 5m cable 80076 Seal set Il 70319 IX KESSEL 10 yah bl See a re ah 7 2 eu Mi a Be a a a ee er a itt a are ES He u Paii a we se eed Tie wel ann er de A 1 In the case that a KESSEL product is de fective KESSEL has the option of repai ring or replacing the product If the pro duct remains defective after the second attempt to repair or replace the product or it is economically unfeasible to repair or replace the product the customer has the right to cancel the order contract or reduce payment accordingly KESSEL must be notified immediately in writing of defects in a product In the case that the defect is not visible or difficult to detect KESSEL must be notified immediately in writing of the defect as soon as it is di scovered Ifthe product is repaired or re placed the newly repaired or replaced product shall receive a new warranty identical to that which the original defec tive product was granted The term de fective product refers only to the product or part needing repair or replacement and not necessarily to the entire product or unit KESSEL products are warranted for a period of 24 month This warranty period begins on the day the product is shipped form KESSEL to its customer The warranty only applies to
15. instructions about the installation of backwater valves Installation in the ground plate Recessed installation in the ground plate Ventilation connection ooccccnncccccc Installation in an exposed wastewater pipe oooccccnccccccccooncconnncnonnnnns Installation in water load Special features of Pumpfix F Comfort UD A REDE NE o lt A Service re MAINTENANCE cccccecccesccescceecceseceseeeseees Mounting the two covers Test Test Standard 22202220en een TEST COMMON na eenee Pump removal ccoonocccccccnnccocccnccononnncnnnonnos Motor installation 0ss44444 een Removing motor ground installation How the emergency valve works o Standard A 2 Comfort u sab Q cq OO 00 O 09 090 NNN O O O O O O OO OO Pr O OY O N U U U U ped pe pe ped Q Q Q D D D D k k _L k KR N Dear customer Before you put your backwater pum ping station Pumpfix F into operation please read through the installation in structions carefully and follow them Check first whether the system has arri ved undamaged In the event of transport damage please follow the instructions in chapter 6 Warranty 1 Safety instructions During installation operation maintenan ce or repair of the system the regulations for the prevention of accidents the perti n
16. near the cable duct to enable the cable to be pulled out again during later inspections see Fig 5 The lip seal must be fitted in the cover plate Care must be taken that the sealing lip and IX KESSEL centring lug are facing upwards during instal lation The centring lug must be placed in the recess see Fig 6 During installation make sure that the function of units in the chamber is not impaired by con struction material Installation of covers with a choice of finis hes tile height max 15 mm With the covers with a choice of finishes tiles or natural stone can be inserted in the cover on site so that they can be matched to the room s flooring Products e g from PCI Schomburg Deitermann are suitable for tile laying To achieve straightforward processing and adhe sion we recommend the following procedure Tile laying a aPrime the cover plate e g with PCI primer 303 Following the respective flash off time lay the tiles with silicone This type of laying is particularly suitable for thinner tiles since the base can be filled up to the required height b Laying the tiles e g using PCI Silcoferm S self adhesive silicone This allows a thin adhesive bed to be used particularly good for thicker tiles Laying natural stone marble granite agglo marble a Prime the cover plate e g with PCI primer 303 Lay the natural stone panels using e g PCI Carralit b Laying the natural stone panels u
17. ntegrated on the drain body and screwed together using the enclosed screws The sheeting used on site can be used as seal sheeting For installation in a waterpro of white tub KESSEL also has matching seal sheeting available made of natural rub ber NK SBR where the bore holes for the screws have already been cut out see Fig 8 If it is necessary to perforate the waterproof concrete tub to connect feed pipes cable conduits etc these holes must also be set up waterproof Maximum groundwater resi stance is 2 m Installation example black tub Installation with extension order no 83071 Use of the extension allows the flange height to be individually adjusted The attachment must be shortened to the re quired height if necessary 3 6 Special features of Pumpfix F Comfort Pumpfix F Komfort has an integrated drai ning function for surface water drainage 3 7 Set up Connection of the draining function to the feed cover is via the enclosed draining connection Insert the draining connection into the prescribed opening and lock using the one handed quick action closure Depending on installation depth installati on depth of the upper cover section the draining connection must be shortened to the respective length see Fig 9 or exten ded using HT pipe DN 70 if recessed in stallation using extension art no 83071 is used a Oe oi e Sealing sheet Pr
18. se pumping capacity decreases or there are vibrations in the pipeline system the pump housing and impeller must be checked for any stubborn soiling or wear 4 2 Maintenance at least every six months CAUTION Disconnect the unit from the mains during all servicing work Heed safety instructions No warranty will be granted in the event of insufficient maintenance All the servicing and maintenance work described below may only be carried out by authorised qualified personnel Repairs may only be carried out by the manufacturer DIN 1986 part 3 must be heeded during maintenance work on systems Maintenan ce work must be carried out at least every six months by authorised qualified staff The following tasks have to be carried out Visual inspection of the complete system e Thorough cleaning of the complete sy stem and the pump e Check on the complete system and pump housing for external damage and visible wear e Check on the pump for free movement wear and deposits e Check the connection cables for mechani cal damage and wear e Check the seal connections for leaks and any recognisable wear Insulation test on the pump motor e Check the control unit for damage and soiling e Check and clean the ventilation valve Clean the optical probe IX KESSEL Standard a Pull the insertable part out Clean all the parts Check the seals Apply lubricant e g fittings grease to the outside of the seals
19. se only the drain body is installed and connected in accor dance with chapter 3 Usually the power connection chapter 4 and subsequent in itial operation chapter 5 cannot be carried out directly Please connect the electric sy stem components pump probes motor and control unit depending on the variant when you put the KESSEL backwater pum ping station Pumpfix F into operation Until this point the enclosed electric package and the control unit must be kept stored ina clean and dry place Only remove the plug end plates when the system is put into ope ration Care must be taken that the system is al ways sealed with an upper cover section and cover or protective hood when set up as Backwater level a free standing device in order to prevent soiling of the system Caution The pump is secured by a trans portation safety tape that has to be removed before initial operation 2 4 General instructions about the in stallation of backwater valves According to DIN EN 12056 backwater val ves may not be used to protect all the drai ning points of a building including those above the backwater level street level be cause if the backwater valve is closed the wastewater from above can no longer be drained into the sewage pipe but will ac cording to the principle of communicating pipes escape from the drainage points fur thest below the backwater level first usual ly basement rooms and thus flood the ba
20. sing e g PCI Carraferm special silicone for natural stone Areas of application analogue to Laying tiles 3 2 Recessed installation in the ground plate order no 83071 Chapter 3 4 must be hee ded for installation in water load Depending on the installation depth one or max two extension pieces can be used bet ween the upper cover section and the adapter The respective seals must be greased accor dingly Please note that with recessed installation you still have to be able to reach down to the drain body for maintenance purposes 3 3 Ventilation connection Pumpfix F is fitted as standard with a ventila tion valve with activated carbon filter Alterna tively ventilation ac cording to standard canbe connected For this the ventilation I valve can be removed E gt and connected direct 5 ly to a ventilation pipe to the roof 3 4 Installation in an exposed wastewa ter pipe The version for free standing set up is deliver ed with a protective hood to prevent damage to the components following commissioning Fig 7 shows the cable ducts 1 or 2 depending on the variant 3 5 Installation in water load Seal set art no 83023 If the valve is to be installed in water load the flange serves as the necessary sealing level for a white or black tub see Figure For this purpose seal sheeting is clamped between the plastic counterflange and the compression seal flange i
21. water protection L Septic Systems Lifting Stations and pumps _ Inspection Chambers Drains and shower channels UJ Rainwater Management 2 Separators Systems Grease Separators Oil Fuel Coalescence Separators Starch Separators Sediment Separators IX KESSEL
22. ways have to be able to be moved freely Note No system components may be installed in protection zone O or 1 in accordance with DIN VDE 0100 701 In the case of flush to floor showers zone 1 is defined as with a radius of 1 20 m projected area on the floor around the water intake point Deviating local regulations must be taken into account The regulations set out by the directives VDE 0100 VDE 01107 IEC or by the local power supply industry must be heeded The control unit must not be installed in rooms where there is an explosion ha zard For the operation of this system these instructions and instructions no 010 846 must be used together 2 1 Use The KESSEL backwater pumping station Pumpfix F has been designed for through wastewater pipes that have soiled water pipes as well as toilets and urinals connec ted to them This guarantees the safe drai ning of draining spots below the backwater level even during backwater The pump only works during backwater and pumps the soi led water into the sewage channel against the backwater During backwater free ope ration the soiled water is discharged into the sewage channel through the natural gradient Pumpfix does not provide protection against rats If there is a rat hazard the sy stem must be protected from damage on site A rat protection flap is available as an opti on and prevents damage caused by gna wing to a large extent Standard only Important

KESSEL - backwater pumping station Pumpfix® F Standard/Comfort

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KESSEL - backwater pumping station Pumpfix&reg; F Standard/Comfort

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KESSEL - backwater pumping station Pumpfix® F Standard/Comfort