Operating Instructions
Contents
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4. and has the following functions Automatic operation switching on of the pump at rising water levels in the sump automatically alternating start of pump 1 and 2 after every base load operation switching on of the resting pump by peak load level controller during excessive inflow or pump malfunction alternative operation without peak load pumps do not work simultaneously but with automatically change over to the resting pump in case of malfunctions alternative operation as a single unit temporary graduated pump start to prevent extreme rushes of current e g after a power failure Outfit modes of operation can be selected by Hand 0 Automatic selectar switches pump operating is signalled by green LED H1 and H2 test run mode turn switch 51 52 into position Hand The pumps will run in continous operation independently from water level the pump will be switched off by a special winding thermostat in case of an overheated motor The pump will be switched on again automatically after cooling down the pump will be switched off by a protective motor switch in case of electrical or mechanical overload and automatically change over to the resting pump manual reactivation at the motor protective switch only BD 25 46 610 wrong power connection is indicated by a rotation control lamp only BD 00 25 46 610 possibility to connect up to 4 level sensors e g submer
5. 0 1 5 5x1 5 mm BD 25 5G25 5x 2 5 mm BD 46 5G25 5x 2 5 mm BD 610 564 0 5 x 4 0 mm Install separate pre fuses For fusing use only slow fuses or automatic circuit breakers with C D G or K characteristic Controf unit Fuse size BDOOE 20A BD 00 16A BD 25 16A BD 46 20A BD 610 25A If the sense of rotation of the mains supply is wrong the HO pilot light will be shining If so change two phases of the main supply at the control device page G Operating Instructions Equipotential bonding Connection to the earthing bar of the control unit with a lead of max 10 mm see wiring diagramm Connection of level control To control the water level in the sump please use a JUNG air diaphragm circuit control unit a JUNG static air level control unit or alternatively a JUNG float switch unit see catalogue The control unit is designed to switch the pump on and off in connection with latching contact operating relays or separate level switches Electrical connection see wiring diagramm The contacts msut have a min load of 0 5 A 30V DC Use only float switches with protective conductor safety class 1 Connection see wiring diagramm 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 At automatic mode there is a risk of a sudden restart Special rules appl
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7. Operating Instructions General Safety Instructions Application Electrical Connection Installation Maintenance 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 gurantee 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 BDOOE 00482 06 BD 00 ID No 00299 06 BD 25 ID No 00302 09 BD 46 14358 05 BD 610 ID No 14359 05 Control unit 27837 1 0 0207 page i 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 ide
8. ctions page 5 Modes of operation Instructions for qualified electricians Malfunctions e Installation instructions for qualified electricians Malfunction indication Mounting Connection of the pump Connection of the mains page 7 e Installation only for qualified electricians Connection of level control Adjustment of standard operation Adjustment as single unit with one pump Operation without peak toad function Connection of external 230 V warning or flashing lights Buzzer shutdown Connection of remote failure indicators e Construction SCHEME ix 5 cccs page 8 Connection of self recharging battery e Spare parts fist Annex Installation drawing for float switches 3 24044 Circuit diagramm BD 23 25 46 610 4 27835 page 3 Operating Instructions Extent of Delivery Technical Data Supply voltage gt x 230 V 50 Hz 1 3 x 230 V 50 230 V AC 12 V DC extra low voltage Switching capacity AC 3 max 2 x 4 0 kW AC3 Max switching frequency 30 h Protective system DIP 44 Weight approx 4 0 kg Control voltage Description Control panel in an enclosure base of insulating material with automatic or manual control The control unit is designed for two d o l starting Jung submersible pumps selected in accordance to the Jung guidelines It is supplied ready for operation
9. he returning mains supply E M wave instructions If you connect Jung submersible pumps and accessories in accordance to the Jung selection guidelines install it as prescribed and operate as directed the unit will meet the protection requirements of the EMV EG direction 89 336 EWG and is suitable for the operation in domestic industrial and municipal applications If the connection ensues to an internal power supply system of an industrial plant with own electricty supply by high voltage transformers you may be will have insufficient resistance to jamming Do not use standard batteries because they might explode page 4 Operating Instructions WARNING To ensure a correct operation always keep the panel casing dry clean and closed Operation instructions Mode of operation Automatic operation The automatic operation is the standard operation Turn switch 51 82 into position Automatik The pumps work automatically and alternating depending on the water level in the sump The operation is signalled by the green LED H1 H2 Test run Turn switch 51 82 into position Hand The pumps will run in continous operation independently from water level A if the pump operates in manual operation for too long air might be sucked into the pump casing Certain types of pumps must be deaereted before being restarted in automatic mode Special rules apply to installation in explosive atmosphere S
10. ion basic load peak load BRX Junper plug for buzzer shutdown page 8 Operating Instructions Spare Parts List ID No Description Diagram Mark 19177 motor contactor DIL EM 10 K 1 1 2 1 19241 earth terminal 20102 panel enclosure base 20104 clear view cover 22664 hand 0 automatic selector switch 51 2 24165 caver for operator panel 27649 printed contra board for BD Printed circuit board 27841 mounting base BD 00 E completely 27842 mounting base BD 00 completely 27843 mounting base BD 25 completely 27844 mounting base BD 46 completely 27845 mounting base BD 610 completely BD OOE 14582 fuse base 1 pole 16 A E 14 F 1 1 2 1 13839 fuse cap D 01 16 A E 14 a 18703 gauge piece D 01 10A T BD 00 05721 fuse base 3 pole 63 A E 18 F 1121 05723 fuse cap D 02 63 A E 48 5 18095 gauge piece D 02 63 A BD 25 46 610 14249 protective motor switch 2 5 4 0 A for BD 25 Ex F 1 1 2 1 14713 protective motor switch 4 0 6 3 A for BD 45 Ex z 14714 protective motor switch 6 3 10 A for BD 610 Ex i Accessories 22665 hour meter soldered aption A1 2 07562 rechargeable battery 9 V 110 mAh A 3 To order spare parts indicate type of control device and part number of unit Qty gt a fe N at ka page 9 LSZ LSLsn npqui3 E0 44049Z jAIUD
11. n as a single unit with one pump Push the selector switch of the connected pump into position Automatik The switch of the missing pump must be in position 0 Operation without peak load pumps do not work parallel switch position function 87 Verriegel Ein on lock out on 58 GL basic load basic load on Disconnect or do not connect the float switch for peak load operation at terminal 24 25 The signal on of the float switch leads to a transfer to the stand by pump Buzzer shutdown Unscrew clear view front cover and pull off the jumper plug BRX on the PCB above H7 To prevent loosing the plug push it on one of of the 2 pole plug connector he pins Connection of additional buzzer Unscrew the terminal cover and connect leads of the buzzer to the terminals S and S The normally open contact has a max load of 30 mA 12 V DC The contact opens again after fault clearence Connection of remote failure indicator Unscrew the terminal cover and connect leads of the indicator to the terminals 40 41 The normally open contact has a max load of 5 250 AC The contact opens again after fault clearence Buzzer signal pulsating continuous switch position function 86 f permanert or flashing operation of K6 K7 and H7 Connecting external 230 V warning or flashlight Unscrew clear view front cover and connect 230 V warning light max 1 A with terminal N and 43 Connec
12. ntified by the following symbol General danger for personnel Dangerous voltage Danger for machine and function 1 Pe 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 invoive the following hazards Failure of important functions of the machine piant 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 instr
13. r details please see data sheet o m Local rules may specify otherwise Because the motor s nominal voltage measured at the terminal board of the pump please consider the voltage drop of long supply cables Replace cables with damaged cable jackets Do not pinch cables or pull them araound sharp edges Malfunctions Pumps do not run Ifthe pumps do not run neither in automatic nor in hand mode and neither operation nor a malfunction is displayed on the PCB please check if there is supply voltage and if the pre fuses are all right If the fuses trigg iteratedly refer the examination to qualified electricians If necessary change the fuses but always with the same nominal value Wrong fuses can cause malfunctions Pumps with winding thermostat Inadmissible high temperatures e g emerged operation or media with high temperature will release the thermostat After cooling down the pump restarts again automatically The malfunction will not be displayed BD 00 and BD 00 The release of fuse s does not automatically lead to a maliunction signal Even if a pump cannot operate with trigged fuse s the operation still can be signalled by the green LED The malfunction will be signalled when the water in the sump reaches the alarm level page 5 Operating Instructions Malfunction indication Indicator HO lights wrong sense of rotation only three phase models cause Wrong phase sequenz of the main
14. s supply or one phase is missing result lower or missing pump flow rate remedy Change two of the three leads prerequisite the pump is connected in the way this manual shows Indicator H3 or H4 lights pump malfunction protective motor switch not at BDOO or BD O0E cause Wrong adjusted protective motor switch electrical or mechanical overload of the pump tightend or blocked impeller electrical motor fault remedy Check pump impeller and remove blocking parts if necessary Resetting of the overload relay and electrical fault finding should only be done by qualified electricians Indicator HS high water level lights and buzzer sounds cause Sump water level is too high because of low pump flow rate or excessive inflow remedy Check pump impeller and tube to remove blocking parts if necessary Remove excessive inflow The buzzer can be tuned out by pushing the reset switch S5 Summer aus Mounting The panel is supplied ready for operation The panel enclosure base must be screwed with 4 screws in vertical position onto the wall Install the control panel in a well ventilated and dry area safe from flooding A high degree of humidity could damage the unit The panel should be mounted at a place higher than the backpressure level and should be easily accessible to facilitate checking in case of trouble The control unit must not be installed in an explosion hazard location or inside the
15. sible ball contact switches bubbling through measurement controt unit Power input Motor protection protective motor switch Terminal capacity Dimensions Ambient temperature 1 control panel BD 00 E 00 25 46 or 610 max 4 VA standby approx 1 W 6 10 A fuses BD 00 00E 1 6 2 4 A BD 25 4 0 6 3 A BD 46 6 3 10 0 A BD 610 up to 2 5 mm 430 x 250 x 155 mm h x wx d 20 C to 50 C Standard mains independent operated alarm device signals inadmissible high water level in the sump by red LED and buzzer H7 buzzer clearence by push button S5 option code No 19160 automatic reset to readiness for service signals pump failures trigged protective motor switch by red LED H4 and H5 only BD 25 46 610 trys to start the base load pump when an inadmissible high water level is reached emergency start on damaged base or peak load level switches includes 2 potential free contacts relay 5 A 250 V ior remote failure indication by a flash light or a buzzer second relay switchable between flashing or permanent operation Main independent alarm The standard alarm device depends on the mains supply To get an alarm signal in the event of a power failure a self recharging battery part number 07562 can be installed Space and connection slot in the control device are available The battery secures an continious alarm signal of 1 hour and is recharged automatically by t
16. sump Electrical Connection Reapairs and maintenance should only be done by qualified electricians Special rules apply to installation in explosive atmosphere Take out the mains fuses to isolate the mains supply before repairs or any other works and make sure it cannot be energized again Connection of the pump The dashed drawed connections in the diagram must be wired at site by the customer To guarantee the perfect performance of the rotation sense control the connection between the control unit and the motor has to be made in accordance to the factory specifactions U1 black lead V1 brown lead W1 blue lead The leads of the motor protective thermostats 30 32 unconditional have to be connected to the terminals 30 32 of the control unit if not the protective motar switch has no function only BD 25 46 610 Do not connect lead 31 of the pump cable cut off the lead end or isolate it 230 V The motor protector switches must be adjusted to the moior rating shown on the pump type plate 10 nominal current x 0 58 Check the efficiency of the protective earthing Check correct rotation of the motors Pumps operating in reverse rotation will show a reduction in capacity accompanied_with excessive noise and vibrations Connection to mains Connection according to wiring diagramm Controf unit Core size Dimension BD 00E 352 5 3 2 BD 00 8
17. t terminal U with terminal 42 by use of an isolated 0 75 mm wire strap see wiring diagramm Circuit is protected by F3 switch position function 56 permanent operation of K6 K7 and H7 58 flashing operation of K6 K7 and H7 page 7 Operating Instructions Connecting the self recharging battery Unserew the front panel Put accumulator onto the connection siot A3 of the printed control board secure it with the cable clamp and connect it with the clip The discharged accumulator will be charged operative within 24 hours Completely charged in 100 hrs Check operatability of the accumulator regularly Accumulator working life 5 10 years Note date of accumulator insert change it after 5 years pravidently Use only 9v accumulator code 07562 By use of usual batteries there is a danger of explosion 5855 HS sa BX se OH BO E E 3 S aiae 30206410 F1 1 F21 motor fuse or protective motor switch of pump 1 2 HO rotary field indicator 1 1 2 1 motor contactor H1 H2__ operation indication pump 1 2 PE equipotential bonding H3 H4 malfunction pump 1 2 81 82 hand 0 automatic selector switch of pump 1 2 H5 high water level H7 buzzer A1 A2__ hour meter option AZ 9 V rechargeable battery option 56 K7 H7 continuous flashing 87 lock out of relay K1 and K2 On Off 58 emergency operat
18. ted All waste emissions such as used oil must be appropriately disposed of ail 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 instalation 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 ar 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 page 2 Operating Instructions List of contents General page 2 page 3 Extent oe Malone page 4 Technical datas Functional characteristics and equipment E M wave instru
19. topping of the pump Turn switch 81 and or 52 into position 0 The pumps stop working If one pumps is left in automatic operation mode it will be switched on by peak load and simultaneously to the high water alarm A Maintenance The control unit is free of maintenance The correct adjustment of the level sensors must be controlied regularly Divergences must be correctced or the float has to be cleaned Far maintenance of the tank and the pump see separate operating instructions In case of repairs or maintenance works do not only turn the switch 51 52 in position 0 but take out the pre fuses to disconnect the mains supply Ensure that it cannot be energized again Enclosure for qualified electricians only Reapairs and maintenance should only be done by qualified electricians Special rules apply to installation in explosive atmosphere Take out the mains fuses to isolate the mains supply before repairs or any other works and make sure it cannot be energized again 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 Use the control unit only in accordance to the data stated on the name plate resp in the technical data on page 4 Jung Pumpen disclaims all responsibility for work done by untrained or and unauthorized personnel Level sensors must be used at low voltage For furthe
20. uctions contained in this manual alt relevant national and local health and safety codes and any other service and safety instructions issued by the plant operator shall be complied with Safety instructions relevant for operation If 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 lt shall be the plant operator s responsibility to ensure that ail 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 decontamina
21. y to installation in explosive atmosphere Connection of maintained contact switches basic load On Off at terminal 21 23 peak load On Off at terminal 24 25 high water alarm at terminal 27 28 8 Connection of separated contact switches basic load On at terminal 21 22 peak load On at terminal 24 25 Of at terminal 22 23 high water alarm at terminal 27 28 Adjustment of standard operation Normal operation with peak load function Position of mica switches as follows switch position function 58 permanent or flashing operation of K7 H7 57 wAus off lock out off S8 Ein on peak load on The selector switches 51 and S2 have to be in position Automatik automatic Only necessary if a warning or flashing light is connected switch position function 58 SL GL GL basic load SL peak load With switch S8 the basic or peak load function in case of high water level can be selected Reapairs and maintenance should only be done by qualified electricians Special rules apply to installation in explosive atmosphere Take out the mains fuses to isolate the mains supply before repairs or any other works and make sure it cannot be energized again 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 At automatic mode there is a risk of a sudden restart Operatio
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