Float Switches And Overflow Sensor; Float Switch Stroke Limiter; Emergency Pump-Out System; Through-Wall Fitting For Drainage Hole And Ball Tap - Zenit blueBOX Manuel D'utilisation Et D'entretien

water solutions
It is advisable to check the diameters of the pipelines and gaskets carefully before drilling the holes in the tank.
Secure all the pipelines so that their weight does not rest on the lifting station.

4.9 FLOAT SWITCHES AND OVERFLOW SENSOR

The blueBOX can be used with pumps equipped with float-switches which start and stop them in response to the liquid level.
If the float switch is not installed directly on the pump, mechanical float switches are fixed to a plastic rod (FIG. 5); multiple contact float switches
are hung from the upper lip of the tank without any additional restraints. Float switches are fixed to the top lip of the tank and the pipe by means of
eye-rings supplied with the device. Zenit supplies the blueBOX complete with any float switches preassembled inside the tank.
Remember that the minimum level of the liquid must never fall below the threshold shown in FIG 6, regardless of the number of pumps installed
in the blueBOX.
The maximum level is set at 450 mm. The pumps' operating thresholds will be set within this range.
Any change to the positions of the float switches changes the way the levels inside the tank are controlled. Zenit accepts no responsibility for
malfunctions, injury or damage if the original positions of the float switches are altered.
An overflow sensor can be supplied (as an optional) to indicate when the liquid level is too high (an electrical panel must be used).

4.10 FLOAT SWITCH STROKE LIMITER

A special accessory can be used to modify the stroke length of the pump's float switch. This accessory should be used to ensure that the pump's
start-up level is not too close to the overflow level.
To install it, proceed as follows: (FIG. 7/A-B-C-D-E)
1. Separate the float switch cable from the handle cable retainer ring (FIG. 7/A)
2. Fit the stroke limiter on the pump as shown (FIG. 7/B)
3. Fix the float switch cable into the stroke limiter cable retainer ring, taking care to leave 100 mm of cable free (FIG. 7/C)
4. Fit the stroke limiter into the handle cable retainer ring as shown (FIG. 7/D)
5. Close the top of the stroke limiter using the band clamp provided (FIG. 7/E)
6. Secure the float switch cable to the stroke limiter using a band clamp, fitting it into the slots provided (FIG. 7/F)

4.11 EMERGENCY PUMP-OUT SYSTEM

blueBOX lifting stations are designed to allow an emergency submersible electric pump to be inserted through the large opening in the top if neces-
sary. The through-wall accessory can be used to connect a drainage tap, and a hand pump if necessary (not supplied).
CAUTION: the through-wall accessory for the hand pump or drainage tap must be installed, if required, by the fitter before the system is put into
operation. (see FIG. 8)

4.12 THROUGH-WALL FITTING FOR DRAINAGE HOLE AND BALL TAP

The bottom of the blueBOX is fitted to take an emergency emptying system.
With the tank empty, drill a hole with a flared grinding tool Ø50 in the chosen point and fit the through-wall joint supplied as standard (FIG. 8/A-
B-C-D)
A plug (supplied as standard) or a tap (recommended) can be fitted to the through-wall fitting.

4.13 CABLE GLAND SYSTEM

Once the pump and any float switches have been positioned, the cables have to be passed through the PATENTED modular system of rubber
cable glands.
The blueBOX 60, 90, 150 and 250 have 4 modular cable glands and the blueBOX 400 has 8 of them.
The cable glands are fitted ready to take the cables but they are still sealed to prevent unpleasant smells from escaping. Simply cut the inside of
the cable gland to perforate the rubber diaphragm and insert the cable. If the pump cable has a moulded plug, a longitudinal cut can be made along
one side of the rubber cable gland to allow it to be opened and then closed again to fit it snugly around the cable (FIG. 9).
The lengths of the cables inside the lifting station then have to be adjusted so that they are not slack.
They must move around as little as possible and must not interfere with float switch travel.

4.14 ELECTRICAL CONNECTION

The electrical connections must be made by qualified staff.
For the electrical connection of the electric pumps and control panels, follow the instructions provided in the relative manuals. In three-phase
pumps it is fundamental to check that the rotation direction is correct.
The power supply socket, or the electrical panel if installed, must be placed in a dry, protected position at least 1.5 metres above the ground.

5. FIRST START-UP

When the system is started up for the first time, the cover must be left open to allow the levels to be monitored. The first step is to fill the lifting
station with clean water. While this is done, the intake gate valve must be closed. Check that there are no leaks in the station and the pumps are
operating correctly. To assess the levels more precisely, the outlet gate valve should be 3/4 closed.
CAUTION: make sure that the submersible electric pump inside the blueBOX is primed; in some cases an air lock may form in the top of the pump
body, preventing liquid from being pumped. Check that the levels set are correct by simulating a pair of duty cycles with clean water.
Once it is certain that the lifting station is operating correctly and there are no leaks, the cover can be closed and the intake pipeline gate valve
can be opened.

6. MAINTENANCE

Maintenance work must be carried out by skilled staff, who must wear suitable safety equipment and use suitable lifting gear when handling heavy
items.
Follow the rules below if work has to be done on the product.
- First, check that all electrical components have been disconnected from the power supply.
- Read the operator's manuals of the electric pumps and control panels with care.
- Open the cover periodically and check the condition of the insides of the tank walls.
- Clean the insides of the tank walls at least once a year, especially the area around the float switches and the switches themselves.
If components are repaired or replaced, use genuine parts only. The use of non-genuine parts might generate the risk of injury or damage, or lead
to the forfeiture of warranty cover.
blueBOX - Translation of the original instructions
EN
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