F Duo/XXL SPF 550 KE
Contents
1. Only authorised maintenance staff may chan ge the settings To do this the KESSEL Cu stomer Service must be contacted for the password 18 Inspection and maintenance The system must be inspected once a month by the opera tor with regard to serviceability and leaks by observing a switching cycle CAUTION Always disconnect the system from the mains supply be fore servicing Observe the safety instructions Only authorised qualified persons may carry out the ins pection and maintenance tasks described below Repairs may only be carried out by the manufacturer When servicing lifting systems the DIN 1986 Part 3 must be observed Maintenance must be carried out regularly by authorised qualified persons IMPORTANT All screws may only be tightened with a maximum force of 3 N The following tasks must be carried out e Visual inspection of the entire system the pumps and the fittings e Thorough cleaning of the entire system and the pump e Inspection of the entire system and pump casing for ex ternal damage and visible wear e Inspection of the pump to ensure it runs smoothly and for wear and deposits e Inspection of the connection lines for mechanical damage and wear e Inspection of the seal connections for leaks in the event of recognisable wear exchange the seals e g O ring e Check the insulation on the pump motor e f necessary test the function of the blocking device e The check val2. iki KESSEL 6 4 2 Information menu Maintenance Attendend time Events Errors Command type Maintenance Date Water level Parameter 6 4 3 Maintenance menu Maintenance SDS 6 4 4 Settings menu SE Maintenance Date time Sensor storage Communication Nominal size Language iki KESSEL Maintenance Date Parameter storage Operating hours Displays all running times of the system Events errors Chronological error and event display see also Chap ter 10 Malfunctions and troubleshooting All modifications to the settings are saved here Control type Displays the output parameters and the sensor confi guration incl combinations e pressure sensor pressure e alarm e compressor comp e float Maintenance date Shows the next and the last maintenance date Note Dates are only available if they have been filed in the Settings menu by the servicing partner Current measured values Displays the mains voltage current battery voltage and filling level Parameter Displays all the system control parameter settings Mains ON delay height of the dynamic pressure bell switch on lock measuring range ON level Manual operation In manual mode the automatic mode is deactivated Self diagnosis system SDS System test similar to initialisation Maintenance date The next maintenance date is entered by the servicing partner
3. Lo 16 mH Lo Ro 106 uH Installation assembly instructions e Observe the respective national regulations and provi sions e The respective installation provisions need to be ob served e Also observe the installation and assembly instruc tions of the non ATEX relevant operating instructions Special conditions for safe operation none Maintenance servicing e When the lid is removed the stated protection class tightness is reduced Check first whether there is a risk associated with a high level of damp splashwater or any other soiling In this case the control system should be disconnected from the power supply first In all cases steps should be taken to prevent water fluids or general dirt from penetrating Only an electrician may open the lid e After opening operation the lid of the casing must be closed again correctly to guarantee the protection class tightness e The device may not be modified Repair work is not possible In the event of a malfunction please contact the manufacturer e f necessary you can order data sheets EC test ex amination test certificates operating instructions and EC Declarations of Conformity from the manufacturer see cover sheet iki KESSEL 3 Technical data 3 3 Electrical switchgear 3 3 1 General technical data Ambient conditions Approved temperature range 0 to 50 C Approved humidity 10 to 80 Not condensing Maximum operating height 2000 m
4. lt 80 db lt 80 db total weight ca 200 kg AC KESSEL 3 Technical data 3 2 Information about safe use in explosive areas Proper use The pump control system serves to operate a dual pump faeces lifting system A pressure switch or another type of switch is used to record the level of faeces The operating equipment must be installed outside the explosive area Classification II 1 GD EEx ia IIC Group Il Category 1 G associated operating equip ment for gas atmosphere The specifications of the standard EN 50014 1997 A1 A2 EN 50020 2002 are satisfied EC type examination certificate of the Zener barriers BAS 01 ATEX 7217 Identification Ex II 1 G EEx ia IIC CE1180 Ta 20 C 60 C Operating instructions Installation commissioning The devices may only be built connected and commis sioned by qualified persons The qualified staff must have expertise regarding ignition protection types ope rating equipment regulations and ordinances in explosi ve areas Check if the classification see above Identification and identification on the device is suitable for the case at hand e Allowed ambient temperature range at the place of use 0 50 C Type double system Level circuit in ignition protection type Intrinsic safety EEx ia IIC terminals OFF ON1 ON2 ALARM Zener barriers MTL 7789 Maximum values Uo 28 V lo 93 mA Ro 300 Po 0 33 W Co 0 083 uF
5. 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 iki KESSEL 31 d Backwater protection _ Septic Systems _ Lifting Stations and pumps Inspection Chambers _ Drains and shower channels LJ Rainwater Management _ Separators Systems Grease Separators Oil Fuel Coalescence Separators Starch Separators Sediment Separators iki KESSEL
6. M Rinckens V ka Lk E Thiemt Leiter Innovationsmanagement Dokumentationsverantwortlicher Vorstand Innovation Management Manager Responsible for Documentation Managing Board Responsable du management pour innovation et de la documentation Conseil d administration iki KESSEL 28 iki KESSEL Important contacts Info 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 Commissioning no KESSEL System operator owner Address Telephone Fax Other remarks The system operator and those responsible were present during the commissioning of this system Place and Date Signature Builder Unterschrift Anlagenbetreiber iki KESSEL 30 Handover Ceritficate Handover certificate copy for the company carrying out the installation RW The initial operation and instruction was carried out in the presence of the person authorised to perform the acceptance and the system operator RW The system operator person authorised to perform the acceptance was informed about the obligation to ser vice the product according to the enclosed operating instructions BW Initial operation and instruction were not carried out The client person responsible for initial operation was handed the following components and or product compo nents
7. Safety information Health risk The wastewater system transports wastewater that contains faeces in turn this faeces may contain harmful substances Whenever working on the system always ensure that there is no direct contact between the wastewater and or soiled system parts and your eyes mouth or skin In the event of di rect contact clean the affected part of your body thoroughly and disinfect if necessary It is also pos sible that the atmosphere in the tank may be harmful Therefore before opening the cleaning aperture or removing the pump ensure that the respective room is adequately ventilated or provide for forced ventilation during the opening process Noise pollution When the pump is operated a noise level is created that may be a nuisance depending on how the pump is installed If there are maximum noise level stipulations that need to be observed appropriate measures need to be taken The sound damping set from KESSEL may also be helpful here Risk of explosion The inside of the tank is considered to be explosive within the meaning of EN 12050 because the bio logical digestive process may create flammable gases hydrogen sulphide methane gas Therefore when unscrewing the pump or the cleaning aperture lid or any other parts ensure that the room Is ade quately ventilated or provide for forced ventilation during the opening process Whilst the tank is open it is forbidden to smoke or carry out any other activitie
8. above sea level Power input max approx 5 VA for simple system Electronic without motor Protection class class 1 Protection type IP 30 if fitted correctly 3 3 2 Power supply Main connection PE N L1 L2 L3 acc to identification on the terminal block and master switch Operating voltage 400 230 V 3 50 Hz 10 three phase current L1 230V AC 50Hz 10 to supply the electronics power units Required fuse max 25 A C phase to be provided for on installation side Leakage current circuit breaker with 30 mA rated residual current 3 3 3 Inputs Every pump has TF1 TF2 bridged do not remove bridge Level inputs respective approx 24 Vda lt 5 mA without ATEX Level inputs via Zener barriers with ATEX iki KESSEL 3 3 4 Outputs Relay Malfunction Two way contact opener middle contact closer respec tively max 42 Vac dc 0 5A for relay Malfunction and War ning separate fuse for external voltage Caution Even when the master switch is switched off there is still external voltage on Relay Warning Two way contact opener middle contact closer respec tively max 42 Vac dc 0 5A Main supply Connect a separate fuse for the external voltage supply Motor 1 2 double system Motor 1 2 PE mains connection Spring terminal on circuit board Motor 1 2 U Terminal 1 6 Motor 1 2 V Terminal 2 7 Motor 1 2 W Terminal 3 8 4 Installation and assembly The delivery includes th
9. connections are tignt 6 2 Pressure discharge pipes DAs standard the pressure discharge pipes of the lifting sy stem are equipped with a check valve and backflow pre venter for each pipe The backflow preventer must always be operational See Fig 1 The flap dotted line is only opened by the flow of the pump a BI o CORRE DRE G l As aan 8 8 eee EES ER Mer WEE Duo apen 8 rt es 2 gt A Ge KES SEL EE The system is operational when the POWER LED shines and if no malfunction ALARM LED are displayed As the level of dirty water in the tank rises the float recognises the ON level and the pump is switched on When the pump ope rates the level of water in the tank drops so that the OFF level is undercut again After the end of the after running pe riod the pump is switched off The float symbols in the dis play show when the respective levels have been reached If the current running time of the pump exceeds the confi gured value of the maximum limit running time the pump is switched off At the same time a malfunction Is indicated by the orange LED and the relay output Malfunction The malfunction LED and relay remains saved until the Alarm key is pressed The pump s can be switched on by pressing the test key iki KESSEL 6 4 Operating the switchgear Aqualift F Duo 400V D iki KESSEL Bei der Erstinitialisierung oder bei der Initialisierung nach einem Reset wird
10. the air hose between blocked the switchgear and level control and if it is in stalled correctly even gradient if necessary correct or exchange Level control is soiled switch Dismantle the level control clean the immersi points set wrongly or illogically on tube check the pressure control check the levels setting values for the levels Revolving field wrong Exchange power cores malfunction message on the switchgear Rotational direction of the pumps Check the pump cores are connected correc is wrong tly 8 2 Error messages Every malfunction is shown on the display If several errors occur at the same time these are shown one after another and can be viewed by scrolling down the display iki KESSEL 8 Malfunctions and troubleshooting Error messages troubleshooting lit up C off slowing flashing fast flashing Battery error Mono POWER LED ALARM LED NIVEAU LED PUMPE LED Duo POWER LED ALARM LED PUMPE LED PUMPE ILLED Mains failure battery mode Mono POWER LED ALARM LED NIVEAU LED PUMPE LED Duo POWER LED ALARM LED PUMPE FLED PUMPE ILLED Motor error Mono POWER LED ALARM LED NIVEAU LED PUMPE LED Duo Pumpe 1 POWER LED ALARM LED PUMPE FLED PUMPE IFLED Duo Pumpe 2 POWER LED ALARM LED PUMPE LED PUMPE I LED acknowledge alarm and alarm key check if the battery is connected exchange discharged battery the charging status of the b
11. ALARM LED NIVEAU LED PUMPE LED iki KESSEL 24 Relay switching cycles Mono POWER LED ALARM LED NIVEAU LED PUMPE LED Duo Pumpe 1 POWER LED ALARM LED PUMPE LED PUMPE IL EI Duo Pumpe 1 POWER LED ALARM LED PUMPE LED PUMPE I LED Relay error Mono POWER LED ALARM LED NIVEAU LED PUMPE LED Duo Pumpe 1 POWER LED amp ALARM LED e PUMPE LED D PUMPE I LED Duo Pumpe 2 j POWER LED amp ALARM LED O PUMPE FLED amp PUMPEII LED Alarm level exceeded Mono POWER LED ALARM LED NIVEAU LED PUMPE LED Duo Pumpe 1 POWER LED ALARM LED PUMPE LED PUMPE I LED 8 Malfunctions and troubleshooting Main contactor has exceeded 100 000 switching cycles gt can be acknowledged main contactor does another 1000 switching cycles before a new message is sent gt Exchange the contactor gt Contact the Customer Service gt After 100000 switching cycles the relay switching cycle error is repeated after every further 1000 cycles Main contactor no longer switches off gt Disconnect the switchgear from the mains gt Exchange the contactor gt Contact the Customer Service Alarm level is achieved by the water level gt Alarm turns off automatically if the alarm level has been undercut again gt LED only turns off after it has been acknowledged manually gt Check intake gt Check level recording and switch points AC KESSEL 25 9 Spare parts and access
12. INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS KESSEL lifting station Aqualift F Duo XXL SPF 550 KE for wastewater with and without faeces for free standing installation in rooms protected from frost Aqualift F Duo XXL SPF 550 KE E Drilling surfaces for further connections m Fully automatic operation m Maintenance friendly PE tank m User friendly menu navigati on via a 6 line display L Installation TT Commissioning J Instruction The installation and service of this unit should be carried out by a licensed professional servicer Subject to technical amend Name Sign Company Telephone No iki KESSEL Edition 10 2010 ID Nr 206 830EN 1 Safety information General safety precautions During installation operation maintenance or repairs to the system please observe the accident pre vention regulations the applicable DIN and VDE standards and guidelines and also the regulations of the local energy and supply companies The systems may not be operated in explosive areas Electrical hazards This system contains electrical voltages and controls rotating mechanical parts Non observation of the operating instructions could lead to serious damage injury or even fatal accidents The system must be securely disconnected from the mains supply before commencing any work on it The local master switch and the cut outs must be turned off i e switch the system to zero poten tial and take p
13. Recording the level Setting the float switch The float switches are fitted and set in the factory Changing the settings can lead to malfunctions Four float switches are required to switch this system OFF ON1 ON2 ALARM The alarm level lies approximately at the same height as the lower edge of the supply pipe If another switching level is required the floats need to be set accordingly However ensure that the alarm float does not switch above the supply pipe and that the OFF float pre vents air from being sucked in Complete flooding of the pump is advisable 5 Electrical connections CAUTION Only qualified electricians may carry out the work descri bed below to the electrical equipment Before commen cing any work on the switchgear the pump or the level control the master switch and cut outs must be switched off and secured against being reconnected 5 1 General information The strain must be taken from all connected cables by means of screw connections Any screw connections that are not used must always be closed correctly IMPORTANT After the end of the installation work all the cables connected to the electrical switchgear need to be affixed by suitable means e g cable ties so that in the 1 error case or if a connection comes undone this does not pose a hazard Please observe the national and local safety regulations Noncompliance could lead to injury Also this will result in a limitation
14. ace if neces Foreign body inside the pump iki KESSEL 21 8 Malfunctions and troubleshooting AbhilfemaBnahme Remove foreign body check pump for dama ge and replace if necessary Leaks in the lifting system Foul smell Pump leaks Check the pump if necessary arrange for re pair or exchange by the Customer Service Pungent smell Motor s too hot overloaded Check the motor and pump run smoothly check the system for switching errors in parti cular the motor circuit breaker Frequent switching on and off of the system due to high supply quantities clarify with the KESSEL Customer Service Contactor too hot due to swit Check system for switching errors ching malfunctions System runs too frequently Supply quantity is too high due to Determine the cause and the remedy switches on without reason external water etc The check valve is defective wa Check the check valve integrated in the pres stewater runs from the pressure Sure discharge pipes of every pump clean and pipe back into the system exchange any damaged parts System does not switch off or Foam is created in the system Reduce the use of washing detergent or was has a variety of malfunctions hing up liquid anks or the pumps have Clean the entire system check incoming grea covered in grease due to high se levels quantity of grease in the supply material Ventilation of the level control ig Check if there is a kink in
15. atteries can be tested in menu 1 5 3 measuring the battery voltage after acknowledging the signal tone press the alarm key again gt switchgear continues to work without the batteries gt no protective function in the event of a mains power failure Check if the mains failure has just affected the room or the entire building Check the cut outs check the error current circuit breaker Check if the mains supply cable is defective Check the micro fuse in the switchgear only use a fuse with the same rated value and tripping characteristics Cause TF1 TF2 motor circuit breaker Remedy If display shows Motor circuit breaker 1 2 gt check the motor circuit breaker 1 2 If display shows TF1a TF2a gt the lower winding temperature switch has triggered gt resets automatically when the motor cools down Error message must be acknowledged with the alarm key If display shows TF1b TF2b gt for lifting systems bridge TF2 defective not installed Exchange install bridge iki KESSEL 23 8 Malfunctions and troubleshooting Limit running time error limit running count error Mono Limit running count error Pump is activated more than 20 times in 3 min POWER LED gt a n E the immersion tube immersion bell and switchgear ALARM LED gt Check if the immersion tube immersion bell is blocked NIVEAU LED i gt Check intake check pump capacity PUMPE LED Limit runn
16. ct KESSEL must be notified immediately in writing of the defect as soon as it is discovered If the product is repaired or replaced the newly repaired or replaced product shall re ceive anew warranty identical to that which the original de fective product was granted The term defective product re fers 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 war ranty period begins on the day the product is shipped form KESSEL to its customer The warranty only applies to newly manufactured products Additional information can be found in section 377 of the HGB 2 In addition to the standard warranty KESSEL offers an addi tional 20 year warranty on the polymer bodies of class Il fuel separators grease separators inspection chambers wastewater treatment systems and rainwater storage tanks This additional warranty applies to the watertightness usa bility and structural soundness of the product 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 corre sponding norms regulations Wear and tear on a product will not be considered a defect Problems with products resulting from improper installation handling or maintenance will also be considered a defect Note Only the manufacturer may o
17. die Bei einem Systemneustart folgende Eingabe verlangt beispielsweise nach einem Netzausfall geht die Steverung in den Automatikbetrieh und zeigt die Systaminto an Datum Uhrzeit Gaum 04 05 2000 Ubrzeit Anzeige Systeminfo d Systeminfo Hebeanlage 1 1k 4 Drepp rau 4 132100 20 45 16 FlilEtant CRU rs iki KESSEL Display display field 2 Movement keys direction keys 3 Confirmation key OK key 4 Return key ESC key 5 Power LED to indicate the system is opera tional 6 Control lamp for alarms QD Activate the pump manually by pressing twice Comment If the lid is lifted the master switch must be switched off regardless of what the system is currently doing The first time the system is initialised the con trol device asks for four basic settings The fol lowing appears in the control device display as king for 1 the user language 2 the date and time 3 sensor configuration 4 output parameter Use the movement keys direction keys to mark the required setting and then press the confirmation key to save the selected setting in the system memory As soon as the 4 preset tings have been made the control device loads the program memory and enters the operating mode The system is now operational 16 Menu navigation The switchgear menu navigation is divided into the sy stem information and also three separate main menu items The background lighting is activated by p
18. e following parts see section 2 2 4 1 Assembly of the sumps Sump with all mounted parts Electrical switchgear Accessories To allow assembly maintenance and servicing work to be carried out on the lifting systems easily they always need IMPORTANT The electrical switchgear must be stored in a frost free and dry place If the system is not connected electrical ly during installation the switchgear must be stored pro perly in the meantime CAUTION Risk due to heavy weights The lifting systems each weigh approx 45 kg single systems and approx 84 kg double sy stem The parts may only be lifted and mounted taking great care and whilst wearing the correct equipment If the system is dropped irreparable damage may be caused to the system parts e g pump or the entire system This da mage is not covered by the warranty INSTALLATION SITE The KESSEL Aqualift F lifting system is designed for free standing installation in frost protected rooms The associated switchgear needs to be installed in a dry room protected from flooding and frost to be installed so that the lifting system can be easily ac cessed and that there is at least a free space of 60 cm aro und the system as stipulated in EN 12056 all round and on top The system must installed horizontally in an appropriate po sition in the room on sound absorbing material available from KESSEL as an accessory The lifting system must be con
19. e ke k k b ES ES a negen AREDEDLES mme el w g a es e MUR DE EE Eng 7 lt EWL We Netz Pumpe 1 Pumpe 2 Schwimmer Mains pumpi pump 2 Floater R seau Pompe 7 Pompe 2 Floteur 400Vac 50Hz 400Vac 50Hz 400Vac 50Hz 24Vdc 1mA AUS EIN EIN Alarm OFF ONT ONZ Alarm iki KESSEL 13 5 Electrical connections Work to be carried out DOUBLE SYSTEM OBSERVE SAFETY INFORMATION Work to be carried out Battery connection e Both batteries 2 x 9V Block must be connected to the circuit board Mains connection Motor supply line Recording the level Outlets iki KESSEL e Mains power cable L1 L2 L3 N PE to terminal left PE N L1 L2 L3 e N and PE always need to be connected e The stipulated pre fuses on the installation side may not exceed 25 A C per phase e f connected wrongly the control system nay become damaged or be destroyed e The motor supply lines 2 x U V W need to be connected logically to the terminals 1 2 3 Pump 1 left or 6 7 8 Pump 2 right The rotational direction of the motors needs to be observed e The temperature sensors strand 5 and 6 and the protective earth PE must be connec ted to the respective pump clamping block The end of the cables of the float switch are connected to the terminals 11 18 as sta ted on the circuit diagram see page 12 e The Malfunction and Warning messages are each sent via a relay two way contact without Malfunctio
20. ies an aanseceeettteeeeeeeeceeeeeeaussecceeeeeeuaauseeeeeseeseaaaaeeeeeesseaaaaeeeeeeeeseagegs Page 26 WENT TT a Page 27 11 Declaration of conformity EE Page 28 12 Handover Ce TG NEE Page 29 WE KESSEL 2 1 Application scope The lifting systems pump the wastewater with and without faeces that is collected below the drain and local back up level into the sewers fully automatically in compliance with the stipulations of EN 12056 They may only be used for household wastewater for example from detached homes and apartment buildings commercial operations hotels and restaurants shops hospitals schools or other similar cases If the incoming flow to the lifting system may not be inter rupted during normal operation the lifting system also needs to be equipped with a second pumping device with the same output level that can switch on automatically if re quired double instead of single system 2 2 Description of the Aqualift F Duo XXL system The KESSEL Aqualift F lifting system is designed for free standing installation in frost protected rooms The associa ted switchgear needs to be installed in a dry room protec ted from flooding and frost The pressure lines must be de signed to be at least DN 80 the ventilation lines at least DN 50 Abrasive media must be kept away from the pump im peller The systems are suitable for permanent wastewater tempe ratures of up to 35 C Brief up to 10 minutes incoming tem perature
21. ing time error Pump runs for longer than 240 min without stopping gt Check the air pipe between the immersion tube immersion bell and switchgear for water inclusions POWER LED gt Check if the immersion tube immersion bell is blocked ALARM LED gt Check intake check pump capacity PUMPE LUED PUMPE II EL Duo Pumpe 1 Duo Pumpe 2 POWER LED ALARM LED PUMPE l LED PUMPE IL EL Sensor error only for XXL systems Level error A float indicates a level although no float below has triggered wrong sequence float gt Check the float cable of the float below gt Check the function of the float in the tank lift gt The pump s is are switched on The switchgear works with the recognised level Mono POWER LED ALARM LED NIVEAU LED PUMPE LED Duo Pumpe 1 2 POWER LED ALARM LED PUMPE LED PUMPE ILLED Revolving field phase errors Revolving field error Wrong revolving field when connected to mains Switchgear gt exchange 2 phases Mono POWER LED ALARM LED NIVEAU LED PUMPE LED Phase error Phase L1 or L2 L3 do not exist gt Check connection to switchgear power cable cut outs Duo Pumpe 1 2 eo Check error current circuit breaker POWER LED a or gt If L1 fails the revolving field direction cannot be recognised gt If L1 fails the switchgear goes into battery mode gt In the case of revolving field errors the pumps are not switched on in manual or automatic mode
22. manual pump if one has been instal led The commissioning process must be documented in writing during which important data such as e g the setting of the motor circuit breaker and the data of the operating hour coun ter are recorded The commissioning process may only be AUS out by T parron ms standard DIN 1986 SE Caution Before starting the commissioning process the intake lines and the pump need to be cleared of solids such as metal sand etc Before starting the commissioning process the pump must be filled with the pumped liquid up to the level of the ven ting borehole in the pump casing The pump may not suction in any air After the whole system and all the extra parts pipes and el ectrical connections have been installed completely and correctly the system can be started All fitted gate valves must be open Before commissioning please ensure that the rated voltage and current type stipulated for the system correspond to the rated voltage and current type on site Before starting the commissioning process check the in Stallation cables again carefully Is the protective earth ef fective Have the relevant standards guidelines been ob served in particular with regard to the explosive area Do not start the system if there is any visible damage to the motor the switchgear or the cables Please always observe the safety instructions in Chapter 1 15 of these instructions IMPORTANT eck all screw
23. n and Warning e Suppressor Interference from inductive loads need to be suppressed externally The idle state current free of the relay is printed onto the circuit board It means that the Malfunction and Warning message is switched on e 42Vdc 0 5A 6 1 General information Commissioning The commissioning process must be carried out by a quali fied person The availability of this person is the responsibili ty of the direct supplier of the wastewater lifting system A test run with water lasting at least two switching cycles is requi red for the commissioning process During the test run steps should be taken to prevent the system running dry The fol lowing need to be tested before during and after the test run a the electrical cut out of the wastewater lifting system ac cording to the IEC regulations and local regulations b the rotational direction of the motor c the valves activation open position tightness d the switching and setting of the switching levels in the sump if not already set by the manufacturer e tightness of the system fittings and lines f testing of the operating voltage and frequency g function test of the backflow preventers h alarm relay i attachment of the pressure line j motor circuit breaker tested by temporarily unscrewing two cut outs two phase run k oil level if there is an oil chamber control lamps and counters m function test of the
24. nected to the ground using the supplied brackets scr ews and wall plugs to prevent it from slipping or turning 4 2 2 Connection of the pipes All pipes must be installed so that they can empty on their own All pipe connections must be designed to be flexible and sound damping A standard plastic sleeve can be pushed over the pipes Connections to the drilling surfaces on the side for supply line or manual diaphragm pump by drilling with the hole saw ins ertion of the matching greased seal and pushing over a plastic pipe see Fig A Pipe opening seal KESSEL accessory iki KESSEL 4 Installation and assembly Inlet pipe The inlet pipe must be laid at a gradient to the KESSEL lif ting station in accordance with EN 12056 and be routed as straight as possible Connection is with DN 150 Ventilation The ventilation pipe sets up pressure compensation to the fresh air for the air flowing into or out of the system during emptying or filling Connection is designed with DN 100 DA 110 mm and must be routed to above the roof to avoid odour pollution Pressure line The pressure line used to drain the dirty water into the sewer system must be connected directly to the respective pres sure line connection In compliance with the specifications of EN 12056 the pressure line must be laid above the local back up level and should be connected to a vented mains pipe or distributing main For acoustic decoupling
25. of liability and warranty exclusion After the com pletion of the work the cover plate and the transparent ca sing lid must be reattached correctly contact and splas hwater protection 11 5 2 Assembly of the switchgear Screw the casing lid tight with a max force of 1 Nm Install the supplied switchgear in a frost free dry room that is pro tected against floods and well ventilated The switchgear is designed for wall mounting on a firm surface To prevent ex cessive inner temperatures ensure there is adequate air cir culation The unit is assembled using 4 screws diameter 6 mm in the corners of the casing The attachment holes can be accessed by opening and folding back the upper lid or removing the lower lid 5 3 Installation wiring The cables pre mounted to the pumps and the pressure level switch have a standard length of 5 m The pump ca bles may only be extended using a VDE conform connec tion 5 4 Checks The motor circuit breaker need to be set to the values for the rated current of the associated pumps as stated in sec iki KESSEL 5 Electrical connections 5 5 Circuit diagram XXL SPF 550 KE Atex i e j KIT aa Eu f L TTE F eyes me LU Netz Pumpe 1 Pumpe 2 Schwimmer Mains pump pump 2 Floater R seau Pompe 7 Pompe 2 Floteur 400Vac 50Hz 400Vac 50Hz 400Vac 50Hz 24Vdc 1mA AUS EIN EIN2 Alarm OFF ONT ONZ Alarm iki KESSEL 12 5 Electrical connections k
26. ories Accessories Designation Order Nr Manual diaphragm pump 28680 Stopcock for manual diaphragm pump 28681 Elastic hose connection with 2 hose clips DN 40 28660 DN 70 28661 DN 100 28663 Flange hose connection DN 80 28655 DN 150 28658 Gate valve made of plastic for unpressurised installation DN 100 28698 DN 150 28699 Seal for pipe opening DN 50 850114 DN 70 850116 DN 100 850117 DN 125 850118 DN 150 850119 Hole saw DN 50 DN 150 50100 Battery 1 unit 197 081 Blocking device DN 100 28683 Compressor set for air bubbling 28048 Air filter for compressor 28048 363 140 Motorschutzschalter 9 14 Amp 363 186 Motor circuit breaker 6 3 10 Amp 363 151 Level sensor 363 138 Float for XXL system 185 043 Motor complete 5 6 kW for XXL system 245 406 Switchgear for XXL system ATEX 363 196 Switchgear for XXL system 363 197 See also KESSEL Catalogue iki KESSEL 10 Warranty 1 In the case that a KESSEL product is defective KESSEL has the option of repairing or replacing the product If the product remains defective after the second attempt to repair or re place 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 pro duct In the case that the defect is not visible or difficult to dete
27. pen sealed components or screw connections Otherwise the warranty may become null and void 01 06 2010 iki KESSEL CE KESSEL rte Late ge LAN OI i Li aF 2 d rA ia ERA e Tih EU KONFORMITATSERKLARUNG EC declaration of conformity D claration CE de conformit Nach der Maschinenrichtlinie 2006 42 EG der Niederspannungsrichtlinie 2006 95 EG Richtlinie der elektromagnetischen Vertraglichkeit 89 336 EWG According to the Machine Guidelines 2006 42 EG the Low Voltage Guidelines 2006 95 EG Electromagnetism Guidelines 89 336 EEC Selon les directives m caniques 2006 42 EG les directives de basse tension 2006 95 EG les directives pour la compatibilit lectromagn tique 89 336 EEC KESSEL AG Bahnhofstrake 31 D 85101 Lenting erklaren wir we declare nous d clarons dass das Produkt that the product que le produit KESSEL Hebeanlage Aqualift F fur fakalienhaltiges und fakalienfreies Abwasser zur freien Aufstellung in frostgesch tzten R umen KESSEL Aqualift F Lifting Station for wastewater with or without sewage for above ground installation in weather protected areas Poste de relevage Aqualift F KESSEL pour eaux us es et eaux vannes pour une installation en local l abri du gel den folgenden Normen entspricht is in agreement with est en accord avec EN 12050 1 EN 12056 4 EN 55082 2 EN 55014 EN 292 EN 55011 EN 60335 Lenting den 23 2 2010 Ay
28. purposes and to avoid the transfer of forces the supplied rubber braided hose of approx 4 m in length always needs to be pushed over the pressure pipes at the pressure connection and fixed via a hose clip The rubber braided hose connection is not a longitudinal force fit connection This must be attached on site e g using hol ders The pressure line must be fitted see below so that the no forces are exerted on to the system and that there is no di rect contact with the building structure borne noise No other drainage objects may be attached to the pressure line The tightness and strength must be guaranteed even under pressure This should be tested when the system is commissioned To avoid pressure shocks the pressure line should not be connected too tightly to the building If cast iron or steel pressure pipes with low damping properties are used a pressure shock damper must be fitted into the pressure line if the pumping height exceeds 5 m A gate valve needs to be installed in the pressure line on site as stipulated in EN 12056 We recommend using the blocking devices for Mono systems Art No 28683 and for Duo systems Art No 28694 from the KESSEL accessories range Check valves to prevent pressure shocks for installation in the pressure line are available as accessories DN 80 check valve from GG Art No 206 199 DN 100 check valve from GG Art No 206 198 Backflow preventer Art No 206 200 iki KESSEL 4 3
29. recautions to ensure it cannot be switched on again If only cut outs are available these must be switched off and a sign attached to prevent third parties from switching the main fuse on again VDE 0100 applies to all electrical work on the system The switchgear and the level control are under voltage and may not be opened Only electricians may work on the electrical equipment The term electrician is defined in the VDE 0105 Steps must be taken to ensure that the electrical cables and all other electrical system parts are in a fully functional condition If any parts are damaged the system may not be operated and or must be immediately shut down Risk of burning fingers and hands The driving engine may become very hot during operation Risk of injury to fingers and hands The pumps are equipped with a closed impeller Therefore work on the pump may only be carried out if the power supply has been disconnected and the rotating parts have stopped rotating Take care on sharp edges during maintenance or repair work Risk due to heavy weights The lifting system models with one pump weigh around 45 kg and with two pumps around 84 kg The systems may only be lifted or mounted by two persons with appropriate care wearing protective equip ment e g protective shoes The pumps may only be removed slowly or placed in the pump flange opening by two persons if sui table precautions to prevent slipping have been taken iki KESSEL 1
30. ressing the operating key once OK key Jumps to the next lower level ESC key Jumps to the next higher level A Navigation within a level The acoustic signal can be acknowledged by pressing once If the error has been rectified the alarm key can be pressed again to acknowledge the optical error If the error has not been rectified pressing the alarm key again will retrigger the acoustic alarm 6 4 1 System menu 0 Systeminfo Leistungsgroke Sensorkonfiguration Datum Uhrzeit If there is a mains power failure the system is not opera tional The switchgear goes into stand by mode battery mode This is signalised by an acoustic and optical alarm The acoustic alarm can be acknowledged by pressing the alarm key The stand by mode is maintained for at least 72 hours If the battery is discharged the device auto matically switches off The switchgear can be switched off manually by pressing the alarm key for more than 5 sec in stand by mode When the mains power comes on again the device in itialises automatically and is operational again Note Some menus are protected by a password to ensure the system is used properly Information Fullstandsanzeige Fehler Ereignisse Maintenance Beispiel 0 gt Systeminfo Display the hierarchy level incl Pump 10A Numbering Floater System type 24 12 2009 20 45 16 Lise Fullstand 17 Control type Date time Current filling level
31. s in the respective room that could cause the gas to ignite e g operation of electrical devices without encapsulated motors metalworking etc iki KESSEL Table of contents t SOON OL ne nn ne Page 2 2 General 2 1 Application SCOpE Page 5 2 2 Description of the system Page 5 3 Technical data 3 1 Ag alint F DUO KA ent or Page 6 3 2 Information about safe use in explosive areas Page 7 4 Installation and assembly 4 1 Notes on the Set Up location Page 9 4 2 Connection of the pipes EE Page 9 4 3 Level recording DEE Page 10 5 Electrical connections 5 1 General information Page 11 5 2 Assembly of the switchgear cccccccccscsstssssssseeeeeeeeeeeeeeeeees Page 11 5 3 Installation wiring ss Page 11 5 4 Checking the rotation direction of the pump 11nnnnnnnnn Page 11 5 5 ROIS 161 110 p PE TS Page 12 6 Commissioning 6 1 General information Page 15 6 2 Pressure discharge pipes cceccccceesssssseesssssseeeeeeeeeeeeeeeeeaes Page 15 6 3 Description of the function Page 15 6 4 Control unit e E e D Page 16 7 Inspection and maintenance 7 1 Information about the pump Page 19 1 2 Information about the backflow preventer ssesesssssnnsssnsen Page 19 1 3 Information about the electrical switchgear cccceeeeees Page 20 8 Malfunctions and 8 1 General malfunctions kk ENNEN ENN Page 21 troubleshooting 8 2 Belge Page 22 9 Spare parts and accessor
32. s of maximum 60 C are allowed 1993 mm ee et ji Ki I S D s i a TA m TX Ho 1923 mm D Intake line DN 150 2 Pressure connection DN 100 3 Ventilation DN 100 4 Two wastewater pumps each with a 5 m connection line 5 Sump made of polyethylene Cleaning aperture CO Blocking device Check valve iki KESSEL 3 Technical data 3 1 Aqualift F Duo XXL Models e Aqualift F Duo XXL double system 3 3 kW with pressure discharge DN 100 e Aqualift F Duo XXL double system 4 2 kW with pressure discharge DN 100 e Aqualift F Duo XXL double system 5 6 kW with pressure discharge DN 100 Pumping capacity diagram Aqualift F Duo XXL EE 400 V 3 3 kw o e 2 400 V 4 0 kw A 3 400 V 5 6 kW m 14 n l F rderh he Max DA 0 10 20 30 40 50 60 70 80 Max F rdermenge Q m3 h 0 5 10 15 20 Max F rdermenge Q l s SPF 260 KE SPF 400 KE SPF 550 KE Rated output P2 D 6 kW 3 5 kW 4 8 KW 1 Cer Operating voltage 400 V DS 400 V DS 400 V DS Rated frequency 50 Hz 50 Hz 50 Hz Rated current 6 4 A 7 9 A 10 2 Power input P 3 3 KW 4 2 KW 5 6 KW 5 m Length 7x1 5mm 5m Length 7x 1 5 mm 5 mLength 7 x 1 5 mm Temperature of pump ma 40 C 40 C 40 C Weight pump 30 kg 30 kg 31 kg Protection class IP 68 24 h 3 mWs IP 68 24 h 3 mWs IP 68 24 h 3 mWs Operating type 52 S2 52 30 Min 50 Min 30 Min Sound level lt 80 db
33. uld be checked once a year and exchanged if necessary Ensure that the replaced battery is disposed of correctly in an environmentally compatible manner It may only be replaced with a battery of the same type e The contactor is a wear part and should be checked once a year and exchanged if necessary Ensure that the replaced battery is disposed of correctly in an environmentally compa tible manner It ay only be replaced with a battery of the same type e After the maintenance work the switchgear lid must be clo sed again correctly contact protection e Repairs may only be carried out by the manufacturer iki KESSEL 20 8 Malfunctions and troubleshooting The following tests and troubleshooting steps may only be undertaken by authorised and qualified persons If in doubt please contact your specialist dealer see stamp on the cover sheet who installed the system initially 8 1 General malfunctions _ Malfunction Troubleshooting 1 Motor circuit breaker has trigge Remove the pump remove the blockage for red motor is blocked eign body in the impeller or casing Motor is labouring Maintenance repair by the Customer Service 1 or 2 phases have no current Check the cut outs and electrical cables Control system fails due to heavy Retrofit a battery in the switchgear and inform fluctuations of the mains supply the power supplier Pumps do not start Wrong revolving field 2 Exchange the phases of the power s
34. upply System is overloaded Check if there is a brief excess of wastewater if necessary refrain from using the drain points temporarily or if possible drain the wastewa ter through a different channel Pumps are running alarm level is reached is displayed Pump output too low e Remove the foreign body from the impeller or casing e Remove the foreign body from the pressure fitting or the pressure pipe e Pumps are worn arrange for them to be exchanged e Lifting system wrongly designed clarify with the KESSEL Customer Service backflow preventer not in operating position au the backflow preventer into the operating po 3 Wastewater does not drain System not switched on EEN backlog in the lowest drain points Electrical power cable to the swit Check cut out Check power supply chgear without current Level control is not working cor Check for soiling check the switch points and rectly function of the level control Supply line to the system is blocked Clean the supply line Intake valve to the system if there is Completely open the intake valve one is not open or not compl ope ned Wastewater temperature is too high over a longer period of time 15 min this limits the suction ca pacity of the system Reduce the temperature of the wastewater Check the pump parts and replace if neces sary 4 System sudden becomes loud E elen body has damaged parts of Check the pump parts and repl
35. ve must be replaced after 2 years service 7 1 Information about the pump The pump should be inspected at regular intervals When the operating noises become louder or there are vibrations in the pipe system the pump casing and impeller need to be checked for any ingrained dirt or wear To do this unscrew the four attachment screws on the motor unit and remove from the pump casing When inspecting the pump casing note that the venting bo rehole must remain open under all operating conditions 19 7 2 Information about the backflow preventer The backflow preventer can be used to completely empty the pressure line by manually lifting the check valve of the lifting system To do this turn the flap opener with a size 8 15 mm wrench and hold see Fig 2 until the pressure line is empty After this the flap opener must be returned to its original position or the marked operating setting See Fig 3 AN Sa Betriebsanleitung be Ill 2 e e Betriebsste Z 4 ER OU ES a Il 3 Note When the screw connections on the lower and upper flan ge of the valve casing are unscrewed the entire valve ca sing can be removed for cleaning and maintenance purpo ses Of course before this happens the pressure line must be blocked and drained iki KESSEL Inspection and maintenance 7 3 Information about the electrical switchgear e The battery is a wear part and sho
Download Pdf Manuals
Related Search