KESSEL – Wastewater Station Aqualift® F for floor
Contents
1. INSTALLATION OPERATION AND MAINTENANCE INSTRUCTIONS KESSEL Wastewater Station Aqualift F for floor slab installation for wastewater with or without sewage Article 28300 28330 28350 Product Advantages m Upper section telescopically height adjustable rotatable and tiltable m Adjustment of cover to the tile grid Compression seal flange for attachment of vapour barrier As a double lifting station for increased wastewater demand 7 53 2 484 ys C Abb zeigt Art Nr 28300 O Installation L Service of this unit should be carried out by a licensed profes sional servicer f a K K ESS a L Edition 2010 02 Number 298 057EN Company Telephone No Subject to technical amendments Safety Instructions This instruction handbook contains important security advices which must be followed at all times during installation operation maintenance and repair of the power unit The security advices are labelled as follows General warning sign according to ISO 3864 B 3 1 tagging endangering of persons AN Warning sign according ISO 3864 B 3 6 to caution against voltage J This word indicates security advices disregarding these will cause severe danger for the station and it s function This instruction handbook must be available at all times in the station Dear customer We are happy you decided to choose a product made by KESSEL Before leaving the factory the whole station has been subje2. 18 A requirement of this additional warranty is that the product is properly installed and ope rated in accordance with the valid installation and user s manual as well as the correspon ding norms regulations 2 Wear and tear on a product will not be con sidered a defect Problems with products re sulting from improper installation handling or maintenance will also be considered a defect EC DECLARATION OF CONFORMITY Electromagnetism Guidelines 89 336 EEC Electromagnetism Guidelines 89 336 EEC Low Voltage Guidelines 73 23 EEC Kessel GmbH D 85101 Lenting we declare that the product KESSEL Wastewater Station Aqualift F for underground installation for wastewater with or without sewage is in agreement with EN 12050 3 EN 12100 2 2003 11 EN 12100 1 2003 11 EN 60335 1 2003 5 EN 60335 2 1996 09 EN 61000 6 1 2002 1 EN 61000 6 4 2002 01 EN 809 1998 11 EN 60730 1 Lenting den 07 03 2007 i ae 7 Lay ll B Kessel A Kessel iki KESSEL Everything for Drainage Solutions from a single source Backwater valves and cleanouts Volatile liquid traps Lifting stations pumps warning and control units gt Rainwater management systems gt Grease starch and oil fuel separators gt Inspection chambers gt Custom projects for industrial applications gt Polymer pipe fittings gt Stainless steel drains and channels iki KESSEL
3. with moisture connection seal Sealing set Article Nu 83023 In the case that this system is installed in a foundation slab which is protected by a full surface moisture membrane to protect against groundwater or high moisture the connection flange system Article Nu 83023 should be used The on site moisture mem brane should be connected to the integrated body flange on the Aqualift F and then fixed in place with the 83023 plastic perimeter flange connection screws are included In the case that a waterproof concrete founda tion slab is used the NK SBR heavy duty sealing membrane included in 83023 should be connected between the integrated body flange and the flange supplied with the 83023 the sealing membrane has pre dril led holes to fit perfectly onto the integrated flange In the case that this water proof slab needs to be penetrated for inlets or conduit pipes each of these penetrations should be properly sealed against groundwater moi sture Illustration Showing Pumpfix F backwater valve MW Installation shows concrete slab with full surface moisture membrane Tiles Screed Insulation Concrete slab Protective concrete layer moisture membrane seal Base concrete slab oe 1 MRE Zz 11 UVU l po tHe 7 11 K
4. ESSEL Pumpfix F Staufix FKA Staufix SWA or Controllfix Sealing flange Article 83023 Extension section Article 83071 Intermediate section DN 100 with stainless steel pressure sealing flange Article 27198 Polymer sealing membrane Article 27159 2 6 Installation with Extension section Article Nu 83071 When using the extension section the flan ge height remains vertically adjustable If re quired the extension section can be shorte ned on site by sawing off the appropriate amount 2 7 Sound Insulation To help improve sound reduction of the sy stem the base of the Aqualift F should be de coupled with the concrete foundation not be in direct contact with slab ik KESSEL Installation recommendation iki KESSEL 3 Initial Operation KESSEL Aqualift F wastewater Station Art 28300 Alarm unit Art 20221 Waterproofing set Art 83023 Outlet set with flexible pressure pipe Art 28040 Ventilation pipe to roof Attention The initial operation must be executed by authorized and qualified per sonnel Prior to operation the installation must be checked accurately It is absolutely neces sary to follow the instructions of the safety regula tions in chapter 1 of the instruction handbook at all times Please read this user s manual for the wastewater station Aqualift F for Tronic version It must be con sidered that liquid level will not drop beneath mini mum ground level
5. In addition to the standard opera tion process the pump will start a weekly self diagnosis run 12 4 Cleaning and Maintenance Attention Prior to working on the pump DISCONNECT MAIN PLUG Follow here all the safety instruc tion mentioned in chapter 1 Prior to main tenance work the seal housing must be pumped dry so a blow out the wastewater is avoided 4 1 Dismantling By dismantling of the one hand fastener and the two lock staples safety lever the pump can be easily taken out without using any tools The non return flap in the pressure joint of the vessel avoids that the wastewater which still remains in the discharge pipe pressure pipe returns back to the unit 4 2 Installation Prior to re installation all sealing faces must be cleaned Grease the lip sealing in the drain Re insert the pump as described in chapter 2 4 4 3 Maintenance For all works at the pump a lifting of the pump out of the unit is recommended as well as to execu te a preliminary cleaning of it Other tasks as de scribed are not allowed to be executed The maintenance work should only be executed by authorized and qualified personnel Repairs are to be exclusively executed by the manufacturer General Maintenance According to DIN 12056 a maintenance must be executed by a specialist specialised company in the following time intervals after 3 months for units installed in commercial businesses e after 6 months fo
6. ase it and mount the upper section The telescopically upper section allows a continously variable adjustment of the pump station Aqualift F into already existing installation depth Ground falling gradient can be levelled out until up to 5 An adjustment of the cover p e the tile pattern is possible picture 2 CAUTION After final adjustment cut outs have to be fixed at the upper section espe cially in the area of cable bushing and where additional inlets were added pictu re 3 After successful water proof check of all exi sting piping the vessel can be poured into con crete bed 2 2 KESSEL Pump Station Aqualift F for depressed installation into the slab with extension Article 83070 Depending on installation depth one or two ex tensions between upper section and connec tor may be used The gaskets are to be grea sed accordingly Thereby the drain pipe must be shortened according to the level adjust ment Installation of covers with selectable sur face For the covers with choice of surface there is the possibility of fixing tile flooring or natural stone into the cover This way you can fit the flooring to the room For tile fixing we recom mend products by PCI Schomburg Deiter mann To achieve an unproblematic work manship we recommend the following ik KESSEL 2 Installation Laying of Natural Stone marble granite agglomerated marble Grounding of slab p e using PCI ground
7. ct to a strict quality control However we kindly ask you to check whether the station has been delivered completely and without any damage In case of transport damage please look for the regulations in chapter guarantee of this instruction Prior to installation and putting into operation of the Aqualift it is in your interest and essential that you carefully read and follow the installation operation maintenance and repair instructions KESSEL AG iki KESSEL Safety Instructions General Precaution For installation operation maintenance or repair purposes of the station all regulations for accident prevention must be followed DIN and VDE Standards and guideline specifications as well as regulation of the local energy supply and utility undertaking must be carefully followed Staff Qualification and Staff Training The staff for operation maintenance inspection and installation must possess appropriate qualification for carrying out these operations Reponsibility competence and supervising of staff must be exactly arranged by the operator In case staff doesn t possess the neces sary know how a training and an instruction unit must be executed for staff By order of the operator of the pump station the produ cer supplier will execute this training if necessary Furthermore the operator has to assure that the content of the manual is fully understood by the staff Herewith an instruction record must b
8. e equipped with an exterior cutter Functional requirement does not include any shielding Therefore do not stay in danger zone of rotating parts and allow sufficient safe distance Do not reach into the cutter head or suction area of the pump Working on the pump is only allowed while the electricity is disconnected and moving parts have fully stopped rotating Pump should only be put into ope ration in installed condition and not outdoor During maintenance and repair work consider the sharpness of the edges Danger of heavy weight stability of unit parts Hold the pump only at the handle and slowly discharge it into the ready mounted construction hole Caution with the parts while lifting and mounting Dangerous to Health Personal Protective Equipment The effluent unit delivers fecal wastewater containing substances which might be dangerous to health Avoid any direct contact of waste water or contaminated unit parts with eyes mouth or hands while working at the unit In any case of direct contact the corresponding body part must be immediately carefully washed and as the case may be disinfected Furthermore the atmosphere in the construction hole may be dangerous to health Switch on Start off operation of the pump Prior to operation check the conditions on site Avoid dry running the pump Do not allow the machine running in dry run or slurping operation at any time that is cutter equipment rotor disc and pump box must be flooded unti
9. e kept Danger caused by voltage This station contains voltages and controls rotating mechanicals parts of the station Disregarding the instruction handbook may result in major property damage injury or even fatal accident Prior to all works at the unit it must be disconnected from the power supply system network Main switch and cut outs must be disconnected AN which means a de energized connection and protection against a restart Do cut outs exist these must be disconnected and indicated with a reference note so third party is not able to restart the main fuse The VDE 0100 applies to all works at the electrical unit The unit provided with a earth fault circuit equipment equipped with a design error current of not more the 30 mA Do not open the switching tool as it is under voltage Only skilled personnel for electro is allowed to execute work at the electrical equip ment VDE 0105 gives a definition what is to be considered as a skilled person for electro according to the regulations It must be guaranteed that all parts of the electrical unit are in perfect condition In case of damage the unit should not be put into opera tion by no means and respectively switched off immediately Electrical wires should be installed so they cannot be buckled and are non tensioned ik KESSEL Safety Instructions Possible risk of burns for Hands and Fingers During operation the prime mover may develop a high temperature The pumps ar
10. ge Pe tesiaain asian cele ote E vasiaereb acu lappa E E ES page APNE ar ne pois EAE nares oe area A A caries A A page E EE E EAE E E AE ootasttes aes A sess shoe T page O O O N N _ 12 12 12 12 13 13 14 15 AC KESSEL 1 1 Application This system is designed for pumping waste water with or without raw sewage Impor tant is that sufficient water is always availa ble pressing the water savings flush on toilets is not recommended Important The KESSEL Aqualift F Wastewater Station is not for use with flammable or ex plosive liquids The system should only be used for the macerating of sewage toilet paper and gray water The warranty of this product does not include damage to the sy stem caused by the pump intaking banda ges tampons cotton swabs razor blades moist towels cotton hair soonges plastic bags washclothes diapers or other objec ts The pumping of solvents and thinners is also not allowed It is recommended that the warning sticker shown below is placed in the proper visible area to prevent improper iki KESSEL items entering the drainage system Con densation fluids from furnaces heaters should be neutralized or adequately diluted with water BZN w eE 1 2 System Description The KESSEL Aqualift F Wastewater Station is a lifting station with an unmatched power to size ratio Through the use of high end permanently resistant plastics the sys
11. increased water level caused by failure of the pump In addition a remote con trol signaller must be installed 2 4 Installation of the pump To avoid damage during transporting the pumps are packed separately Check whether the sewage station is free of solid contamination and building material Whe reas this is not the case the complete equip mentis to be cleaned Prior to installtion clea ning of all sealed surfaces is essential Insert the pump into the pump slab and fix it with the help of the two lock staples safety hook Fix and lock the rotatable connection with the one hand fastener see picture 5 Assure a back up of 1 m minimum for the length of the tube for installation to allow to lift out the pump and put it on the tile flooring for main tenance service A Caution Check after installation whether the pump is mounted sta tionary As there are existing two versi ons please follow further proceedings a Aqualift F Mono with float After installation the float has to be inserted into the separate opening Pull the cable to gether with the plug through the cable con duit The unit is ready for operation as soon as the power supply is available AC KESSEL 2 Installation b Aqualift F Tronic Duo Pull the transparent tube of the already in stalled pressure sensor through the cable conduit Pay attention to a unbuckled and permanent rising of installation In addition the optical sensor a
12. l minimum submersion depth at all times The pump builds up a discharge pressure overpressure iki KESSEL Table of Content General Installation Operation Treatment Maintenance Specifications Assistance in case of failure Accessoiries Spare Parts Guarantee raat E T E E E oe tse teen A TERE A E A page Description of OM ssscshsissestesnysscmnnenicactesnstccanesnigigyedaeeeebteabsnet heweatetsactaeries page Installation in floor slab vacssesedsansasantaneddaddansdasdeessereidassiatiecvsdiasniasabednndes page Deepened installation into the floor slab c cssseeeeeeeeeeeeeeeeeeees page CONNECHOTFS sacacsansasseece seccaeaatinccecte pcscnianesecb cent eadeatec edaeiecoadentes tadese sees page Installation of PUMP ain cates eiceencentaeatnosincavaccinechsdaiaextssetuerindsuteniaiadasines page Installation into pressurised water c ccsseeeeeeeeeeeeeeeeeeessnaeees page Installation rECOMMENCALTION ccccccccceseesseeeeeessssseseeeeeeeeeeeeeeeneegs page PEREN EAE AEA clita owt cctv cide E E E A E E page KOMOVI E E ER EEEE EA EEEE EEEE page MENS MNO a E E E ot E E E A A E A page SEENE IES o E E eso E E E E E E page Maintenance with integrated backwater valve n s page Removal of pressure Sensor ccceeeeeeeesesesssteneeseeeeeeeeeeeeeeseeseneeas page Sede DANING G asra a EE EEE page Performance DiagramS a5 se ctecetopeccet e eacce sep eceeetereucese cictenemiceeteiene pa
13. larm device is to be ins erted into the designated opening Hereby the purple sealing plug is to be removed The Tronic version is ready for operation as soon as the cables are connected to the con trol unit according to the instructions given in the manual Refill the vessel with water and proof check iki KESSEL the functions of the floating switch respec tively the pressure sensor 2 5 Installation in concrete slabs sub ject to high groundwater moisture gasket set Article Number 83023 In case of installation in concrete slabs sub ject to high groundwater moisture the KES SEL wastewater pumping station can be ea sily and unproblematically sealed Herewith a seal sheeting is clamped between the coun terflange made of polymer and at the inte grated compression seal flange of the carrier and bolted with the attached screws Any on site used sealing foil is acceptable For in Stallation into a water resistant sump pan KESSEL offers an additional matching sea ling sheet made out of natural latex material with counterflange Here the drill holes for bolting are already stamped out Article Number 83023 see picture 6 If it is necessary to make an opening for ex ample into the concrete sump pan for the ac cess of the inlet cable conduit access and so 10 on these interpenetrations must be executed so watertightness is guaranteed Gasket set 83023 seal flange 2 Installation 2 5 Installation
14. ng unit ventilation unit pressure access pressure sensor ik KESSEL 5 Technical Dates 5 1 Dimensioned drawing O Wastewater Aqualift F Mono undergro und single unit with removable pump in cluding floater Article 28300 2 Wastewater Aqualift F Tronic under ground single unit with removable pumpe including SDS switch unit self diagnosis system Article 28350 3 Wastewater Station Aqualift F Duo underground double unit with two remo vable pumps including SDS switch unit self diagnosis system Article 28330 iki KESSEL 14 5 Technical Dates 5 2 Performance diagram Maximum delivery Q m3 h 0 0 3 0 5 0 6 5 7 8 9 0 10 0 Pumping head H m 8 0 7 5 6 8 6 0 5 00 4 0 2 8 Pumping head H mWS O N A O0 CO O 0 1 2 3 4 5 6 7 8 9 10 Delivery m3 h 00 0 W AC n 1000 W Paper erma eeye sar 230V 53A foo 4 2800 min ntegratea 53730 Allowed ambient Eene 0 50 C Maximum wastewater temperature up to 40 C AC KESSEL 15 6 Assistance support in case of Failure T Ki ia Pump is not running B no mains power supply check main power B mains cable damaged check fuse box B defective float switch or repair only by KESSEL pressure control unit customer service check float switch or pressure see chapter 4 5 or repair by KESSEL customer service B ventilation pipe clogged clean ventilati
15. on drilling Rotor blocked contamination solid and coarse material are cleaning of pump jammed between rotor and suction flange Reduced delivery B wearing of the suction flange cleaning of pump B wearing of the rotor cutting unit Replace suction basket impeller B ventilation pipe clogged cutting assembly clean ventilation pipe Pump is running although no gt defective leaking non return flag exchange non return flag wastewater is entering system B pressure switch clogged clean pressure access B gt defective blocked float switch inspection of tightness for all parts of the unit iki KESSEL 16 7 Auxiliary Equipment Spare Parts Position 2 Nomes 29802 Upper section 400x400mm 220mm height 83061 Upper section gasket 173 028 eb Sewage pump without oat switch 298 020 e Noemie TG 8 Pump connec Miro 10 Ventilation pipe 5 meter only for Tronic models fi Safeylock O 2 Sensor SSS 80S Bo Seeing oa 288 008 Pressure switch only for Tronic models Length 310 mm models up to March 2010 298 046 Length 250 mm models from April 2010 298 091 415 Odour trap 47200 Lo Battery 2 required only for Tronic models 197 081 In the case that the control unit up to model Rev 6 4 is replaced with a new control unit the 250mm long pressure switch should be used iki KESSEL 17 1 In the case that a KESSEL product is de fective KESSEL has the option of repairing or replacing the
16. product If the product remains defective after the second attempt to repair or replace the product or it is economically un feasible to repair or replace the product the customer has the right to cancel the order contract or reduce payment accordingly KES SEL must be notified immediately in writing of defects in a product In the case that the de fect is not visible or difficult to detect KESSEL must be notified immediately in writing of the defect as soon as it is discovered If the pro duct is repaired or replaced the newly repai red or replaced product shall receive a new warranty identical to that which the original defective product was granted The term de fective product refers only to the product or part needing repair or replacement and not ne iki KESSEL cessarily to the entire product or unit KESSEL products are warranted for a period of 24 month This warranty period begins on the day the product is shipped form KESSEL to its cu stomer The warranty only applies to newly manufactured products Additional information can be found in section 377 and 378 of the HGB In addition to the standard warranty KESSEL offers an additional 20 year warranty on the polymer bodies of class II fuel separators grease separators inspection chambers wa stewater treatment systems and rainwater sto rage tanks This additional warranty applies to the watertightness usability and structural so undness of the product
17. r units installed in multifamily housings For single family houses the maintenance servi ce must be executed after six months A visual check of the unit site must be executed The unit must be checked regarding sediments and wearing For the following parts a visual check must be executed if necessary the parts of the unit must be cleaned from sediments 4 4 Maintenance of the integrated back flow flap Remove the pump Slightly open the backflow flap and therefore allow the water remaining in the pipe to run back into vessel After dismantling the pump fixing Release of the recessed head screw the backflow flap 13 can be taken out and be cleaned This way an unobstructed access for cleaning of the pressure pipe is possible 4 5 Withdrawl of Pressure Sensor Release the air tube out of the bolting Check free pass to the control unit if necessary re move condensation water Disassemble air tube fixing from pumping slab By opening of the one hand fastener check for contamination Check pressure sensor Disassemble air tube fixing and dip into a provided bucket If the pump is re activated by dipping the pressure sensor than the functionality is granted If this is not the case please contact immediately our customer service Prior to re installation of the pressure sensor into the pumping slab the water must be pumped out of the sump vessel otherwise the setting of the switch points is not correct cutti
18. tem is able to handle household acids and bases ph value from 6 5 to 10 as well as cold and hot water up to 95 deg C for short periods The lifting station consists of a pump with non return flap quick release flange connection vertically adjustable upper sec tion and a 300 kg rated tileable cover with an integrated odour free floor drain For deeper installations in floor slabs the extension section Article Number 83071 should be used KESSEL recommends the connection of a closure valve to the outlet pressure pipe of the system The Aqualift F Wastewater Station is avail able in three models single pump with float switch Article Number 28300 single pump with SDS control unit Article Number 28350 twin pumps with SDS control unit Article Number 28330 2 Installation Important Pump station is to be installed in frost free and dry area Do not immerse cable ends into the water while installation and moun ting Electrical plug connection is to be protected from moisture In case of floo ding danger the mounting of the electrical plug connection should be executed in an area where there is no danger of flooding Prior to installation of KESSEL pump sta tiontion Aqualift F all parts must be checked upon loss during transport 2 1 Installation in slab The pump box is to be levelled up horizontal ly on a granular subbase Insert the enclosed rubber gasketed seal into the recessed gasket area gre
19. used for the PVC ad hesive bond The delivery pipe has to be guided via the local defined backwater level and connected to a ventilated ground collecting line d cable conduit access For installation of the electrical lines and if ne cessary of the air tube for the pressure sen sor a cable conduit on site must be provided see picture No 4 The empty conduit can be installed in the provided cable bushing which is located in the connector To avoid conden sation water the cable conduit must not be sealed air tight 2 Installation The venialtion tube must be in A stalled with a constant increa sing slope to the control unit e Ventilation vent Ventilation vent shall be provided at all times A ventilation pipe must be installed with this system For this pumping system it must be installed at a minimum of a nominal width DN 70 To avoid unpleasant odour it must be gui ded across the roof A fixture access is provided This is sealed by a socket plug Remove it for installation purpo ses For the Tronic option it is recom mended to install the optical sensor prior to the installa tion of the fixture vent tL Ventilation w max deepth 4 cm f Alarm device For installation of the float switch version the alarm device is strongly recommended Her ewith failures during operation will be indica ted p e an
20. varnish 303 For laying of the slabs use p e PCl Carrament Laying of the slab p e using PCl Carra ment special Natural Stone silicion area of application analogue to 1 2 3 Connections a off set inlet connection Fully equipped connection socket according to DIN 100 available The inlet piping must be installed allowing a minimum of 2 fal ling gradient Attention Do not drill the vessel Improper drilling may cause da mage of the inner vessel which may cause leakiness of the pumping equip ment b drainage connection The installation of the drainage connection is only possible after installation of pump accor ding to the instruction in point 2 4 The connec iki KESSEL tion of the drainage function to the sump is exe cuted through the attached drainage connec tion Insert the drainage connection into the pre setted wall chase and lock it with the single hand quick release fastener Using a stormwater tight cover plate auxiliary equipment the wall chase must be closed using the provided sealing plug Depending on the inlet depth mortise depth of upper section the drainage connection can be trimmed to the particular length see picture No 3 c pressure conncection Pressure connection 1 male thread The pressure pipe set Article No 28 040 includes a 5 m pressure pipe tube DA 40 and an adapter with a pipe clamp Alternati vely a pressure pipe diameter 40 mm mini mum 38 mm can be
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