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AQUATO K-PILOT 18.1 Operation Manual

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AQUATO
K-PILOT
®
18.1 / 18.3 / 18.4 Controller
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
inspect it at any time.

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Summary of Contents for AQUATO K-PILOT 18.1

  • Page 1 › Operation Manual AQUATO K-PILOT ® 18.1 / 18.3 / 18.4 Controller 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 inspect it at any time.
  • Page 2 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Manufacturer ® AQUATO Umwelttechnologien GmbH Ernstmeierstr. 24 D-32052 Herford All rights reserved. Infringements will lead to compensation. Duplication and passing on to third parties is only allowed with the consent of the manufacturer.

  • Page 3: Table Of Contents

    Duty of care of the operator ............13 General safety instructions ............14 Safety instructions for qualified personnel........ 15 Rescue measures ............... 15 Area of application of the controller ....16 K-Pilot 18.1 ................. 17 K-Pilot 18.3 ................. 17 K-Pilot 18.4 ................. 17 Page 3...
  • Page 4 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Installation manual for the controller ....18 Safety instructions ..............18 Controller with wall bracket ............19 Controller in outdoor cabinet or wall cabinet ......20 Connections to the controller ......
  • Page 5 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Main display ................48 Menu ..................49 8.4.1 Menu structure ..............49 8.4.2 "Service" menu ..............50 8.4.3 "Settings" menu ..............69 8.4.4 Other menus with displays or settings ......72 Faults / Alarm ................79 Power failure alarm ..............
  • Page 6 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Presets ..................121 Switching times – Basic settings ..........121 10 Operation with buffer ........122 11 Operation with UV lamp for hygienisation ..125 12 Operation with disinfectant for hygienisation .

  • Page 7: Ii List Of Abbreviations

    ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 II List of abbreviations TGS = Top Ground Surface = maximum water level in the plant W max = required minimum water level in the plant W min S = Float switch S1 = Float switch 1...

  • Page 8: Manufacturer's Declaration

    Manufacturer’s declaration Declaration of Conformity ® This certifies the conformity of the AQUATO K-Pilot 18.1 / 18.3 / 18.4 controllers with the EC directives for CE marking. Device type: Electronic control devices for the automatic operation of a fully biological small wastewater treatment plant according to DIN 4261-2 ®...

  • Page 9: Important Information

    Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Important information General information This manual describes the operation of the K-Pilot 18.1, K-Pilot 18.3 and K-Pilot 18.4 controllers. ® With the AQUATO K-Pilot 18.1/18.3/18.4 controller, you receive a quality product that is designed for controlling small wastewater treatment plants.
  • Page 10 ® If the AQUATO controller 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.
  • Page 11 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Installation work may only be carried out by qualified electricians. When working on the device, always pull out the power plug. Never operate a device that ► has a malfunction, ► was dropped, ► was otherwise damaged or ►...

  • Page 12: Safety Instructions

    AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Safety instructions General information on the safety information This manual contains basic instructions that must be observed during installation, commissioning and maintenance. The manual must be kept directly at the plant so that both the operator and qualified personnel can inspect it at any time.

  • Page 13: Warning Symbols Used

    ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 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...

  • Page 14: General Safety Instructions

    AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 General safety instructions The accident prevention regulations for work on wastewater plants (DGUV regulation 21 and DGUV regulation 22, formerly: BGV C5) must be observed. The work should only be carried out by skilled personnel.

  • Page 15: Safety Instructions For Qualified Personnel

    ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 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, the personnel have received instruction, have read and understood the operation manual.

  • Page 16: Area Of Application Of The Controller

    K-Pilot 18.1/18.3/18.4 controllers. The K-Pilot 18.1/18.3/18.4 controls also allow the use of a float switch as a pure flood detector – without affecting the cycle.

  • Page 17: K-Pilot 18.1

    K-Pilot 18.1/18.3/18.4 K-Pilot 18.1 The K-Pilot 18.1 controller has an electrical output as a socket for the compressor as well as a float switch input. The K-Pilot 18.1 controller can be used to operate SBR and SSB plants. It is suitable for the standard operating modes of performance classes C and D with a compressor and compressed air lifters.

  • Page 18: Installation Manual For The Controller

    AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Installation manual for the controller Safety instructions 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.

  • Page 19: Controller With Wall Bracket

    ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 With a 2-compressor plant, the following type is used: microfuse, slow-blow, type 5.00 A, 5 x 20 Note: For larger plants, a stronger fuse may be installed (max. 6.3 A T). Always replace fuses with a fuse of the same current rating.

  • Page 20: Controller In Outdoor Cabinet Or Wall Cabinet

    AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Controller in outdoor cabinet or wall cabinet 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 advisable to install a control cabinet heater and/or cooling fan.

  • Page 21: Connections To The Controller

    ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Connections to the controller The following figure shows the standard version of the K-Pilot 18.1/18.3/18.4 controller with all connections on the housing. Depending on the application, additional electrical connections may be added. Hose bend...

  • Page 22: Air Connections - K-Pilot 18.1/18.3/18.4

    AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Air connections – K-Pilot 18.1/18.3/18.4 The air inlet for the air supplied by the compressor is located on the right side of the controller. If the compressor is placed below the controller and the hose connection (see Figure 2) is turned downwards, it must be ensured that the air hose inside the controller is not twisted.

  • Page 23: Assignment For Ssb Plants

    ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 6.1.1.1 SBR plants with 2 compressors If 2 compressors are used, the air from the outputs of the two compressors is brought together and then led in a hose to the reactor. Here, the air is distributed to the individual membrane diffusers.
  • Page 24 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 6.1.3.1 Standard variant During commissioning, "Aeration 1st chamber" is selected. The front red output marked 3 is used to aerate the first chamber(s). The rear black output marked 1 is used to aerate the last chamber(s).
  • Page 25 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 6.1.3.2 Special variant If aeration should only take place via output 1, this must be set in the controller, i.e. during commissioning, "Aeration 1st chamber" is selected in the second line "(NEW)" "NO". The air must be distributed accordingly to the individual chambers using distributors (e.g. Y-pieces, etc.).
  • Page 26 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 6.1.3.3 SSB plants with 2 compressors Systems with 2 compressors can only be operated with controllers K-Pilot 18.3/18.4, which offer extended connection options (for connection information, see Chapter 6.2.5).
  • Page 27 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 6.1.3.4 SSB plants with 3 compressors Systems with 3 compressors can likewise only be operated with controllers K-Pilot 18.3/18.4, which offer extended connection options (for connection information, see Chapter 6.2.5). In such plants, the first tank is aerated directly by compressor 3. Tank 2 is aerated directly by compressor 2.

  • Page 28: Electrical Connections

    After plugging in the plug, the controller starts with a self-test with a duration of approx. 3 seconds while displaying "booting system...". 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. A few seconds later, the standard display appears.
  • Page 29 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Power supply from controller No signal in case of RCD fault! Potential-free contacts Lamp Figure 10: Potential-free contact with error indication – power supplied by controller Power supplied by external circuit Alarm even if RCD fault!

  • Page 30: Socket For Compressor - K-Pilot 18.1/18.3/18.4

    Float switch – K-Pilot 18.1 controller The float switch for the "Float" control type is connected to the K-Pilot 18.1 controller via the lustre terminal attached to the rear panel of the controller (see Figure 12). This controls the clear water discharge and the aeration times and gives a flood alarm.

  • Page 31: Other Connections - K-Pilot 18.3/18.4

    ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 6.2.5 Other connections – K-Pilot 18.3/18.4 6.2.5.1 Connections – K-Pilot 18.3 In the K-Pilot 18.3 controller, there is a circuit board with 4 electrical connections at the top of the rear panel. Of these, the two left connections are outputs and the two right connections are inputs. The float inputs are permanently occupied.
  • Page 32 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 6.2.5.2 Connections – K-Pilot 18.4 In the K-Pilot 18.4 controller, there is a circuit board with 4 electrical connections at the top of the rear panel of the controller.
  • Page 33 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 6.2.5.3 Float switch – K-Pilot 18.3/18.4 As a standard, a normally closed contact is used with the control voltage: 230 V~ approx. 5 mA; switching between input L and N. For the K-Pilot 18.3 and K-Pilot 18.4 controllers, the float switch for the "Float" control mode is connected to the designated terminals IN 1, N, PE on the circuit board at the top of the rear panel of the controller (see Figure 15).
  • Page 34 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 6.2.5.4 Float switch as flood detector – K-Pilot 18.3 With the K-Pilot 18.3 controller, if the float switch for the "Float" control mode is connected to the designated terminals IN 1, N, PE on the circuit board at the top of the rear panel of the controller and "FLOAT"...
  • Page 35 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 6.2.5.5 Float switch for buffer – K-Pilot 18.3 A float switch for a buffer (see Chapter 8.4.2.5) can also be connected to the K-Pilot 18.3 controller. This float switch is connected to the designated terminals IN 2, N, PE on the circuit board at the top of the rear panel of the controller (see Figure 17).
  • Page 36 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 6.2.5.6 Double float – K-Pilot 18.3 With the K-Pilot 18.3 controller, it is possible to work with a double float switch. For this purpose, the float switch (S1) for the "Double Float"...
  • Page 37 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 6.2.5.7 Clear water pump A clear water pump is used to overcome greater delivery heads. This then replaces the clear water lifter. A pump and an external float switch are used. The float switch is attached to the pump holder of the clear water pump.
  • Page 38 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Connection for float switch for "Float" control type at terminals IN 1, N, PE Figure 21: Float connection for clear water pump in K-Pilot 18.3/18.4 controller 6.2.5.8...
  • Page 39 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Three additional units and one float switch can be operated with the K-Pilot 18.4 controller. When operating with two additional compressors, these are operated in parallel – via a double safety socket – with the setting "2ND AERATOR" and connected to one output. This allows an additional unit to be connected to the K-Pilot 18.3 controller (or 2 additional units to the K-Pilot 18.4...

  • Page 40: Commissioning Of The Plant

    AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Commissioning of the plant Prior to commissioning The relevant accident prevention regulations, guidelines, safety rules and leaflets of the responsible employers' liability insurance association (DGUV),...

  • Page 41: Commissioning

    After plugging in the plug, the controller starts (see 8.2 and 9.2) 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.

  • Page 42: Operation As Aquato Stabi-Kom

    AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 ® Operation as AQUATO STABI-KOM The small wastewater treatment plant must be operated by the owner or a competent person commissioned by the owner (operator).
  • Page 43 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 In the event of a fault, the red LED flashes and the buzzer sounds. The standard display on the LCD shows the date and time in the top line and the current cycle phase in large letters below, e.g.

  • Page 44: Commissioning Of The Controller

    3 seconds while displaying "booting system...". 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. The check of the valve runs simultaneously.
  • Page 45 8.4.2.3). The various functions can be checked in manual mode. Once manual mode has been ended, the valve position required for the automatic cycle is approached, then the controller displays the message "booting system...", after which the start message "AQUATO" appears again and the valve is checked.
  • Page 46 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 The commissioning engineer must ensure that the parameter settings have been made in such a way that they comply with the requirements (e.g.
  • Page 47 ** Select "2x Float" only makes sense for K-Pilot 18.3, as only in this controller are suitable connections available. Figure 23: Commissioning sequence for K-Pilot 18.1/18.3/18.4 controller Do not select any additional functions for K-Pilot 18.1, as there are no physical outputs for these functions, i.e. they do not work, although they are displayed in the Manual Mode and Parameters menus.

  • Page 48: Main Display

    AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Main display In the standard display, the controller shows the switching status of the plant and the units, e.g.: 1st line: Date and time and, if the setting aeration 1st chamber "Aeration 1st ch"...

  • Page 49: Menu

    See right for more ® Figure 24: Menu structure of the AQUATO STABI-KOM The exact display depends on the status of the system and the set parameters. The different variants of the display are explained in more detail below.

  • Page 50: Service" Menu

    AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Use the buttons to move from menu to menu. If you move constantly in the same direction, you will eventually return to the standard display.
  • Page 51 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 The function test of the float switch is only carried out at the beginning of the system test with the "FLOAT" CONTROL MODE. During test mode – which lasts approx. 100 seconds – the main display of line 2 changes to: "Test since XX sec".
  • Page 52 The different settings for the "Aerator" and the "Valve Position" can be made in the manual mode of the K-Pilot 18.1 controller. The exact display depends on the parameters set (during commissioning). In manual mode, the “AERATOR” can be switched "ON" or "OFF"...
  • Page 53 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 The selected position is then approached. This is indicated by the progress bar in the menu. Once the position has been reached, the function is also carried out with the compressor switched on as in automatic mode, as in this example the clear water discharge, and can also be checked in the tank.
  • Page 54 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 8.4.2.3 Manual mode with the K-Pilot 18.3 and 18.4 controllers In addition to the "Aerator" and "Valve position" parameters, which are always available, the manual mode of the K-Pilot 18.3 and 18.4 controllers allows further settings to be made.
  • Page 55 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 The selected position is then approached. This is indicated by the progress bar in the menu. Once the position has been reached, the function is also carried out with the compressor switched on as in automatic mode, as in this example the clear water discharge, and can also be checked in the tank.
  • Page 56 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Manual mode is ended via the menu item "...END MANUAL MODE". The valve is moved to its initial position. At the end of manual mode, the treatment cycle continues.
  • Page 57 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 All queries in the Factory Settings menu must be answered with "NO". The "CLEAR COUNTER" window opens. If "NO" is selected, the menus with the individual units are skipped and the "CLEAR LOG" window opens immediately.
  • Page 58 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 8.4.2.5 Selecting a plant type with the K-Pilot 18.1/18.3/18.4 controller In this menu, you can set/change the plant type and size as well as other parameters required for operation.
  • Page 59 Therefore "NO" must be selected for the query "Float for buffer". ("NO" → continue with → Select Plant Size PE number) For K-Pilot 18.1/18.4, be sure to select "NO" for the "Float for buffer" query, as there is no physical input for an additional float.
  • Page 60 All parameters for the treatment cycle are automatically preset through this selection, but can be readjusted if necessary. For plant sizes from 21 to 50 PE, please select "AQUATO>20 STABI SSB". The cycle presets for plant sizes from 21 to 50 PE are the same;...
  • Page 61 If password 1 was used, the menu item "SELECT PLANT SIZE" is completed at this point for both the K-Pilot 18.1 and the K-Pilot 18.3 and K-Pilot 18.4 controllers and the software jumps back to the "SERVICE" main menu.
  • Page 62 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 If you have selected "YES" for the query "3~ AERATOR", you will be asked whether the three-phase compressor should be monitored for current errors.
  • Page 63 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 menu by pressing "BACK"); for dosing, always select the "FLOAT" control type beforehand, - "BUFFER" (if "Buffer operation with lifter" was not previously selected) for operating a buffer with a pump. For operation with "UV" lamp or "DOSAGE", "FLOAT" must always be selected beforehand as the control type.
  • Page 64 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 If you connected additional units, such as a clear water pump or a 2nd compressor (see Chapter 6.2), you must assign the outputs selected when you connected them to these units in this menu.
  • Page 65 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 The output "T1.4" may not be assigned when using the K-Pilot 18.3 controller, as it is not physically available! If a function is assigned to this output, it cannot be performed Output "T1.4" is only available for the K-Pilot 18.4 controller.
  • Page 66 The buffer can only be emptied on a purely time-controlled basis. For K-Pilot 18.1/18.4, be sure to select "NO" for the "Float for buffer" query, as there is no physical input for this float.
  • Page 67 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 In this case, after exiting the menu, a query appears asking for the desired/required type of "DOSAGE". If a phosphate precipitation is to be operated, select "PO3"; if a C source is to be added, select "C".
  • Page 68 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 8.4.2.6 Displaying the additional functions The "ADDITIONAL FUNCTIONS" menu (only available on the K-Pilot 18.3 and 18.4 controllers) displays the special functions selected during commissioning, such as "Clear Water Pump" or "Dosage", as well as the outputs to which they have been assigned.

  • Page 69: Settings" Menu

    ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 8.4.3 "Settings" menu The operator settings can be configured in the "SETTINGS" menu. Press the middle button to enter the menu to select the desired item. 8.4.3.1 Setting the date and time To correct the time and/or date, use the buttons to select the "SET TIME"...
  • Page 70 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 8.4.3.3 Alarm buzzer (Alarm break) By default, the acoustic alarm is switched off from 17:00 to 6:00. During this time, errors are only displayed optically. This setting can be changed in the menu item "CLEAR ALARMS".
  • Page 71 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 8.4.3.5 Delete alarm If a fault (alarm) has occurred, the alarm message can be reset by pressing the button after selecting the "CLEAR ALARMS" line. A window with the message "OK" opens for approx. 1 second and then the display in the menu changes to "NO ERROR".

  • Page 72: Other Menus With Displays Or Settings

    AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 8.4.4 Other menus with displays or settings In the following menus, all current parameters of the plant can be displayed and, in some cases, individually set.
  • Page 73 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 8.4.4.3 Aeration and +Aeration The "AERATION" menu displays the selected aeration intervals in normal mode, i.e. for how many minutes aeration is alternately switched "ON" / "OFF" (clocking). In addition, it displays the total aeration duration ("DURATION:").
  • Page 74 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Note: This menu is only visible if "AERATION 1st CH" was selected when selecting the plant type. This menu displays the aeration interval, i.e. for how many minutes aeration is switched "ON"...
  • Page 75 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 8.4.4.4 Denitrification Note: This menu is only visible if denitrification is activated. The "DENITRIFICATION" menu displays the selected aeration intervals in normal mode, i.e. for how many minutes aeration is alternately switched ON / OFF (clocking).
  • Page 76 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 8.4.4.5 Parameters 1 Different parameters are displayed in the "PARAMETERS 1" menu depending on the setting. The parameters "SLUDGE" discharge, "SEDIMENTATION" phase and "CLEAR WATER" discharge are always available.
  • Page 77 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 8.4.4.6 Parameters 2 Different parameters are displayed in the "PARAMETERS 2" menu depending on the setting. The parameters "CURRENT MONITORING", "MIN. PRESSURE" and "MAX. PRESSURE" are always available. If the controller switches on a unit (e.g. the compressor or a pump), it is not ensured with certainty that it will run.
  • Page 78 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 8.4.4.7 Parameters 3 Additional parameters may be displayed in the "PARAMETERS 3" menu depending on the presetting. The exact appearance of the menu depends on the respective presets.

  • Page 79: Faults / Alarm

    ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Faults / Alarm Faults are indicated by flashing of the red operating LED and the sounding of the buzzer. In the display, errors are reported by the display in the main menu in alternation with the fault display. The following figures show an example of an error message: These three views alternate until the error is acknowledged.
  • Page 80 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 The following faults/messages may be shown in the display depending on the preset: Flooding, with "Float" control type: Following the clear water discharge, the float switch has not...

  • Page 81: Power Failure Alarm

    ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Power failure alarm The controller has a power failure alarm. In the event of a power failure, an alarm tone sequence is generated approx. every 30 seconds in order to notify the operator that wastewater treatment has stopped. The display shows "No power available"...

  • Page 82: Presets

    AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Presets Number of inhabitants: Aeration 1st Ch Control mode: Time Denitrification: Switching times – Basic settings Aeration Aeration Denitrification Denitrification Normal mode Economy mode...

  • Page 83: Operation As Aquato Kom

    ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 ® Operation as AQUATO 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.
  • Page 84 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 In the event of a fault, the red LED flashes and the buzzer sounds. The standard display on the LCD shows the date and time in the top line and the current cycle phase in large letters below, e.g.

  • Page 85: Commissioning Of The Controller

    3 seconds while displaying "booting system...". 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. The check of the valve runs simultaneously.
  • Page 86 9.4.2.3). The various functions can be checked in manual mode. Once manual mode has been ended, the valve position required for the automatic cycle is approached, then the controller displays the message "booting system...", after which the start message "AQUATO" appears again and the valve is checked.
  • Page 87 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 The commissioning engineer must ensure that the parameter settings have been made in such a way that they comply with the requirements (e.g. effluent class) of the approval and the water law license for the system on which the controller is to be used.
  • Page 88 * Select "2x Float" only makes sense for K-Pilot 18.3, as only in this controller are suitable connections available. Figure 26: Commissioning sequence for K-Pilot 18.1/18.3/18.4 controller Do not select any additional functions for K-Pilot 18.1, as there are no physical outputs for these functions, i.e. they do not work, although they are displayed in the Manual Mode and Parameters menus.

  • Page 89: Main Display

    ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Main display In the standard display, the controller shows the switching status of the plant and the units, e.g.: 1st line: Date and time 2nd line: Current SBR phase, including "Fillingphase," "Aeration", "Sedimentation", "Clearwater”...

  • Page 90: Menu

    AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Menu 9.4.1 Menu structure In the "Aeration" and "Denitrification" menus, economy mode is only visible if a float switch is installed and set.

  • Page 91: Service" Menu

    ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Use the buttons to move from menu to menu. If you move constantly in the same direction, you will eventually return to the standard display. To access the submenus in the menu displayed, the middle button must be pressed.
  • Page 92 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 The function test of the float switch is only carried out at the beginning of the system test with the "FLOAT" CONTROL MODE.
  • Page 93 The different settings for the "Aerator" and the "Valve Position" can be made in the manual mode of the K-Pilot 18.1 controllers. The exact display depends on the parameters set (during commissioning). In manual mode, the "AERATOR" can be switched "ON" or "OFF"...
  • Page 94 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 The selected position is then approached. This is indicated by the progress bar in the menu. Once the position has been reached, the function is also carried...
  • Page 95 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 9.4.2.3 Manual mode with the K-Pilot 18.3 and 18.4 controllers In addition to the "Aerator" and "Valve position" parameters, which are always available, the manual mode of the K-Pilot 18.3 and 18.4 controllers allows further settings to be made. The exact display depends on the parameters set (during commissioning).
  • Page 96 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 The selected position is then approached. This is indicated by the progress bar in the menu. Once the position has been reached, the function is also carried...
  • Page 97 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Manual mode is ended via the menu item "...END MANUAL MODE". The valve is moved back to its initial position. At the end of manual mode, the treatment cycle continues. If the manual mode is not ended with "...END MANUAL MODE", the controller automatically switches back to automatic mode 15 minutes after the last pressing of a button.
  • Page 98 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 All queries in the Factory Settings menu must be answered with "NO". The "CLEAR COUNTER" window opens. If "NO" is selected, the menus with the individual units are skipped and the "CLEAR LOG"...
  • Page 99 All parameters for the treatment cycle are automatically preset through this selection, but can be readjusted if necessary. For plant sizes from 21 to 50 PE, please select "AQUATO>20 KOM SBR". The cycle presets for plant sizes from 21 to 50 PE are the same;...
  • Page 100 If password 1 was used, the menu item "SELECT PLANT SIZE" is completed at this point for both the K-Pilot 18.1 and the K-Pilot 18.3 and K-Pilot 18.4 controllers and the software jumps back to the "SERVICE" main menu.
  • Page 101 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 The additional functions are only available for the K-Pilot 18.3 and 18.4 controllers and can be put into operation with password 2 only. First, you can select "YES" in the lower line of the window with the query "3~ AERATOR"...
  • Page 102 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Then the menu for selecting the further additional functions opens. Depending on the previously selected settings, some of the additional functions are not available and are therefore not displayed in this menu.
  • Page 103 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 In order to activate a unit, the line with the desired/required additional function must be selected with the buttons. Then the button is used to select the electrical output to be used. Each time the button is pressed, the display changes in the selected line.
  • Page 104 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 If a "UV" lamp is to be used for hygienisation, such as in this example, it is essential to additionally select the "CLEAR WATER PUMP".
  • Page 105 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 The output "T1.4" may not be assigned when using the K-Pilot 18.3 controller, as it is not physically available! If a function is assigned to this output, it cannot be performed Output "T1.4" is only available for the K-Pilot 18.4 controller.
  • Page 106 The buffer can only be emptied on a purely time-controlled basis. For K-Pilot 18.1/18.4, be sure to select "NO" for the "Float for buffer" query, as there is no physical input for this float.
  • Page 107 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 In this case, after exiting the menu, a query appears asking for the desired/required type of "DOSING". If a phosphate precipitation is to be operated, select "PO3"; if a C source is to be added, select "C".
  • Page 108 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 9.4.2.6 Displaying the additional functions The "ADDITIONAL FUNCTIONS" menu (only available on the K-Pilot 18.3 and 18.4 controllers) displays the special functions selected during commissioning, such as "Clear Water Pump" or "Dosing", as well as the outputs to which they have been assigned.

  • Page 109: Settings" Menu

    ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 9.4.3 "Settings" menu The operator settings can be configured in the "SETTINGS" menu. Press the button to enter the menu to select the desired item. 9.4.3.1 Setting the date and time To correct the time and/or date, use the buttons to select the "SET TIME"...
  • Page 110 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 9.4.3.3 Alarm buzzer (Alarm break) By default, the acoustic alarm is switched off from 17:00 to 6:00. During this time, errors are only displayed optically. This setting can be changed in the menu item "CLEAR ALARMS".
  • Page 111 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 9.4.3.5 Delete alarm If a fault (alarm) has occurred, the alarm message can be reset by pressing the button after selecting the "CLEAR ALARMS" line. A window with the message "OK" opens for approx. 1 second and then the display in the menu changes to "NO ERROR".

  • Page 112: Other Menus With Displays Or Settings

    AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 9.4.4 Other menus with displays or settings In the following menus, all current parameters of the plant can be displayed and, in some cases, individually set.
  • Page 113 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 9.4.4.3 Aeration The "AERATION" menu displays the selected aeration intervals in normal mode, i.e. for how many minutes aeration is alternately switched "ON" / "OFF" (clocking). In addition, it displays the total aeration duration ("DURATION:").
  • Page 114 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 9.4.4.4 Denitrification Note: This menu is only visible if denitrification is activated. The "DENITRIFICATION" menu displays the selected aeration intervals in normal mode, i.e. for how many minutes aeration is alternately switched ON / OFF (clocking).
  • Page 115 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 9.4.4.5 Parameters 1 Different parameters are displayed in the "PARAMETERS 1" menu depending on the setting. The parameters "FILLINGPHASE", “SLUDGE” discharge, “SEDIMENTATION” phase “CLEAR WATER” discharge are always available. This menu displays – depending on the setting – the duration of the following cycle phases: - “FILLINGPHASE”...
  • Page 116 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 9.4.4.6 Parameters 2 Different parameters are displayed in the "PARAMETERS 2" menu depending on the setting. The parameters "CURRENT MONITORING", "MIN. PRESSURE" and "MAX. PRESSURE" are always available.
  • Page 117 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 9.4.4.7 Parameters 3 Additional parameters may be displayed in the "PARAMETERS 3" menu depending on the presetting. The exact appearance of the menu depends on the respective presets. If no relevant functions are selected, the menu remains empty.

  • Page 118: Faults / Alarm

    AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Faults / Alarm Faults are indicated by flashing of the red operating LED and the sounding of the buzzer. In the display, errors are reported by the display in the main menu in alternation with the fault display. The following figures show an example of an error message: These three views alternate until the error is acknowledged.
  • Page 119 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 The following faults/messages may be shown in the display depending on the preset: Flooding, with "Float" control type: Following the clear water discharge, the float switch has not dropped below the lower switching point...

  • Page 120: Power Failure Alarm

    AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Power failure alarm The controller has a power failure alarm. In the event of a power failure, an alarm tone sequence is generated approx. every 30 seconds in order to notify the operator that wastewater treatment has stopped.

  • Page 121: Presets

    ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Presets Number of inhabitants: Control mode: Time Denitrification: Switching times – Basic settings Aeration Aeration Denitrification Denitrification Normal mode Economy mode Normal mode Economy mode 1.0 15.0 1.0 15.0 1.0 15.0 1.0 15.0 1.0 15.0 1.0 15.0...

  • Page 122: Operation With Buffer

    AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Operation with buffer If the emptying of an additional buffer is activated, this is carried out after the surplus sludge discharge. The buffer can be set up in the main or bypass flow. The buffer emptying process runs as long as the charging process (see Switching times –...
  • Page 123 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 In the example, the buffer pump in the K-Pilot 18.3 controller is connected to output T1.2 and the float in the buffer to IN2. Output: Output: Input: Input: T1.2 T1.3 grey blue green grey...
  • Page 124 The subsequent query, "FLOAT FOR BUFFER" control type, can only be answered with "YES" for the K-Pilot 18.3 controller if a float switch is used in the buffer, otherwise with "NO". For the K-Pilot 18.1 and K-Pilot 18.4 controllers, the answer must be "NO", as no float can be installed for the buffer.

  • Page 125: Operation With Uv Lamp For Hygienisation

    ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Operation with UV lamp for hygienisation Hygienisation by means of a UV lamp is always carried out during clear water discharge. To ensure the flow through the UV reactor, it is necessary to use a clear water pump which pumps the mechanically and biologically purified water through the reactor.
  • Page 126 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 commissioning (or under "Select plant size"). Likewise, the output selected for the clear water pump must be assigned to the additional function Clear Water Pump .
  • Page 127 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 The Parameters 3 menu displays the remaining running time of the UV lamp and the total running time of the UV lamp as "UV OP. HRS". The settings of "REMAINING RUNTIME" are reset here to 2000 hours after the lamp has been changed.

  • Page 128: Operation With Disinfectant For Hygienisation

    AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Operation with disinfectant for hygienisation Hygienisation with a disinfectant (e.g. chlorine) always takes place during clear water discharge. The mechanically and biologically purified water is hygienized in the downstream tank (or downstream chamber) by dosing the disinfectant.
  • Page 129 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 The hygienisation function must be activated during commissioning or in the additional functions in the "Select plant types" menu. For the procedure, see Commissioning of the controller, Chapter 8.2 and 9.2 and/or Selecting a plant type, Chapter 8.4.2.5 and 9.4.2.5 During commissioning (or under "Select plant type"), select "FLOAT"...
  • Page 130 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 In the example, the Cl dosing time "CHLORINATION" is being changed from 90 to 10 seconds cycle. In order to set how long the precipitant supply will last, use the buttons to select the line "CHLORINATION...

  • Page 131: Operation With Precipitant Dosing For Phosphate Precipitation

    ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Operation with precipitant dosing for phosphate precipitation The addition of precipitant for phosphate precipitation takes place before the sedimentation phase, after which the reactor is mixed again in order to distribute the precipitant, thereby achieving a good degree of efficiency.
  • Page 132 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 During commissioning (or under "Select plant size"), select "FLOAT" as the control mode and, in the Additional Functions menu, the option "DOSAGE" with the output selected during installation to connect the pump.
  • Page 133 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 In the example, the PO3 dosing time is being changed from 60 to 12 seconds cycle. In order to set how long the precipitant supply will last, use the buttons to select the line "PREPICITANT...

  • Page 134: Operation With Carbon Dosing

    AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Operation with carbon dosing In order to keep the microorganisms alive for extended periods without an increase in wastewater, the plant can be operated with carbon dosing. The C-source is only added during holiday mode, i.e. when no fresh wastewater has flowed in for 3 days or longer.
  • Page 135 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 During commissioning (or under "Select plant type"), select "FLOAT" as the control type and, in the Additional Functions menu, the option "DOSAGE" with the output selected during installation to connect the pump. In the query that follows, "C" must be selected (see Chapter 8.2, 9.2, 8.4.2.5 and 9.4.2.5).
  • Page 136 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 In the example, the C dosing time is being changed from 60 to 509 seconds per dosing (For setting the dosing frequency, see select plant size, Chapter 8.4.2.5 and 9.4.2.5)

  • Page 137: Operation With Double Float (2X Float)

    ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Operation with double float (2x FLOAT) With the K-Pilot 18.3 controller, it is possible to work with a double float switch, i.e. to use one float switch (S1) for the lower switching point and another float switch (S2) for the upper switching point, thereby increasing the buffer.

  • Page 138: Error Messages And Troubleshooting

    AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Error messages and troubleshooting Display Possible cause Remedy I aer. - Compressor defective - Replace compressor The compressor has not - Fuse defective...
  • Page 139 ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Display Possible cause Remedy - Inflow of outside water - Locate and stop inflow Flood: After the clear water has - Receiving water backed up - Possibly a one-time event been discharged, the float switch...
  • Page 140 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 POWER ON - Power has been switched on POWER OFF - Power has been switched off - Switch on power > 15 min:...

  • Page 141: Technical Data

    ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Technical Data Temperature range (operation) 0 °C … + 40 °C Temperature range (storage) 20°C … + 70 °C Air humidity (operation and storage) 0 … 90% RH non-condensing Protection class double-insulated Protection class IP 54 Dimensions approx.

  • Page 142: Operation Log

    AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Operation log In order to guarantee long-term smooth operation of your small wastewater treatment plant, the following checks are prescribed by the operator in accordance with the user approval.

  • Page 143: Decommissioning And Disposal

    ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 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. Before starting the final disassembly, switch off the plant by pulling out the power plug.

  • Page 144: Addresses

    AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ® ® Operation Manual AQUATO K-Pilot 18.1/18.3/18.4 Addresses Manufacturer ® Company AQUATO Umwelttechnologien GmbH Ernstmeierstr. 24 Address 32052 Herford +49(0)5221 / 10 21 9-0 Telephone Internet www.aquato.de info@aquato.de E-mail Plant supplied / installed by...
  • Page 146 AQUATO K-PILOT 18.1 / 18.3 / 18.4 Controller Operation Manual ®...
  • Page 148 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...

This manual is also suitable for:

K-pilot 18.3K-pilot 18.4

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