KESSEL-Lifting station Aqualift€F (230V) for wastewater with and
Contents
1. CAUTION Athermal warning re initialises itself automatically after the motor temperatures has cooled Arelay failure can not be re initialised If this occurs the lifting station will not function In order to silen ce the alarm the lifting station must be disconnec ted from the power source Display of last service maintenance or display of last error The last warning or error message is saved by the control unit memory and can be re called multiple times in order to aide in diagnosing the problem Pre requisites for this are The warning or error has been cleared The wastewater level is below the pump ON and alarm ON level meaning that only the green power LED is lit Pressing the ALARM button for more than 5 seconds will turn off the 4 LEDS on the control unit The warning or error will be displayed again by the LEDs for approximately 5 se conds The system now returns to normal operation mode see table 8 2 iki KESSEL 20 8 Warnings Errors and Troubleshooting 8 2 Display of Warnings and Errors Display Problem cause Problem effect Cause no longer LED display pattern exists for last Warning or Error Warning Alarm LED blinks Maximum pump run time exceeded during level control Alarm LED blinks blink Power and Alarm LED s blink Maximum pump run time exceeded during pump run time control Alarm LED blinks Alarm level exceeded Alarm LED is on Alar2. se oil build up Ventilation pipe of pneumatic level sensor blocked Check pneumatic cable to control unit for kinks or improper installation loops or tangles in cable repair or replace Pneumatic level control dirty clog ged or level improperly set of de fective Remove level control system can clean check pressure switch and re set or replace if neces sary iki KESSEL 24 8 Warnings Errors and Troubleshooting 8 5 Illogical switching sequence The control unit monitors the pump ON and Alarm ON levels as well as each switch position open or closed and properly timed switching sequence closed and opened depending on the wastewater level The correctly timed sequence is as follows Wastewater level reaches ON level On level switch closes pump turns on Wastewater level falls below ON level On level switch opens pump turns off or Wastewater level reaches ON level On level switch closes pump turns on Wastewater level reaches ALARM level Alarm level switch closes pump remains in operation Wastewater level falls below ALARM level Alarm level switch opens pump remains in operation Wastewater level falls below ON level On level switch opens pump turns off The control can detect malfunctions or errors and display this warning via the control unit The control can detect illogical switching sequences such as the ALARM level is re
3. connection diagrams see section 9 Break the seal in the control unit cable access hole as seen in illustration a insert the cable as shown in b and connect to the properly connec tion terminal as shown in c When the connection is comple te be sure to properly secure the plastic nut by hand see il lustration d If a potential free contact is to be installed please follow the technical information supplied with that part The cable access ports at the base of the control unit which are not used should remain as they are and the protective seal should not be pierced The pre installed motor and level sensor cables have a stan dard length of 5 meter The motor cable can be extended to a maximum length of 20 meters only with the use of a VDE approved extension connection CAUTION The transparent air hose on the level sensor transfers air pressures to the control unit which are monitored a few important points concerning this follow This air hose must be laid with a continuous slope to the control unit The hose should not be kinked coiled loo ped or rolled up Not following the above requirements can lead to improper pressure readings resulting in improper pump operations Caution Pressure switch cable must be layed with a constant downward slop to the lifting station The cable should not be coiled or kinked ei 13 iki KESSEL 5 Electrical connectio
4. 1 The flap opens itself automati cally by the force of the water being pumped out of the lif ting station 1 H DEN al Varr enun Q Ai Anliiftevorricht G Betriebsstem sn j 4 3 7 A Betfiebsanleitung D Y EI 25 2 a En E Fig 1 6 3 System Commissioning After all mechanical and electrical systems have been pro perly installed and connected commissioning can begin Connect the control unit s power cable to an appropriate power supply The control unit will sound a acoustical alarm signal appro ximately 1 second long Each LED on the control unit will light beginning with the top LED The pump will perform an automatic pump test which lasts approximately 2 seconds If no error occurs in the automatic initialization of the lifting station the system will go into normal operational mode meaning that the green LED on the control unit panel will be on The lifting station operates with factor set settings see the pre set factory settings table 15 iki KESSEL If during initialization an error was detected a temperature error will be displayed on the control unit If an additional error was detected this will also be displayed on the control unit In either case the system is not ready for operation mea ning the control unit s plug should be removed from the out let and the error should be inspected and corrected see Warning and Error table If only a warning was d
5. be connected to any other circuit or power source The jacks are marked with a switch symbol Connection of level sensors built after and including January 2010 The transparent hose must be laid with a continuous positive slope from the pump to the control unit No kinks or loops coils are allowed in this hose The connection of the level sensor cable must be connected and screwed firmly to the proper connection on the control unit Potential free contact the potential free contact is capable of handling 42 V AC 0 5 Amp The poten accessory number 80072 tial free contact must be supplied with external power within the previous stated range The potential free contact allows malfunctions such as a power outage war nings malfunctions to be transfered via relay to a secondary alarm or BMS sour ce Inductive loads must be protected from the potential free contact The relay contacts have no internal connection to any supply or operational vol tage and are completely separate up to a voltage of 300 V according to Table D 10 from Norm EN 61010 Power surge category 2 u Contamination level 2 5 4 4 Completion of Control Unit Connections After the connection work has been completed the control unit cover should be closed and properly secured with the four screws to a torque of approx 1 Nm iki KESSEL 6 1 General Instructions Follow DIN 1986 Part 31 during commissioning of the lifting station
6. parts and replace if necessary Debris object in motor impeller area Remove any debris objects check pump for damage and replace if required 6 Bad odour Sharp biting odour Lifting station is not water air tight Check to make sure ventilation pipe inlet and outlet pressure pipe are not leaking Pump body leaking Check pumps contact customer service for repair or replacement Motor overheating Protectors too hot due to switching malfunctions Check motor impeller for free rotation check system for switching failure especially motor protection switch Too frequent start stops of the pump due heavy incoming wastewater flow check with KESSEL Customer Service Check system for switching failure 7 Lifting station running too often starting without rea son Incoming wastewater amount too high Find cause of problem and correct Outlet non return flap defective pumped out wastewater flowing back into pump holding tank Check outlet non return valve clean or replace if necessary Outlet non return valve is located in the black pressure outlet 8 Pump does not turn off or signals various warnings errors Potential foam suds build up insi de holding tank body Potential solidified grease oil build up inside tank or pump Reduce amount of shampoo detergents soaps which enter lifting station Clean system including interior check for grea
7. period be gins on the day the product is shipped form KESSEL to its cu stomer The warranty only applies to newly manufactured products Additional information can be found in section 377 of the HGB pu AIL eur T le 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 wa stewater treatment systems and rainwater storage tanks This additional warranty applies to the watertightness usability and structural soundness of the product Arequirement 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 corresponding norms regulations 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 be considered a defect Note Only the manufacturer may open sealed components or screw connections Otherwise the warranty may become null and void 01 06 2010 33 iki KESSEL Cc iE KESSEL EU KONFORMITATSERKLARUNG EC declaration of conformity D claration CE de conformit Nach der Maschinenrichtlinie 98 37 EG der Niederspannungsrichtlinie 73 23 EWG Richtlinie der elektromagnetischen Vertraglichkeit 89 336 EWG und Richtlinie f r Druckgerate 97 23 CEE According to the Machine Guidelines 98 37 EC th
8. remain active 6 10 Operational Test The various functions of the lifting station in relation to the wastewater level inside the holding chamber can be checked This can be done simply by allowing water from any fixture connected to the lifting station to drain into the sy stem iki KESSEL 7 Inspection and maintenance The system must be checked once every month by the ope rator through observation of the switching routine for opera tional ability and leaks CAUTION Disconnect the unit from the mains during all mainte nance work Heed safety instructions All the servicing and maintenance work described below may only be carried out by authorised qualified personnel Repairs may only be carried out by the manufacturer or his authorised service partner DIN 1986 part 31 must be heeded during maintenance work on lifting stations Maintenance work must be carried out regularly by authorised qualified staff IMPORTANT All screws may only be tightened with a maximum torque of 3 Nm The following tasks have to be carried out Visual inspection of the complete system pumps and fitting parts Thorough cleaning of the complete system and the pump Check on the complete system and pump housing for ex ternal damage and visible wear Check on the pump for free movement wear and deposits Check the connection cables for mechanical damage and wear Check the seal connections for air ti
9. sure all work on the system has been done accurately and correctly Caution Only certified electricians should perform the following work on this electrical system Prior to any work being con ducted on the control unit motor or pressure switch the system must be completely disconnected from its power source Also it should be insured that the power is not ac cidentally re connected during this work 5 1 General instructions An external main switch must be installed for the control unit that can be used in an emergency to switch off all power to the system This must be installed so that it is clearly visible All cables entering the control unit must be secured with the included fastening nuts for strain pull relief Inlets to the control unit which are not used must be properly seals with the included plastic nuts IMPORTANT All the cables connected to the electrical switch unit must be fixed in place using suitable measures e g cable ties so that they do not cause a hazard in the 1 error case i e if a connection becomes loose Please heed national and local safety regulations If these are not observed personal hazard injury may be the result In addition no liability or warranty will be granted After work has been completed the control unit housing cover must be sealed properly again to assure the control unit is protected from water moisture and unallowed access The level sensor cable should not be lai
10. 240 026 Flap opening lever 10a 1 240 023 Non return flap for 1 1 KW pump 10b 1 240 064 Non return flap for 2 2 kW pump 12 1 240 037 O ring 32 10 Accessories and replacement parts 10 2 8 Pump flange complete Article Number 206 161 Pos Piece Art Nr Description 1 1 206 126 Pump flange 2 1 206 160 Pump flange base 3 14 206 134 Washer 4 2 071 106 M6 screw 5 12 206 139 M6 screw 6 14 206 135 Weld nut 7 12 206 052 Threaded nut 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 repla ce the product or it is economically unfeasible to repair or re place 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 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 re placed 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 month This warranty
11. Activates Relay activates Ventilation port under current ex pump closes blocked running without water Pump intaking air Over current failure Activates Relay activates Check to see if impel The third start attempt fai closes ler spins freely led pump imeller Remove any objects blocked blockages in outlet impeller area Relay failure The control unit sensed a Activates Relay activates Disconnect power to system unplug con trol unit iki KESSEL 22 8 Warnings Errors and Troubleshooting 8 4 General failures Failure Cause Solution 1 Pump does not start Control unit not plugged in Plug in control unit Over current or thermal switch has activated due to motor overheating Remove motor remove blockage in impeller or pump housing area caution pump hou sing may be hot impeller blocked jammed Inspection maintenance from customer service no power Check fusing and electrical supply not power to control unit fluctuating power to control unit Attempt to re initialise system remove plug and after 10 second plug back in Level sensor not airtight of PE air hose not connecte Check all screws to make sure they are secure 2 Pump does not start alarm level is reached and dis played on control unit Lifting station is receiving too much wastewater Check to see if unexpected high volumes of wastewater are entering the lifting sta
12. CAUTION Before placing the lifting station in operation make sure that all debris metal sand stone objects have been re moved from inside the holding tank Before placed into operation the pump must be filled with water to the height of the pump s ventilation hole The pump should not intake any air After the lifting station has been properly installed including proper connection of all inlets the outlet and the control unit the lifting station may be placed into operation Make sure that all gate closure valves are in the open position IMPORTANT The commissioning of the lifting station should only be handled by an authorized professional Before placing the system into operation make sure that the power supply matches the requires of the system and that it has been properly connected Make sure that all electrical guidelines and regulations have been followed and that all explosion risks have been considered Do not place the system into operation if damaged is seen or expected to the motor control unit of cabling Please make sure to follow all safety instructions in Section 1 of the manual IMPORTANT All screws should be checked to make sure they are se cure 6 2 Pressure Outlet The outlet of the lifting station is equipped with an inte grated non return flap with release lever During normal operation this flap should never be locked in the open po sition see Illustration
13. INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS KESSEL Lifting station Aqualift F 230V for wastewater with and without sewage for free standing installation in frost protected rooms Lifting station Aqualift 230 V E Simple connection through moulded connecting pieces m Drilling surfaces for further Connections E Fully automatic operation B Maintenance friendly PE tank E General technical approval no Z 53 2 424 Installation Commissioning Instruction The installation and service of this unit should be carried out by a licensed professional servicer Name Sign Date Town Company Telephone No Edition 07 2010 it KESSEL Subject to technical amendment EIER Tu Safety El GE TO Page 4 2 General 2 1 Application SCOpe nee eee op ante Page 5 2 2 Description of the system esscr Page 5 3 Technical data 3 1 DIMONSIONS T Page 6 3 2 ST Page 6 3 3 Lifting Station Performance Cune Page 8 3 4 Electrical Control Un Page 8 4 Installation and assembly 4 1 Area of Installation Page 9 4 2 Connection of drainage pipes eeeeeeeeeeeeeeeeerereereee Page 9 4 3 3 Level sensor control Page 11 5 Electrical connections 5 1 General Information Page 12 5 2 Assembly of the oewitchgesr AAA Page 12 5 3 Installation WITING ssss
14. a ged the lifting station is no longer operational closes Description Cause Audible Alarm Potential Free Solution Contact Warnings Maximum Pump Run The pre set max run time Activates Relay open Check incoming Time exceeded was exceeded too much wastewater flow By level control wastewater pump Check level switch performance not sufficient Check pump perfor level failure mance impeller Maximum Pump Run Pump start up limit has Activates Relay open Check incoming Time exceeded By been exceeded too wastewater flow level control much wastewater pump Check level switch performance not suffi Check pump perfor cient level failure mance impeller Alarm level exceeded The alarm level has been Activates Relay activates Check incoming exceeded too much wa closes wastewater flow stewater pump perfor Check level switch mance not sufficient Check pump perfor level failure mance impeller Level error The level switch senses an Activates Relay activates Check level switch illogical switching squence closes for example alarm level has been reached without first reaching pump ON level Fehler Temperature error The thermal switch in the Activates Relay activates After the pump cools motor activates closes the thermal switch will signal a proper opera ting temperature and the error will be era sed The pump is again in normal ope ratin mode Under current failure The control unit senses
15. a way that no forces are transferred to the system and there is no direct contact with the building structure borne noise No other drainage pipes or fixtures may be connected to the pressure pipe Air tightness and material strength must be guaranteed under pressure load This must be checked during commis Sioning of the system Non return flaps installed in the pressure outlet pipe are available as accessories DN 80 cast iron non return flap Article 206 199 DN 100 cast iron non return flap Article 4 206 198 Ventilation system Article 206 200 4 3 Level sensor control CAUTION Prior to any work taking place on the control unit pump or pressure switch the main power supply to the system must be disconnected and secured against accidental ac tivation This system is equipped with a wastewater pump Two wa stewater levels are monitored to control the system ON and ALARM levels The pressure level sensor is installed and pre set at the factory The pump activation ON level is set for a wastewater level of 160 mm the alarm activation ALARM level is set for a wastewater level of 200 mm The levels can be changed by re setting the control unit if custom ON or ALARM levels are required However it is important that the ALARM level is not set too low to prevent unneces sary alarm signals as well as the ON level should not be set too high to prevent wastewater back up into the inlet pipes as well as too freque
16. ached without the pump ON level being reached this results in a level error warning The pump operates until the wastewater level falls below the ALARM on level If in this case the pump ON switch closes then the pump will remain in operation until the wastewa ter has fallen below the pump ON level the pump ON switch is always in the closed ON position The pump remains in operation until the wastewater level again falls below the pump ON level If the pump remains in operation for an over extended period of time then con trol unit will signal that the max pump run time has been exceeded or that the thermal switch in the motor has ac tivated The pump ON switch is in the ON position and that ALARM switch is continuously on The control unit will immediate ly signal an alarm level warning The pump will remain in operation until the wastewater level falls below the pump ON level or until the motor s thermal switch automatically turns off the pump A max pump run time warning will not be displayed because the ALARM level warning has a hig her priority The following switching errors can not be detected by the control unit The alarm level switch does not close the control unit thinks that the wastewater level never reaches the ALARM level The pump ON switch never opens the control unit thinks that the wastewater level never falls below the pump OFF level Illogical switching positions sequences of the level switch ca
17. ation Mounting bracket Lifting station body Floor mount Vibration matt optional 4 2 Connection of drainage pipes All drainage pipes connected to the lifting station must be in stalled so that they can completely drain into the lifting stati on no standing water in the drainage pipes All pipe connec tions must be flexible and sound insulated There are two types of connections possible l Use of existing integrated connecting spigots on the tank for connection of main inlet pipe ventilation and manual diaphragm emergency pump according to Fig A Capped spigots should be cut off as shown on the diagram at by cutting off the front cap as shown in Fig C Ventialtion DN 70 OD 75mm Inlet Connection OD 110m INS Emergency pump conenction DN 32 OD 40mm Fig A Single pump system The socket side of a standard drainage pipe can now be fitted over the cut off spigot lubricated appropriately see Fig C iki KESSEL 4 Installation and assembly Alternatively the connection of a plastic pipe with DN 100 for the inlet or DN 70 for ventilation can be carried out using rub ber type connection couplings with stainless steel fastening brackets To prevent damage to the plastic spigots during tightening of the stainless steel clamps a suitable steel sup porting ring must be inserted into the outer end of t
18. d in the same con duit as the power cable or any other electrical cable to pre vent electrical interference 5 2 Control unit mounting The supplied control unit should be installed in an easily ac cessible location in a frost free weather protected flood free and properly ventilated area The control unit should be mo unted to a firm wall as eye level To prevent elevated inter nal temperatures sufficient air circulation should be availa ble The supplied template should be used to properly drill the four holes into the wall where the control unit will be moun ted The four supplied dowels should be inserted into these four holes the control unit placed over the four dowels and the back wall of the control unit fixed to the dowels with the four supplied screws Control unit cover hinges 2 Plastic dowels 5x25mm 4 3 Fastening screws M3 5x30 4 Cover screws max 1 Nm torque 4 When the control unit cover is open the IP 54 protection class is no longer provided Prior to operation it should be confir med that excessive moisture or spraying water will not ne gatively effect the system After any work is done on the control unit the cover must be closed and properly fastened in order to provide the proper dust moisture protection iki KESSEL 5 Electrical connections 5 3 Installation Cable connections All cable connections should be done as shown in the
19. d meaning that only the green power LED it on During normal operation the 4 settings can be checked by si multaneously pressing both the ALARM and PUMP buttons Seven different setting can be displayed by various combi nation of a single blinking LED or two blinking LEDs The set tings can be checked via the LEDs being displayed 1 Setting 2 Setting 3 Setting 4 Setting Lighted LEDs Power Power Power Power gray colored background Alarm Alarm Alarm Alarm Niveau Niveau Niveau Niveau Pump Pump Pump Pump 17 iki KESSEL Uln order to access any four of the setting stages do the following Simultaneously press and keep pressed the ALARM and PUMP buttons a beep signal will be heard the NETS LED will light setting 1 release the ALARM and PUMP buttons beep signal is off setting 1 pump start delay time will now be displayed by one or two blinking LEDs 6 9 Changing settings Pressing the ALARM button will change the settings Settings 1 to 7 are displayed by blinking LEDs In order to access the 1 to 4 setting stages To enter the second third or fourth setting simply repeat the process of pressing the ALARM and PUMP buttons In order to exit the pump setting mode simply press the PUMP button so long until a beep sound is heard The lifting station now is back in normal operation mode In the case that no buttons are pressed within 20 seconds after entering one o
20. d will run until the Pump Run Time is up Depending on the level of wastewater inside the holding tank this process may repeat itself until the wastewater level has fallen below the pump ON level C Pump Run Time Control without interruption When the ON level is reached by incoming wastewater into the lifting station the pump start delay begins After the delay is over the pump begins operation and the Pump Run Time will begin After the pre set pump run time is over the pump will stop operation if at that time the wa stewater level is below the pump ON level If the waste water level is still above the pump ON level after the pre set pump run time has elapsed the pump still stop but then immediately begin operation without any pump start delay The pump will then continue running until the wa stewater level has fallen below the pump ON level 6 5 Manual Pump Start The pump can also be started by simply pressing the Pump button on the control unit The pump will run as long as the button remains pressed or for a minimum of two second The pump will run regardless of the wastewater level inside the storage tank While the pump is running the orange Pump LED will blink CAUTION Operating the pump without water causes heat build up inside the motor and results in increased wear and tear on the motor Excessive operation of the motor without water for over 5 minutes can lead to irrepa rable damage to the pump Damage res
21. dition still exists f the control unit again senses over current it will repeat the above process a second time and if necessary a third time In the case any of the three attempts are successful the lif ting station will go back into normal operational mode If over current occurs again after this then the pump will re 6 7 Factory Pre settings will display visually and acoustically the over current error The pump will no longer be started If the control unit goes into error mode due to this the pro cess is stopped Step 1 2 3 14 I5 6 Z Factory Your custom Settings settings 1 Setting Pump Start Delay O 10 2 0 4 10 6 0 8 11 0 1 2 0 2 Sek 2 Setting Pump Stop Delay with level control 05 11 0 1 5 12 0 2 5 13 0 3 5 1 0 Sek Pump Run Time Basic Setting 3 A 5 6 7 8 10 keine with Pump Run Time Control 3 Setting Limit Run Time with level control 10 20 30 140 60 90 120 30 Min Run Time multiplication factors for the two 10 20 30 40 60 90 120 keine chosen basic settings by run time control 4 Setting System Type A B C V A A Level Control B Pump Run Time Control with interruption C Pump Run Time Control without inter ruption 6 8 Checking the settings Requirement for checking of the settings are The warning or error has been cleared Neither the pump ON or the alarm ON level has been ex ceede
22. e Low Voltage Guidelines 73 23 EEC Electromagnetism Guidelines 89 336 EEC and the Pressure System Guidelines 97 23 CEE Selon les directives m caniques 98 37 EG les directives de basse tension 73 23 EWG les directives pour la compatibilit lectromagn tique 89 336EWG et les directives pour appareil pression 97 23 CEE KESSEL AG Bahnhofstra e 31 D 85101 Lenting erklaren wir we declare nous d clarons dass das Produkt that the product que le produit KESSEL Hebeanlage Aqualiff F f r fakalienhaltiges und fakalienfreies Abwasser zur freien Aufstellung in frostgesch tzten Raumen KESSEL Aqualif 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 Zur Kennzeichnung der bereinstimmung der Produkte ist auf dem Typenschild das Zeichen der Richtlinie 93 68 EWG angebracht The 93 68 EEC code mark should be located on the ID plate on the product Le marquage et l indentification du produit figurent sur la plaquette d identification selon les directives 93 68 EWG Lenting den 16 11 2009 CL A Kessel E Thiemt Vorstand Vorstand Managing Board Managing Board Conseil d administration Con
23. e 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 ina fully functional condition If any parts are damaged the system may not be operated and or must be im mediately 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 Safety instructions Dear Customer 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 direct contact clean the affected pa
24. et Article Number 28646 DN100 n a I L IIl vert J ISO Ansicht iki KESSEL 3 Technical Data 3 2 Pump Type 230 V 1 1 kW Nominal capacity P2 1 1 kW Rated capacity P1 1 7 kW Operating voltage 230 V Rated frequency 50 Hz Nominal current T 3A Start up current 18 5 A Capacitor 40 uF 400 V AC DB Fuse 10 A slow blow Connection cable 5 m length 7 x 1 5 mm Pumping medium temperature 35 C Weight pump 30 kg Protection Class IP 68 up to 3 m Operational class S3 6096 max operation times Noise level 70 db Lifti tati rf Ing staton performance cuve Qnin nach DIN EN 12056 4 Vmn 0 7 m s f r DN 80 f r DN 100 9 ZS e o 2 o Y N T Te 0 u 6 x Ki 5 4 Cs 3 Te 2 1 F rderstrom Q 0 gt m3 h 0 4 8 12 16 20 24 28 32 36 40 44 48 l 0 2 4 6 8 10 12 Qs iki KESSEL 3 Technical Data 3 3 Pump volume The factory set pumping volume is 20 liter which is control led by the pneumatic switch and the control unit 3 4 Electrical Control Unit 3 4 1 General technical data Control Unit Dimensions Lx W x H 180 x 200 x 70 mm Control Unit Weight 1100 g Ambient conditions Allowable temperatu
25. etected and displayed during initia lization then the system is operational see Warning and Error table 6 4 Normal operation When the ON level or the ALARM level is reached the ac cording level switch closes activates When the ON level or the ALARM level then goes below the switching point the Switch opens deactivates The red ALARM LED shows that the ALARM level was rea ched The orange LEVEL LEVEL LED shows that the pump on level was reached The orange PUMP LED shows that the pump is currently in operation A Level Control this is the factory setting When the ON level is reached by incoming wastewater into the lifting station the pump start delay begins After this short delay the motor will begin activation and run until the level falls below the activation level When the level falls below the activation level a pump stop delay begins As soon as this short pre programmed pump stop delay is over the pump will stop B Pump Run Time Control with interruption When the ON level is reached by incoming wastewater into the lifting station the pump start delay begins After the delay is over the pump begins operation and the Pump Run Time will begin After the pre set pump run time is over regardless of the current wastewater level currently in to the storage tank the pump will stop If the level at this time is still above the pump ON level the pump will begin again to operate as soon as the pump start delay elapses an
26. f the four setting modes the system will automatically return itself to normal operation mode and a beep signal will be heard Step 1 2 3 4 5 6 7 Power Power Power Power Power Power Netz Lighted LEDs gray colored Alarm Alarm Alarm Alarm Alarm Alarm Alarm background Level Level Level Level Level Level Level Pump Pump Pump Pump Pump Pump Pump Simultaneously press and keep pressed the ALARM and PUMP buttons a beep signal will be heard the NETS LED will light setting 1 release the ALARM and PUMP buttons beep signal is off the current setting 1 setting the pump start delay time set ting will now be displayed by one or two blinking LEDs The current setting can now be changed by pressing the ALARM button The new setting will now be displayed by one or two blin king LEDs When the desired setting has been reached simply press and keep pressed the PUMP button until a beep signal is heard The new setting has now been saved and stored The lifting station now is back in normal operation mode In order to access setting stages 2 3 or 4 simply repeat the above process In the case that the PUMP button is not pressed within 20 se conds after making any changes the system will automati cally return itself to normal operation mode and no changes will be saved beep signal will be heard In the case of a power outages any properly made and saved changes will
27. g components and or product components 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 respon sible 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 35 Leading in drainage U Backwater protection LI Septic Systems U Lifting Stations and pumps LI Inspection Chambers U Drains and shower channels L1 Rainwater Management L Separators Systems Grease Separators Oil Fuel Coalescence Separators Starch Separators Sediment Separators a KESSEL
28. ghtness and replace the seal e g O ring if there any indications of wear Insulation test on the pump motor If applicable check non return valve for function The above checks should also be taken if the lifting station has stood idle for an extended period of time 7 1 Notes on the pump The pump should be checked at regular intervals If opera tional noises increase pumping capacity decreases or there are vibrations in the pipeline system the pump housing and impeller must be checked for any blockages build up or wear and tear To do this the motor unit must be loosened at the four attachment screws refer also to section 10 2 1 and be removed from the pump housing When checking the pump housing care must be taken that the ventilation bore hole is kept open under all operating conditions 7 2 Notes on the aerating device The aerating device can be used to completely empty the pressure pipe through manual lifting of the backwater flap on the lifting system To do this an size 8 Allen key or a size 15 wrench must be used to hold the flap opener turned see Fig 2 as long as necessary to completely drain any wastewater in the pressure outlet Then the flap opener must be retur ned to its initial position which is the marked operating posi tion see Fig 3 7 3 Hinweise zum elektrischen Schaltgerat Nach Wartungsarbeiten mu der Gehausedeckel wieder fachgerecht verschlossen werden Reparaturen d rfen nur durc
29. h den Hersteller vorgenommen werden BetriebsstellunV y Betriebsanleitung be Fig 2 Fig 3 cell 19 iki KESSEL 7 Inspection and maintenance Note The complete flap housing can be removed for cleaning and maintenance purposes see Fig 4 by loosening the screw connections on the lower and upper flange of the flap housing Prior to this work the outlet pressure pipe must sealed closed and any waster drained from the sy stem 7 3 Notes for electrical control unit After any work has been done on the control unit make sure that the control unit cover is closed and properly secured with the four screws Repairs may only be carried out by the manufacturer or his authorised service partner 8 Warnings Errors and Troubleshooting The following checks and repairs should only be handled by an authorized service company If there is any doubt contact the manufacturer or the service company which installed the System 8 1 General Comments Warnings warnings serve to inform the user but do not cause the system to stop operating meaning that the system remains in normal operational mode Errors Errors cause the system to stop operating and re quire corrective action by a qualified service provider This means the system will not return to operation until repaired Errors are higher ranked that Warnings In the case that a war ning exists and foll
30. he spigot see Fig D P saw off inlet cap NE Lifting station body Ill C Pu pe connection Pipe sleave H Pa off inlet cap Hose clamp Support ring ILD Il Connection of additional inlets on the flat connection surfaces on the side of the lifting station body ad ditional inlets can be connected to the body by drilling out the proper sized hole inserting a properly sized pipe gas ket and then inserting a lubricated drainage pipe see Fig E Hole saw drill connectors and pipe gaskets avai lable from KESSEL Ventialtion pipe seal 27777 Pipe connection Lifting station body Ill E KESSEL Accessories IMPORTANT In the case that additional inlets are connected to the side of the lifting station body it should be noted that during normal operation the wastewater level will reach the base of the main inlet spigot or slightly above Any additional inlet connection below this level will mean that wastewa ter will stand in the drainage pipes which over time could lead to blockages of the inlet pipe iki KESSEL 4 Installation and assembly The inlet pipe must be laid as straight as possible and aat a gradient to the KESSEL lifting station in accordance with EN 12056 Inlets connected too low on the tank could result in blocka ges of the inlet pipe please see the Imp
31. iriirrscersierrinrsernnriaeninan ariaren Page 13 5 4 Completion of Control Unit Connections Page 14 6 Commissioning 6 1 General Information Page 15 6 2 Pressure Outlet Page 15 6 3 System Commissioning sene Page 15 6 4 Normal operation eene Page 16 6 5 Manual Pump Gtart Page 16 6 6 Additional functions A Page 16 6 7 Factory Pre settings A Page 17 6 8 Checking the settings seen Page 17 6 9 Changing settings AAA Page 18 6 10 Operational Test Page 18 7 Inspection and maintenance 7 1 Notes on the pump sssssssssssissrssrsrnnrnsnnnrnsrunennnnnnsnnnnnnnnnnnnae Page 19 7 2 Notes on the aerating device A Page 19 7 3 Notes for electrical control unit AA Page 20 8 Malfunctions Errors and 8 1 General Comments seseeeeeeeeeieereieieieiiersrneisinersrneerees Page 20 troubleshooting 8 2 Display of Warnings and Errors sess Page 21 8 3 Correction of Warnings and Errors s es Page 22 8 4 General Failures eseeseeeeeeseseeeeiereiesiersriersrnrrsrnnereeernns Page 23 8 5 Illogical switching sequences s e Page 25 8 6 What to do wen Page 25 9 Control unit 9 1 General description ssssseeeee Page 26 with Connection plan 9 2 Display and Operation Buttons Description Page 26 9 3 Connection plan Page 27 10 Replacement parts and accessories 10 1 w
32. m level exceeded Alarm LED blinks LED Power blinks the pump remains off power source to control unit must be disconnected After acknowledging begins again The control unit places the system back in normal operation mode Level error Alarm LED blinks LED Niveau blinks Error LED Alarm on Temperature error Failure After pump cools Alarm and Pumpe LED s Niveau and System is again LED s blink Pumpe blink operational LED Alarm on Under current failure Abort After acknowledging Power Alarm and LED Pumpe blink The control goes into After acknowledging Pumpe LED s error mode and the begins again The blink pump remains off control unit places the system back in normal operation mode Over current failure Abort After acknowledging Niveau and Pumpe LED s blink LED s Power Alarm Niveau and Pumpe blink Relay failure Abort the pump remains off power source to control unit must be disconnected After plugging in the power supply the control unit returns to normal operation mode Power Leve and Pumpe LED s blink 21 iki KESSEL 8 Warnings Errors and Troubleshooting 8 3 Correction of Warnings or Errors motor current even though the pump did not activate this means the relay contacts are dam
33. n be caused by technical defect short circuit or break in the control unit cables improper connection of cables inside control unit Service of these errors should only be handled by a certi fied electrician 8 6 What to do when when a malfunction which is not discussed in this user s manual occurs Contacta certified pump service firm preferably the com pany which originally installed the lifting station the control unit does not react to any of the buttons on the front of the control unit Unplug disconnect power to the control unit for at least 10 seconds and then re connect to power source If the system does not properly re initialize itself then please contact a certified pump service firm preferably the com pany which originally installed the lifting station 25 iki KESSEL 9 Control unit 9 1 General description L eit 2 0 9 Control unit housing PUMP LED orange 4 x screws max torque 1 Nm 9 ALARM button 3 Control unit power cable PUMP button Abbreviated operation manual M Pump cable connection 8 POWER LED green 2 Pneumatic level switch connection ALARM LED red 3 Potential free conect connection LEVEL LED orange 9 2 Display and operation buttons description Control unit display Normal operation Power green Power supply ok information for the operator Alarm red ALARM level exceeded Niveau orange P
34. ns The individual connection tasks are listed in the following table and in the connection diagrams on page 28 The explanati ons in Section 9 Electric Control Unit must also be heeded position of the control elements view of the inside of the con trol unit Single Pump Lifting Station Follow all safety instructions Required Connections Description Connect batteries Both 9 volt batteries must be connected to the circuit board Akkus up to 11 09 Power connection The power supply must offer a full pole main switch that is directly connected to the controls The required fusing on site must not exceed 16 Amps The power chord for the entire system is a 1 7 meter long cable Motor cables and The motor cables are to be connected to the proper connection jacks marked motor temperature sensor motor inside the control unit Please follow the correct order Motor PE PE jack Motor U1 Z1 jack 2 Motor U2 z jack 1 Motor Z2 jack 3 Temperature switch T1 jack 4 Temperature switch T2 jack 5 The ground cable should be connected to the PE jack on the motor connec tion jack Level sensor Level signal ON ALARM for units up to and including December 2009 The level sensor cables are to be connected to the proper connection jacks white cable right brown cable left on connection Ein green cable right and yel low cable left on connection Alarm The level sensor connection jacks cannot
35. nt pump activation for pumps manu factured on June 2009 or earlier 4 3 1 Custom setting of level sensor The ON pump activation level can be adjusted using screw 1 and the ALARM activation level can be adjusted using Screw 2 as seen on the diagram Turning the adjustment screw in the clockwise direction increases the activation level turning in the counter clockwise direction lowers the activation level Turning a screw half was around will ad just change the activation level by 10 mm 8 37 dch n H 4 3 2 2 Level sensors for Jan 2010 an on The transparent air hose must be laid with a continuous up ward slope to the control unit so that no condensation liquid can build up in the hose Make sure that the hose is not loo ped or coiled up If the air hose is too long it can be shorte ned on site The air house can be extended to a maximum length of 20 meters The activation levels have be set at the factory and can be changed by control unit adjustments Ad ditional information is available from the KESSEL customer Service department iki KESSEL 5 Electrical connections The pump power cable and level sensor cable have been connected to the control unit at the factory Independent from this the further instruction in this section of the manual must be followed In the case installation work has already been done this manuals instructions should be reviewed and checked to make
36. o a freier z akt E Netz Anschluss 230U 50Hz Pouer Connexion eletrique Pumpenmotor 1 1KW Niveau Dr uck schalter 230U S Hz mt Temper atur schalter Motor uith thermal membrane sensitive suitch switch pressostat membrane Moteur avec automate ther mostatique s o a e N b t 5 z B k Ex Schutz R Gi SE f Temp Schalter I U eu U 12U I 10 5mA I max SmA en eim l 2 5 U x Gi o S sj al Gs St Alarm Ein f 5 Anschlup f r potential freien Schaltkontakte max 230U AC 2A Potential free suitch contact connexion libre de contact Edit 12 99 iki KESSEL 28 10 Accessories and replacement parts 10 1 Accessories Description Order Number Manual emergency diaphragm pump 28680 Flexible hose connection with 2 hose connection brackets DN 40 28660 DN 70 28661 DN 100 28663 Pipe closure valve for non pressure drainage pipe DN 100 28698 DN 150 28699 Shut off valve for emergency pump 28681 Rubber anti vibration matt Single pump lifting station 28692 Twin pump lifting station 28693 Pipe insert gasket DN 50 850114 DN 70 850116 DN 100 850117 DN 125 850118 DN 150 850119 Hole saw DN 50 DN 150 50100 Rechargeable battery up to 11 09 20230 Battery beginning 12 09 197 081 Manual closure valve for the outlet pressure pipe DN 100 28683 Compressor pump for air insertion to air pre
37. ortant section on page 10 Connection to the tank can be carried out as de scribed under section or II above The ventilation pipe equalized the air pressure inside the lif ting station which occurs during filling or pumping out of the pump body According to DIN 1986 the ventilation pipe must have as least the DN 70 size and be connected directly through the roof of the building to ambient air which will pre vent nuisance odours Connecting the ventilation pipe to the lifting station body can be handled as described in the pre vious section 4 2 Connection of drainage pipes The pressure pipe for pumping out collected wastewater into the adjoining sewer should be connected directly to the out let pressure pipe To reduce noise and force transfer into the pressure pipe the supplied rubber pressure connection coupling must be used It should be fitted at least 4 cm over the outlet spigot of the lifting station and be secured with a stainless steel pipe clamp The supplied rubber pressure connection does not offer any type of lateral force connection which must be handled on site for example with pipe connection clamps secured to the wall or ceiling According to the regulations of EN 12056 the pressure pipe must be routed above the backwater level and connected to a ventilated drainage pipe to the sewer A gate closure valve should be connected on site to the pressure pipe The pressure pipe must be connected see above in such
38. owing this an error occurs the error signal is displayed A general troubleshooting guide for handling warnings and errors can be seen in the Display of Warnings and Errors section Turning off audible alarms Warnings and errors are signalled by an audible alarm from the control unit This audible alarm can be turned off by pres sing the ALARM button on the control unit The LED display warning or error will remain on the control unit CAUTION During a relay failure the audible alarm will remain on and cannot be turned off by pressing the ALARM but ton If this occurs the lifting station will not function In order to silence the alarm the lifting station must be disconnected from the power source Re initialising a warning Pre requisites for re initialising a warning are The audible alarm has been turned off The cause of the alarm no longer exists By pressing and keeping pressed the ALARM button a war ning alarm will be cancelled The system is now back in normal operation mode Re initialising an error Pre requisites for re initialising an error are The audible alarm has been turned off The cause of the error has been repaired By pressing and keeping pressed the ALARM button an error alarm will be cancelled This will cause all 4 LEDs to turn off The LED error message will be displayed once more for approx 5 seconds The process starts again new and the System returns to normal operation mode
39. parts Position Piece Article Nr Description 20 4 206 074 Clean out screws 21 8 017 199 Outlet flange screws 22 8 017 012 Washer 23 4 017 213 M6 screws 10 2 2 Pneumatic level switch Article Number 206 208 Starting December 2009 Pos Piece Article Nr Description 1 1 197 333 Base screws O 2 1 197 340 Clamping ring for base screws 3 1 197 339 Connection nuts for base 4 1 344 012 O ring DRE Pressure sensor Article Number 206 017 beginning November 2009 02 D Pos Piece Art Nr Description SS 1 1 206 023 Pressure sensor base 2 1 206 008 Single pump pressure pipe 10 3 1 206 050 Single pump pressure sensor 4 1 206 014 Pressure sensor upper section 5 1 205 084 cable connection 6 5m 206 047 Cable 7 4 099 119 Connection receptacle 8 4 011 050 Cable end sleeve 9 La 10 1 206 043 O ring 11 1 206 053 O ring 12 2 017 153 PT screws iki KESSEL 31 10 Accessories and replacement parts 10 2 5 Single pump flap housing DN 100 Article Number 240 051 iki KESSEL Pos Art Nr Description 2 1 240 048 110 mm connection 3 8 240 039 M8 nut 4 8 240 038 M8 screw 1 1 240 046 Flap housing 3 1 240 019 Flap lever 4 1 240 034 Flap washer 5 2 091 017 O ring 6 2 049 018 O ring 7 1 134 025 PT screws 8 1 206 010 Flap holder 9 1
40. pening 1 4 Inlet connection for DN 100 drainage pipe 1 5 DN 70 ventilation connection 1 6 DN 40 connection for emergency manual diaphragm pump 1 7 DN 100 outlet connection with integrated non return flap and flap release lever 1 8 Areas for connection of additional inlets The KESSEL lifting station Aqualift F has been designed for free standing installation in frost protected rooms The in cluded control unit must be mounted in a flood proof dry and frost protected area The system s wastewater pumps are equipped with a single vane impeller and have a free pas sage of 40 mm The pressure pipe connection must be size DN 80 at a minimum the ventilation pipes must be size DN 70 at a minimum Abrasive media must be kept away from the pump s impeller The systems are suitable for constant wastewater tempera tures up to 35 C A maximum temperature of 60 C is per missible briefly up to 10 minutes 2 2 Electrical control unit see illustrations in chapter 9 3 3 Accessory parts not illustrated 3 1 Brackets with screws and dowels for fixing the pump body to the floor 3 2 Rubber connection coupling stainless steel clamps for the pressure pipe connection 3 3 Sound insulating underlay mat Mono Art no 28692 Duo Art no 28693 A detailed description of the system set up can be found in chapter 10 Spare parts iki KESSEL 3 Technical Data 3 1 Dimensions Single 1 1 kW lifting station with DN 100 pressure outl
41. re range O0 bis 40 C Allowable humidity 10 bis 80 96 non condensing Maximum elevation of system 2000 m above sea level Power consumption Approx 5 VA without motor Protective class Class 1 with function grounding of the secondary electro nics circuit PELV Protective rating IP 54 with screwed shut cover and cover gasket 3 4 2 Power Supply Operating power 230VAC 1 NIPE 50Hz 10 Power cable 1 7 meter power cable with protective contact connection in control unit Required power supply fuse max 16A to be provided on site 3 4 3 Inputs In and Level level inputs Operational current 6 V DC switching power each 10 mA Thermal motor switch Supply current 12 V DC Switching power ON 9 mA Switching power OFF 5 mA 3 4 4 Outputs Potential free contact Switch opener middle contact close max 42 V AC 0 5 A without system internal protective switch for inductive loads Pump Motor Connection of the protective lead and the single phase win dings of motor iki KESSEL 4 Installation and assembly The following parts are included in the scope of supply see section 2 2 Collecting tank with all components mounted Electric Control Unit plug in ready Accessories IMPORTANT The electric switch unit must be stored in a frost free and weather protected area prior to installation If the control unit is to be connected at a later date it should be properly stored as sta
42. rt of your body thoroughly and disinfect if necessary It is also possible 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 mea sures 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 activities in the respective room that could cause the gas to ignite e g operation of electrical devices without encapsulated motors metalworking etc Thank you for choosing a KESSEL product This product passed strict internal quality control standards before leaving the factory Please check now to make sure that all parts have arrived and have arrived undamaged In
43. seil d administration Pr fstelle Accredited Laboratory Bureau de v rification LGA QualiTest GmbH T V Rheinland Group Dreikronenstraf e 31 D 97082 W rzburg 13 Commissioning Protocol for installer Type description KESSEL order number Date of manufacture according to type plate invoice Object description system operator Planner Adress Telephone Planner Adress Telephone Installation company involved Adress Telephone Person authorised to perform the acceptance Adress Telephone Person responsible for handover Other remarks The initial installation and instruction listed was carried out in the presence of the person authorised to perform the accep tance and the system operator Place date Signature of authorised person Signature of system operator 9 Commissioning Protocol for installion company Handover certificate copy for the company carrying out the installation The initial operation and instruction was carried out in the presence of the person authorised to perform the acceptance and the system operator d The system operator person authorised to perform the acceptance was informed about the obligation to service the pro duct according to the enclosed operating instructions LI Initial operation and instruction were not carried out The client person responsible for initial operation was handed the followin
44. ssure sensor hose provides operationalreliability for wastewater with high grease content or hygiene products 28048 Upgrade set from membrane pressure switch to control unit pressure sensor 28049 up to 11 2009 also see KESSEL catalog iki KESSEL 29 10 Accessories and replacement parts 10 2 Spare parts 10 2 1 Explosion diagram Position Quantity Article Nr Description 1 1 206 004 Lifting station body 2 1 206 161 Pump flange assembly 3 1 367 001 Pump FPF 110W KE FH 4 1 240 051 Pump outlet assembly DN 100 5a 1 206 017 Pneumatic pressure sensor until Dec 2009 5b 1 206 208 Pneumatic pressure sensor starting Jan 2010 5c 5m 298 045 Transparent 6 x 4mm tube 6 1 206 018 Clean out access 7a 1 206 091 Control unit until Dec 2009 7b 1 243 206 Control unit starting Jan 2010 8 1 003 155 Pressure connection coupling D 110 x 6 fur DN 100 9 2 003 144 Pressure seal D 110 x 6 for DN 100 10 2 206 021 Floor bracket 11 1 206 042 Flange gasket 12 1 049 010 Gasket 13 1 049 011 Gasket 14 1 049 005 O ring 15 16 206 090 Bracket screws 16 4 017 095 Pump screws 17 2 206 055 Floor mounting screws 18 2 017 114 Floor mounting washers 19 2 206 051 1Dowels Control unit and pressure switch must be from same series both from 2009 or earlier or both 2010 or newer 5a 7a 5b 7b iki KESSEL 30 10 Accessories and replacement
45. ted above Caution Danger due to heavy weights The lifting station weig hs approx 45 kg single system The parts may only be lifted and or assembled using suitable equipment and exercising appropriate caution If the system is dropped this can lead to irreparable damage to system parts e g pump or the entire system Such damage is not covered by the warranty INSTALLATION SITE The KESSEL lifting station Aqualift Fhas been designed for free standing set up in frost protected rooms The area of installation should be protected against flooding A submergence of the lifting station for more than 24 hours can cause the system to stop operating and can lead to irreparable damage The included control unit should be mounted in a flood protected dry and frost proof room 4 1 Area of installation In order to prevent improper installation service or repair of the lifting staition it must always be installed in such a way that there is sufficient access to all areas of the lifting station and replacement of all components is possible DIN 1986 requires at least 60 cm of access space on all sides of the system The system must be set up in a appropriate area of a room aligned horizontally and placed on a sound insulating matt available as an accessory from KESSEL The lifting station must be properly secured to the floor with the included This will prevent unwanted movement twisting of the system during start ups and oper
46. the case that damage occurred during shipping please see the Warranty section at the end of this manual Before this Aqualift F lifting station is installed and placed into operation itis in your best interest to thoroughly read through this installation and operation manual and follow it closely KESSEL iki KESSEL 2 1 2 1 Area of application This lifting station pumps wastewater with and without se wagethat occurs below the sewer and backwater level fully automatically into the sewage system in accordance with the requirements of DIN 1986 They are only suitable for use for domestic wastewater for example in single family and mul tifamily homes hotels and restaurants department stores hospitals schools or similar commercial applications In case the area of application will not allow down time due to the breakdown of a single pump system the lifting station must be equipped with a second pump of the same capaci ty which switches on immediately when required twin stati on instead of single station 2 2 Description of the system The KESSEL Aqualift F lifting station operates on alterna ting current and consists of the following main parts 1 2 3 1 5 1 3 1 Agas and water tight collecting tank made of LLD PE low linear density polyethylene with 1 1 A wastewater pump with 5 meter power cable 1 2 Pneumatic level control with 5 m cable 1 3 Access cleaning o
47. tion Temporarily do not use drainage fixtures connected to lifting station Pump performance not sufficient Remove object blockage in impeller or pump housing Remove object blockage in the pressure outlet or pressure pipe Pumps are worn out replace pumps Lifting station not proper for specific application contact KESSEL Customer Service 3 Pump runs loud or rough Motor rotating in wrong direction Check motor rotation if rotating in wrong di rection check phases Pump damaged and not performing properly Check motor any damaged parts should be replaced by customer service 4 Wastewater is not pumped out fixtures connected to lifting station are backing up Control unit not plugged in Plug in control unit No power being supplied to control unit Check fusing Check power supply Level sensor damaged Check level sensor for proper function or blockage Inlet to lifting station blocked Clean inlet pipes Gate valve on inlet side of pump shut or not opening properly Open inlet gate valve Wastewater temperature over exten ded period of time 15 minutes too high suction capability of system li mited Lower incoming wastewater temperature 23 a KESSEL 8 Warnings Errors and Troubleshooting Failure Cause Solution 5 System suddenly begins running loud Pump damaged due to debris objects Check pump
48. ulting from this not covered by the warranty 6 6 Additional functions Anti blocking function In order to keep the motor in proper working condition the motor will automatically turn itself on for 2 seconds in the case that it has nor operated over the last 7 days Potential free contact The potential free contact will pass on a warning signal in for any warning or error that may occur with the pump as well as a power loss Under Current When the control senses a under power condition for ex ample the motor is running without water an under power error signal will be displayed by the con trol unit the pump will no longer operate if due to this the control goes into error mode the process is stopped Over Current In order to prevent damage to the motor due to over current for example outlet blockage or jammed impeller the pump initially turns itself off In an attempt to free the blockage the motor will automatically turn itself on three times in the following manner Control unit senses over current Pump is turned off automatically An over current error is displayed The control unit waits three second plus the pump start iki KESSEL peat the three attempts to clear the over current Ifthe three attempts are not successful then the control unit delay period The pump turns on again this is the first start attempt The control unit tests to see if an over current con
49. ump ON level exceeded orange Pump in operation Malfunction see section 8 2 Display of Warnings and Errors Operational controls Buttons Alarm Turning off acoustical alarm Acknowledgement of Warnings and Errors Choosing and changing settings Pump Manual pump activation Choosing and saving new pump settings iki KESSEL 26 9 Control unit 9 3 Connection plan built on or after Jan 2010 Netz Drucksensor Power Preassure Probe Connexion electrique Senseur Pression 230VAC 50Hz potential freier Kontakt Potential free switch contact Connexion libres de contact max 42V 0 5A Motor Motor Moteur 230VAC 50Hz 27 externer Signalgeber Signaling Device Alarme 197 319 06 09 64845 iki KESSEL 9 Control unit 9 4 Connection plan built up to and including December 2009 Schaltgerat BNR 206 078 Kondensator MKP 4 uF 5 280U C10000h K1 B e amp 2 kl wo N qT ND Schr ack RP3SLBI2 120 oc m Sromuandler N Kondens c D N 0 D arr O10 0 o0 aur Su ge C1500 CCO225PT Trafo BU 6726 PRI 23 U 50 60Hz d E SEK 12U Sun 7 9 SIEMENS 2x1 mH 258U 882222 J2102 NI S t D D E S 5 E E ZE pot ETZ PUMPE THERMO EIN ALARM Kont g ninno nu a Md ald als r BE E a EI D g a fe R u 9 v LES A o c CG
50. w P Page 29 10 2 Replacement Parts airasia Page 30 R I CIS Page 33 12 Declaration of conformity sssssseeeneneeneee nennen nnne nennen nnne nnt nnne nennen Page 34 13 Handover record 2ssnesene nene tite eni nien hn n ridi arp Enea aa Page 35 iki KESSEL 1 Safety instructions 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 potential and take precautions 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 Th
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