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Kessel Aqualift F Installation Manual

Pumping station for all wastewaters (with / without sewage) for underground / sub-surface installation
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ANLEITUNG FÜR EINBAU, BEDIENUNG UND WARTUNG
KESSEL-Pumping station
Aqualift F /Aqualift F Duo Komfort
For all wastewaters with / without sewage)
For underground / sub-surface installation.
Aqualift F
Installation
The installation and service of this unit should be carried
out by a licensed professional servicer
Company
Edition 2010/06
Aqualift F Duo
Service
Date / Town
Product advantages
Quick and easy installation
due to light weight chamber
Long-life / durable due to
watertight chamber and
resistance to aggressive
soils/fluids
Additional inlets easily
connected on-site.
Vertically adjustable and
tiltable upper section
Company stamp
ID-Nr.. 328-199EN

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Summary of Contents for Kessel Aqualift F

  • Page 1 ANLEITUNG FÜR EINBAU, BEDIENUNG UND WARTUNG KESSEL-Pumping station Aqualift F /Aqualift F Duo Komfort For all wastewaters with / without sewage) For underground / sub-surface installation. Product advantages Aqualift F Duo Aqualift F Quick and easy installation due to light weight chamber...
  • Page 2 In case any parts are missing please follow the instructions listed in the ´Guarantee` section of this user´s manual. Before the KESSEL - Aqualift F Pumpstation is installed and placed into operation please carefully read and follow all of the instructions contained in this Installation, Maintenance and User´s Manual.

  • Page 3: Table Of Contents

    Table of Contents ..................Page 1. Safety instructions Application / Installation ..........Page Aqualift F description...........Page 2. General Pumps.................Page Switching levels............Page 3. Technical Data Electrical control unit ..........Page Assembly of the pump chamber........Page 10 Pipe connections ............Page 13 4. Installation Installation of the submersible pump(s) ......Page 14 Setting the float switches ...........Page 14...
  • Page 4 It is important that all electrical cables and units relating to the Aqualift F are always in perfect operating conditi- on. If damage to any of the electrical cables or systems of the Aqualift F is noticed, the Aqualift F unit must be immediately disconnected and taken off line.

  • Page 5: Safety Precautions

    The Aqualift F is designed to pump wastewater containing untreated raw sewage which may pose a health hazard. It is important that no direct or indirect contact between the Aqualift F and skin, eyes or mouth occurs. If contact does occur it is important to immediately wash and disinfect the contamina- ted area.

  • Page 6: Application / Installation

    The pump support bases, closure valve, backflow preventi- wastewater flow is not allowed or desired, a twin pump sy- stem (Pumpstation Aqualift F Duo) is required in which the flap, outlet pressure pipe and float switches have already second pump will activate during times of heavy flow or if the been installed in the base of the chamber.
  • Page 7 3. Technical Data 3.1 Explosion proof pumps according to ATEX Type Rated input (P1) 1,75 kW 2,6 kW TPF 1,3 TPF 1,9 Rated output (P2) 1,3 kW 1,9 kW Operating voltage 400 V DS Frequency 50 Hz Current 3,56 A 4,5 A Fusing 3 x 16 A träge...

  • Page 8: Electrical Control Unit

    (Jacks – N, L1, L2, L3 PE) 230 V (AC) / 50 Hz +- 10% to supply control unit in areas at risk of explosion electronics The control unit is designed to operate KESSEL single or Entry electrical circuit twin pump wastewater lifting station. Float switches or other...
  • Page 9 3. Technical Data Electrical explosion protective shield MTL 7787+ • After maintenance is completed on the control unit, it is important Highest value: Uo = 15,8 V that the control unit cover is properly closed and secured. Io = 93 mA Ro = 300 Ω...

  • Page 10: Assembly Of The Pump Chamber

    4.1 Installation The base / bottom of the excavation in which the Aqualift F the chamber. This plate needs to be steel reinforced – is to be installed should be prepared with 30 cm even layer a plan for this is available upon reques).
  • Page 11 3 adjustment scr- ews which should be upside down Access steps (included with KESSEL 1000 chamber) (Avai- (screws heads lable as accessory with KESSEL 800 chamber). Access should be at bot- steps may be installed prior to assembling the individual tom –...
  • Page 12 Class D (40.0 metric ton Possible installation depths KESSEL – Pumpstation Aqualift F in System 1000 Inspection Chamber Installation depths from 1.63 to 5.13 meters KESSEL – Pumpstation Aqualift F in System 800 Inspection Chamber...

  • Page 13: Pipe Connections

    All pipes are to be laid with negative slope into the Pump- tion as it is filled with wastewater or as wastewater is pum- station Aqualift F Chamber – meaning that wastewater will ped out of the system. Since these systems are normally in- flow with gravity out of the pipes and into the pumpstation.

  • Page 14: Installation Of The Submersible Pump(S)

    4.3 Installation of the submersible sewage pump(s) Single Pump Unit the Aqualift F submersible TPF 1.3 kW and 1.9 kW pumps CAUTION: weigh 39 kg. These pumps should only be lifted and in- This pumping station is equipped with one submersible se- stalled in the pumpstation using appropriate lifting and pul- wage pump.

  • Page 15: General Instructions

    5.1 General instructions the system. No external power may be supplied to the float The control unit for the Pumpstation Aqualift F must be connected to a separate main switch so that if required switch Off, On, On1/On2 or alarm connection jacks. As re- theentire system can be switched off line.
  • Page 16 5. Elektroanschluss 5.5.2 Securing of electrical connection cables The pump power cables must be taught and firmly connec- ted in the chamber to prevent these cables from being sucked into the pumps 5.5.3 Overload Protection System The motor(s) are protected from overloading by a thermal de- layed overload protection according to VDE 0660.
  • Page 17 5. Electrical Connections On-site electrical connection work is described in the table below as well as on the control unit connection plan (see pages 27 and 29). Please take note of instructions listed in Chapter 8 – Electrical Control Unit (position of the operating panel and an interior view of the control unit).

  • Page 18: Checking The Motor Protection Switches

    5. Electrical Connections Double Pump Systems – Follow all safety regulations! Connection Instructions • both 9-volt batteries located inside the control unit must be connected. Battery connection • Power cables L1, L2, L3, N and PE should be connected to their appropriate jacks. •...

  • Page 19: General Instructions

    6.1 General instructions Commissioning The commissioning of the Aqualift F should be handled by a Max pumping medium temperature of explosion rated 6.1.2 Pumping medium temperature licensed professional. The system should be filled with water pumps –...

  • Page 20: Description Of Operation

    POWER LED on the control unit is lit and no failu- res or warnings are displayed. As the wastewater level insi- de the Aqualift F storage chamber rises the level will reach 6.4 Control unit operation Control unit digital display...
  • Page 21 OK button. As soon as the four selections are set, the control unit will automatically load the set- ting – the control unit is now in operation and the entire Aqualift F pumping station is now in normal operation mode. Pumpstation Schwimmer Menu Display control unit will automatically re-initialize itself.

  • Page 22: System Menu

    6. Commissioning 6.4.1 System Menu Information Informationen Systeminfo System information Leistungsgröße System size Sensorkonfiguration Maintenance Sensor configuration Wartung Datum Uhrzeit Date and Time Füllstandsanzeige Level indicator Fehler/Ereignisse Error Event Settings Einstellungen Beispiel: display of level including number Pumpstation 1,3 kW Systeminfo Lifting station type Schwimmer...

  • Page 23: Maintenance Menu

    ´„ The next maintenance date is entered by the servicing partner. 6.4.4 Settings menu Only authorised maintenance staff may chan- ge the settings. To do this, the KESSEL Cu- Parameter stomer Service must be contacted for the pas- sword. Systeminfo...
  • Page 24 2 screws (ass seen in Section 10.2.1 and Inspection The Pumpstation Aqualift F should be inspected monthly by 10.2.2) and be removed from the pump housing. When ins- the owner to make sure it is functioning properly and is water pected the pump housing make sure that the ventilation open tight.

  • Page 25: Electrical Control Unit

    KESSEL customer service partner. 7.4 Non-Return flap information In the case that the Aqualift F system needs to be serviced, the non-return flaps can be manually opened to allow any wa- stewater in the outlet system to drain back into the Aqualift F storage tank before a pump or the entire tank is removed.

  • Page 26: Pumps

    8. Problems and Remedial Actions The following problems and solutions should only be checked and handled by a licensed professional . 8.1 General problems Problems Reasons Remedial actions / Solutions Motor protecting switch has ac- Remove pumps, inspect for blockage at impel- tivated, impeller is blocked ler or intake area Pump(s) do not start...

  • Page 27: Irregular Level Conditions

    Sharp smelling odour protection switch) Too much wastewater volumes causing in- crease start / stop of the pumps – check with KESSEL Customer Service. Check switching / activation errors Protectors too hot Check causes and correct Incoming wastewater volume too...

  • Page 28: Disturbances / Internal Controls

    Pump Off level. The pumps remain in operation. A level mal- function warning occurs. Each motor of the Pumpstation Aqualift F is equipped with • “Pump 2 On” float switch which does not activate. two temperature sensors which send data to the control unit.

  • Page 29: Malfunction Warnings

    • The Aqualift F no longer reacts to incoming signals - unp- - Running times / level lug the control unit of the Aqualift F for at least 10 seconds - Relay error and then plug back in. In the case that the Aqualift no lon-...
  • Page 30 8. Malfunctions and troubleshooting = lit up = off ● = slow flashing ❍ = fast flashing Error messages / troubleshooting - acknowledge alarm and alarm key Battery error - check if the battery is connected - exchange discharged battery - the charging status of the batteries can be tested in menu 1.5.3 (battery power check) - after acknowledging the signal tone, press the alarm key again...
  • Page 31 8. Malfunctions and troubleshooting Limit running time error / limit running count error - Limit running count error: Pump is activated more than 20 times in 3 min --> Check the air pipe between the immersion tube/immersion bell and switchgear for water inclusions -->...
  • Page 32 8. Malfunctions and troubleshooting Relay switching cycles Main contactor has exceeded 100,000 switching cycles --> can be acknowledged, main contactor does another 1000 switching cycles before a new message is sent --> Exchange the contactor --> Contact the Customer Service -->...

  • Page 33: Control Unit Connections For Single Pump

    • The control unit can be operated without needing to open • The setting on the motor protection switch must match the the control unit cover. However, the cover can be opened pumps in the Aqualift F unit. for service work. • After settings have been successfully completed, make •...
  • Page 34 10. Replacement Parts Replacement Parts For Explosion proof rated systems, only originally marked replacement parts from the manufacturer may be used. When ordering replacement parts please always use data li- sted on the ID code plate on the control unit. Example –...
  • Page 35 Note: Only the manufacturer may open sealed components or warranted for a period of 24 month. This warranty period be- gins on the day the product is shipped form KESSEL to its cu- screw connections. Otherwise, the warranty may become null stomer.
  • Page 37 __________________________________________________________ Planner __________________________________________________________ Address __________________________________________________________ Telephone / Fax __________________________________________________________ Contracted plumbing company __________________________________________________________ Address __________________________________________________________ Telephone / Fax __________________________________________________________ KESSEL-Commissions no.: System operator /owner __________________________________________________________ Address __________________________________________________________ Telephone / Fax __________________________________________________________ User __________________________________________________________ Address __________________________________________________________ Telephone / Fax __________________________________________________________ Person of delivery...
  • Page 38 Handover-Ceritficate 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. The system operator/person authorised to perform the acceptance was informed about the obligation to ser- ❏...
  • Page 39 Backwater protection Septic Systems Lifting Stations and pumps Inspection Chambers Drains and shower channels Rainwater Management Systems Separators -Grease Separators -Oil-/ Fuel-/Coalescence Separators -Starch Separators -Sediment Separators...

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Aqualift f duo

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