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ACO Powerlift Pro Instructions For Use Manual

Powerlift prefabricated pumping station
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Instructions for Use
Powerlift prefabricated pumping station
For non-faecal and faecal wastewater, for installation in the
ground
Powerlift Pro
Type PSD-P: Pumpstation Duo
(2 Pumps)-Polymerbeton
Powerlift Concrete
Type PSD-B: Pumpstation Duo
(2 Pumps)-Concrete
For safe and proper use, read carefully through the instructions for use and all other
documents enclosed with the product, pass them on to the end user and keep them until the
end of the product's life.
V1.0_DE
Original Instructions
ACO Civil Engineering
Issued: 2019-09-26

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  • Page 1 ACO Civil Engineering Instructions for Use Issued: 2019-09-26 Powerlift prefabricated pumping station For non-faecal and faecal wastewater, for installation in the ground Powerlift Pro Type PSD-P: Pumpstation Duo (2 Pumps)-Polymerbeton Powerlift Concrete Type PSD-B: Pumpstation Duo (2 Pumps)-Concrete For safe and proper use, read carefully through the instructions for use and all other documents enclosed with the product, pass them on to the end user and keep them until the end of the product's life.
  • Page 2 Introduction Introduction ACO Tiefbau Vertrieb GmbH (referred to as ACO in the following) thanks you for your trust and hands over to you a product which is state-of-the-art and has been tested for proper condition as part of quality controls carried out before delivery.

  • Page 3: Table Of Contents

    Powerlift prefabricated pumping station Table of Contents Table of Contents For your safety ....................6 Intended use ...................... 6 Normative specifications ..................7 Personnel qualifications..................7 Personal protective equipment ................8 Warnings ......................8 Responsibility of the Owner ................. 9 Transport and storage ..................
  • Page 4 Powerlift prefabricated pumping station Table of Contents Electrical installation ..................54 3.5.1 Overview of the electrical installation work ..........54 3.5.2 Supplying heating (optional) and work plug socket (optional) with current .. 55 3.5.3 Installing the control ................55 3.5.4 Connecting the control to the power supply ..........
  • Page 5 Powerlift prefabricated pumping station Table of Contents Technical Data ....................88 Prefabricated pumping station ................88 6.1.1 Dimensions ..................88 6.1.2 Key data ....................89 Submersible pumps – non-faecal wastewater ............90 6.2.1 SAT-100/D, SAT-150/D and SAT-200/D ..........90 6.2.2 SAT-50/2/32/D and SAT-75/2/32/D ............

  • Page 6: For Your Safety

    Powerlift prefabricated pumping station For your safety For your safety Read the safety instructions before installing and operating the prefabricated pumping station, in order to prevent personal injuries and damage to property. 1.1 Intended use The prefabricated pumping station is used for collecting and automatic lifting of non-faecal and faecal wastewater above the backflow level.

  • Page 7: Normative Specifications

    For your safety Other possible uses and changes are not allowed. Installation of unapproved parts impairs safety and excludes any guarantee from ACO. In the event of replacement, only use original ACO parts or spare parts approved by ACO. 1.2 Normative specifications...

  • Page 8: Personal Protective Equipment

    Powerlift prefabricated pumping station For your safety 1.4 Personal protective equipment Personal protective equipment must be made available to the personnel and supervisors must check that it is used or worn. Manda- tory Meaning sign Safety footwear provides good slip resistance, especially in wet conditions, as well as a high degree of penetration resistance (e.g.

  • Page 9: Responsibility Of The Owner

    1.6 Responsibility of the Owner Due diligence in the owner’s, or the operator’s, area of responsibility: ACO recommends that an operating log be kept and that inspections, servicing, maintenance work, repairs etc. be documented, so that verification exists in case of an insurance claim.

  • Page 10: Transport And Storage

    Powerlift prefabricated pumping station For your safety 1.7 Transport and storage IMPORTANT Note during storage and transport: Store the plant parts in frost-protected premises. ■ If intermediate storage is required, then the manhole base section must be protected ■ against water ingress. Never drive the forks of a fork-lift truck or lift truck directly under the plant parts.

  • Page 11: Product Description

    Powerlift prefabricated pumping station Product Description Product Description 2.1 Product features 2.1.1 Basic equipment Powerlift PSD-P Powerlift PSD-B Base shaft tank made of high-quality polymer Base shaft tank made of high-quality, quality- ■ ■ concrete, optimised against biogenic monitored concrete corrosion Largely deposit-free collection area (partly with ■...
  • Page 12 Powerlift prefabricated pumping station Product Description Powerlift PSD-P Powerlift PSD-B Tank nominal size 1,000 mm (clear opening Tank nominal size 1,000, 1,500 or 2,200 ■ ■ width) mm (clear opening width) with assembled mechanical seal Pipework made of PVC-U up to approx. 30 cm ■...
  • Page 13 Powerlift prefabricated pumping station Product Description Powerlift PSD-P Powerlift PSD-B Shaft rings made of polymer concrete: Manhole rings made from ■ ■ concrete according to/similar to Nominal size 1,000 mm with heights from … DIN 4034-1: 250 to 1,000 mm Nominal size 1,000 with heights from 250 …...

  • Page 14: Accessories

    Powerlift prefabricated pumping station Product Description 2.1.2 Accessories Utilising the pump- Product Description ing station Pump pull chain Stainless steel with a pull force of 500 kg (metre goods) Shackle For fastening the pump pull chain on the pump handle Guide pipe PSD-P-1000, PSD-B-1000 DN/OD 43 - GRP pipe for extending the short guide pipe...
  • Page 15 Powerlift prefabricated pumping station Product Description Utilising the pump- Product Description ing station Multi Control control With submersible pumps For level regulating for liquid filling levels: The ■ system level can be optionally determined via pneumatic SAT-100/D ■ pressure (with/without air bubble injection), an SAT-150/D ■...
  • Page 16 Powerlift prefabricated pumping station Product Description Utilising the pump- Product Description ing station Level Control PS 2 Control With submersible pumps LCD plain text display ■ System Thermal monitoring for the pumps SAT-Q 750/80/D ■ ■ Manual – 0 – Auto functions SAT-Q 1000/100/D ■...
  • Page 17 Powerlift prefabricated pumping station Product Description Utilising the pump- Product Description ing station Open back pressure Measuring principle: pneumatic filling level ■ bell recording. When the liquid reaches the bottom of the compression bell, the air within the bell is compressed.

  • Page 18: Components

    Powerlift prefabricated pumping station Product Description 2.2 Components Hochwasser- Störung MultiControl Duo Alarm Betrieb Nachlauf Automatik Handbetrieb Pumpe 1 Pumpe 2 HAND Anzeige AUTO Auswahl Quittung Pumpe 1 Pumpe 2 Figure: Type PSD-B 1000 1 = Cover 13 = Clip on nipple 2 = Chain holder 14 = Ball retaining valve 3 = Type plate...

  • Page 19: Operating Principle

    Powerlift prefabricated pumping station Product Description Socket seal (connection on-site to inlet pipe) 31 = Shaft ring (optional) for adapting the installation depth 27 = Mechanical seal according to DIN 4034 32 = Connecting cable Pump 1 28 = Control cable and/or connection cable for level sensor 33 = Connecting cable Pump 2 29 =...
  • Page 20 Powerlift prefabricated pumping station Product Description If the water level reaches the baseload (BL), then a pump switches on and pumps the wastewater through the pressure pipe above the “Pipe invert, backflow loop” level. From there the wastewater flows by gravity to the drainage sewer. Two ball retaining valves prevent backflow from the pressure pipe and into the tank.

  • Page 21: Installation

    Powerlift prefabricated pumping station Installation Installation The specifications of EN 12056-4 and the regional directives must be complied with for the installation. Following installation, the launch must be carried out by a qualified person, according to the requirements in these instructions for use, Chapter 4 “Commissioning”.

  • Page 22: Overview Of Earthwork And Installation Works

    Powerlift prefabricated pumping station Installation 3.2 Overview of earthwork and installation works Hochwasser- Störung MultiControl Duo Alarm Betrieb Nachlauf Automatik Handbetrieb Pumpe 1 Pumpe 2 HAND Anzeige AUTO Auswahl Quittung Pumpe 2 Description Item Work Chapter Digging the excavation 3.3.2 Backfilling the excavation 3.3.11 Installing shaft components with PSD-P...
  • Page 23 Powerlift prefabricated pumping station Installation Description Item Work Chapter Laying and connecting the on-site ventilation pipe 3.3.7 – Execute leak test 3.3.12 23/ 122...

  • Page 24: Earthworks

    Powerlift prefabricated pumping station Installation 3.3 Earthworks 3.3.1 Specifications Installation site Load class D 400: truck trafficable – the safe solution for heavy goods vehicles and storage areas and side strips (hard shoulders) of carriageways Installation depth In Germany, the minimum depth for frost-free earthworks is regulated in DIN 1054. In this standard, the depth is cited as min.

  • Page 25: Digging The Excavation

    Powerlift prefabricated pumping station Installation Slings for transport using lifting gear Tank and cover plate: Use 3-part harness with at least 5 m long strands made from ■ chain or cables with load hooks and NG 5 shackles according to DIN 82101 Cover and shaft components: Use 3-type part harness with at least 5 m long strands ■...

  • Page 26: Installing Shaft Components With Psd-P

    Powerlift prefabricated pumping station Installation 3.3.4 Installing shaft components with PSD-P Shaft rings with connection collars, cover plate, support rings, cover and adhesive are supplied loose. IMPORTANT All joints must be sealed with the supplied 2-component adhesive. ■ Transport eyes on the shaft components are designed for their own weight load. Do not ■...
  • Page 27 Manhole rings of nominal size 1,000 can be installed between the manhole ring and cover plate to adapt to the installation depth. Manhole rings with construction heights from 250 to 1,000 mm can be optionally purchased from ACO. Arrange the shaft ring centrally (e.g.
  • Page 28 Supporting rings can be installed between the cover and the cover plate to adjust to the upper level of the terrain on site. Supporting rings with construction heights from 40 to 100 mm can be optionally purchased from ACO. IMPORTANT Compensate out maximum. 300 mm of height difference with supporting rings.

  • Page 29: Installing Shaft Components With Psd-B

    Shaft rings with connection collars, cover plate, supporting rings and cover are supplied loose. Shaft components delivered by ACO ■ according to/similar to DIN 4034-1 have an ACO mechanical seal for joint sealing. The mechanical seal is a compression mechanical seal with a wedge-shaped cross section and a factory-made, closed, pre-lubricated slide sleeve.
  • Page 30 Shaft rings with construction heights from 265 to 2,515 mm can be optionally purchased from ACO. Arrange the shaft ring centrally above Î...
  • Page 31 Standard supporting rings can be installed between the cover and the cover plate to adjust to the upper level of the terrain on site. Support rings with construction heights from 70, 90 to 110 mm can be optionally purchased from ACO. (Height details with 1 cm mortar joint).

  • Page 32: Laying And Connecting The On-Site Inlet Pipe

    Powerlift prefabricated pumping station Installation Installation, product-accompanying documentation: Instruction "Multitop manhole ■ cover". Clean and moisten the sliding rebate of Î the cover plate and/or the supporting ring and the underside of the cover. Apply mortar bed on the surface of the Î...

  • Page 33: Laying And Connecting The On-Site Blank Cable Pipe

    Powerlift prefabricated pumping station Installation Choose resistant material (e.g. KML, PP, PE, PVC). ■ Use acid-free lubricant to grease the Î spigot of the vent stack and the sealing lips of the socket seal. Push the spigot into the socket seal. Î...
  • Page 34 Powerlift prefabricated pumping station Installation Connect the pressure pipe stress-free. ■ 34/ 122...
  • Page 35 Powerlift prefabricated pumping station Installation Pressure pipe DN 50, DN 70 or DN 80 Compression fitting ID 63 mm to ID 75 and 90 can be purchased from ACO as an optional item. Cut the on-site pressure pipe at aright- Î...

  • Page 36: Installation In The Outdoor Cabinet (Optional)

    Use base filler (fill material for reducing the formation of condensation). ■ An outdoor cabinet for accommodating the control, flashing light, horn, etc. can be purchased from ACO as an optional product. In general, components such as the control are already pre-installed in the outdoor cabinet.

  • Page 37: Backfilling The Excavation

    An outdoor cabinet for accommodating the backflow loop can be purchased from ACO as an optional product. Make a hole in the ground for the Î outdoor cabinet (3), note the buried...

  • Page 38: Leak Test

    3.4 Installation work 3.4.1 Assembling the access ladder The access ladder is an integral part of the basic equipment and can be optionally purchased from ACO. Assembly, product accompanying instructions. IMPORTANT Access ladders must not be assembled in the inlet pipe area.

  • Page 39: Assembling The Chain Holder And Guide Pipe

    2 cable lugs are additionally included as loose. Pump pull chains (metre goods) and shackle can be optionally purchased from ACO. The description applies to both submersible pumps: Assemble the chain with shackle on the Î...
  • Page 40 Powerlift prefabricated pumping station Installation Thread the coupling piece for the pump Î onto the guide pipe: Position X. Lower the pump further until the Î coupling sits in the underwater automatic coupling. Hook the chain onto the chain holder. Î...

  • Page 41: Assembling The Level Sensor (Optional)

    ■ Installing the sealing plug A sealing plug can be optionally purchased from ACO. Installing the sealing plug enables the cable entry position for all connecting cables and/or the control cable in the reserve cable conduit to be sealed (vapour-proof).
  • Page 42 Powerlift prefabricated pumping station Installation Longitudinal measurement L [cm] Pump type PSD-P-1000 PSD-B--1000 PSD-B--1000 T Basin 685 T Basin 480 T Basin 1070 SAT-50/2/32/D SAT-75/2/32/D SAT-V 75/2/50/D SAT-V 150/2/50/D SITA 150 N-ex SITA 200 N-ex SITA 300 N-ex SITA 550 N-ex Powerlift PSB-P-1500 and PSD-B-2200 Longitudinal measurement L [cm] Pump type...
  • Page 43 Powerlift prefabricated pumping station Installation Push the control cable through the Î cable gland, set it to the longitudinal measurement L and tighten the union nut of the cable gland as hand-tight. Lift the cover out of the cover frame and Î...
  • Page 44 Powerlift prefabricated pumping station Installation Use the pull wire to pull the connection Î cable together with the pump connecting cable through the cable duct up to the mounting location of the control. Keep sufficient excess control cable Î (approx. 0.5 m), to enable the connection to the control.
  • Page 45 Powerlift prefabricated pumping station Installation Closed back pressure bell The closed back pressure bell with 40 m control cable will be assembled on the probe bracket. Lift the cover out of the cover frame and Î store to the side. Lower the closed back pressure bell in Î...
  • Page 46 Powerlift prefabricated pumping station Installation Use the pull wire to pull the connection Î cable together with the pump connecting cable through the cable duct up to the mounting location of the control. Keep sufficient excess control cable Î (approx. 0.5 m), to enable the connection to the control.
  • Page 47 Powerlift prefabricated pumping station Installation Powerlift PSD-B-1500 Longitudinal measurement L [cm] PSD-B-1500 PSD-B-1500 T Basin 395 T Basin 795 Pump type SAT-Q 300/65/D SAT-Q 300/80/D SAT-Q 400/65/D SAT-Q 400/80/D SAT-Q 300/80/4/D KL-AT-M 200/4/80/D-Ex KL-AT-M 300/4/80/D-Ex KL-AT-M 400/4/80/D-Ex KL-AT-V 400/2/80/D-Ex KL-AT-V 400/4/100/D-Ex KL-AT-V 550/2/80/D-Ex Powerlift PSD-B-2200 Longitudinal measurement L [cm]...
  • Page 48 Powerlift prefabricated pumping station Installation Longitudinal measurement L [cm] PSD-B-2200 PSD-B-2200 PSD-B-2200 T Basin 515 T Basin 505 T Basin 585 Pump type KL-AT-M 200/4/80/D-Ex – – – – KL-AT-M 300/4/80/D-Ex – – – – KL-AT-M 400/4/80/D-Ex – – – –...
  • Page 49 Powerlift prefabricated pumping station Installation Guide the control cable length below the Î cable gland into the recess ( ) of the ● probe bracket (1). Lower the float switch until the cable Î gland sits on the probe bracket (2). Pull the connecting cable upwards (not Î...
  • Page 50 Powerlift prefabricated pumping station Installation Level probe The level probe has a 20 m, 50 m and/or 80 m long connecting cable (connected and sealed on the level probe). A protective pipe (total length 1,700 mm), a tensioning clamp and a cable eyelet are delivered as loose in the as-delivered condition.
  • Page 51 Powerlift prefabricated pumping station Installation Longitudinal measurement L [cm] Pump type PSD-B--1500 PSD-B--1500 PSD-B--2200 PSD-B--2200 PSD-B--2200 T Basin 395 T Basin 795 T Basin 515 T Basin 505 T Basin 585 SAT-Q 300/80/4/D – LW-KP 1325...421 – – – – LW-KP 1325...422 –...
  • Page 52 Powerlift prefabricated pumping station Installation Fix the length (projection of 20 mm) with Î the tensioning clamp and centre it in the protective pipe. Lift the cover out of the cover frame and Î store to the side. Lower the “protective pipe with level Î...
  • Page 53 Powerlift prefabricated pumping station Installation Pull the connecting cable for the level Î probe upwards (not while energised) until it reaches the chain holder. Place the loop around the cable eye ( Î ● and fasten with cable tie. ● Hang the cable eye on the chain holder.

  • Page 54: Electrical Installation

    IMPORTANT Voltage failures caused by longer cable routes must be considered on site. The MultiControl Duo control and/or Level Control PS 2 Control System, air bubble injection, outside cabinet and Ex-barrier can be optionally purchased from ACO. 3.5.1 Overview of the electrical installation work...

  • Page 55: Supplying Heating (Optional) And Work Plug Socket (Optional) With Current

    Select the maximum spacing according to the lengths of the connection cables of the ■ pumps and level sensor and/or control cable for level sensor. If necessary, versions with longer connection cables or control cable can be purchased from ACO as optional components. Installation in the outdoor cabinet Chapter 3.3.10 “Outdoor cabinet installation”...

  • Page 56: Connections For The Control

    Powerlift prefabricated pumping station Installation 3.5.5 Connections for the control MultiControl Duo Hochwasser- Störung Alarm Betrieb Nachlauf Automatik Handbetrieb Pumpe 1 Pumpe 2 HAND Anzeige AUTO Auswahl Pumpe 1 Pumpe 2 Quittung Figure: MultiControl Duo Control 1 = Connection, pneumatic level switching control cable 4 = Pump 1 power supply connection and/or back pressure bell) 5 = Pump 2 power supply connection...
  • Page 57 Powerlift prefabricated pumping station Installation electronics. 57/ 122...

  • Page 58: Check The Rotational Direction Of The Pumps

    A suitable cable connection box with membrane must be utilised e.g. ACO Article Number 711892. Insert the connection cable into the terminal compartment of the control and connect to Î...

  • Page 59: Connecting The Air Bubble Injection

    Powerlift prefabricated pumping station Installation 3.5.9 Connecting the air bubble injection Assembling the mini compressor onto a wall The mini compressor has a 1.5 m long connection cable with Schuko earthed safety plug. Requirement: Flood-proof and free wall surface of 100 mm x 200 mm (Width x Height) near the control unit Connecting the mini compressor to the power supply Note when executing the electrical installation: Note the connection value 230 V/50 Hz.

  • Page 60: Connecting The Malfunction Or Fault Signalling Equipment (Optional)

    Powerlift prefabricated pumping station Installation Connecting the control pipe In the as-delivered condition, the connection parts are enclosed with the mini compressor as loose items. IMPORTANTIn order to prevent malfunctions: Utilise a cutting knife to adjust the control pipe length at right angles. Cut the control pipe (12).

  • Page 61: Commissioning

    Powerlift prefabricated pumping station Commissioning Commissioning Based on the normative requirements (EN 12056-4), the start-up must be carried out by an appropriately competent person. The commissioning must be documented, Appendix: “Commissioning record”. 4.1 MultiControl Duo control Will be utilised in combination with the following pumps, Chapter 2.1.2 “Accessories”.
  • Page 62 Powerlift prefabricated pumping station Commissioning Function of the controls Description Function Explanation The rotary knob can be used to select the menu items in the display panel. Selection of the Display menu items The display automatically changes back to the basic setting after 20 seconds.

  • Page 63: Menu Items And Settings

    Powerlift prefabricated pumping station Commissioning 4.1.2 Menu items and settings Display panel Messages in the display panel: Top line: ■ The water level in the tank (if no pump is in operation) … Setting option … Bottom line: ■ Operating hours of the pumps (if pumps are not in operation) …...
  • Page 64 Powerlift prefabricated pumping station Commissioning Top row Bottom row Explanation (menu item) (settings) Is activated = If the pumps are not requested for a duration Is switched off 24 h operation of 24 hours, they run automatically for the duration of the set 1 –...

  • Page 65: Changing The Settings

    Powerlift prefabricated pumping station Commissioning 4.1.3 Changing the settings Notes: Settings can only be changed in service mode. If Service mode is not activated the ■ settings are displayed, but cannot be changed or saved. If no entry is made within 20 seconds the display automatically switches back to the ■...
  • Page 66 Powerlift prefabricated pumping station Commissioning 1 = Rotaryknob for “Display” 9 = LED green “Automatic/Manual mode” (P1 and/or 2 = Display 10 = Housing 3 = Button for “Manual” (P1 and/or P2) 11 = Main switch Button “0” (P1 and/or P2) 12 = Button “Auto”...

  • Page 67: Menu Items And Settings

    Powerlift prefabricated pumping station Commissioning Description Meaning Explanation LED illuminates: Automatic mode Pump P1 or P2 LED flashes irregularly: Manual mode Automatic operation mode LED flashes irregularly: Manual operation was switched off automatically after approx. 2 minutes 4.2.2 Menu items and settings Display panel Messages in the display panel: Top line:...
  • Page 68 Powerlift prefabricated pumping station Commissioning Top row Bottom row Explanation (menu item) (settings) Interpump delay 0 – 60 sec. When both pumps are simultaneously requested, Pump 2 also initially switches on after the set time. 24 h operation Is switched on, Is activated = When the pumps are not requested for 1 –...

  • Page 69: Changing The Settings

    Powerlift prefabricated pumping station Commissioning 4.2.3 Changing the settings Notes: Settings can only be changed in service mode. If Service mode is not activated the ■ settings are displayed, but cannot be changed or saved. If no entry is made within 20 seconds the display automatically switches back to the ■...

  • Page 70: Powerlift Psd-P-1000 With T

    Powerlift prefabricated pumping station Commissioning 4.3.1 Powerlift PSD-P-1000 with T = 685 Basin Menu Pump type Settings with level sensor: point SAT-100/D 80 70 60 11 98 88 78 18 80 70 60 11 Flood AL SAT-150/D 80 70 60 11 98 88 78 18 80 70 60 11 = AL SAT-200/D...

  • Page 71: Powerlift Psd-B-1000 With T Basin = 480

    Powerlift prefabricated pumping station Commissioning 4.3.2 Powerlift PSD-B-1000 with T = 480 Basin Menu Pump type Settings with level sensor: point SAT-100/D 101 91 81 11 119 109 99 18 101 91 81 11 Flood AL SAT-150/D 101 91 81 11 119 109 99 18 101 91 81 11 = AL SAT-200/D...

  • Page 72: Powerlift Psd-B-1000 With T Basin = 1070

    Powerlift prefabricated pumping station Commissioning 4.3.3 Powerlift PSD-B-1000 with T = 1070 Basin Menu Pump type Settings with level sensor: point SAT-100/D 42 32 22 11 60 50 40 18 42 32 22 11 Flood AL SAT-150/D 42 32 22 11 60 50 40 11 42 32 22 11 = AL SAT-200/D...

  • Page 73: Powerlift Psd-B-1500 With T Basin = 795

    Powerlift prefabricated pumping station Commissioning 4.3.4 Powerlift PSD-B-1500 with T = 395 Basin Menu Pump type Settings with level sensor: point SAT-Q 300/65/D 94 84 74 11 125 115 105 31 94 84 74 11 Flood AL SAT-Q 300/80/D 94 84 74 11 125 115 105 31 94 84 74 11 = AL SAT-Q 400/65/D...

  • Page 74: Basin = 505

    Powerlift prefabricated pumping station Commissioning 4.3.5 Powerlift PSD-B-1500 with T = 795 Basin Menu Pump type Settings with level sensor: point SAT-Q 300/65/D 54 44 34 11 85 75 65 31 54 44 34 11 Flood AL SAT-Q 300/80/D 54 44 34 11 85 75 65 31 54 44 34 11 = AL SAT-Q 400/65/D...
  • Page 75 Powerlift prefabricated pumping station Commissioning 4.3.6 Powerlift PSD-B-2200 with T = 515 Basin Menu Pump type Settings with level sensor: point SAT-Q 300/65/D 118 108 98 11 149 139 129 31 118 108 98 11 SAT-Q 300/80/D 118 108 98 11 149 139 129 31 118 108 98 11 SAT-Q 400/65/D 111 101 91 11 149 139 129 38...
  • Page 76 Powerlift prefabricated pumping station Commissioning Menu Pump type Settings with level sensor: point 20 mA => – – – level Language – German Previously set under “level control” menu item = Set 20 mA => Level = 400. 4-20mA Interface “and under” Value = 0 with version with air bubble injection.
  • Page 77 Powerlift prefabricated pumping station Commissioning Menu Pump type Settings with level sensor: point After-running period SAT-Q 300/65/D SAT-Q 300/80/D SAT-Q 400/65/D SAT-Q 400/80/D SAT-Q 550/80/4/D SAT-Q 750/80/D 15.9 Maximum current SAT-Q 1000/100/D 21.6 – 1 SAT-Q 1000/100/4/D 20.0 SAT-Q 1500/100/D 28.8 Maximum SAT-Q 300/80/4/D...

  • Page 78: Basin = 585

    Powerlift prefabricated pumping station Commissioning 4.3.8 Powerlift PSD-B-2200 with T = 585 Basin Menu Pump type Settings with level sensor: point Flood AL LW-KP 1325...421 130 120 110 11 180 170 160 49 130 120 110 11 = AL Peak load LW-KP 1325...422 130 120 110 11 180 170 160 49 130 120 110 11...

  • Page 79: Settings For The Installed Prefabricated Pump Station

    Powerlift prefabricated pumping station Commissioning 4.3.9 Settings for the installed prefabricated pump station The settings made during the commissioning must be entered in the following table by hand. Menu item Pump type Settings with level sensor: Base load ON Base load OFF Peak load ON Flood AL After-running...

  • Page 80: Starting Up The Submersible Pumps

    Powerlift prefabricated pumping station Commissioning 4.4 Starting up the submersible pumps The description is valid for both submersible pumps. IMPORTANT To ensure dry-running protection, the pump chamber must be vented during the initial start-up. It can be filled with drinking water, rainwater or process water (when this complies with the local discharge conditions for effluent).

  • Page 81: Execute Test Run

    Powerlift prefabricated pumping station Commissioning Pull the pump at an angle and lower Î further. Air escapes from the pump chamber. Lower the pump further until the Î coupling sits in the underwater automatic coupling. Hook the chain onto the chain holder. Î...
  • Page 82 Powerlift prefabricated pumping station Commissioning Requirement for design with open back pressure bell without air bubble injection: 82/ 122...
  • Page 83 Nachlauf Automatik Handbetrieb Powerlift prefabricated pumping station Pumpe 1 Pumpe 2 Commissioning HAND The water level at the "after-running period OFF” is located at approx. 50 mm below the lower Anzeige edge of the back pressure bell. The tank can be filled via the inlet pipe or via the inspection opening. Starting automatic mode: Press both buttons to start automatic Î...
  • Page 84 Powerlift prefabricated pumping station Commissioning Fill the tank Î When the water level reaches the “Base load” (BL) level, Pump 1 switches on. Increase the inlet flow so that the water Î level continues to rise. When the water reaches the “Peak load” (PL) level, Pump 2 also switches on.

  • Page 85: Setting The Air Bubble Injection (Optional)

    Powerlift prefabricated pumping station Commissioning Acknowledging a malfunction: Press the button to acknowledge the Î Auswahl malfunction. Quittung A fault message is no longer displayed and the LED for the “Flood alarm” goes out. The trial run is finished. Final work: Position the cover again ■...

  • Page 86: Troubleshooting

    ■ only, Chapter 1.3 "Personnel qualifications". Only use original spare parts. ■ Have prefabricated pumping station repairs carried out by ACO or an ACO ■ Service partner, Chapter Introduction, “ACO Service”. Prevent contact with wastewater and wear protective equipment, ■...
  • Page 87 Pressure pipe obstructed Clean the pressure pipe or tank full Impeller or grinder (pump) blocked Pump maintenance required (ACO Service) Pump parts are worn Pump repair required (ACO Service) Pump only runs in Control pipe of the level switching is leaking,...

  • Page 88: Technical Data

    Powerlift prefabricated pumping station Technical Data Technical Data 6.1 Prefabricated pumping station 6.1.1 Dimensions Type of n x D3 Short prefabricated pumping caracters station PSD-P-1000/T Basin PSD-B-1000/T Basin PSD-B-1000/T 1,070 Basin PSD-B-1500/T Basin PSD-B-1500/T Basin PSD-B-2200/T Basin PSD-B-2200/T Basin PSD-B-2200/T Basin 30 - 40°...

  • Page 89: Key Data

    Powerlift prefabricated pumping station Technical Data = Construction height with joints for circular rotating mechanical seal (15 mm) or mortar H3, H4, T and T Basin (10 mm) H maximum = Maximum installation depth of the tank relative to the tank base EL = Ventilation pipe connection DN 100/OD = 110 mm: details for pipe bottom on request KL = Blank cable pipe connection DN 100/OD = 110 mm: details for pipe bottom on request ¹...

  • Page 90: Submersible Pumps - Non-Faecal Wastewater

    Powerlift prefabricated pumping station Technical Data 6.2 Submersible pumps – non-faecal wastewater 6.2.1 SAT-100/D, SAT-150/D and SAT-200/D Characteristic data and use limits Key data 100/D 150/D 200/D Type of cable for connection cable: Pump motor operating voltage [V]: Frequency [Hz]: Pump motor speed [1/min.]: 2,700 2,665...
  • Page 91 Powerlift prefabricated pumping station Technical Data Performance diagram SAT-100/D - DRO 100/2/G50H A0CT5 - DRO 100/2/G50H A0CT5 SAT 100/D Head H / m 12,8 12,4 11,6 11,2 10,8 10,4 1 ,6 ▕ ◄ Application range ►▏ Anwendungsbereich Q / m³/h 91/ 122...
  • Page 92 Powerlift prefabricated pumping station Technical Data Performance diagram SAT-150/D - DRO 150/2/G50H A0CT5 - DRO 150/2/G50H A0CT5 SAT 150/D Head H / m 16,5 15,5 14,5 13,5 12,5 11,5 10,5 1 ,5 ▕ ◄ Application range ►▏ Anwendungsbereich Q / m³/h 92/ 122...
  • Page 93 Powerlift prefabricated pumping station Technical Data Performance diagram SAT-200/D - DRO 200/2/G50H A0CT5 - DRO 200/2/G50H A0CT5 SAT 200/D Head H / m 18,5 17,5 16,5 15,5 14,5 13,5 12,5 11,5 10,5 ▕ ◄ Application range ►▏ Anwendungsbereich 0 ,5 / m³/h 93/ 122...

  • Page 94: Sat-50/2/32/D And Sat-75/2/32/D

    Powerlift prefabricated pumping station Technical Data 6.2.2 SAT-50/2/32/D and SAT-75/2/32/D Characteristic data and use limits Key data 50/2/32/D 75/2/32/D Type of cable for connection cable: Pump motor operating voltage [V]: Frequency [Hz]: Pump motor speed [1/min.]: 2,830 2,830 Pump motor power input P1 [kW]: Pump motor output P2 [kW]: Pump motor nominal current [A]: Maximum starts per hour:...
  • Page 95 Powerlift prefabricated pumping station Technical Data Performance diagram SAT-50/2/32/D - DRE 50/2/G32V A0BT5 - DRE 50/2/G32V A0BT5 SAT-50/2/32/D Head H / m 0 ,8 Q / m³/h 95/ 122...
  • Page 96 Powerlift prefabricated pumping station Technical Data Performance diagram SAT-75/2/32/D Head - DRE 75/2/G32V A0BT5 - DRE 75/2/G32V A0BT5 SAT-75/2/32/D H / m 12,8 12,4 11,6 11,2 10,8 10,4 0 ,4 ▕ ◄ Application range ►▏ Anwendungsbereich Q / m³/h 96/ 122...

  • Page 97: Sat-V 75/2/50/D And Sat-V 150/2/50/D

    Powerlift prefabricated pumping station Technical Data 6.2.3 SAT-V 75/2/50/D and SAT-V 150/2/50/D Characteristic data and use limits SAT-V Key data 75/2/50/D 150/2/50/D Type of cable for connection cable: Pump motor operating voltage [V]: Frequency [Hz]: Pump motor speed [1/min.]: 2,830 2,642 Pump motor power input P1 [kW]: Pump motor output P2 [kW]:...
  • Page 98 Powerlift prefabricated pumping station Technical Data Performance diagram SAT- V 75/2/50/D - DGE 75/2/G50V B0BT5 - DGE 75/2/G50V B0BT5 SAT-V 75/2/50/D Head H / m 0 ,6 ▕ ◄ Application range ►▏ Anwendungsbereich Q / m³/h 98/ 122...
  • Page 99 Powerlift prefabricated pumping station Technical Data Performance diagram SAT- V 150/2/50/D - DGE 150/2/G50V B0CT5 - DGE 150/2/G50V B0CT5 SAT-V 150/2/50/D Head H / m 14,4 13,6 13,2 12,8 12,4 11,6 11,2 10,8 10,4 0 ,8 ▕ ◄ Application range ►▏ Anwendungsbereich Q / m³/h 99/ 122...

  • Page 100: Sat-Q 300/65/D, Sat-Q 300/80/D, Sat-Q 400/65/D, Sat-Q 400/80/D And Sat-Q 750/80/D

    Powerlift prefabricated pumping station Technical Data 6.2.4 SAT-Q 300/65/D, SAT-Q 300/80/D, SAT-Q 400/65/D, SAT-Q 400/80/D and SAT-Q 750/80/D Characteristic data and use limits SAT-Q Key data 4G1.5+ 4G1.5+ 4G1.5+ 4G1.5+ 4G1.5+ Type of cable for connection cable: 3x0.75 Pump motor operating voltage [V]: Frequency [Hz]: Pump motor speed [1/min.]: 2,835...
  • Page 101 Powerlift prefabricated pumping station Technical Data Performance diagram SAT-Q 300/65/D SAT-Q 300/65/D - DRN 300/2/65 A1DT5 Head H / m Eff. 71,3% ▕ ◄ Application range ►▏ Anwendungsbereich Q / m³/h Performance diagram SAT-Q 300/80/D Head SAT-Q 300/80/D - DRN 300/2/80 A1DT5 H / m Eff.
  • Page 102 Powerlift prefabricated pumping station Technical Data Performance diagram SAT-Q 400/65/D SAT-Q 400/65/D - DRN 400/2/65 A1FT5 Head H / m Eff. 50,3% ▕ ◄ Application range ►▏ Anwendungsbereich Q / m³/h Performance diagram SAT-Q 400/80/D SAT-Q 400/80/D Head - DRN 400/2/80 A1FT5 H / m Eff.

  • Page 103: Sat-Q 300/80/4/D And Sat-Q 550/80/4/D

    Powerlift prefabricated pumping station Technical Data Performance diagram SAT-Q 750/80/D SAT-Q 750/80/D - DRP 750/2/80 A0HT5 Head H / m Eff. 43,6% ▕ ◄ Application range ►▏ Anwendungsbereich Q / m³/h 6.2.5 SAT-Q 300/80/4/D and SAT-Q 550/80/4/D Characteristic data and use limits SAT-Q Key data 300/80/4/D...
  • Page 104 Powerlift prefabricated pumping station Technical Data Performance diagram SAT-Q 300/80/4/D SAT-Q 300/80/4/D - DRN 300/4/80 A1FT5 Head H / m Eff. 57,8% 2 ,5 ▕ ◄ Application range ►▏ Anwendungsbereich Q / m³/h Performance diagram SAT-Q 550/80/4/D SAT-Q 550/80/4/D Head H / m Eff.

  • Page 105: Sat-Q 1000/100/D, Sat-Q 1000/100/4/D And Sat-Q 1500/100/D

    Powerlift prefabricated pumping station Technical Data 6.2.6 SAT-Q 1000/100/D, SAT-Q 1000/100/4/D and SAT-Q 1500/100/D Characteristic data and use limits SAT-Q Key data 1000/100/D 1000/100/4/D 1500/100/D Type of cable for connection cable: 7G1.5+3x0.75 7G1.5+3x0.75 7G2.5+3x0.75 Pump motor operating voltage [V]: Frequency [Hz]: Pump motor speed [1/min.]: 2,890 1,436...
  • Page 106 Powerlift prefabricated pumping station Technical Data Performance diagram SAT-Q 1000/100/4/D SAT-Q 1000/100/4/D - DRP 1000/4/100 A0HT5 Head H / m Eff. 65,5% ▕ ◄ Application range ►▏ Anwendungsbereich Q / m³/h Performance diagram SAT-Q 1500/100/D SAT-Q 1500/100/D Head H / m Eff.

  • Page 107: Lw-Kp 1325

    Powerlift prefabricated pumping station Technical Data 6.2.7 LW-KP 1325...421, LW-KP 1325...422, LW-KP 1325...423 and LW-KP 1325...424 Characteristic data and use limits LW-KP Key data Type of cable for connection cable: 7G2.5+2x1.5 7G2.5+2x1.5 7G2.5+2x1.5 7G2.5+2x1.5 Pump motor operating voltage [V]: Frequency [Hz]: Pump motor speed [1/min.]: 1,455 1,465...
  • Page 108 Powerlift prefabricated pumping station Technical Data Performance diagram LW-KP 1325...421 H /m LW-KP 1325...421 Q /l/s Performance diagram LW-KP 1325...422 H /m LW-KP 1325...422 Q /l/s 108/ 122...
  • Page 109 Powerlift prefabricated pumping station Technical Data Performance diagram LW-KP 1325...423 H /m LW-KP 1325...423 Q /l/s Performance diagram LW-KP 1325...424 H /m LW-KP 1325...424 Q /l/s 109/ 122...

  • Page 110: Submersible Pumps - Faeces-Containing Wastewater

    Powerlift prefabricated pumping station Technical Data 6.3 Submersible pumps – faeces-containing wastewater 6.3.1 KL-AT-M 200/4/80 D-Ex, KL-AT-M 300/4/80 D-Ex and KL-AT-M 400/4/80 D-Ex Characteristic data and use limits KL-AT-M ... D-Ex Key data 200/4/80 300/4/80 400/4/80 Type of cable for connection cable: 4G1.5+2x0.75 4G2.5+2x0.75 4G2.5+2x0.75...
  • Page 111 Powerlift prefabricated pumping station Technical Data KL-AT-M ... D-Ex Key data 200/4/80 300/4/80 400/4/80 Weight [kg]: Performance diagram KL-AT-M 200/4/80 D-Ex Head KL-AT-M 200/4/80 D-Ex - MAN 200/4/80 A1DT5 H / m Eff. 64,7% 1 ,5 ▕ ◄ Application range ►▏ Anwendungsbereich Q / m³/h 100 105 110 115...
  • Page 112 Powerlift prefabricated pumping station Technical Data Performance diagram KL-AT-M 300/4/80 D-Ex KL-AT-M 300/4/80 D-Ex - MAN 300/4/80 A1FT5 Head H / m Eff. 72,5% ▕ ◄ Application range ►▏ Anwendungsbereich Q / m³/h Performance diagram KL-AT-M 400/4/80 D-Ex KL-AT-M 400/4/80 D-Ex Head - MAN 400/4/80 A1FT5 H / m...

  • Page 113: Kl-At-V 400/2/80 D-Ex, Kl-At-V 400/4/100 D-Ex And Kl-At-V 550/2/80 D-Ex

    Powerlift prefabricated pumping station Technical Data 6.3.2 KL-AT-V 400/2/80 D-Ex, KL-AT-V 400/4/100 D-Ex and KL-AT-V 550/2/80 D-Ex Characteristic data and use limits KL-AT-M ... D-Ex Key data 400/2/80 400/4/100 550/2/80 Type of cable for connection cable: 4G2.5+2x0.75 4G2.5+2x0.75 4G2.5+2x0.75 Pump motor operating voltage [V]: Frequency [Hz]: Pump motor speed [1/min.]: 2,842...
  • Page 114 Powerlift prefabricated pumping station Performance diagram KL-AT-V 400/4/100 D-Ex KL-AT-V 400/4/100 D-Ex - DGN 400/4/100 A1FT5 Head H / m Eff. 43,6% 1 ,5 ▕ ◄ Application range ►▏ Anwendungsbereich Q / m³/h 100 105 110 115 120 Performance diagram KL-AT-V 550/2/80 D-Ex KL-AT-V 550/2/80 D-Ex Head - DGN 550/2/80 A1FT5...

  • Page 115: Sita 150 N-Ex, Sita 200 N-Ex, Sita 300 N-Ex And Sita 550 N-Ex

    Powerlift prefabricated pumping station 6.3.3 SITA 150 N-Ex, SITA 200 N-Ex, SITA 300 N-Ex and SITA 550 N-Ex Characteristic data and use limits SITA ... N-Ex Key data Type of cable for connection cable: 4G1.5+2x0.75 4G1.5+2x0.75 4G1.5+2x0.75 4G2.5+2x0.75 Pump motor operating voltage [V]: Frequency [Hz]: Pump motor speed [1/min.]: 2,850...
  • Page 116 Powerlift prefabricated pumping station Technical Data Performance diagram SITA 200 N-ex Head - GRF 200/2/G40H A1CT5 SITA 200 N-Ex H / m Eff. 54,3% ▕ ◄ Application range ►▏ Anwendungsbereich Q / m³/h Performance diagram SITA 300 N-ex SITA 300 N-Ex Head - GRN 300/2/G50H A1DT5 H / m...

  • Page 117: Multicontrol Duo Control

    Powerlift prefabricated pumping station Technical Data Performance diagram SITA 550 N-ex - GRN 550/2/G50H A1FT5 SITA 550 N-Ex Head H / m Eff. 45,8% ▕ ◄ Application range ►▏ Anwendungsbereich Q / m³/h 6.4 MultiControl Duo control 6.4.1 Key data Key data Values Operating voltage:...

  • Page 118: Circuit Diagram

    Powerlift prefabricated pumping station MultiControl Duo Technical Data ver. 1.19 6.4.2 Circuit diagram Relaisausgänge und Signaleingänge 118/ 122...

  • Page 119: Level Control Ps 2 Control System

    Powerlift prefabricated pumping station Technical Data 6.5 Level Control PS 2 Control System 6.5.1 Key data Key data Values Operating voltage: ~ 400 V (L1, L2, L3, N, PE), 50 Hz Control voltage: 230 VAC, 50 Hz Motor current limitation 0.3 A to 12 A (with duo: adjustable for each pump) Power intake (contactors operated): <...

  • Page 120: Appendix: Commissioning Report

    Powerlift prefabricated pumping station Technical Data Appendix: Commissioning report Commissioning and instruction of a qualified person takes place in the presence of the authorised acceptance inspection representative and the plant operating company. Commissioning date: Handover date: Powerlift prefabricated pumping station Prefabricated pumping Access Submersible pumps...
  • Page 121 Powerlift prefabricated pumping station Technical Data Check list for commissioning (Qualified person) Two trial runs are required before, during and after start up, Chapter 4.5 “Performing a trial run”. Tests & Inspections (no claim is made that the list is complete) Electrical fusing of the plant in accordance with the IEC regulations or national and local regulations Rotational direction of pump motors...
  • Page 122 ACO Civil Engineering ACO Tiefbau Vertrieb GmbH Am Ahlmannkai D 24782 Büdelsdorf Tel.: + 49 4331 354-500 Fax: + 49 4331 354-358 www.aco-tiefbau.de ACO. creating the future of drainage...

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