KESSEL - Aqualift F Lifting Station (230 Volt) For all wastewaters
Contents
1. Daz 110mm a Abb A Einzelanlage etf Stutzen absagen Rohranschlufs r zr EE I r in l Schlaud X TIT chlauch 8 schellen ae v bergangs schlauchstuck FB ten absagen Zulauf Anschluk f Schlauch A schelle Tem St tzring Behalter Hebeanlage Abb C Abb D Stutzen abs gen Saw off outlet stub RohranschluB Outlet pipe connection Zulauf AnschluB Inlet connection Schlauchschellen Steel coupling fastener Beh lter Hebeanlage Storage chamber Ubergangsschlauchst ck Rubber coupling Stutzen abs gen Saw off outlet stub St tzring Interior support ring IE 11 4 Installation Il Connecting using the flat connection areas on the Aqualift F Additional inlets can be connected to the Aqualiff F by drilling out properly sized holes with a hole saw in the flat connection area of the Aqualiff F as seen in illustration E Properly sized inlet gaskets are then inserted in the cut out hole Additional pipes can then be inserted into the gaskets Rohrdurchf hrungsdichtung Inlet gasket Rohranschlu Inlet pipe Offnung gebohrt Sawed out inlet hole Beh lter Hebeanlage Storage chamber Beh lter Hebeanlage Abb E Important If additional pipes are connected to the flat connection areas it is important that they are not too low The bottom of all attached inlet pipes should be at the2. Pump remains turned on Wastewater below alarm level Alarm level switch de activates e Pump remains turned on Wastewater below on level On level switch de activated e Pump is turned off The control unit is able to detect when the float switch send illogical message to the control unit For example the Alarm level has been reached without the Pump On Level ever being reached this will produce a Warning level failure The pump will continue to run until the wastewater level falls below the Alarm level If the Pump On Level has also been reached then the pump will continue to run until the wastewater level has fallen below the Pump On level The Pump On Level is continuously on The pump will continue to run until the wastewater has fallen below the Pump On level If the pump continues to run it will eventually either display that Maximum Run Time has been exceeded for the may operating temperature will be exceeded which will turn the pump off The Pump On Level is activated and the Alarm Level is continuously on The control unit will immediately display the warning that the alarm level has been exceeded The pump will continue to operate until the wastewater level falls below the Pump On level or until the max pump temperature has been reached which will turn off the pump The Maximum Run Time warning will not be displayed in this case because the Alarm Level warning has a higher priority The control unit cannot detect the followin
3. control unit to the pump no zig zags or positive slopes upwards is allowed The plastic hand nut sealing the pressure switch cable with the control unit must not be tightened over a torque of 2 5 Nm this could put unwanted pressure on the hollow equalization tube Not abiding by the above three conditions could cause the pressure switch as well as the pump to malfunction IE 15 5 Electrical connections Cable connection table for Aqualiff F 230 Volt single pump system Connections Description Power Cable The power cable must be connected to an all polar outlet The fuse for the outlet to which the Aqualiff F is connected may not be over 16 Amps The length of the Aqualiff F power cable is 1 7 meters Pump cables amp temp cables Cables for the pump and the temperature sensor must be connected to their corresponding marked jacks Motor PE Jack marked PE Motor U1 Z1 Jack marked 2 Motor U2 Jack marked 1 Motor Z2 Jack marked 3 Temp T1 Jack marked 4 Temp T2 Jack marked 5 Pressure switch The cables for the pressure switch should be connected to their corresponding jacks connect the white cable to the left side and the brown cable to the right side of two jacks marked Ein For the jacks marked Alarm connect the green cable to the right jack and the yellow cable to the left jack Potential Free Contact The potential free relay is designed for 230 V 2 Amp o
4. Flange The outlet pressure flange is equipped with a backflow flap and a manual opening lever During standard operation the backflow flap must be in the operational position as seen in Illustration 1 During pumping the flap will be forced open by the pressure of the outgoing wastewater as seen by the dotted lines IE 17 6 3 Connecting the Aqualift F to a power source After all electrical and mechanical connections have been properly made the Aqualif F may be connected to a live power source Plug the Aqualiff F power chord into an appropriate outlet The control unit will emit a signal approx 1 second in duration LEDs on the control unit will light from top to bottom The pump will activate for approx 2 seconds If all connections have been made correctly the Aqaulift F will now be operation the green Netz LED will be lit on the control unit If the plug in test run was not successful a temperature failure notice will be shown If any other problem occurred it will also be displayed on the control unit If this is the case the should not be placed into operation and should immediately be removed from its power source and the problem identified see the warning and problem table If only a warning is displayed the Aqualiff F will still be in operational status see warning and problem table 6 4 Standard Operation When the On or Alarm level are reached inside the Aqualiff F the appropriate relay will close
5. Schematische Darstellung des Schaltgerates ohne Elektronik Bauteile After the control unit is mounted be sure to securely close the cover IE 14 5 Electrical Connections 5 3 Control unit cable connections Cables for the pump and the pressure switch have already been connected at the factory If other systems such as a potential free contact need to be installed please do in the following manner unscrew the desired plastic hand nut from the bottom of the control unit and place over the wire which is to be connected With a sharp instrument pierce the rubber seal see illustration a Now insert the cable through the pierced rubber seal and insert until the required amount of cable length is inside the control unit Replace the plastic hand nut and tighten Cables can know be connected to their corresponding jack by the method illustrated in illustration c The pump and pressure switch have a 5 meter cable which is connected to the Aqualiff F control unit Only the pump s cable can be lengthened using a VDE certified connection CAUTION The pressure cable is a special cable containing a small hollow pipe used to equalize pressure fluctuations in the pressure switch Important points concerning the pressure switch cable The pressure switch cable can not be lengthened on site Any custom cable lengths must be ordered from KESSEL The cable for the pressure switch should have a constant and equal downward slope from the
6. When the wastewater level falls below the On or Alarm level the relay will open The red Alarm LED displays when the Alarm level has been reached and the orange Niveau LED displays when the On level has been reached The orange Pumpe LED displays when the pump is in activation The Aqualiff F operated by level control Meaning that when the wastewater level inside the Aqualiff F reached specific level the pump turns on after a factory set start delay The pump will continue to run until the level falls below this specific level and the factory set stop delay has expired 6 5 Hand Operation During normal operation the motor can be activated by pressing the Pumpe button on the control unit regardless of the amount of wastewater inside the Aqualiff F The motor will operate for a minimum of 2 seconds or however long the button is pressed Caution Please note that the motor can not properly cool itself while running without water this leads to increase wear and tear on the motor which after 5 minutes of running dry can lead to significant damage of the motor this type of damage is easily identifiable and is not covered under any warranty IE 18 6 6 Additional Functions e Anti Blocking Function In order to keep the motor in operating condition and to keep the impeller from seezing an automatic test run will take place for 2 seconds if the motor has not run in one week e Potential Free Contact The potential
7. from its power source before any work on the pressure switch control unit or pump is undertaken Also make sure that while this work is being done that the Aqualiff F will not be mistakenly re connected to a power source The pressure switch is designed to monitor the wastewater level inside the Aqualiff F storage chamber The wastewater levels at which the pump activates and a second level at which the alarm activates can be changed by re setting the pressure switch The Aqualiff F is supplied with factory settings which turn on the pump when the wastewater level reaches approximately the 160mm level and the alarm will activate when the wastewater level reaches approximately the 200mm level levels measured from the bottom of the Aqualiff F storage chamber If for whatever reason a custom pressure switch activation level is required it can be set by doing the following Remove the cover of the pressure switch and find the two setting screws marked 1 and 2 in the illustration Screw 1 controls the pump activation level and screw 2 controls the alarm activation level Turning a screw in the clockwise direction will increase the activation level as turning a screw in the counter clockwise direction will decrease the activation level A complete turn of a screw 360 deg will change the activation level by 20 mm half a turn 180 degrees will provide a 10 mm change After setting the activation levels it is important to replace the pressure swit
8. parts 10 1 Accessories Description Emergency hand pump Rubber connection couplings Stainless steel pipe supports Flange rubber connection Order Number 28680 28660 DN 40 28661 DN 70 28662 DN 80 28663 DN 100 28653 DN 70 28654 DN 100 28655 DN 80 Flange rubber connection Flange sleeve adapter Flange sleeve adapter Closure cover when pump is removed Shut off valve Shut off valve Shut off valve for emergency hand pump Rubber vibration dampening matt for under Aqualiff F Rubber inlet seal for additional inlets into Aqualift F Hole saw attachment for drill Batteries Shut off device for single pump units IE 28656 DN 100 28657 DN 100 28658 DN 150 28678 28687 DN 80 28688 DN 100 28681 28692 850114 DN 50 850116 DN 70 850117 DN 100 50100 20230 28683 31 10 Accessories and Replacement parts 10 2 Replacement parts 10 2 1 Replacement parts for entire Aqualift F Position Quantity Order Number Name 1 1 206 004 Chamber for single pump 2 1 206 161 Pump flange 3 1 206 162 Complete motor 1 1 KW 230 volt 4 1 240 051 Housing for backflow flap 5 1 206 017 Complete pressure switch for 1 pump 6 1 206 018 Inspection port cover 7 1 206 091 Control unit for single pump 8 1 003 155 Rubber pipe connector 9 2 003 144 Connector fasteners for DN 100 10 2 206 021 Floor fasten
9. 2 phases on motor cable in control unit 4 Wastewater is not pumped away Backwater problems in fixtures connected to Aqualiff F is not plugged in Plug in Aqualiff F Cable to control unit not receiving power Check outlet and fuse Insure outlet is supplying power Level switch malfunction Check and clean float switch Inlet s to Aqualiff F blocked Check and clean inlet s to Aqualiff F Aqualift F Wastewater temperature too high for extended time period 15 min Reduce wastewater temperature run cold water into system IE 26 8 Warnings Failures and Shut Downs 5 Pump suddenly runs loud Phases on house electrical system switched Check impeller rotation Damage to pump parts caused by foreign objects Check pump and impeller Replace if necessary Foreign object stuck in pump impeller Remove foreign object 6 Bad odor smell Sharp acidic odor System is not airtight Ventilation inlet outlet inspection port float switch seal check for leaks Pump not leak proof Check pump and contact customer service replace pump if necessary Motor s too hot overloaded Check motor and pump for ease of rotation Too frequent starting stopping of the motor Too much incoming wastewater Contactor too hot due to switch malfunction Check Aqualiff F for switch malfunction 7 System runs too much S
10. 5082 2 EN 55011 EN 55014 EN 60335 Lenting 01 01 1999 m B Kessel G Vanetta IE 38 Everything for drainage Backwater valves and cleanouts Grease separators Polymer and cast iron drains gt Oil fuel and coalescence separators gt Volatile liquid traps gt Inspection chambers Lifting stations pumps warning and Custom projects for industrial control units applications Rainwater management systems iK KESSEL
11. KESSEL Aqualift F Lifting Station 230 Volt For all wastewaters with without sewage For installation in frost free areas Aqualift F Lifting Station 230 V Product Advantages Easy connection to pre formed inlets Connection areas for additional inlets Fully automated operation Maintenance friendly Polyethylene PE housing Certification No Z 53 2 424 BK ssELM AES fA N garan ee i SI The installation and service of this unit should be carried out by a licensed professional servicer Company Telephone No Edition 08 2003 HG ID number 010 605 Subject to technical amendments IK Dear Customer Before the KESSEL Aqualiff F 230 V Lifting Station is installed and placed in operation please carefully read and follow all of the instructions contained in this Installation Maintenance and User s Manual Upon delivery of the lifting station please thoroughly inspect it to make sure that it has not been damaged during shipping In case damage has occurred to the separator please follow the instructions listed in the Guarantee section of this user s manual The Aqualiff F is not to be installed or operated in an explosion endangered area KESSEL GmbH Table of Contents 1 Safety Precautions page 5 2 General 2 1 Application Installation page 6 2 2 Aqualiff F description page 6 3 Technical Data 3 1 Dimensions page 7 3 2 Pump page 8 3 3 Operating Volum
12. L to its customer The warranty only applies to newly manufactured products Additional information can be found in section 377 and 378 of the HGB 2 Wear and tear on a product will not be considered a defect Problems with products resulting from improper installation handling or maintenance will also not be considered a defect 01 01 2002 IE 36 Important contacts Info Type KESSEL Order Number Production Date Project description Building services supervisor Address Telephone Fax Planner Address Telephone Fax Contracted construction company Address Telephone Fax Contracted plumbing company Address Telephone Fax Contracted electrical company Address Telephone Fax System operator Address Telephone Fax Other remarks The system operator and those responsible were present during the commissioning of this system Place and Date IE 37 Declaration of EC Conformity according to machine guide line 89 392 EWG of 14 06 1989 and modification guidelines 91 368 EWG of 20 06 1991 93 44 EWG of 19 07 1993 and 93 68 EWG of 22 07 1993 low voltage guideline 73 23 EWG and guideline regarding electromagnetic compatibility 93 97 EWG of 29 10 1993 The producer KESSEL GmbH D 85101 Lenting confirms that the product KESSEL Aqualift F lifting station for free standing installation was developed and produced in accordance with the following norms EN 292 VDE 31001 VDE 0113 EN 5
13. The audible beep will now be off The current setting can now be determined by LEDs on the control unit and the above table To change between the 7 settings press the Alarm button this will advance to the next step The current step can be determing by observing the current LEDs lit on the control unit and comparing them with the above table After the appropriate setting has been reached it can be entered by pressing the Pumpe button until a confirmation beep is heard If the new setting is not confirmed within 20 seconds the control unit will return automatically to normal operations all unconfirmed settings will be lost The new setting has now been set and the Aqualiff F is back in normal operation In order to change the steps in setting 2 3 or 4 the above listed procedure must be repeated In the case of a complete power failure all confirmed settings will remain in the Aqualiff F s memory IE 21 7 Inspection and Maintenance The Aqualiff F should be visually checked once per month by the operator This involves a visual check to make sure no cable are damaged and that the holding chamber is water tight During this inspection a fixture connected to the Aqualift F such as a sink or toilet should be run until the Aqualiff F pump activated this will confirm that the float switch system and the pump is operating properly Thorough inspections should take place at regular intervals according to DIN 1986 Part 31 These i
14. aliff F with single pumps weigh approximately 45 Kg approx 100 pounds and double pump systems weight approximately 84 Kg approx 185 Kg The Aqualiff F units should be handled by at least two people equipped with appropriate equipments e g safety shoes back support Health Safety The Aqualiff F is designed to pump wastewater containing untreated raw sewage which can cause health hazards It is important that no direct or indirect contact between the Aqualiff F and skin eyes or mouth occurs If contact does occur it is important to immediately wash and disinfect the contaminated area Also in cases when the pump itself is to be removed from the Aqualiff F make sure that the room is properly ventilated to allow and methane or biogases to escape or be diluted Noise During operation of the Aqualiff F emits approximately 65 5 dB Based on the installation of the Aqualift F this could present an unwanted noise Take care in selecting the installation location of the system A vibration dampening support matt available from KESSEL may be placed underneath the Aqualiff F to reduce noise vibration Explosion Risk The interior of the Aqualiff F is deemed as an explosion risk area by EN 12050 In the case that the pump pressure switch or inspection port is to be removed it is important to first assure that the room is well ventilated During this time it is also important that no source of ignition occurs such as smoking electri
15. cal work welding cooking IE 2 1 Application Installation The Aqualiff F is designed to pump wastewater with or without sewage collected below the outgoing sewer level up to the sewer level so that it may flow with gravity out of the building and into a septic system public sewer piping Installation examples of the Aqualiff F would be single and multi family homes commercial buildings hotels restaurants hospitals schools or similar buildings In circumstances where the interruption of wastewater is not allowed or desired a twin pump system Aqualiff F Duo is required for installation The Aqualiff F is designed to be installed on a sturdy floor in a room which can be ventilated and is protected from freezing temperatures The Aqualift F control unit is designed for installation flood protected frost proof dry room The Aqualiff F is equipped with a single vane impeller and has a free passage of 40mm The outlet is size DN 100 and the ventilation port is size DN 70 Abrasive materials should not come in contact with the impeller The Aqualiff F is designed constant usage with wastewater at 35 deg C 95 deg F and can also handle for short durations max 10 minutes temperatures up to 60 deg C 140 deg F 2 2 Aqualift F description The KESSEL Aqualiff F lifting station is run on alternating current AC current and consists of the following main components 1 Polyethylene collection chamber gas and wate
16. ch cover and properly tighten IE 13 5 Electrical Connections The cables for the pump and pressure switch have been connected to the Aqualiff F control unit at the factory Caution All electrical work concerning the Aqualiff F should be handled by a licensed professional electrician and should follow all local and national electrical guidelines 5 1 General Notice After the control unit has been wall mounted it is important that the cover is securely closed and that the cable entering the control unit are secured to the wall to prevent the cables from being accidentally pulled or tugged out of the control unit The power cables for the pump and the pressure switch should not be installed next to each other this will prevent interference which could potentially cause false starts alarms 5 2 Control unit installation mounting The control unit for the Aqualift F should be installed in a frost free dry well ventilated room which is protected from flooding It should be securely mounted on a sturdy wall preferably at eye level To mount the control unit first place the provided drilling template on the desired wall location and drill out the four holes Place the provided plastic screw housings into the four holes mount the control unit over the 4 holes and secure with the provided four screws 1 Hinges 2x 2 Plastic wall plugs 5 x 25 mm 4 x 3 Mounting screws M3 5x30 4x 4 Cover screws 4x
17. ch lI 1 ch N N Tsch 1 ech 1 a 240 037 O ring 34 10 Accessories and Replacement Parts 10 2 5 Pump Flange Part Number 206 127 Position Quantity Order Number Name 1 1 206 126 Pump flange 2 1 206 160 Lower portion pump flange 3 14 206 134 Washers 4 2 071 106 Short fastening screws 5 12 206 139 Long fastening screws 6 14 206 135 Bolts 7 12 206 052 Threaded nut IE 35 11 Guarantee 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 replace the product or it is economically unfeasible to repair or replace the product the customer the has the right to cancel the order contract or reduce payment accordingly KESSEL must be notified immediately in writing of defects in a product In the case that the defect is not visible or difficult to detect KESSEL must be notified immediately in writing of the defect as soon as it is discovered If the product is repaired or replaced the newly repaired or replaced product shall receive a new warranty identical to that which the original defective product was granted The term defective product refers only to the product or part needing repair or replacement and not necessarily to the entire product or unit KESSEL products are warranted for a period of 24 months This warranty period begins on the day the product is shipped from KESSE
18. city to operate rotating and mechanical parts Not following the User s Manual can result in damage to the unit as well as injury or a possible fatal accident Before maintaining or servicing the Aqualiff F make sure to disconnect it from ALL power sources and secure that power cannot be re connected during maintenance servicing During electrical installation or servicing of the unit VDE 0100 and all applicable safety regulations should be followed The control unit and pressure sensor switch are electrically powered systems which should not be opened or serviced except by licensed professional electricians Licensed professional electrician is defined in VDE 0105 It is important that all electrical cables and units relating to the Aqualiff F are always in good operating condition If damage to any of the electrical cables or systems of the Aqualiff F are noticed the Aqualiff F unit must be immediately disconnected and taken off line Danger of hot surfaces During operation the Aqualiff F can become hot Take caution before touching or coming into contact with all hot surfaces on the Aqualift F A Danger for hands and fingers The Aqualiff F pump is equipped with a closed impeller Any inspection or maintenance work must take place after the Aqualiff F has been fully disconnected from its power source Also during maintenance and inspection take caution of any sharp surfaces or edges Heavy weight Caution KESSEL Aqu
19. d using the control unit After a relay failure it should be assumed that the system no longer functions The only way to cancel a failure warning is to unplug the control unit Display of last warning or last failure notice The last warning or failure is always saved in the control unit s memory and can be recalled in the future if desired Prerequisites for recalling a past warning failure are The warning or failure was originally cancelled Both the float switches are not in on mode the pump is not in activation and only the green Netz LED is lit on the control unit In order to recall the last warning or failure notice press the Alarm button for more than 5 seconds this will shut off all 4 of the control unit s LEDs The last warning or failure will then be displayed in coded LED form for approximately 5 seconds The Aqualiff F then automatically returns to standard operation mode IE 23 8 Warnings Failures and Shut Downs 8 2 Warning and Failure displays Display Problem cause Result Problem solved Display code for last warning failure Warning Alarm LED blinks Max running time Alarm LED blinks Netz and exceeded during Alarm LED level control blinks Max running time Alarm LED blinks Alarm LED exceeeded during blinks run time control Alarm LED on Alarm level Alarm LED blinks Netz LED blinks exceeded Level failure Alarm LED bl
20. e page 9 3 4 Electrical control unit page 9 4 Installation 4 1 Installation location tips page 10 4 2 Pipe connections page 10 4 3 Setting the pressure switch page 13 5 Electrical Connections 5 1 General Notice page 14 5 2 Control unit installation mounting page 14 5 3 Control unit cable connections page 15 5 4 Finishing of electrical works page 16 6 Commissioning 6 1 Genera Instructions page 17 6 2 Outlet Pressure Flange page 17 6 3 Connecting the Aqualiff F to a page 18 power source 6 4 Standard Operation page 18 6 5 Hand Operation page 18 6 6 Additional Functions page 19 6 7 Factory settings page 20 6 8 Checking the settings page 20 6 9 Changing the settings page 21 7 Inspection and Maintenance 7 1 Pump Information page 22 7 2 Backflow Preventer Information page 22 7 3 Control Unit Information page 23 8 Warnings Failures and Shut downs 8 1 General notices page 23 8 2 Warning and Failure displays page 24 8 3 Removal of Warnings and Failures page 25 8 4 General problems page 26 8 5 Illogical functioning of the level page 27 alarm switches 8 6 What to do when page 28 Table of Contents 9 Control Unit 9 1 General Description page 29 9 2 Description of control unit display page 29 and button functions 9 3 Connection plan page 30 10 Replacement Parts Accessories 10 1 Accessories page 31 10 2 Replacement parts page 32 11 Guarantee page 36 1 Safety Precautions Caution The Aqualift F uses electri
21. er 11 1 206 042 Seal for pump flange 12 1 049 010 Seal for pressure switch 13 1 049 01 1 Seal for inspection port 14 1 049 005 Roll ring 15 16 206 090 Fastening screws 16 4 017 095 Fastening bolts 17 2 206 055 Half round wooden screws 18 2 017 114 Washers 19 2 206 051 Screw housing 20 8 206 074 Fastening screws 21 8 017 199 Fastening bolts 22 8 017 012 Washers IE 32 10 Accessories and Replacement Parts 10 2 2 For Pressure Switch Part Number 206 017 Position Quantity Order Number Name 1 1 206 023 Hollow air holding pipe 2 1 206 008 Pressure sensor 3 1 206 050 Pressure controller 4 1 206 014 Cover for pressure switch 5 1 205 084 Cable nut 6 5 meters 206 047 Pressure switch cable 7 1 206 043 O ring 8 1 206 053 O ring 9 2 017 153 Fastening screws IE 33 10 Accessories and Replacements Parts 10 2 3 Mono Backwater Flap Housing Part Number 240 051 Pos Quantity Order N Name 1 1 240 052 Housing connection 2 1 240 048 Outlet hose connection 3 8 240 039 Securing nuts M8 4 8 240 038 Secuting bolts M8 Pos Quantity Order N Name 240 046 Flap housing 240 019 Flap lever 240 034 Lever bolt 091 017 O ring 049 018 O ring 134 025 PT fastening screw 206 010 Flap holder 240 026 Flap opener 240 042 Backflow flap O O N O 01 Go N O IE lt Le
22. floor with the supplied anchors and bolts to prevent it from being moved or shifted Beh ller Hebeanlage g 3 B v 2 a D mpfungsmatte optional 4 2 Pipe connections All drainage pipes connected to the Aqualiff F should be laid with the proper slope so that they run completely empty no standing water in pipes All connected pipes should be properly secured to prevent vibration and provide a flexible connection to the Aqualiff F body IE 10 4 Installation Two types of connection to the Aqualift F I Connecting using the preformed closed inlets The Aqualiff F has preformed closed inlet stubs for the main inlet ventilation pipe and the emergency manual pump as seen in Illustration A The closed tip of all needed preformed inlets should be cut off with a standard saw as seen in Illustration C A standard drainage pipe HT pipe with gasket can then be push fit over the open inlet An additional alternative to connecting pipes is to use rubber couplings these can provide additional flexibility and help prevent the preformed inlet stubs from becoming deformed from forces stress caused by pumping If couplings are used itis important to insert a metal reinforcement ring inside the preformed inlet as seen in Illustration Entl ftung Ventilation port Zulauf AnschluB Inlet connection Anschlu Handmembranpumpe Emergency hand pump connection Einzelanlage Single pump unit Zulauf Anschlu
23. free contact is used to notify power failures warnings and problems in other areas where the Aqualiff F is not located e Under power conditions When the control unit senses an under power condition for example when the motor dry runs The control unit will display visually and acoustically the problem The pump will not longer receive power from the control unit The control unit will show an operation failure and shut down the system e Over power conditions In order to prevent damage to the pump due to over power conditions for example impeller blockages the pump will automatically shit itself off when it detects this condition In an attempt to remove the blockage the pump will automatically turn itself on three times This will happen in the following order 1 Control unit detects over power over load 2 Control unit turns off the pump 3 No over load warning will be displayed 4 The control unit waits three seconds plus the start delay time period 5 The pump will turn on first of the three start attempts 6 Control unit checks to see if the blockage has been removed and the pump runs free At this point if the control unit detects again an over load blockage the same procedure will be repeated a second and if necessary a third time If the second or third attempt is successful the pump will return to normal operation After an unsuccessful third attempt an overload failure will be audibly and visually displayed
24. ften provide quick diagnosis of a problem and information on how the problem should be repaired Cancelling of audible alarms Warnings and Failures are notified from the control unit by an audible alarm This audible alarm can be turned off by quickly pressing the Alarm button on the control unit the LED display of the problem will remain Attention The audible alarm cannot be turned off by pressing the Alarm button when a relay problem or failure exists The only way to stop the alarm during a relay problem is to unplug the control unit Cancelling of warning notices In order to cancel a warning notice first the audible alarm must be turned off and the cause of the warning must be corrected after this has been accomplished the Alarm button must be pressed for an extended period of time The system is now back to standard operation Cancelling of failure notices In order to cancel a failure notice first the audible alarm must be turned off and the cause of the failure must be corrected after this has been accomplished the Alarm button must be pressed for an extended period of time The system is now back to standard operation Attention A warming or failure caused by the temperature sensors cannot be manually corrected This will correct itself automatically if and when the temperature sensors have sensed standard operating temperatures and bring the Aqualift F back on line A relay failure can also not be cancelle
25. g float switch failures For whatever reason the Alarm level switch will not activate The control unit is tricked and thinks that the wastewater level never reaches the Alarm level For whatever reason the Pump On level switch never turns off The control unit is tricked and things that the wastewater level never falls below the Pump On level Illogical float switch problems can be cause by the following a technical defect a short circuit or interruption of the float switch cables improper connection of the float switch cables to the control unit 8 6 What to do when When a problem occurs that is not described in this User s Manuals please contact a licensed professional When the control unit does not react to the pressing of any of the buttons on the control unit please unplug the control unit for at least 10 seconds make sure that no water is entering the Aqualiff F at this time Plug the control unit back in and check that the button function properly If the buttons still do not react when pressed please contact a licensed professional IE 28 9 Control unit 9 1 General Description T Ai S 1 Control housing 8 Pumpe LED Orange Pump LED 2 Screws for control unit cover 9 Alarm button 3 Power cable 10 Connection for Pump cables 4 Abbreviated operation instructions 11 Connection for Pressure switch 5 Netz LED Green Power LED 12 Connection for P
26. inks Niveau LED blinks Failure Alarm LED on Temperature shut Interruption After cool down all Alarm and Niveau and down systems return Pumpe LEDs Pumpe blinking automatically to blinking operation Alarm LED on Underload Stoppage After confirming Netz Alarm Pumpe LED Control displays the underload and Pumpe blinking failure and pump system returns to LEDS blinking remains off normal operation Overload Stoppage After confirming Niveau and Pump remains the underload Pumpe LEDS Off control unit system returns to blinking must be normal operation unplugged All LEDS blinking Relay Stoppage After plugging in Netz Niveau Pump remains control unit system and Pumpe off control unit returns to normal LEDs blinking must be operation unplugged IE 24 8 Warnings Failures and Shut Downs 8 3 Removal of Warnings and Failures Description Audible Alarm Potential free Correction Tips contact Warning Max running The set running time is activates no change Check inlets time exceeded exceeded too much float switch level control incoming water poor pressure outlet pump performance level failure Max running The number of running activates no change Check inlets time exceeded times is exceeded too float switch run time much incoming water pressure outlet control poor pump performance level failure Alarm level The Ala
27. iveau Niveau Pumpe Pumpe Pumpe Pumpe IE 20 In order to enter the setting mode to change between settings 1 2 3 or 4 the Alarm and the Pumpe buttons on the control unit must be pressed at the same time An audible beep will be heard and the LED Netz will light Release the two buttons on the control unit The audible beep will now be off The current setting can now be determined by LEDs on the control unit and the above table In order to advance to the next setting all of the above listed steps must be re done In order to leave this setting mode and return the Aqualiff F to normal operation press the Pumpe button until a confirmation beep is heard The Aqualiff F is now back to standard operation If the Pumpe button is not pressed within 20 seconds the Aqualiff F will return automatically to normal operation this will be confirmed by a beep 6 9 Changing the settings Step 1 2 3 4 5 6 7 Lit LEDs are in BOLD Netz Netz Netz Netz Netz Netz Netz letters with grey Alarm Alarm Alarm Alarm Alarm Alarm Alarm background Niveau Niveau Niveau Niveau Niveau Niveau Niveau Pumpe Pumpe Pumpe Pumpe Pumpe Pumpe Pumpe In order to change between steps 1 2 3 4 5 6 or 7 the Alarm and the Pumpe buttons on the control unit must be pressed at the same time An audible beep will be heard and the LED Netz will light Release the two buttons on the control unit
28. lowest equal to normal operational wastewater level inside the Aqualiff F chamber This will prevent stagnant water and the build up of solids in inlet pipes which have been attached too low All inlet pipes should be laid with the appropriate slope according to DIN 1986 The DN 70 ventilation pipe is critically important to the proper operation of the Aqualiff F The ventilation pipe prevents positive and negative air pressures from building up inside the chamber The ventilation pipe should be run to the exterior of the building preferably to a high point on the roof of the building The DN 100 outlet of the Aqualiff F is to be connected to the outlet pressure pipe with the included rubber coupling The rubber coupling should be fitted approximately 4 cm over the outlet of the Aqualift F and then secured This rubber connection is important in providing a flexible connection between the Aqualiff F and the outgoing pressure pipe this will also greatly reduced vibrations in the outlet pressure pipe The outgoing pressure pipe should be plumbed to a height over the local backwater level normally ground or street level and then into the main wastewater pipe exiting the home building A closure valve should be installed in this pressure pipe preferably close to the outlet of the Aqualiff F IE 12 4 Installation 4 3 Setting the pressure switch controls on level of pump Caution Aqualiff F must be completely disconnected
29. n Illustrations 2 and 3 below can be used to empty the vertical section of the outlet pressure pipe This must be done in order to disconnect the Aqualiff F from the outlet pressure pipe as seen in Illustration 4 With a size 8 15 mm wrench turn the bolt clockwise until the wastewater collected in the outlet pressure pipe begins running back into the Aqualiff F chamber After all the wastewater is out of the vertical section of the pressure pipe it is important to close the flap again be turning the bolt counter clockwise until closure IE 22 7 Inspection and Maintenance 7 3 Control Unit Information Be sure to unplug the Aqualift F control unit before any maintenance work is done Repairs should only be handled by the manufacture After maintenance work is done be sure that the control unit cover is closed and that the four cover screws are firmly tightened 8 Warnings Failures and Shut Downs The following checks and shut down procedures should only be handled by a licensed professional 8 1 General notices Warnings are used to inform the user of current pump conditions without interfering with the operation of the pump Failures are used to prevent damage to the Aqualiff F system and must be inspected and repaired by licensed professionals to bring the Aqualiff F back into operation A list of standard warnings and failures which frequently occur are listed later in Chapter 8 These listings o
30. nspections should only be handled by a licensed professional Repairs of the Aqualiff F should only be handled by the manufacturer The inspection should include the following Visual inspection of the entire unit including the pump and accessories Cleaning of the entire unit including the pump Inspection of entire unit including pump housing for exterior damage or wear and tear Check pump to make sure movable parts move freely and that now deposits have developed Check all cables of the Aqualiff F to make sure they are in excellent condition Check all connections of the Aqualiff F to make sure they are firm and water tight Important All screws and bolt on the Aqualift F should be tightened to a maximum torque of 3 Nm The above listed inspection should also be carried out after the Aqualiff F has been stored or not operated for an extended period of time 7 1 Pump Information The Aqualiff F pump should be inspected in regular intervals In the case that pump operates louder than normal or loses pumping efficiency the pump and its impeller must be well cleaned and inspected To do this the 4 holding screws for the pump must be removed as seen in Illustration 10 2 1 and the entire pump taken out of the chamber for inspection During this inspection it is important to check that the ventilation port on the pump body is open and free of any debris 7 2 Backflow Preventer Information The backflow preventer seen i
31. on the control unit The control unit will then shut down the Aqualiff F system until the blockage problem has been fixed IE 19 6 7 Factory settings Increment 1 2 3 4 5 6 7 Factory Your setting personal setting 1 Setting Start delay O 02 04 0 6 0 8 1 0 1 2 0 2 seconds 2 Setting Stop delay 0 5 1 0 11 5 20 2 5 30 3 5 1 0 for level control seconds Running time 3 4 5 6 7 8 10 none for run time control 3 Setting Max running time 10 20 30 40 60 90 120 30 minutes for level control Running time 10 20 30 40 60 90 120 none multiplication factor for 3 Setting for run time control 4 Setting Unit type A B C A A level control B run time control with interruption C run time control without interruption 6 8 Checking the settings The setting can only be checked when the control unit is currently not displaying any warnings or problems and when the pump is not running both float switches are in the off position and only the green Netz LED is lit The setting can be checked by pressing the Alarm and the Pumpe buttons on the control unit Use the table below to determine which of the four setting the Aqualift F is currently set to Setting 1 Setting 2 Setting 3 Setting 4 Lit LEDs are Netz Netz Netz Netz in BOLD letters Alarm Alarm Alarm Alarm with grey background Niveau Niveau N
32. otential Free Contact 6 Alarm LED Red Alarm LED 7 Niveau LED Orange Level LED 9 2 Description of control unit display and button functions Display Normal operation Net s green Unit receiving power Alarm red Alarm level exceeded niveau orange Pump on level exceeded Pumpe orange Pump is operating Control unit buttons for entering settings Alarm button Used to turn off audible alarm to confirm warnings and failures to change and confirm settings Pumpe button to manually start pump to change and confirm settings IE 29 9 Control unit 9 3Connection plan Schaltgerat BNR 206 078 Kondensator MKP 4 uF 5 280U C190000h Kl1 B PRI 238U 50 68Hz SEK 12U SUA 2 9 CCO225PT 4 ZE pot freier PUMPE THERMO EIN ALARM Kontakt ee lolol oooooo000 E 882722 J2182 Nl 8 polig Signalgeber Relais 12V DC Tupenschild ER kein Ex Schutz Temp Schalter U ei 12U A ER max SmA H 5UU F 361 5 S2 Alarm Anschlup f r Pugpen otos 1 Iud potential freien Netz Anschluss Ni veau Oruck schal ter 230U S HZ mit Se tkont akte 230U 52Hz Temper atur schalter p Motor uith thermal Potential free switch ouer membrane sensitive suitch Suitch contact Connexion eletrique pressostat membrane Moteur avec automate Connexion libre de thermostat que contact Stand der Zeichnung 12 99 IE 30 10 Accessories and Replacement
33. peller pump housing caution pump may be hot Motor difficult to turn Check for free rotation of impeller call for professional repair No power Check fuses and electrical cables that they are properly attached Check that all 3 phases are fonctioning 2 Pump operates but alarm level is reached Aqualif F is receiving too much wastewater Check to see if multiple fixtures are being drained simultaneously if so temporarily do not use certain fixtures or if necessary disconnect fixtures from Aqualiff F Aqualiff F does not pump enough wastewater Check for blockage in impeller or pump housing Check for blockages in outlet or pressure pipe Impeller is worn replace impeller replace pump Aqualiff F improperly installed consult KESSEL Customer Service Ventilation improper or not connected Repair or install proper ventilation pipe 3 Pump operates rough or noisy and LED Phase Drehfeld lights Wrong motor rotation Check impeller rotation Switch cable polarity For twin pump units both motors rotate wrong Switch 2 phases on main cable in control unit Low pump performance to due damage Check motor and impeller Replace if necessary Pump operates rough or noisy and LED Phase Drehfeld does not light Wrong motor rotation Check impeller rotation Switch cable polarity For twin pump units both motors rotate wrong Switch
34. peration Power for the potential free contact must come from an external source The potential free contact is used to notify the user of power failures operation problems and relay failures 5 4 Finishing of electrical works After all control unit connections have been made be sure to close the cover to the control unit and secure with the 4 screws IE 16 6 1 General Instructions Please follow DIN 1986 Part 31 when commissioning pumps lifting stations Caution Before commissioning the Aqualiff F make sure that all inlet pipes as well Aqualift F storage chamber and the pump is free from metal sand or any other potentially damaging debris Before commissioning the Aqualiff F must be filled with water wastewater to at least the elevation of the ventilation port on the pump housing Pump must not intake air Only place the Aqualiff F into operation after it has been thoroughly checked to assure that installation and pipe and electrical connection have been properly made Make sure that all closure valves are fully open before starting Important The commissioning of the Aqualiff F must be handled by a licensed professional Make sure to follow all safety instructions in Part 1 of this Users manual and do not place the Aqualiff F in operation if the pump control unit or cables show any signs of damage Important All screws bolts should be tightened to a maximum of 3 Nm 6 2 Outlet Pressure
35. r tight with 1 1 Wastewater pump with 5 meter cable 1 2 Pneumatic pressure switch with 5 meter cable 1 3 Access Cleaning port 1 4 Connection for DN 100 inlet 1 5 Connection for DN 70 ventilation mandatory 1 6 Connection for DN 40 manual emergency pump 1 7 DN 100 pressure pipe outlet with integrated backflow flap and release lever 1 8 Area for additional connection of inlet pipes 2 Electrical control unit see illustration in Chapter 9 3 Accessories without illustration 3 1 Securing brackets for secure installation with sub surface 3 2 Flexible coupling for attaching DN 100 Aqualiff F outlet to outlet piping A complete list of main pump parts is illustrated in Chapter 10 IE 3 Technical Data 3 1 Dimensions Dimensions of Aqualift F 1 1 kW DN 100 outlet Article Number 28646 IE 3 Technical Data 3 2 Pump Type 230 Volt 1 1 kW Operating power 1 1 kW Starting power 1 7 kW Voltage 230 volt Frequency 50 Hz Operating current 7 3 Amps Starting current 18 5 Amps Capacitor 40 uF 400 Volt AC DB Fuse 10 Amp slow blow Connection cables length 5 meters 1 5 square mm 7 inner cables Advised wastewater temperature 35 deg C 95 deg C Weight pump only 30 Kg 77 Kg Protection IP 68 2 meter water head Operation S3 60 starting period Performance curve Lifting height meters Flow cubic meters hour Leistung
36. rm level is activates activates Check inlets exceeded exceeded too much float switch incoming water poor pressure outlet pump performance level failure Level failure The control unit detects activates activates Check float an illogical float switch switch set up ex Alarm level is on the pump start level is off Failure Temperature The temperature activates activates After the motor failure sensor in the motor has cooled and detects too high temps the sensor senses normal temps the failure will automatically be deleted and the system brought back on line Underload The control unit detects activates activates Ventilation hole failure under load pump blocked or pump running dry is intaking air Overload failure The third automatic activates activates Check for free restart attempt was rotatation of unsuccesful Pump impeller Check impeller is blocked for blockages in impeller and pump housing Relay failure The control unit senses activates activates Control unit motor power even must be though the motor is off unplugged Relays fuse together Aqualiff F is not longer operational IE 25 8 Warnings Failures and Shut Downs 8 4 General problems Problem Reason Solution 1 Pump does not start Control unit not plugged in Plug in control unit Switch control unit to Auto Over load or max temp exceeded motor is blocked Remove motor remove obstacle from im
37. sdiagramm F rderh he m F rderstrom Q Leistungsdiagramm Qmin nach DIN 1986 Vmin 0 7 m s f r DN 80 F rderh he m eel CH Zo m U LN CC CH SE UE ERN E E Pa ER E E E m E EZE m EES sp Te TE ATT TTT TTT at TTT TTT TTT AT ETT F rderstrom Q 0 4 8 12 16 20 24 28 32 36 40 44 48 0 2 4 6 8 10 12 ae Ms IE 3 Technical Data 3 3 Operating Volume As delivered the Aqualiff F will pump approximately 20 litres per activation The pumping level can be changed by setting the pneumatic switch this will be explained in detail in Chapter 4 3 4 Electrical Control Unit 3 4 1 General technical information Control unit dimensions length 180mm width 200mm depth 70mm Control unit weight 1100 grams Ambient conditions for control unit Allowable temperature range 0 to 40 deg C 32 to 104 deg F Humidity 10 to 80 96 no condensation Max elevation 2000 meters above sea level Power consumption from electronics without pump 5 VA Protection Class Class 1 Protection Type IP 54 with closed control unit cover and factory gasket 3 4 2 Supply Operating power 230 Volt AC 1 N PE 50 Hz 10 Power connection Standard plug from control unit with 1 7 meter length Required protection max 16 A to be supplied on site multi polar main fuse switch for power to control unit 4 Ins
38. tallation When the shipment arrives please inspect it immediately for damages which may have been caused durinq transport shipping Important After the receiving the Aqualiff F but before installation it is important that the control unit is stored in a dry frost free area until time of connection Caution KESSEL Aqualift F with single pumps weigh approximately 45 Kg approx 100 pounds and double pump systems weight approximately 84 Kg approx 185 Kg The Aqualiff F units should be handled by at least two people equipped with appropriate equipments e g safety shoes back support Installation area The KESSEL Aqualiff F lifting station is to be installed on a sturdy floor in a frost free area The accompanied control unit is designed to be wall mounted in a dry flood protected frost protected room 4 1 Installation location tips In order to provide easy of installation operation and maintenance it is important that the Aqualiff F is installed in a location where it is easily accessible from all sides According to DIN 1986 a minimum distance of 60 cm should be kept free completely surrounding the Aqualiff F including above the unit The Aqualiff F should be installed level on a solid floor To further dampen the noise level of the Aqualiff F F during operation it is recommended that the unit is placed on top of a rubber dampening mat available from KESSEL The Aqualiff F is to be securely bolted to the
39. tarts without reason Too much incoming wastewater Check for cause of excessive incoming wastewater Backflow prevent defective wastewater returning into Aqualiff F chamber after it is pumped out Check backflow preventer for blockage or improper function 8 System does not stop running Foam build up inside Aqualiff F chamber Reduce use of soap or cleansers Interior of chamber pump impeller float switch coated with grease fat Completely clean all parts coated with grease fat Reduce amount of grease enterring system Ventilation tube inside float switch cable blocked Check float switch cable for kinks bends Make sure properly layed with continuous slope to Aqualiff F Pressure switch system dirty Pressure switch improperly connect defect Remove pressure switch clean tube coated 8 5 Illogical functioning of the level alarm switches The control unit continuously monitors the position of both the level switch and the alarm switch A proper chronological operation of the switches is as follows On level is exceeded On level switch activates Pump is turned on Wastewater below on level On level switch de activated Pump is turned off OR On level is exceeded On level switch activates Pump is turned on Alarm level is exceeded IE 27 8 Warnings Failures and Shut Downs Alarm level switch activates e Alarm sounds
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