Zehnder Pumpen MICROBOY Manual de usuario

Wastewater

lifting unit

MICROBOY

Operating instructions

Contents:

page

Declaration of Conformity....................................................................... 3

1. General............................................................................................... 4

1.1 Application........................................................................................ 4

1.2 Technical data................................................................................... 4

1.3 Areas of application........................................................................... 4

1.4 Accessory.......................................................................................... 5

2. Safety................................................................................................ 5

2.1 Marking of information in the instruction for use.............................. 5

2.2 Danger arising due to non-compliance with safety advice............. 5

2.3 Safety conscious working .................................................................. 5

2.4 Safety information for owner / operator.............................................. 5

2.5 Safety information for maintenance, inspection and fitting................ 5

2.6 Non-manufacturer modification and spare part production................ 6

2.7 Unauthorised usage........................................................................... 6

3. Description........................................................................................ 6

4. Installation and commencement of operation..................................... 6

5. Operation.......................................................................................... 7

6. Maintenance/Servicing...................................................................... 7

7.Disturbance,cause and elimination..................................................... 7

8. Spare parts......................................................................................... 9

9. Warranty............................................................................................ 10

10.Technical modification..................................................................... 10

Declaration of Conformity

- In accordance with EG- low voltage specifiactions i.d.F. 93/68/EWG, appendix I

- In accordance with EMV 92/31/EWG und 93/68/EWG

- In accordance with 2006/42/EG

----------------------------------------------------------------------------------------------------

We the following ZEHNDER Pumpen GmbH

Zwönitzer Straße 19

08344 Grünhain-Beierfeld,

declare that the wastewater lifting-unit Microboy

conforms to the following specifications:

- EMV 92/31/EWG und 93/68/EWG

- EG- low voltage specifiactions i.d.F. 93/68/EWG, appendix I

- 2006/42/EG

Applied harmonized norms, particularly

- EN 809

- EN 60 335-1

- EN 60 335-2-41

- EN 50 081-1

- EN 50082-1

Grünhain, 22.12.2009

Matthias Kotte

Product development manager

1.General

1.1. Application

This operating instruction is valid for the wastewater lifting-unit type MICROBOY.

Non-compliance with the operating instructions - in particular with the safety instructions - as well as non-

manufacturer modification or use of non-original spare parts will result in loss of guarantee coverage. The

manufacturer accepts no liability for damage or injury resulting from incorrect use of the equipment.

This compact unit can be used for waste disposals from one toilet and additionally other sanitary applications

such as hand-basins, showers and bidets which are located beneath the canalization (f.e. in cellar rooms).

This unit is designed only to pump household sewage water and not any harmful material according DIN 1986

T3.Sanitary towels, food, long-fibres, sanitary articles and similar subjects are prohibited.

Also it is not allowed to connect washing machines.

Manufacturer: Zehnder Pumpen GmbH

Zwönitzer Straße 19

08344 Grünhain-Beierfeld

Instruction last modified: January 2009

1.2Technical data:

Power P1......................................0,65 kW

Voltage U....................................230 V-50 Hz

Nominal current ..........................2,5 A

Speed...........................................2800 U/min

Max. capacity Qmax......................10 m3/h

Max. head Hmax ...........................10 m

Max. temperature tmax..................40°C

Outlet connection........................11/4 inch

Weight.........................................11 Kg

Overall dimensions......................454x254x299 mm

Materials:

container......................................ABS

cover............................................ABS

pump-body..................................PP

impeller .......................................PA 6

shaft.............................................Stainless steel

outlet hose...................................EPDM

seals.............................................NBR

1.3 Areas of application

This compact unit is designed for direct connection to a toilet basin equipped with a horizontal discharge pipe.

The sewage water of this toilet and additionally of a hand-basin, shower or bidet can be pumped to the

canalization at a higher level or to a sewarage far away.

This unit is constructed to handle waste water of households. All sanitary objects must be installed in the same

room as this lifting unit.

Connection of washing-machines is not allowed !

Also waste-water with sanitary towels, food, long-fibres,solvents,acids and similar cannot be

pumped

Attention !

1.4 Accessory

This unit is ready for plug-in,complete with pressure connection,check-valve and all necessary seals.

2. Safety

These instructions for use contain general information, which should be noted when setting up, using and serving

the equipment.

2.1 Marking of information in the instruction for use

danger symbol in accordance with DIN 4844 - W9,

for warnings regarding electrical current the following symbol is used

danger symbol in accordance with DIN 4844 - W8

Instructions which must be complied with if damage to the equipment and malfunctioning is to be avoided are

indicated by the presence of the words

- Attention! or Important! -

2.2 Dangerous arising due to non-compliance with safety advice

Ignoring of security instructions can lead to danger of personnel and to the environment as well as causing

possible damage to the equipment. Non-compliance with security instructions can lead to the loss of right to

claim damages.

Non-compliance with security instructions can lead for example to:

- Breakdown in important functions of the equipment

- Breakdown in prescript methods for maintenance and upkeep

- Danger of injury from electrical, mechanical or chemical sources

- Environmental damage resulting from leaks of environmentally dangerous substances

2.3 Safety concious work

These safety instructions, as well as all national safety requirements and extra internal company precautions or

such laid down by the owner of the euipment must be observed.

2.4 Safety information for the owner / operator

- Any parts of the machine which could de a possible source of hot or cold burns should be covered.

Covering for moving parts (e.g. couplings) should not be removed while the machine is in use.

Leak out of dangerous substances (e.g. explosives, poisons, hot liquids) have to be handled in such a way

that no danger to persons or the environment may occur. Legal requirements must be observed.

- Danger resulting from electrical current must be prevented (For more information consult the

specifications of the VDE or your local electricity board).

2.5 Safety information for maintenance, inspection and fitting

The owner must ensure that all maintenance, inspection and fitting work is carried out by qualified and authorised

personel who are familiar with the operating instructions for equipment. In general all maintenance work must be

carried out while the equipment is not in operation. The instructions for turning off the equipment contained in

these operating instructions must be observed.

Pumps and units which carry hazardous materials must be decontaminated.

Immediately after completion of the work all safety and protection coverings should be reinstalled and / or

switched on.

Before switching the equipment on again the points covered in the section concerning first use of the equipment

should be consulted.

2.6 Non-manufacturer modifications and spare part production

Modifications or changes to the pump are only allowed after consulting the manufacturer. Original spare parts

and accessories authorised by the manufacturer should be used to ensure safety. The use of other parts may lead

to loss of liability.

2.7 Unauthorised usage

The safety of the delivered pump is only guaranteed by usage according to the section 1 - General of the

instructions. The listed maximum ratings as per specification should under no circumstances be exceeded.

3. Description

This unit is a waste water lifting plant according DIN 19762.

The standard voltage is 230 V-50 Hz.

The unit works automatically by a built-in pressure switch.The sewage water flows into the tank by gravity.

At a definated level this pressure switch starts the pump and the liquid will be delivered to the canalization.

At a minimmum water level the pressure switch disconnects from mains and a time-relay inside the control-box

keeps the pump working for another 10 seconds.During this time the cutting device will be cleaned.

After this the pump stops.

In case of a mal-function the water level inside the tank will not decrease.Another 30 seconds later the alarm

buzzer will be activated.

For manual tests the pump can be started by pressing the switch at the units top.

4. Installation and commencement of operation

Before installing and starting please check the pump at possible demages (f.e. during trans

port) to prevent personal injury by electrical shock.

Prior to working (installing,servicing,repairs etc.) the main plug must be disconnected from

power supply.

Attention! The pump unit has a cutting device (rotating knife!) at the suction side.

Danger of injury !

Before installing the transport securing (carton) between pump unit and cover must be removed.

Loosen the screws of this cover,remove , take out this carton and fasten the cover.

Connection of lavatory:

The lifting unit has to be connected to the lavatory by using the main seal. The distance between toilet and unit

must be min. 1 cm.

Installing of pressure outlet:

The construction allows installation of the outlet pipe to the right or left side.Therefore turn the bend into

preferred direction.Use the clip to fix the pressure hose to this bend and shorten it to the appropriate length.

The pressure pipe has to be connected at the thread of the check-valve.

The minimum diameter of the pressure pipe must be 25 mm and has to be connected to the next sewage pipe

frost-resistant and in uptaking position.

Please take care for the right position of the check-valve to pretend return flow from canalization.It is

recommendable to install a gate valve.

Installing of ventilation pipe:

The ventilation of the unit is possible either by the integrated carbon filter into the room directly or by an external

pipe over the roof.The diameter of this pipe must be 40 mm. In case of external ventilation the integrated carbon

filter and ball must be removed.

Additional connections:

On both sides of the unit are two optional inlets 40 mm to connect a hand basin, shower etc.

The plastic caps must be removed to connect this additional waste pipes.

5. Operation

Because of the rotating cutting edge at the pumps shaft the screw lid is secured by a screw. During

operation this lid must be closed For repairs or servicing the unit must be disconnected from electrical

net.

All connections must be checked up if fitted correctly and tightly.

To check the function of the unit toilet must be flushed.(may be two times to fill the tank to the starting level.

The pump starts automatically and is in operation for about 6-12 seconds which depends on the lifting head.

During this time the tank will be emptied but the pump will work for another 15 seconds additionally to clean the

cutting device. This time can be changed by adjusting the time relay inside the control-box.

6. Maintenance/Servicing

- Disconnect the plug before working

Cleaning:

- All outside surfaces (tank,cover and screw lid cover) with usual domestic cleansing agent.

- In case of using WC cleansing agent it is necessary to flush several times to be sure that there are no remains

inside the container.

-Permanent cleaners inside the toilet basin must fixed carefully !

Dismantling of pump unit and control box must be done by authorized personal !

May not be initiated among other things:

·Firm materials, fibrous materials, tar, sand, cement, cinder, coarse paper, paper towels, cardboard,

rubble, garbage, battle rubbish, fat, oils.

·All drainage objects lying about the back up level (EN 12 056-1).

·Sewage with injurious materials (German Institute for Standardization 1986-100), e.g., adipose

sewage of canteen kitchens. The introduction may occur only over a fat separator to German Institute

for Standardization 4040-1.

7. Disturbance,cause and elimination

-Disconnect from mains before working!

Disturbance

Cause

Elimination

1. Motor doesn`t turn

- no voltage

- connect plug

- check wall socket and fuse

- cutting edge is blocked

- remove cover,turn shaft clockwise

with screwdriver

-inform service at recurrence

- motor overloaded

- thermical overload stops motor,reset

-inform service at recurrence

- level-switch damaged

- use push botton to empty tank

and inform service

- control system damaged

- inform service

- motor defective

- inform service

2. motor turns,but no pumping

- outlet hose clogged or buckled

- clean or repair,testrun

- air vent of pump housing clogged

- remove hose and clean hose and

nipple

- check-valve installed in wrong

direction

- turn and test run

- ventilation of tank insufficient

- replace carbon filter

3. motor starts and stops

- ventilation clogged

- cleaning

- check-valve leak

- cleaning/exchange

- toilet flush defected

- check/repair

4. motor turns very noisy

- solid inside

- inform service.

5. alarm buzzer is activated

- max. level of liquid (reasons see

above)

- use push botton /inform service

8. Spare parts

With spare part order give please always the investment type with standard number!

assembly

drawing

no.

Qty

nomination

Article

number

assembly

lifting unit

1.0

Assembly unit complete

11017E2

1.10/1.20

Container MICROBOY; complete without pump and

switching device

117620

1.120

O-ring 30x3

117703

1.140

Valve insert PE

117186

1.150

Lip seal

117188

1.160

Covering cap MICROBOY

117602

1.170

Check lid

117012.1

1.180

Cover for Check lid

117603

1.190

O-ring 125x8

117013

1.200

Sleeve

117015

1.210

Activated carbon filter

117016.0

1.220

Blind cover

117017

1.230

Valve ball

117189

1.270

Gasket ring Pg 9

117025

1.290

Sleeve gasket grey

117029

1.300

0,15m

Venting hose 12x2x150 long

117030

1.310

Angle nozzle G3/8

117031

1.320

Pressure hose MICROBOY

117604

1.330

Hose clip 20-32

117033

1.340

O-ring 34,52x3,53

117034

1.350

Rubber foot

117035

1.360

Countersunk 3,5x9,5

117605

1.370

Non return valve valve

117056

1.410

Lense head screw 4,8x22

117045

1.460

Reducing fitting G 1 ¼

117055

1.470

Threaded sleeve G 1 ¼-IG-IG

117195

1.570

Locking device for check lid cover

117149

1.580

Lense head screw 3,5x13

117614

1.590

Rubber disc

117150

1.720

Hose sewer small

129011

1.730

Cap nut

129910

1.770

Lens head screw 3,9x13

207022

1.800

Protection cap from silicone

117406

1.810

Clamping piece

117044

1.820

O-ring 15x2

117206

1.830

Counternut G 3/8

117205

assembly: pump

2.0

Pump MICROBOY-E2; complete

117502

2.10

End shield

200.040

2.20

Cablel failead

117040

2.30

Supply cable pump

117009

2.50

Shoulder bolt M5x130

800.078

2.60

Hex-nut M5

800.077

2.70

Stator MICROBOY

117132.1

2.80

Rotor MICROBOY

117052.1

2.90

Compansating disk

270029

Baugruppen

Pos.-Nr.:

Stückza

Bezeichnung

Artikelnummer

assembly: pump

2.100

Ball bearing 6202

270017

(continuation)

2.110

Compensating disk 24x35x0,5

270018

2.120

Shaft seal 12x26x7

117125

2.130

Mechanical seal bonnet

270921

2.140

Mechanical seal bottom section

270021

2.160

Impeller

272905

2.170

Locking ring A12x1

270028

2.180

Shim ring 6/1x12

117200

2.190

Shim ring 6/0,5x12

117201

2.200

Shim ring 6/0,1x12

117202

2.210

Cutter

117197

2.220

Retaining ring S6

117006

2.230

Socket head srew M6x12

117005

2.240

Pump housing MICROBOY-E2

100.400

2.250

Bottom flange MICROBOY-E2

117002.1

2.280

O-ring 120x2,5

117007

2.290

Lens head screw 4,2x19

270024

2.300

O-ring 72x3,5

117700

2.310

Cutting plate

117198

2.320

Countersunk M4x8

117199

2.330

Hose nozzle, in-line G 3/8

117191

2.340

Clamping piece

117182

2.350

Socket head screwM6x8

117026

assembly:

Switch device

3.0

Switching deviceMICROBOY-E2; complete

117410.1

3.10

Switching box bonnet

117606

3.20

Switching box bottom section

117607

3.25

Circuit board MICROBOY-E2

600.250

3.30

Cable H05-VV-F-3G1-1,5m with male connector

117047

3.40

Control cable H03-VV-F-2x0,75-0,5m

117048

3.50

Pushbutton

117042

3.60

Cable fairlead d=8

117040

3.70

Cable fairlead d=5

117041

3.80

Manostat type 901.10

117024

3.90

Protection cap for manostat

117024.2

3.200

Lens head screw 2,9x6,5

117347

3.220

Lens head screw 3,5x13

117614

3.260

Capacitor

297226

9. Warranty

This unit carries a 24 month manufacturer warranty on material and workmanship. The warranty period begins

with the date of purchase by the end user. Proof of purchase should be retained. This warranty does not cover

frost damage, dry running, thermal overloading or pumping abrasive parts in the liquid.

Warranty claims are recognized only if the unit is returned fully assembled to your dealer. Consequential

damages are not covered by the manufacturer.

10. Technical modification

.................. without prior notice

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