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› Installation Manual › Operation Manual › Maintenance Manual AQUATO STABI-KOM ® sewage treatment plant ® PLEASE NOTE THE FOLLOWING: The installation manual and the operating diary must be kept directly at the facility, so that both operators and qualified personnel can...
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AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® The current approvals for AQUATO STABI-KOM can be found on the ® AQUATO homepage at: ® www.aquato.de/en/download/zulassungen/ Manufacturer ® AQUATO Umwelttechnologien GmbH Ernstmeierstr. 24 D-32052 Herford All rights reserved. Infringements will lead to compensation.
The maintenance service ............19 Product description ................ 20 General information ..............20 Intended use ................20 3.2.1 Wastewater discharge ............. 20 3.2.2 Harmful substances ............20 Tanks..................20 Scope of supply of the AQUATO® STABI-KOM retrofit kit ..21...
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Control cabinet and controller ..........36 6.3.1 Setting up the outdoor cabinet ........36 6.3.2 Connecting the controller ..........37 ® Installation manual for the AQUATO STABI-KOM retrofit kit ... 38 6.4.1 Environment ..............38 6.4.2 Preparatory work............. 38 6.4.3 Attachment of coarse material separator and baffle ..
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AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® 6.4.6 Possible installation variants ..........46 6.4.7 Diffuser................48 6.4.8 Adjusting the air hoses ............ 48 6.4.9 Air hoses and cables ............48 6.4.10 Laying and fitting the hoses ..........49 6.4.11 Connections to the controller ..........
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Maintenance .................. 72 Maintenance work ..............72 Sludge volume measurement ..........73 Instructions for sludge removal ..........74 Maintenance of the air compressors ........75 9.4.1 Maintenance work on linear diaphragm compressors ..75 9.4.2 Maintenance work on free piston compressors ....75 9.4.3 Maintenance work on rotary vane compressors ....
EN 12566-3 refers to small wastewater treatment plants prefabricated in the factory or installed on site. The AQUATO® STABI-KOM complete plant is a small wastewater treatment plant prefabricated in the factory which has already passed inspection according to EN 12566-3.
® Accompanying CE document AQUATO STABI-KOM Distributor: EN 12566-3 Prefabricated small wastewater treatment plant for the treatment of domestic wastewater – Reference number of the product: "ASK" – Material: concrete Efficiency of treatment: COD: 95.0% Efficiency of purification performance (with a certified daily organic pollution load 99.0%...
AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® ® Accompanying CE document AQUATO STABI-KOM for plants according to verified voluntary manufacturer's declaration Distributor: EN 12566-3 Prefabricated small wastewater treatment plant for the treatment of domestic wastewater – Reference number of the product: "ASK"...
® CE marking AQUATO STABI-KOM EC Declaration of Conformity Manufacturer: Aquato Umwelttechnologien GmbH Ernstmeierstraße 24 32052 Herford Tel.: +49(0)5221 / 10 219-0 Fax: +49(0)5221 / 10 219-20 Internet: www.aquato.de E-mail: info@aquato.de We hereby declare that the product ® AQUATO STABI-KOM for small wastewater treatment plants from 4 to 50 PE meets the following directives.
® Important information Dear Sir or Madam, ® We are pleased that you have decided to purchase an AQUATO STABI-KOM small wastewater treatment plant. Please read this information in advance to ensure proper operation and compliance with the required discharge values.
The small wastewater treatment plant must always remain in operation! ® The controller of the AQUATO STABI-KOM indicates faults acoustically and optically. It features a mains-independent power failure monitoring system. Only wastewater that neither damages the small wastewater treatment plant nor impairs its function may be allowed to flow into the plant.
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STABI-KOM Installation, Operation and Maintenance Manual ® If the AQUATO small wastewater treatment plant is used for other purposes without the express consent of AQUATO Umwelttechnologien GmbH and/or if the safety instructions are disregarded, this may result in danger or injury to persons and malfunctions or defects in the plant.
® Mode of operation of the AQUATO STABI-KOM ® The STABI-KOM small wastewater treatment plant operates according to the SSB process. The acronym stands for the German sequenzielles schlammstabilisierendes Belebungsverfahren (sequential sludge-stabilizing activation process). The plant employing this process is an aerobic wastewater treatment plant with integrated sludge stabilization.
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AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® All operations in the plant are performed in regular cycles set at the control device. A treatment cycle consists of the following 4 phases: 1. Aeration phase In this phase, the pollution load of the wastewater is biologically decomposed by the microorganisms in all chambers.
for the float switch to exceed the upper switching point, the plant automatically switches back to normal mode with the cycles described above. Harmful substances and their proper disposal In recent years, liquid detergents have increasingly established themselves in the detergent sector for cleaning garments in washing machines and continue to enjoy increasing popularity.
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AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® Substances that do not belong in the What they cause: Where they belong: sink or the toilet: Chemicals Contaminate the wastewater, lead to Collection points decomposition of concrete Paints Contaminate the wastewater...
– Reading of the operating hours counter of the fan and the pumps. It is not necessary to make a ® written entry in the operation log when using the AQUATO STABI-KOM plant, as the controller records the operating hours in an electronic logbook.
Chapter 2.3. Tanks Installation is performed at the factory or on site in adequately dimensioned tanks. The wastewater calculations carried out by Aquato as well as the valid approval form the basis for the installation.
Scope of supply of the AQUATO® STABI-KOM retrofit kit AQUATO® STABI-KOM 3.4.1 ® The AQUATO STABI-KOM installation kit comprises the following components: Ventilation, separation and conveying equipment Controller with bracket Fastening material and any required further accessories Clear water lifter...
AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® AQUATO® STABI-KOM chained plant 3.4.2 ® The AQUATO STABI-KOM chained plant installation set comprises the following components: Ventilation, separation and conveying equipment Controller with bracket Fastening material and any required further accessories...
® AQUATO STABI-KOM-PAKT 3.4.3 ® The AQUATO STABI-KOM-PAKT installation set comprises the following components: Ventilation, separation and conveying equipment Controller with bracket Fastening material and any required further accessories Partition wall bracket with clear water lifter and Controller and compressor...
AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® Accessories 3.4.4 Model X7 outdoor cabinet, colours: grey, granite or green Model 2.1 outdoor cabinet Wall cabinet Model 6N Model 6.1 Additional outdoor outdoor cabinet cabinets and wall cabinets available...
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Additional disc diffuser with concrete base Float switch with fastener Model 3 clear water pump, Model 1 clear water pump, suspension on partition wall suspension on chain bracket Reducer for Sampling unit, optionally for 2-way manifold Flashing light plastic partition walls, concrete or plastic tank approx.
Partition wall retrofit for 1-chamber concrete tank 3.4.5 ® The partition wall retrofit for 1-chamber concrete tanks can be used for AQUATO STABI-KOM plants. The clear water lifter and the excess sludge lifter are attached to the crossbar set. The PE film must...
Hazard analysis ® The AQUATO STABI-KOM plants were developed according to the state of the art and subjected to a risk analysis. To eliminate or minimize risks, please follow the instructions below.
AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® Warning symbols used Below you will find an overview of the symbols used in this manual and their meanings: Warning of a danger point Warning of dangerous electrical voltage Duty of care of the operator Make sure that •...
Risk of electric shock in case of defective compressor or defective power cables. ® The fine-bubble aeration of the AQUATO STABI-KOM causes a mixture of water and air bubbles that has a lower density than pure water. This reduces the buoyancy in the water. Should a person accidentally fall into the reactor, he/she would not be able to swim.
AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® Safety instructions for qualified personnel Installation, maintenance and repairs may only be carried out by qualified personnel. Before carrying out the work, it must be ensured that • the knowledge and skills of the personnel are adequate to the intended use, •...
Rescue measures Ensure that a second person is always available for protection when working in the tank. Never climb in after an unconscious person, but get help. Never climb in after an unconscious person, but get help.
The dimensions of the complete plants and retrofit kits depend on the PE number and are not listed here individually. If necessary, the dimensions can be viewed at any time in the approvals on the AQUATO® Umwelttechnologien GmbH website at www.aquato.de. Depending on the system, the plants are delivered in boxes or on a pallet.
Installation Before installation Before installation, check the dimensions of the tanks so that the excavation pit can be adapted if necessary. Installation manual for the STABI-KOM tank The installation instructions of the tank manufacturer of the respective tank must be observed.
AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® Depth of the excavation pit 6.2.4 The depth of the excavation pit depends on the tank height, frost resistance and existing pipes to be taken into account. Frost resistance 6.2.5 With respect to frost resistance, DIN 1986-100 stipulates an installation depth of at least 800 mm up to the upper edge of the sewage pipe in Central Europe;...
The relevant accident prevention regulations, guidelines, safety rules and leaflets of the responsible employers' liability insurance association (DGUV), as well as the regulations of the Association of German Electrical Engineers (VDE) must be observed when constructing and operating wastewater treatment plants.
AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® The empty conduit can be integrated on the side of the control cabinet location via a DN 100 to DN 150 bore. It is recommended to foam the remaining openings in the masonry with PU foam after the air hoses and the cable have been fed through.
max. filling top ground surface filling soil stabilisation grate gravel Figure 1: Setting up the outdoor cabinet Connecting the controller 6.3.2 A 230 V / 50 Hz power supply line must be laid on site to the location of the controller and separately protected with a B 16 A slow-blow fuse and a 25 A / 30 mA RCD fuse.
STABI-KOM Installation, Operation and Maintenance Manual ® ® Installation manual for the AQUATO STABI-KOM retrofit kit The plant may only be set up by qualified personnel. Ensure that the qualified personnel can inspect the Installation, Operation and Maintenance Manual and the Controller Operation Manual before they begin work.
• If your plant is subdivided into several individual pits, an additional DN 100 empty conduit for the return sludge line must be laid by the shortest route with a slight gradient from the last tank to the first tank if the existing connection cannot be used for this purpose. •...
AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® The baffle is installed on the other side (on the side of the last chamber with activation / secondary sedimentation) in front of the opening with the supplied fastening material. Here too, the baffle ends above the highest water level.
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Vented lid Surplus sludge lifter Clear water lifter Inlet Outlet Passage opening Figure 2: Installation of technology in a two-chamber concrete pit...
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AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® ® 6.4.5.1 AQUATO STABI-KOM wall mounting Please note: For partition walls with a plastic design, special installation accessories are required that are not automatically included in the scope of delivery, but must be ordered separately.
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The outlet of the surplus sludge lifter should be installed at the same height as that of the clear water lifter. In 1-tank systems, the outlet connector of the surplus sludge lifter only has to extend over the partition wall into the first chamber. In 2-tank systems, the 30 mm hose is connected to the hose connection of the surplus sludge lifter.
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AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® ® 6.4.5.2 AQUATO STABI-KOM chained plant The surplus sludge lifter and the clear water lifter are fastened to a PE supporting tube with clamps. The PE supporting tube has a stainless-steel retaining bracket at the top that can be suspended with 2 shackles and 2 chains (each 1.5 m long).
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® 6.4.5.3 AQUATO STABI-KOM-PAKT The surplus sludge lifter and the clear water lifter form a unit by means of a polyethylene partition wall bracket. This unit is suspended as a whole on the partition wall in such a way that the lifters are located in the last chamber.
AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® 6.4.5.4 Special case: Deviating delivery heads The standard lift height (delivery head) of our STABI-KOM plant for clear water discharge is max. 50 cm, which roughly corresponds to the distance H to the pit outlet.
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2 x ¼ chamber for coarse material separation / sludge storage / activation, ½ chamber for activation / secondary sedimentation. As above... ½ and ¼ chamber for coarse material separation / sludge storage / activation, ¼ chamber for activation / secondary sedimentation. As above...
AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® Diffuser 6.4.7 Carefully place the membrane diffuser(s) with the concrete base in the middle of each chamber of the tank(s). Make sure that the membrane diffusers are always at the same height.
Laying and fitting the hoses 6.4.10 Installation steps: • Cut the hoses for the lifters (must be led to the controller) and the hoses for the membrane diffusers (must be led to the membrane diffusers via the supplied hose connectors). •...
AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® Connections to the controller 6.4.11 The hose connections are named on the front of the controller with colour coding (STABI-KOM: see ® graphics, bottom row: SSB Aeration of last chamber(s) (rear)= black ...
Setting the aeration 6.4.12 With the SSB plant, all chambers of the plant are aerated. The first chamber must receive the largest portion of the injected air (approx. 2/3), the remaining air (approx. 1/3) enters the rear chamber(s). All chambers of the plant are connected to each other below the minimum water level H W min 6.4.12.1 Special aeration control The special aeration control is used if the "1st CHAMBER"...
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AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® Figure 12: 2-tank system with underwater connection Figure 13: 3-tank system with underwater connection Figure 14: 4-tank system with underwater connection...
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6.4.12.2 Standard aeration control Normally, the standard aeration control is applied by selecting the "1st CHAMBER" aeration option when the controller is put into operation (or under Select plant types in the Service menu) (see Controller Operation Manual). With this setting, the front red output marked 3 is used to aerate the first chamber(s).
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AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® Figure 17: 4-tank system without underwater connection Figure 18: 4-tank system, front tanks without underwater connection The following describes the procedure for aeration with standard control. If the aeration is to be...
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6.4.12.3 1-tank systems with 1 compressor In a 2-chamber pit, a compressor is used to aerate the first chamber via the front red connection of the controller marked 3; the aeration time is 2/3 of the total aeration time. With the remaining 1/3 aeration time, the second chamber is aerated via the rear black connection marked 1 (see Figure 10 and Figure 19).
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AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® In a 3-chamber pit, a compressor is used to aerate the first chamber via the front red connection of the controller marked 3; the aeration time is 2/3 of the total aeration time. With the remaining 1/3 aeration time, the second and third chambers are aerated via the rear black connection marked 1.
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6.4.12.4 2-tank systems with 1 compressor In a 2-tank system, a compressor is used to aerate the first tank via the front red connection of the controller marked 3; the aeration time is 2/3 of the total aeration time. With the remaining 1/3 aeration time, the second tank is aerated via the rear black connection marked 1 (see Figure 12, Figure 15 and Figure 21).
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AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® 6.4.12.5 3-tank systems with 1 compressor In a 3-tank system, a compressor is used to aerate the first tank via the front red connection of the controller marked 3; the aeration time is 2/3 of the total aeration time. With the remaining 1/3 aeration time, the second and third tanks are aerated via the rear black connection marked 1.
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6.4.12.6 Systems with 2 compressors and 3 tanks Systems with 2 compressors can only be operated with controllers K-Pilot 18.3 and 18.4, which offer extended connection options (for connection information, see Controller Operation Manual). In such plants, the first tank in a 3-tank system is aerated directly by compressor 2 (next to or under the controller in the outdoor cabinet).
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AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® 6.4.12.7 Systems with 3 compressors and 4 tanks Systems with 3 compressors can only be operated with controllers K-Pilot 18.3 and 18.4, which offer extended connection options (for connection information, see Controller Operation Manual). In such plants, the first tank in a 4-tank system is aerated directly by compressor 3 (next to or under the controller in the outdoor cabinet).
Compressor sizes 6.4.13 The required compressor size depends on the plant size (= PE number – see following table). The specified compressor sizes with the standard hose diameters apply to hose lengths of up to 10 m. The possible calculated water depths are calculated from the water pressure on the membrane diffusers, the air resistance in the hoses, the output of the compressor and some other factors.
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AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® Installation of the float switch: • The holder is attached to the pipe with hose clamps • The height can be adjusted by sliding on the pipe • Set the float switching point to H...
Clear water discharge with submersible pump 6.4.15 ® The pump of the clear water outlet for AQUATO STABI-KOM plants was designed as an alternative to the clear water lifter. By using this pump design, it is also possible to pump the purified wastewater over greater distances or heights.
AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® Installation manual for the controller and the compressor Safety instructions 6.5.1 The controller is intended for wall mounting and is therefore pre-mounted on a bracket. However, it can also be accommodated in a wall cabinet or an outdoor cabinet.
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• If a fuse is defective, it may only be replaced by a microfuse of the following type: microfuse, slow-blow, type 3.15 A, 5 x 20 mm according to EN 60127-2/III with a maximum power loss of 1.5 W. This fuse is also installed at the factory. Note: For larger plants, a stronger fuse may be installed (max.
AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® Controller with wall bracket 6.5.2 Hose bend 230 V socket for compressor 4 hose connections Power cable with safety plug Figure 28: Controller and compressor on bracket The controller is fully mounted on the wall bracket.
Controller in outdoor cabinet or wall cabinet 6.5.3 The same principles as described above apply to the installation. Set up the outdoor column in a shady and wind-protected location. In climatically unfavourable locations, it is important to install a fan for cooling and/or a control cabinet heater for heating, controlled by thermostats.
AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® Commissioning of the plant Prior to commissioning 7.1.1 The relevant accident prevention regulations, guidelines, safety rules and leaflets of the responsible employers' liability insurance association (DGUV), as well as the regulations of the Association of German Electrical Engineers (VDE) must be observed when constructing and operating wastewater treatment plants.
"Commissioning of the controller") with a self-test with a duration of approx. 3 seconds. Then the start message "AQUATO" appears. The display Vx.xx.xx (e.g. V2.07.09) in the lower part of the message is the version number of the software.
AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® Operation Responsibilities of the operator The small wastewater treatment plant must be operated by the owner or a competent person commissioned by the owner (operator). After commissioning, the plant is operated fully automatically. It is controlled by a PLC. The sequence and flow of the phases are programmed in the controller.
Operation and displays of the controller The controller has a graphic LCD display with 128 x 64 pixels. Indications are made in plain text. Operation is carried out via three buttons and two LEDs. Arrow button for selecting menu items Middle button to confirm inputs Arrow button for selecting menu items Figure 30: Control elements of the controller K-Pilot 18.1/18.3/18.4 KOMBI...
AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® Maintenance Maintenance work Maintenance must be carried out at least twice per year by qualified personnel only and includes the following activities: • Inspection of the operation log with verification of regular operation (target/actual comparison) •...
Sludge volume measurement To determine whether sludge removal is necessary, the sludge volume in the last chamber must be determined as SV30. The sludge volume must be measured in a 1,000 ml graduated cylinder. Before sampling, switch on the aeration (if it is not active already) and allow the tank to mix for a short time.
AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® Instructions for sludge removal Sludge is only removed from the front chamber(s), not from the last chamber. Attention: Sludge must not be removed from the last chamber! Please note the following when removing sludge: There is at least one membrane diffuser in each chamber.
Maintenance of the air compressors The air compressors are operated without lubricants and are largely maintenance-free. Please refer to the operation manual included in the packaging of the air compressor for the exact procedure for maintenance. Keep this together with the other documents at the plant. Whenever performing maintenance, it is recommended to check the air filter regardless of the compressor type.
AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® Decommissioning and disposal Ensure that only qualified personnel with suitable safety equipment have access to the plant. Ensure that the general safety regulations and the safety regulations at the installation site are observed.
Assembly and commissioning checklist Checklist for the installer Work performed Completed completed Special features Assembly Assembly of the controller/control cabinet Air hose connections Float switch connection (optional) Inoculation of the plant (optional) Commissioning Function check Controller / alarm function ...
AQUATO STABI-KOM Installation, Operation and Maintenance Manual ® Maintenance checklist Checklist for the maintenance service Work performed Completed completed Special features Inspection of the operation log Inspection of the structural condition acc. to approval Check of ventilation General cleaning work...
Addresses Manufacturer ® Company AQUATO Umwelttechnologien GmbH Ernstmeierstr. 24 Address 32052 Herford +49(0)5221 / 10 21 9-0 Telephone Internet www.aquato.de E-mail info@aquato.de Plant supplied / installed by Company Address Telephone Internet E-mail Your maintenance company Company Address Telephone Internet E-mail...
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The warranty will void if operation and maintenance of the sewage treatment plant are not carried out in accordance with the instructions and specifications of the operating instructions. VERSION 10.2019 Installation Company: AQUATO Umwelttechnologien GmbH ® Ernstmeierstr. 24 fon +49 5221 10219-0 www.aquato.de...
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