Graf one2clean+ Instruction For Operation And Maintenance
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Graf one2clean+ Instruction For Operation And Maintenance

Small wastewater treatment systems
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See also: Instruction and Installation Manual
start-up, operation and maintenance
one2clean+
one2clean+ XXL
Small wastewater treatment
systems
Control unit version KL24plus
The points described in these in-
structions must be observed in all
cases. Failure to do so shall invali-
date the warranty. For any addi-
tional items purchased through
GRAF, you will receive separate
installation instructions in the
transport packaging.
The components must be checked
for any damage before the system
is transferred to the pit.
You will receive separate instruc-
tions for installation of the system.
Be sure to read before starting
up!
Instructions for
Contents
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Summary of Contents for Graf one2clean+

  • Page 1: Table Of Contents

    You will receive separate instruc- 10. Technical data tions for installation of the system. 11. Template for weekly / monthly check notes 12. Maintenance log for GRAF small wastewater treatment systems Be sure to read before starting 13. Notes 1 / 40...

  • Page 2: General Information

    1. General information 1. General information Below you will find some important information for safely operating your system for a long time to come. • The SBR system is designed to receive all domestic wastewater. Other wastewater, e.g. from restau- rants and / or commercial premises etc., may only be received if this was specified and taken into account in the system's design.

  • Page 3: Safety

    2. Safety 2. Safety This chapter contains details relating to safety measures and residual risks. Read this chapter through carefully before using the system to ensure that it is used as safely as possible. Intended use The control unit was specifically developed for use in SBR small wastewater treatment systems. The con- trol unit must not be used in areas representing a danger to life and limb: ...
  • Page 4 2. Safety Danger notices To ensure safety, everyone who comes into direct contact with the system must note the content of this documentation. The system must not be used for any purpose other than that described by the manufacturer. Local operating and safety requirements and legislation must be followed at all times, even if they are not explicitly mentioned in these instructions.
  • Page 5 2. Safety Warning notices Be sure to observe this information. Failure to do so may result in personal injury or damage to property! Ensure that the machine cabinet is not installed above or in the direct vicinity of water vessels. There is a risk of electric shock if improperly installed. Installation loca- tion Only connect the machine cabinet to a correctly installed 230 V socket or earth cable...

  • Page 6: Description Of Function

    3. Description of function 3. Description of function Description of the wastewater treatment process The one2clean+ wastewater treatment system is a fully biological system and functions on the principle of the retention process with extended aeration (Sequencing Batch Reactor). The system basically consists of an aerobic stage, which is split into a rest and an aeration zone, linked together in the lower section.
  • Page 7 3. Description of function Structure of one-tank systems Sampling point Clear water lifter Scum baffle Pipediffusors Figure 1: One-tank system Structure of multi-tank systems Sludge return Sampling point Clear water lifter Pipediffusors Pipe Diffusors Connection pipe Figure 2: Two-tank system 7 / 40...

  • Page 8: Control Unit

    4. Control unit 4. Control unit Connections to the KL24plus control unit The figures below show the basic structure of the switch cabinet of a two-tank system. Compressor Control unit Compressor connection Connection 6 mm for level sensor Connection for power supply sludge lifter discharge lifter aeration...
  • Page 9 4. Control unit Connections on the rear of the control unit Figure 5: Rear of KL24plus control unit Connections: Connection for mains cable 230 V AC ~ 50 Hz X1: Pre-assembled valve cable X2: two pin plugs for the air compressor connection COM: Connection for communication module (optional) and/or port for PC F1: T6.3A main fuse, slow blow F2: T2A fuse for UV module, slow blow...
  • Page 10 4. Control unit Starting up the control unit Once the system has been connected to the power supply, perform a brief system test. The system test takes a few seconds and checks the real-time buffering. During this time, the LED lights up red. Then the LED switches to green and the start phase is complete.
  • Page 11 4. Control unit Instructions for operating the wastewater treatment system The system is operated using a microprocessor in the control unit. The microprocessor allows operating parameters to be set, operating statuses to be displayed, system parameters to be queried and operating times to be programmed by a specialist.
  • Page 12 4. Control unit 4.5.2 Operating status display Figure 6 View of KL24plus operating unit The system's operating status is indicated by the LEDs (Green = Operation / = Fault) and by text on the screen. In normal operating mode (aeration mode), the display looks like this: Aeration Remaining: 120:10min...
  • Page 13 4. Control unit Operating the control unit You can start various queries when in automatic mode. Pressing takes you to the first operating level. Now you can call up the individual queries by pressing the two arrow keys followed by Display Meaning KL24plus...
  • Page 14 4. Control unit 4.6.2 Manually controlling the valves and cabinet fan using "Manual mode" Press , then press the arrow key until the following appears on screen: Manual mode function Manual mode can now be set for all functions by again pressing and using the arrow keys make the relevant selection.
  • Page 15 4. Control unit 4.6.3 Setting date/time Press , then press the arrow keys until the following appears on screen (example): 20:15:56 2014-12-19 Mo By pressing you can set the time and date using the arrow keys . To confirm each change, you must press Pressing once takes you back on to holiday mode.
  • Page 16 4. Control unit Pressing the key saves the input of data for holiday mode and exits this function.  Note: Holiday mode can be set for a maximum of 90 days. If no key is pressed for 2 minutes, normal mode engages automatically without the date just entered being saved.
  • Page 17 4. Control unit If the system is disconnected from the mains (e.g. due to a power cut, should the internal fuse blow or by disconnecting from the socket), the indicator issues an acoustic and optical signal in turn regardless of the cause.

  • Page 18: Start-Up

    5. Start-up 5. Start-up When starting up, the functionality of the small wastewater treatment system is checked by means of a test run. The start-up also includes setting the control unit and instructing the operator. Preparations Before starting up, the following should be ensured for correct operation: ...

  • Page 19: Level Measurement

    6. Level measurement 6. Level measurement The control units are fitted with an integrated pressure sensor as standard. This can establish the level by means of the aeration unit (membrane aerator) secured to the base of the tank. This level measurement is mainly used: 1.
  • Page 20 6. Level measurement 1st step: Calibrating the pressure sensor It is absolutely essential that the sensor is calibrated for first starting up. Please carefully work through the following points in order: Go to "Service code", press the key and enter the following code when Service menu prompted to do so: 9 9 9 9 Calibrate?
  • Page 21 6. Level measurement 3rd step: Function check The level measurement can now also be manually activated in manual operation for checking purposes. This requires the level measurement to be activated under Manual mode using the key. The control unit automatically takes a measurement once switched on. After the measurement is complete, the meas- ured level appears in the display.

  • Page 22: Operation And Maintenance

    7. Operation and maintenance 7. Operation and maintenance This wastewater treatment system is a fully aerated system without an anaerobic pre-treatment stage. It is therefore absolutely essential that the control unit and compressor are not switched off – other than for maintenance purposes by specialist staff.
  • Page 23 7. Operation and maintenance Solids or liquids which Why not: Correct disposal: should not be disposed of via the sink or toilet: Paintbrush cleaners Contaminate the wastewater Local collection point Cleaning agents, except chlo- Contaminate the wastewater, corrode piping and Local collection point rine-free products (environ- seals...
  • Page 24 7. Operation and maintenance Maintenance by a maintenance specialist The maintenance should be undertaken by a specialist company (experts) at regular intervals (every 6 months). The intervals and work defined by the local water authority in the licence issued under water law also apply.
  • Page 25 7. Operation and maintenance Determination of the sludge removal Definition: A settlement sample should be taken at the maintenance intervals to determine whether the wastewater treatment system requires sludge removal. The SV30 (VS) is measured for this settlement sample. The SV30 is the volume of sludge that 1000 ml of aerated sludge absorbs after a settlement period of 30 minutes.
  • Page 26 7. Operation and maintenance 1000 ml 30 min < 250 ml Figure 7: Sludge volume measurement with undiluted aerated sludge sample 670 ml water from PN aerated sludge 30 min < 233 ml (dilution factor of 3) Figure 8: Sludge volume measurement with 1+2 diluted aerated sludge sample 26 / 40...
  • Page 27 7. Operation and maintenance Sludge removal instructions Removing sludge from the wastewater treatment system should be carried out according to the following points: 1. Remove the cover 2. Remove the deposits on the water surface and on all visible surfaces (baffle, sample container, siphon) 3.

  • Page 28: Fault Messages And Rectification

    8. Fault messages and rectification 8. Fault messages and rectification Technical system operation faults (failure of a unit) are indicated on the control unit display. Fault message on display Fault message as text on the LCD, Operating control light flashes red. Display LCD Possible cause Corrective action...
  • Page 29 8. Fault messages and rectification Display LCD Possible cause Corrective action KL24plus tered in the Service menu are too high  Air compressor defec- tive  Temperature sensor defective  Temperature sensor is  Replace sensor **Fault** Temp Sensor  Ensure secure connection between con- missing ...
  • Page 30 8. Fault messages and rectification Unusual water levels - troubleshooting Observation Possible cause Corrective action The water level in the  Plant is running in holiday mode.  Ending of holiday mode aeration tank is unu-  Plant is constantly running in cycle ...

  • Page 31: Ec Conformity Declaration

    9. EC conformity declaration 9. EC conformity declaration Manufacturer: Otto Graf GmbH Carl-Zeiss-Straße 2-6 DE-79331 Teningen hereby declares that the one2clean+ small wastewater treatment system meets the requirements of the following directives: 2006/42/EC Directive of the European Parliament and of the Council of 17 May 2006 on machines and changes to Directive 95/16/EC.

  • Page 32: Technical Data

    10. Technical data 10. Technical data 10.1 Technical data for control units Programmable logic microcontroller T3,15A fuse (internal) Wide-range 100-240 VAC/ 50-60 Hz power supply Real-time clock with deviation of 5 min./a, with battery buffer Log book, resistant to zero voltage Cable failure monitoring compressor by measuring the output currents Operating/error message display with LED (green/ red) Operating temperature range 0°C …+55°C...
  • Page 33 10. Technical data 10.2 Circuit diagrams 10.2.1 Circuit diagram for KL24plus control unit in EPP cabinet 33 / 40...

  • Page 34: Template For Weekly / Monthly Check Notes

    11. Template for weekly / monthly check notes 11. Template for weekly / monthly check notes for systems requiring maintenance twice a year, the parameters should be noted monthly Operating hours counter Valve 1 Valve 2 Valve 3 Total 34 / 40...
  • Page 35 11. Template for weekly / monthly check notes for systems requiring maintenance twice a year, the parameters should be noted monthly Operating hours counter Valve 1 Valve 2 Valve 3 Total 35 / 40...
  • Page 36 11. Template for weekly / monthly check notes for systems requiring maintenance twice a year, the parameters should be noted monthly Operating hours counter Valve 1 Valve 2 Valve 3 Total 36 / 40...

  • Page 37: Maintenance Log For Graf Small Wastewater Treatment Systems

    12. Maintenance log for GRAF small wastewater treatment systems 12. Maintenance log for GRAF small wastewater treatment systems Location (address): Maintenance company: Date of maintenance: Serial number: Order no.: System size: Actual connection Operator's name: Customer no.: 1st line of address: Tel.
  • Page 38 12. Maintenance log for GRAF small wastewater treatment systems Comments: Blower: Blower type: Blower OK Change the slats (slat length: mm): Change the membranes Filter change Cooling fan OK Comments: Time of sampling: Date: Time: Sampling site: Sampling shaft SBR chamber...

  • Page 39: Notes

    13. Notes 13. Notes 39 / 40...
  • Page 40 13. Notes 40 / 40 www.graf.info 2017-10...

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One2clean+ xxl

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