Page 1: Table Of Contents
Instructions for start-up, operation and maintenance Klaro Easy SBR wastewater treatment system Control unit version KLbasic / KL24base KLplus / KL24plus Contents General building authorities' ap- proval: GENERAL SAFETY NOTICES Carat In the septic tank: SCOPE OF SUPPLY No.: Z-55.31-319 FUNCTION OF THE SBR SYSTEM (discharge class C) CONTROL AND MACHINE CABINET...
Page 2 The warranty only applies to the wastewater treatment technology. Accessories and addi- tional options are not covered by the warranty. Within the warranty period, Otto Graf GmbH shall replace materials free of charge. No other services are covered by the warranty.
Page 3 Dear Sir/Madam, We are delighted that you have chosen to buy a modern Klaro Easy SBR system. Klaro Easy is a quality product that as a complete system meets the requirements of DIN EN 12566-3 and DIN 4261-1, making it a fully biological small wastewater treatment system. Below you will find some important information for safely operating your system for a long time to come.
Page 4: General
1. General General Details about your system In case you have any queries while operating the system, please enter the details of your sys- tem here as follows. Should you encounter a fault, these details will enable our staff to find a remedy faster.
Page 5 "Safety of machinery – Safety-related parts of control systems. – EN 13849-1: 2008 Part 1: General principles for design." This EC declaration of conformity ceases to apply if the product is modified without consent. Responsible for documentation: Otto Graf GmbH Teningen, 31.03.15 Arne Schröder (Product management team leader)
Page 6: Safety Notices
2. Safety notices Safety notices 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. Explanation of warning notices and prohibitions Warning of danger Warning of dangerous voltage Warning of tripping risk...
Page 7 2. Safety notices Safety precautions must never be removed or bypassed during normal operation of the ma- chine. Safety precautions may only be temporarily bypassed or deactivated by the mainte- nance fitter during repairs and maintenance. When working with chemical substances, contact with the chemicals should be avoided as far as possible.
Page 8 2. Safety notices Warning notices Ensure that the machine cabinet is not installed above or in the direct vicinity of water vessels. Risk of electric shock if improperly installed. Installation location Only connect the machine cabinet to a correctly installed 230 V socket or earth cable which is fused with an upstream 16 A fuse as specified in the technical data.
Page 9: Scope Of Supply
3. Scope of supply Scope of supply The wastewater treatment system basically comprises the septic tank with wastewater treat- ment technology setting-up kit and control cabinet. These main parts are connected to one an- other using air hoses laid in the ground. The septic tank(s) is(are) split into two areas, the sludge reservoir and buffer in the inlet area and the SBR reactor in the outlet area.
Page 10 3. Scope of supply One-tank system in the Carat septic tank 140-340 Sludge SBR- storage/ Schlamm- SBR- speicher/ reactor Reaktor buffer Puffer Two-tank system in the Carat tank Sludge storage/ buffer SBR-reactor sludge return One-reservoir system in a TWIN underground tank 10 / 54...
Page 11: Function Of The Sbr System
4. Function of the SBR system Function of the SBR system The Klaro Easy is a fully biological small wastewater treatment system, which functions on the principle of the SBR process (aeration system in retention process). The system basically com- prises 2 stages: A sludge reservoir with integrated upstream buffer and activated sludge stage in closed retention mode (SBR reactor).
Page 12 4. Function of the SBR system Step 3: Settling phase This step is a rest phase in which no aeration takes place. The activated sludge settles with gravity (sedimentation phase). A clear water zone forms at the top and a sludge layer at the bottom.
Page 13 4. Function of the SBR system Systems with extra nitrogen elimination (discharge class D) Nitrogen is also removed biologically using certain strains of microorganisms. In systems which are also designed for additional denitrification, a short burst of aeration is undertaken at the start of the aeration phase to circulate the water and stimulate denitrifying bacteria which convert nitrate into elementary nitrogen.
Page 14: Control And Machine Cabinet
5. Control and machine cabinet Control and machine cabinet All the system's mechanical and electrical components are installed in a switch cabinet. The cabinet for internal installation is made from expanded polypropylene (EPP; used for wastewater treatment systems for 4-10 inhabitants) or is a powder-coated metal cabinet (used for wastewater treatment systems for 11 or more inhabitants).
Page 15 5. Control and machine cabinet The electrical connection of the switch cabinet must only be carried out by a qualified electrician. Fuse con- nections! EPP switch cabinet for indoor installation (380 x 580 x 300 mm) The EPP machine cabinet is secured to a wall with the hanger bolts supplied.
Page 16 5. Control and machine cabinet Plastic column for outdoor installation The plastic column intended for installation out of doors should be sunk into the ground up to the mark on the front of the cabinet (see installation instructions). A ditch of a suffi- cient depth should be dug.
Page 17 5. Control and machine cabinet A cabinet made from facing concrete is needed for a compressor size of DT 4.16 or more. This requires a concrete foundation (foundation plan available from GRAF). Figure 1: Inside of two-door concrete cabinet Figure 2: Two-door concrete cabinet When starting up the system (i.e.
Page 18 5. Control and machine cabinet System response to disconnection from the voltage supply If the system is disconnected from the mains (e.g. due to a power cut), the control program and the operating hours counted are retained in the system control's memory. An intermittent warn- ing tone sounds.
Page 19: The Small Wastewater Treatment System'scontrol Unit
6. The small wastewater treatment system's control unit The small wastewater treatment system's control unit The system is operated using the control unit in the cabinet door (or inside the cabinet with out- door cabinets). The control unit allows operating parameters to be set, operating statuses to be displayed, system parameters to be queried and operating times to be programmed by a spe- cialist.
Page 20 6. The small wastewater treatment system's control unit KLbasic/KL24base control unit KLplus/KL24plus control unit The following operating phases are displayed: KLbasic / Process undertaken KLplus / KL24base display KL24plus display Charchng Valve 1 is activated, the feed lifter pumps the charging wastewater to be cleaned from the sludge res- ervoir into the bio reactor.
Page 21 6. The small wastewater treatment system's control unit KLbasic/KL24base control unit KLplus/KL24plus control unit Symbol Key assignment Function Symbol Enter Select operating mode, confirm input Scroll Display the operating modes and queries Acknowledge- Acknowledge input without saving ment Acknowledge fault messages Numbers Program system by entering numbers -----------...
Page 22 6. The small wastewater treatment system's control unit KLbasic/KL24base control unit KLplus/KL24plus control unit Connection for temperature sensor, 7 X4: Connection for extension cable: external "must be plugged in!", indicator. X3: Connection for extension cable: UV module and metering pump, X4: Connection for external indicator and contactor monitor, 10 P: Connection for pressure measuring...
Page 23 6. The small wastewater treatment system's control unit KLbasic/KL24base control unit KLplus/KL24plus control unit Operating the control unit You can start various queries when in automatic mode. Pressing takes you to the first operating Pressing takes you to the first mainte- level.
Page 24 6. The small wastewater treatment system's control unit KLbasic/KL24base control unit KLplus/KL24plus control unit 6.3.1 Operating hours query Press the key. Screen shows: Press the key. Screen shows: Operatin hours operating hours meter reading By again pressing , the operating hours can Pressing again displays the number of be called up for valves 1-4 in turn using the ar-...
Page 25 6. The small wastewater treatment system's control unit KLbasic/KL24base control unit KLplus/KL24plus control unit Taking the example of valve 1, the screen You can activate and deactivate the selected now shows: valve by pressing manual operation The individual valves can be selected with the valve1: arrow keys .
Page 26 6. The small wastewater treatment system's control unit KLbasic/KL24base control unit KLplus/KL24plus control unit Press , then press the arrow keys Press , then press the arrow keys until the following appears on screen: until the following appears on screen: Vacationinput vacation date setup...
Page 27 6. The small wastewater treatment system's control unit 6.3.6 Displaying settings The current control unit settings can be viewed under this menu item. These settings cannot be changed. This menu item is used to analyse the settings without changing them. 6.3.7 Service menu and action code Operating parameters can be changed in the Service menu.
Page 28 Using a screwdriver, apply a little pressure to the head of the fixture and anchor the fuse by turning the head one quarter turn to the right (clockwise). Note: If you are not able to remedy the problem, please contact your maintenance company or GRAF as soon as possible. Function of the power cut detector The control unit is equipped with a power cut detector, which is powered via an integrated emergency power supply (buffer).
Page 29 6. The small wastewater treatment system's control unit  After the 5-second delay, there is an intermittent beep with a red flashing signal. Five flashing signals and one beep repeat at intervals of 5 seconds for around 12 hours (if the emergency power supply is fully charged).
Page 30: Additional Function Of The Klplus/Kl24Plus And Klbasic/Kl24Base Control Unit
7. Additional function of the KLplus/KL24plus and KLbasic/KL24base control unit Additional function of the KLplus/KL24plus and KLbasic/KL24base control unit Underload detection (KLplus/KL24plus)  Please note: Level-dependent operation should be activated by a mainte- nance fitter or an expert. Incorrect calibration of the system could cause it to operate constantly in economy mode (with cycle pause).
Page 31 7. Additional function of the KLplus/KL24plus and KLbasic/KL24base control unit 7.1.2 Start-up When working with an open cesspit cover, there is a risk of stumbling and falling! Suitable measures must be taken to cordon off the open pit. Risk of fall- The first chamber (sludge reservoir/buffer), where the feed lifter is located, must be filled with water up to the height at which a cleaning cycle is to be triggered.
Page 32 7. Additional function of the KLplus/KL24plus and KLbasic/KL24base control unit Recommended maximum buffer heights in sludge reservoir / buffer: SBR chamber Concrete semi-circle Ø 200 cm Concrete semi-circle 250 cm in diameter No. of inhab. b [cm] SBR chamber Concrete full circle Ø 200 cm Concrete full circle Ø...
Page 33 7. Additional function of the KLplus/KL24plus and KLbasic/KL24base control unit 1st step: Calibrating the pressure sensor It is absolutely essential that the sensor is calibrated for starting up underload detection. Please carefully work through the following points in order: Go to "SERVICE CODE INPUT", press the key and enter the following service code code when prompted to do so:...
Page 34 7. Additional function of the KLplus/KL24plus and KLbasic/KL24base control unit To activate, measure the height between the base of the tank and bottom edge of the emergen- cy overflow in the dividing wall or, in full circle systems, on the discharge. With tanks, you can enter the relevant value for your system from the table (see p.32).
Page 35 7. Additional function of the KLplus/KL24plus and KLbasic/KL24base control unit 7.3.2 Connecting a contactor to switch the compressor If the inbuilt compressor has a power consumption in excess of 6 A, a contactor for controlling the compressor is also fitted in the cabinet. The switching status of the contactor is monitored via the contactor monitoring input X4.
Page 36 7. Additional function of the KLplus/KL24plus and KLbasic/KL24base control unit 7.3.4 Phosphate precipitation with dosing pump Attention: The precipitant (ferric chloride or polyaluminium chloride) is harmful to health when swallowed and irritates the skin. There is the danger of serious eye injuries. There is a danger of explosion in conjunction with alkali metals, allyl chlo- ride and ethylene oxide.
Page 37 7. Additional function of the KLplus/KL24plus and KLbasic/KL24base control unit  Feed the suction hose into the precipitant container far enough to ensure suction from the base.  Connect the suction and pressure hoses to the hose nozzles of the pump and fix them with the cap nuts.
Page 38: Operation And Maintenance
8. Operation and maintenance Operation and maintenance The system must be kept switched on at all times. As the operator of a small wastewater treat- ment system, you are obliged to ensure that the system runs perfectly. Almost all operating problems will result in the system's cleaning capacity being impaired.
Page 39 8. Operation and maintenance Weekly checks (Weekly checks are not prescribed, but are recommended)  Check water levels, sludge must not enter the SBR chamber uncontrolled.  Check the supply and discharge routes for blockages (visual check).  Read operating hours counter for air compressor (total operating hours), aeration (valve 2) and sludge return (valve 4) and if necessary any other units and note in operating log.
Page 40 8. Operation and maintenance The following should be noted when removing sludge:  First remove the floating sludge from the surface, then place the intake pipe on the floor of the pit.  Around 10 cm of water should be allowed to remain in the pre-treatment section. ...
Page 41 8. Operation and maintenance – oxygen concentration (O /l > 2 mg), if necessary adapt the compressor operating times – sludge as proportion of volume (< 400 ml/l)  if the sludge makes up more than 400 ml/l, the sludge should be removed more frequently in agreement with the manufacturer;...
Page 42: Fault Messages And Rectification
9. Fault messages and rectification Fault messages and rectification Technical system operation faults (failure of a unit) are indicated both visually and acoustically. The control unit's acoustic fault signal can be deactivated by pressing . The optical error display is only acknowledged once is pressed again.
Page 43 9. Fault messages and rectification Display Possible cause Rectification Liquid crystal display KLbasic / KLplus / KL24base KL 24plus (see maintenance instructions in Annex). Valve 3 valve 3 error failure Valve 4 valve 4 error failure  UV module not working ...
Page 44 9. Fault messages and rectification Display Possible cause Rectification Liquid crystal display KLbasic / KLplus / KL24base KL 24plus  Batteries in module are  Wait 5 minutes until batteries are charged modem error  Connect modem to the mains not yet fully charged ...
Page 45 9. Fault messages and rectification Possible faults on solenoid valves Observation Possible cause  Connection voltage is interrupted or is insufficient. Anchor does not make con-  Solenoid defective. tact.  Anchor blocked in dirty tube space. If the anchor does not reach the stroke end position, when the AC coil is excited this will soon result in coil failure (due to thermal overload).
Page 46: Operating Instructions
10. Operating instructions 10. Operating instructions Basically only substances with the characteristics of domestic wastewater may enter the sys- tem. Biocides, toxic substances or substances which are not biocompatible or biodegradable must not enter the system because they cause biological process problems. The following are not permitted: ...
Page 47 10. Operating instructions The table below contains a list of substances which must not be disposed of in the wastewater treatment system: Solids or liquids which should not be disposed Why not: Correct disposal: of via the sink or toilet: Does not break down Dustbin Chemicals...
Page 48 GRAF Iberica Tecnología del Plástico S.L. – Marquès Caldes de Montbui, 114 – ES-17003 Girona – Tel.: +34 972 913767 – Fax: +34 972 913766 GRAF UK Ltd – Target House – Thorpe Way Ind. Estate – Banbury – Oxfordshire – UK-OX16 4SP – Tel.: +44 1608 661-500 – Fax: + 44 1295 211333...
Page 49: Annex I: Template For Weekly / Monthly Check Notes
11. Annex I: Template for weekly / monthly check notes 11. Annex I: Template for weekly / monthly check notes For systems requiring maintenance three times a year, the parameters should be noted weekly; for systems requiring maintenance twice a year, the parameters should be noted monthly Operating hours counter Valve 1 Valve 2...
Page 50 11. Annex I: Template for weekly / monthly check notes For systems requiring maintenance three times a year, the parameters should be noted weekly; for systems requiring maintenance twice a year, the parameters should be noted monthly Operating hours counter Valve 1 Valve 2 Valve 3...
Page 51 11. Annex I: Template for weekly / monthly check notes For systems requiring maintenance three times a year, the parameters should be noted weekly; for systems requiring maintenance twice a year, the parameters should be noted monthly Operating hours counter Valve 1 Valve 2 Valve 3...
Page 52: Maintenance Log For Klaro Small Wastewater Treatment Systems
12. Maintenance log for KLARO small wastewater treatment systems 12. Maintenance log for KLARO 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 53 12. Maintenance log for KLARO small wastewater treatment systems Sludge accumulator + buffer: Sludge height: Floating sludge height: The operator should arrange for the cesspit to be emptied. SBR reactor: Oxygen concentration: mg/l (normally approx. 4-6 mg/l, at least 2 mg/l) Sludge as proportion of volume: ml/l (maximum 400 ml/l)
Page 54 12. Maintenance log for KLARO small wastewater treatment systems Dry substance Activated sludge kg SOL / m³ total Substances that can ml / l settle ml / l ml / l ml / l ml / l Additional comments: Operating log available. Maintenance noted in the log.

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