KESSEL – Pumpstation Aqualift F / Aqualift F Duo
Contents
1. Table of Contents 1 Safety precautions page 4 2 General 2 1 Application Installation page 6 2 2 Aqualift F description page 6 3 Technical Data 3 1 Explosion proof pumps according to ATEX page 7 3 2 Switching levels page 8 3 3 Electrical control unit page 8 4 Installation 4 1 Installation page 11 4 2 Pipe connections page 15 4 3 Installation of the submersible pump s page 16 4 4 Setting the float switches page 16 5 Electrical Connections 5 1 General instructions page 17 5 2 Mounting the control unit page 17 5 3 Information concerning explosion protection page 17 5 4 Installation cable connection page 17 5 5 Impeller Motor rotation page 20 5 6 Motor protection switch page 20 5 7 Pump configuration control page 20 5 8 Completion of electrical work page 20 6 Commissioning 6 1 General instructions page 21 6 2 Description of operation page 21 6 3 Operational test page 22 7 Inspection and Maintenance 7 1 Pump page 23 7 2 Control unit page 24 8 Problems and Solutions 8 1 General problems page 25 8 2 Irregular level conditions page 26 8 3 Disturbances Internal controls page 27 8 4 Failure warnings page 28 8 5 Alarm warnings page 28 8 6 What to do when page 28 9 Control Unit 9 1 Control unit for single pump page 29 9 2 Control unit for double pump page 32 10 Replacement parts page 35 11 Warranty page 36 1 Safety precautions General Safety Precautions During installation operation mainten2. 200 EXT 280 320 360 400 440 480 520 seo 600 640 The pump stop delay time can be custom set by adjusting the S603 switch This can be set between 0 5 and 8 seconds in 0 5 second increments tolerance 0 1 seconds se To 2s ts sto 7 ef otaleatc o e e e fos RA 15 20 25 sofas ao as so ss eoles ro 75 eo Before making any of the above adjustments make sure to disconnect the Aqualift F from its power source Any setting changes should be handled by a licensed professional and should be documented in this User s Manual Make sure that the pump control switches Hand 0 Auto are switched to the Auto setting 5 8 Completion of electrical work After all electrical work has been completed on the Aqualift F or the control unit make sure replace the cover and the transparent cover of the control unit IE 20 6 1 General instructions Please follow DIN 1986 Part 31 when commissioning pumps lifting stations Caution Before commissioning the Aqualift F make sure that all inlet pipes as well Aqualift F storage chamber and the pump is free from metal sand or any other potentially damaging debris Only place the Aqualift F into operation after it has been thoroughly checked to assure that installation and pipe and electrical connection have been properly made Make sure that all closure valves are fully open before starting Important the commissioning of the Aqualift F must be handled by a lic
3. Power connections grey double inlet jack Motor U T1 Protection Motor V T2 Protection Motor W T3 Protection Motor double pump unit Motor PE Power connection quadruple power jacks Motor U T1 protection Motor V T2 protection Motor W T3 protection 12 IE 10 4 Installation When the shipment arrives please inspect it immediately for damages which may have been caused during transport shipping The delivered shipment should include the following KESSEL Inspection Chamber delivered in sections for assembly on site Sewage pump s Electrical Control Unit Caution The base of the inspection chamber as well as the pumps and chamber cover each way over 30 kg Be sure that appropriate personel and equipment e g safety shoes back support etc The pumps should be placed into the chamber after the chamber is installed and lowered into the chamber only with an appropriate winch lowering assembly Important After the receiving the Aqualift F but before installation it is important that the control unit is stored in a dry frost free area until time of connection The cable ends of the float switches must not come in contact with water while they are being stored Caution Danger of slipping While enterring or working in or around a chamber the danger of slipping is always present Due to this it is mandatory that a second worker always remains outside of the chamber to aide observe the other Cautio
4. Pump Off foat switch does not shut off the alarm warning will be activated when the wastewater level rises above the Pump On level The pump will turn off when the wastewater level falls below the Pump On level Pump On float switch which does not shut off The alarm will activate and the pump will start when the wastewater rises above the Alarm On level Pump will turn off when the level falls below the Pump On level Pump On float switch which is stuck in the On position A warning will be displayed after the wastewater falls below the Pump Off level The pump will now turn on only when the wastewater level has risen above the Alarm level and will turn off after the level falls below the Pump Off level The warning can be cancelled by pressing the Alarm Reset button after the float switch has been repaired Alarm float switch is stuck in the On position A warning will be displayed after the wastewater level has fallen below the Pump On level the warning will be a continuous non stop warning During this situation the pump will start when the wastewater level has risen above the Pump On level and will stop after the level has fallen below the Pump Off level Double pump Aqualift F Pump Off float switch which does not shut off In the case that the Pump Off foat switch does not shut off the alarm warning will be activated when the wastewater level rises above the Pump 1 On level Bo
5. Reset button once the internal signal will be cancelled By pressing the Alarm Reset button twice the Temperature B will be erased 8 4 Failure warnings Failure warnings will occur by e the activation of the failure relay and the connected warning device display of the type of failure by LEDs on the control unit resulting from Single pump units Double pump units Phase rotation problems Phase rotation problems Motor protection switch Pump 2 MSS Temp Motor temperature Pump 1 MSS Temp Running times level Running times level 8 5 Alarm warnings Alarm warnings occur from the activation of the Alarm relay and the connected warning device the internal signal Two situations can result in an alarm warning 1 The wastewater level inside the chamber rises above the level of the Alarm float switch The internal audible alarm can be turned off by pressing the Alarm Reset button As soon as the wastewater has fallen below the Alarm float level both alarms signal and relay will be cancelled 2 lf a loaded battery is placed in the control unit an audible alarm will be activated in the case of a power failure This audible alarm will continue for up to 3 hours depending on the power in the battery This alarm can be cancelled by pressing the Alarm Reset button 8 6 What to do when The motor protection switch is activated Open the transparent cover of the control unit and press the START butt
6. authorized professional and should include the following e Visual inspection of the pump and the pump pump housing chamber e Check for obvious wear and tear and build up of deposits on the pump Connection cables should be inspected for damage e Closure valve to be tested to assure function e Inspection chamber checked for leaks and for any build up of deposits Scheduled maintenance should be scheduled as follows v Units in commercial application should be maintained every 3 months v Units in residential multi family homes should be maintained every 6 months v Units in single family homes should be maintained every year 7 1 Pump Caution Take caution when lifting or moving the Aqualift Additional help or a lifting device may be needed to safely remove the pumps from the chamber For general maintenance it is recommended after the power source to the pump is disconnected that the pump is removed from the chamber placed on a firm surface and cleaned for example using a garden hose Only the inspection and maintenance work described in this section should be undertaken no other work is recommended 7 1 1 Seals water tightness The seals on the rotor shaft should be inspected after the first 500 hours of pump use After this initial inspection the seals should be checked every six months or after 1000 hours of operation whichever comes first The seal on the rotor between the motor and the pu
7. be accomplished with specials cable sealing inserts or with special expansion foams The ventilation pipe serves to compensate vacuums or pressure build ups which can occur inside the Pumpstation as it is filled with wastewater or as wastewater is pumped out of the system Since these systems are normally installed close to the building which they serve it is recommended that the Pumpstation s ventilation pipe be run to the roof of the building this will prevent odor nuisances in the future If the opportunity exists the Pumpstation s ventilation pipe can be connected to the building s existing ventilation pipe The Pumpstation is shipped with installed inlet and ventilation port inlets including gaskets These should be used for connection of the inlet and ventilation pipes These gaskets should be lubricated before KG inlet and ventilation piping is attached The outlet pressure pipe connected to a private or public sewer system should be connected to the supplied outlet using PN 10 PEHD DN 50 OD 63mm or DN 80 OD 90mm piping This connection can be made by welding the plastic together or by using appropriate heavy duty couplings It is important that this outlet pipe be plumbed over the local backwater height and then down into the private or public sewer A direct solid connection from the pressure pipe outlet to the building should not exist this will prevent noise vibrations being transferred to the building i Pa Kabelleerro
8. ignition protection type pressure protection encapsuled Leistungsdiagramm 35 Power Curve Qmn nach DIN 1986 ven 0 7m s f r DN 50 f r DN 80 30 F rderh he m 25177 20 TPF 120 KE IT F rderstrom Q 0 vum AU S SSA NIE SS D BRA Ham N mama SE SSA PTA S SA BAR ZUR MIR ME ST mm S SED mem SA S SS MIR ZUR BER SS SE BA S S mama mar oa 0 5 10 15 m 1 2 4 l s IK 3 5 Im h 4 Technical data 3 2 Switching levels Separate power source with blue cables and float switches Chamber 800 Chamber 1000 Pumping Vol I Height difference Pumping Vol I Height difference cm cm Single Pump Unit Off On 100 18 180 18 On Alarm 110 20 200 20 Double Pump Unit Off On1 180 18 Oni On2 100 10 On2 Alarm 100 10 The alarm levels are at the approximate level of the inlet 3 3 Electrical control unit with separator power source according to ATEX 3 3 1 General technical data Required Fuse max 16 Amp phase sourced on site 3 3 2 Protection IP 65 based on appropriate installation and securely closed see thru cover IP 21 without see thru cover and standard wall installation 3 3 3 Appropriate use Information concerning the appropriate use of the control unit in areas at risk of explosion The
9. or replace the product the customer the has the right to cancel the order contract or reduce payment accordingly KESSEL must be notified immediately in writing of defects in a product In the case that the defect 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 product is repaired or replaced the newly repaired or replaced product shall receive a new warranty identical to that which the original defective product was granted The term defective product refers only to the product or part needing repair or replacement and not necessarily to the entire product or unit KESSEL products are warranted for a period of 24 months This warranty period begins on the day the product is shipped from KESSEL to its customer The warranty only applies to newly manufactured products Additional information can be found in section 377 and 378 of the HGB 2 Wear and tear on a product will not be considered a defect Problems with products resulting from improper installation handling or maintenance will also not be considered a defect 01 01 2002 IE 36 Important contacts Info Type KESSEL Order Number Production Date Project description Building services supervisor Address Telephone Fax Planner Address Telephone Fax Contracted construction company Address Telephone Fax Contracted plumbing company Address Telephone Fax Contracted e
10. von 1 63 bis 5 13 Meter KESSEL Pumpstation Aqualift F in 800 Inspection Chamber Installation depths from 1 46 to 1 96 meters KESSEL Pumpstation Aquailift F im Schachtsystem 800 Einbautiefe von 1 46 bis 1 96 Meter IE 14 4 Installation 4 2 Pipe connections All pipes are to be laid with negative slope into the Pumpstation Aqualift F Chamber meaning that fluids will flow with gravity out of the pipe and into the Pumpstation All pipe connections must be flexible connections and be installed with sound dampening accessories The DN 100 pipe connections for the inlets ventilation and cable supply can be made with standard DN 100 KG piping According to DIN 1986 the inlet pipe s must have a minimum 2 slope into the Pumpstations Bends and fittings should be used as little as possible The connection to the DN 100 inlet to the Pumpstation can be made with a female female fitting All electrical cable going to or from the Pumpstation should be installed in one cable supply pipe This cable supply pipe may be used for no other purpose other then running cables Curves Bends in the cable supply pipe should be handled with 30 or 45 degree fittings no 67 or 90 degree bends should be used which could complicate running cables at a later date After all electrical installations have been completed it is important that the cable supply pipe is completely seals against air or waste penetration This can
11. 0 pounds and double pump systems weight approximately 84 Kg approx 185 Kg The Aqualift F units should be handled by at least two people equipped with appropriate equipments e g safety shoes back support Health Safety The Aqualift F is designed to pump wastewater containing untreated raw sewage which can cause health hazards It is important that no direct or indirect contact between the Aqualift F and skin eyes or mouth occurs If contact does occur it is important to immediately wash and disinfect the contaminated area Also in cases when the pump itself is to be removed from the Aqualift F make sure that the room is properly ventilated to allow and methane or biogases to escape or be diluted Noise During operation of the Aqualift F emits approximately 65 5 dB Based on the installation of the Aqualift F this could present an unwanted noise Take care in selecting the installation location of the system A vibration dampening support matt available from KESSEL may be placed underneath the Aqualift F to reduce noise vibration Pump operation Before placing the pump s into operation please observe the conditions on site The use and operation of the pumps must be in accordance with explosion proof regulations A Dry running or semi submersion of the pumps must not occur The cutting blades impeller and pump housing must always be submerged underwater The minimal submersion level must always be maintained The pum
12. 1 Warning Relay Um 253 V Jacks L1 L2 L3 U 400 V 10 less then or equal to 4KW 50 Hz motor protection switch Control unit power circuit passive Control unit and buttons Single pump lifting station Power level circuit in ignition protection characteristics EEx ia IIC IIB Jacks OFF ON ALARM Highest values Uo 15 8 V lo 22 mA Po 86 mW linear curve Maximum effective interior inductiveness and capacities are minimal Eex ia IIC IIB highest certifiable exterior inductivity 73 mH 290 mH highest certifiable exterior conductivity 478 nF 2 88 uF If concentrated capacities capacities exist in the power level circuit the following highest certifiable values should be used Eex ia IIC IIB highest certifiable exterior inductivity 2 mH 5 mH highest certifiable exterior conductivity 420 nF 1 8 uF Double pump lifting station Power level circuit in ignition protection characteristics EExja IIC IIB Jacks OFF ON1 ON 2 Highest values Uo 18 8 V lo 29 mA Po 115 mW linear curve Maximum effective interior inductiveness and capacities are minimal Eex ia IIC IIB highest certifiable exterior inductivity 42mH 2 168 mH highest certifiable exterior conductivity 478 nF 2 88 uF If concentrated capacities capacities exist in the power level circuit the following highest certifiable values should be used Eex ia IIC IIB highest certifiable exterior inductivity 2 mH 5 mH highest certifiable exterior conductivity
13. 1mm 2 x 1mm each licensed professional electrician Schwimmerschalter Float switches Follow VDE and EVU protection guidelines Netzanschlussklemmen Power jacks Control units should not be installed in rooms areas Schutz Protection which present an explosion risks Pumpe Pump Before starting set overload switch to Inenn setting Motorschutzschalter Motor protection switch Check rotation of pumps St rmeldung Warning notice IE 31 9 Control unit 9 2 Control unit for double pump pumpstation Aqualift F 9 2 1 Description of displays and operational button on control unit Normal operation Betrieb green power supply functioning Information for User Alarm level yellow Alarm level reached On 2 level yellow pump 2 on level reached On 1 level yellow pump 1 on level reached Off level yellow Pump off level reached Pump1 green pump outlet 1 activated Pump2 green ump outlet 2 activated Warnings Phase red onstant phase not active Information for Tradesman blinking rotating field problem Pump 2 MSS Temp red onstant Pump 2 motor protection switch activated blinking Pump 2 thermal witch Pump 1 MSS Temp red onstant Pump 1 motor protection switch activated blinking Pump1 thermal witch Running time level red onstant running time ailure blinking level failure Buttons Hand 0 Auto Pump 1 Rotating switch Chooses Pump 1 operating type Hand 0 Auto Pump 2 Rotat
14. 410 nF 1 8 uF IK 3 Technical data Installation Assembly All appropriate local and national codes must be followed e Regulations including safety regs concerning the installation must be followed Also consider the installation and assembly instruction of non ATEX relevant units Maintenance Removal of the see thru control unit cover reduces the water moisture proof effectiveness of the control unit In the case that the control unit is in very moist humid or splash endangered area make sure to disconnect power to the control unit before handling or maintenance work is attempted Removing the cover of the control unit should only be done by a licensed service professional After maintenance is completed on the control unit it is important that the control unit cover is properly closed and secured No changes should be made to the control unit such as removal of the protective see thru cover In the case that the control unit does not function or is damaged please contact the manufacturer elf required date sheets EG certifications User s Manuals and EG conformity certifications can be requested form the manufacturer 3 3 4Control unit outputs Malfunction relay Change over contact opener middle contact closer each with max 2A Alarm relay Change over contact opener middle contact closer each with max 2A Power 2xN max 2A each 2xL1 max 2A each Motor single pump unit Motor PE
15. F v Entry E7 Cable 6 from should be connected on the left in entry E7 remove the bridge if necessary Float switch connections Off On and Alarm gt The cable ends of the float switches are to be connected to their corresponding marked jacks gt No other cables or power sources should be connected in the jacks for the float switches gt The connection jacks are marked with switching symbols Outputs L1 N 230 Volt 50 Hz The L1 and N outputs 2 each are designed for an external extra warning for the Malfuntion and Alarm functions These outputs may not be used for any other purposes Rechargeable battery 6 A NiCd 9V Block rechargeable battery Type IEC 6F22 is to be used inside the control unit The purpose of this battery is to power the alarm and notification devices on the control unit during power outages failures 7 Only remove or replace the battery in the control unit when the power to the entire control unit has been turned off disconnected 8 In the case that a dead or power less rechargeable battery is placed in the control unit the unit will require approximately 36 hours to completely re charge the battery After this 36 hours the battery and the control unit will be fully operational IE 18 5 Electrical connections Cable connections for pumpstation Aqualift F double pump unit Power cable connections 6 Power cables L1 L2 L3 N and PE should be connected to their appr
16. INSTALLATION AND OPERATING INSTRUCTIONS KESSEL Pumpstation Aqualift F Aqualift F Duo For all wastewaters with without sewage For underground sub surface installation ECEE SEE Quick and easy installation due to leigth weight chamber Long life durable due to watertight chamber and resitance to aggressive soils fluids Additional inlets easily connected on site Vertically adjustable and tiltable upper section The installation and service of this unit should be carried out by a licensed professional servicer Company Telephone No Edition 02 2004 HG ID number 010 607 Subject to technical amendment IK This User s Manual should always remain with the Pumpstation Aqualift F Dear Customer thank you for choosing a KESSEL pumping station This entire system has passed a strict quality control inspection before leaving KESSEL headquarters Upon delivery of the lifting station please thoroughly inspect it to make sure that it has not been damaged during shipping and that the delivery is complete In case damage has occurred to the lifting station or the delivery was not complete please follow the instructions listed in the Guarantee section of this user s manual Before the KESSEL Aqualift F Pumpstation is installed and placed into operation please carefully read and follow all of the instructions contained in this Installation Maintenance and User s Manual KESSEL GmbH
17. a The conrol unit is to be installed on a solid wall Screw holes can be drilled using the available template To access the control unit mounting screws first remove the see thru cover The cables for the pump s and the float switches should be run through an empty pipe to the control unit To connect these cables please follow the instructions in Chapter 5 4 Installation Cable connection 5 3 Information concerning explosion protection When connected cables inside the control unit make sure that the cables are connected to their appropriate jacks Float switch cables must be connected to float switch jacks and power and pump cables must be connected to their appropriate jacks Improper connection of cables could damage the system as well as nullify the explosion proof rating of the system 5 4 Installation Cable connection The cables for the pump s and the float switches are 10 meters in length The cables between pumping station and building must be run in a empty pipe as discussed in Chapter 4 2 In the case that the 10 meter cable lengths is not sufficient the cables may be extending following VDE codes Important All electrical cables must be installed so that they do not come in contact with the submersible pump s and are clear of the access steps The cables must also be installed to allow the removal of one or both of the submersible pumps for inspection and or maintenance purposes IE 17 5 Electrical connect
18. ance servicing During electrical installation or servicing of the unit VDE 0100 and all applicable safety regulations should be followed The control unit and pressure sensor switch are electrically powered systems which should not be opened or serviced except by licensed professional electricians Licensed professional electrician is defined in VDE 0105 It is important that all electrical cables and units relating to the Aqualift F are always in good operating condition If damage to any of the electrical cables or systems of the Aqualift F are noticed the Aqualift F unit must be immediately disconnected and taken off line A Danger of hot surfaces During operation the Aqualift F can become hot Take caution before touching or coming into contact with all hot surfaces on the Aqualift F Danger for hands and fingers The Aqualift F pump is equipped with a closed impeller Any inspection or maintenance work must take place after the Aqualift F has been fully disconnected from its power source Also during maintenance and inspection take caution of any sharp surfaces or edges Slip Crush Fall dangers Due to risks during entry into the pumping station chamber it is important that a second party remain outside of the chamber and oversee the person enterring and performing work on the pumping system IK 1 Safety precautions Heavy weight Caution KESSEL Aqualifts with single pumps weigh approximately 45 Kg approx 10
19. ance and repair of this system it is important to follow all appropriate DIN and VDE safety precautions as well as any application precautions in your area Additionally the safety precautions relating to explosion risks in wastewater pumping systems must be followed In danger areas such as pump stations or septic systems it is important that systems with explosion proof ratings are installed Installation and connection of these units should only be handles by licensed professional installers Qualified Personnel Personnel responsible for the operation maintenance inspection and repair of this system must be fully trained and licensed It is the responsibility of the owner or operator of this system to insure that the person s responsible for this system are fully trained and licensed If this is not the case the existing personnel must be immediately trained or replaced with trained and licensed personnel It is also the responsibility of the owner or operator to make sure that the responsible personnel have read through and are completely familiar with this User s and Maintenance Manual Caution The Aqualift F uses electricity to operate rotating and mechanical parts Not following the User s Manual can result in damage to the unit as well as injury or a possible fatal accident Before maintaining or servicing the Aqualift F make sure to disconnect it from ALL power sources and secure that power cannot be re connected during mainten
20. andle continuous inflow of wastewater up to 40 deg C 104 deg F The Aqualift is designed constant usage with wastewater at 35 deg C 95 deg F and can also handle for short durations max 10 minutes temperatures up to 60 deg C 140 deg F 2 2 Aqualift F description The KESSEL Pumpstation Aqualift F in single or twin pump variations is mainly comprised of the following systems Single or double sewage pumps with cutting assembly KESSEL Inspection Chamber 800 or 1000 mm diameter Curve Closure valve Backflow flap Pressure pipe outlet connection PN 10 from PEHD DN 50 Outside Diameter 63 mm or DN 80 Outside Diameter 90 mm Connection for ventilation pipe Connection for power control cables Connection for inlet 10 Float switch 11 Electrical control unit OnahWN ON Illustration shows KESSEL Pumpstation Aqualift F twin pumping unit Options for the KESSEL Pumpstation Aqualift F include Single 1 pump or Twin 2 pumps Pumps with 1 33 kW or 2 66 kW In KESSEL 800 or 1000mm diameter Inspection Chamber Installation depths from 1 5 to 5 meters The closure valve backflow flap outlet pressure pipe and float switch have already been installed in the base of the chamber The pump s additional chamber sections and the electrical control unit are shipped separately packaged with the system The pumps depending on their size are shipped either in the chamber upper section or
21. control unit is designed to operate KESSEL single or double pump lifting stations with the use of float switches The control unit is not to be installed in an area designated as at risk of explosion Classifications I1 1 G Eex ia IIC IIB Group Il Category 1 G designated for us in gaseous atmospheres The requirements of Norms EN 50014 1997 A1 A2 EN 50020 2002 have been fulfilled EG Certification PTB 03 ATEX 2133 Identification I1 1 G EEx ia IIC II CEO123 Ta 0 50 C Installation Commissioning The lifting stations must be installed connected and commissioned by a licensed professional This professional must be trained and certified in areas including types of ignition regulations and work in areas at risk of explosion Check to make sure that the pump classification listed above satisfies the requirements of the installation area Temperatures in the immediate area of installation must be between 0 50 deg Celsius 32 122 def F IK 3 Technical data Electrical data Connections Power supply 3 x 400 Volt AC 50 Hz 10 Jacks N L1 L2 L3PE 230 V AC 50 Hz 10 to supply electronics Um 253 V Based on type max 11 VA Electronic with protection up to max 16 VA Electronic with protection Incoming power Switch contact U 24V I 20mA jacks TF TF1 TF2 E7 E8 E9 E10 based on model PTC switch Um 253 V Exiting power U 230 V 10 2A 50 Hz Jacks N L
22. data to the control unit Temperature level A not recorded The Motortemperatur LED blinks with doule pump units the Pumpe MSS Temp LED blinks when temperature level A has been reached Temperature level B recorded The Motortemperatur LED turns on continuously on with double pump units the Pumpe MSS Temp LED blinks when temperature level B has been reached In the case that temperature level A has been reached the Motortemperatur LED will blink also Pumpe MSS Temp LED with double pump units will blink and the St rung relay will activate Also the control unit will shut down the pumps As soon as the pumps cool down below the specified level the pump will return to normal operation In the case that temperature level B has been reached the Motortemperatur LED will turn on and remain on Pumpe MSS Temp LED will blink with double pump units and the St rung relay will activate Also the control unit will shut down the pumps and this failure will be recorded by the control unit and must be erased by pressing the Alarm Reset button This is only possible when the temperature sensors sense a normal operating temperature In the case of a power outage the Temperature B information will not be recorded In the case that the Temperature B level has been reached and the wastewater level has reached the Alarm level the following can be performed By pressing the Alarm
23. ensed professional Make sure to follow all safety instructions in Part 1 of this User s manual and do not place the Aqualift F in operation if the pump control unit or cables show any signs of damage Important All screws bolts should be tighten to a maximum of 3 Nm 6 2 Description of operation 6 2 1 Auto mode Single pump unit The single pump Pumpstation Aqualift F is in standard operating mode when the control unit switch is set to Auto and no failures or warnings are displayed As the wastewater level inside the Aqualift F storage chamber rises the level will reach the Pump Off level and then reach the Pump On level After the wastewater level has reached the Pump On level and after the pump start delay time has elapsed the pump will begin operation As the wastewater level decreases the Pump Off float switch level will be reached and the motor will continue pumping until the pump stop delay time has elapsed In the case that the pump runs for longer than the set maximum pump run time the pump will turn off and at this time the Laufzeit LED will turn on to let the operator know that the motor has run to its maximum run time The warning will remain until the Alarm Reset button is pressed Pressing the Alarm Reset button will then allow the pump to restart Double pump unit The double pump Pumpstation Aqualift F is in standard operating mode when both control unit pump switches are set to Auto and no failur
24. ent screws quantity 4 After the distance has been set holding screws should be firmly tightened These holding screws should be secured with LOCTITE 242 or WEICON AN 302 42 IE 23 7 Inspection and maintenance 7 1 3 Bearings The bearings are permanently lubricated and are maintenance free However if operation of the motor becomes louder and louder the bearings should be inspected This can be confirmed if the rotor is difficult to turn by hand or when turning the rotor impeller by hand it is noticed that the rotation axis is not exact rotor is not firmly in place 7 1 4 Impeller In cases where the performance of the pump decreases the condition of the impeller should be checked for wear and tear Before placing the Aqualift F Pumpstation in service or if the Aqualift has not been in service for an extended period of time the impeller should be turned by hand to make sure that it rotates smoothly Rillenkugellager Schragkugellager Wellen Gleitringdichtung l bzw motorseitig Wellen Gleitringdichtung produkt bzw f rdermediumseitig 3 N 4 IS 1 1 I___L Befestigungsschrauben V 1 47 Laufrad Sr 4 Stk Innensechskantschraube M6 x 12 Justierschraube ehe 4 Stk Gewindestift M8 x 12 ad Schneideinrichtung mit au enliegendem feststehendem Messer und innenliegender rotierender Schneide _______ Innensechskant 7 2 Control u
25. es or warnings are displayed Alternating operation The pumps in the double pump Pumpstation Aqualift F are designed to operate alternatively After the wastewater inside the chamber reached the pumping height one of the pumps will turn on and pump out the entire contents of the chamber The next time the wastewater reaches the pumping height the other pump will turn on and pump out the entire contents of the chamber If one of the pump malfunctions or is improperly connected the other pump will handle all pumping of the wastewater IE 21 Parallel operation In the case that one pump cannot handle the incoming amounts of wastewater the second pump will also activate when the wastewater level inside the chamber has reached the Pump 2 On level Both pump will then continue to operate simultaneously until the Pump Off level has been reached In the case that one or both of the pumps runs for longer than the set maximum pump run time the pump s will turn off and at this time the Laufzeit LED will turn on to let the operator know that the motor has run to its maximum run time The warning will remain until the Alarm Reset button is pressed Pressing the Alarm Reset button will then allow the pump to restart 6 2 2 O Mode When the switch for a pump is set to the 0 setting this pump will not operate although the warning and failure displays on the control unit will continue to function If both switches are set to O neit
26. g Motor protecting switch has activated and is blocking motor Inspect pump impeller and remove any obstruction Motor turns with difficulty Customer service repair required 1 or 2 phases not receiving power Check fuses and cable connections 2 Pump s run but cannot handle volume of incoming wastewater Too much wastewater enterring system Check incoming wastewater source shut down unnecessary sources or redirect specific sources away from system Pump performance not remove obstruction from impeller satisfactory remove obstruction from outlet pipe make sure backflow flap is completely open Pump s impeller s worn out and need replacement umps too weak to handle Improper specification of system p olumes 3 Pump s run rough or loud and Phase Drehfeld LED does not light Motor Impellers rotating in wrong direction Check rotation switch 2 phases cables of main power cable With double pump system both motors Impellers rotating in wrong direction Switch two phases from the main power cable on control unit Low pump performance due to damage Pump s and motor s to be checked and repaired by customer service if necessary Pump s run rough or loud and Phase Drehfeld LED does not light Motor Impellers rotating in wrong direction Check rotation switch 2 phases cables of main motor power cable 4 Wastewa
27. he wastewater level reaches the Pump 1 On level and the second pump will activate when the Pump 2 On level has been reached Both pumps will turn off after the Pumps Off level has been reached 8 3 Disturbances Internal controls The control unit continuously monitors the signals from the motor protection switches and the motor temperature sensors In the case of a disturbance the pump will either be shut off or prevented from starting This will result in a corresponding alarm and the lighting of an LED 8 3 1In the case that L2 and or L3 fail the Phase Drehfeld LED will continuously light and the St rung relay will activate Since the control of L1 is still active the failure of L1 will not be displayed In the case that the motor rotation is wrong left the Phase Drehfeld LED will blink IE 27 8 Problems and solutions In the operational mode Hand it is possible to run the pump with the incorrect rotation in all other operational modes the control unit will block the functioning of the motor in the case that the rotation is incorrect 8 3 2 In the case that a motor protection switch is activated either manually by a short circuit or by an overload the Motorschutzschalter LED will activate Pumpe MSS Temp LED With double pump systems the LED Pumpe MSS Temp has priority over a motor pump temperature warning 8 3 3 Each motor of the Pumpstation Aqualift F contains two temperature sensors which send
28. her of the pumps will operate 6 2 Hand Mode When the control unit is set to the Hand mode the pump will begin or continue to run regardless of the wastewater level inside the Aqualift F until switched back to the O or Auto setting Attention A pump running without water circulating through it causes increase temperatures and a drastic increase on the wear and tear of the motor Excessive dry running of the pump s above 5 minutes can lead to irreparable damage to the pump s This damage is easily detectable and is not covered under the Pumpstation Aqualift F warranty 6 3 Operational test The functions of the Aqualift F dependant on wastewater levels inside the unit should be tested after installation by filling up the Aqualift F with wastewater to specific levels Filling of the unit should take place by draining fixtures connected to the unit IE 22 7 Inspection and maintenance Inspection The Pumpstation Aqualift F should be inspected monthly by the owner to make sure it is functioning properly and is water tight Caution Before conducting any maintenance on this unit make sure to unplug the entire unit from its power source All of the inspection and maintenance instruction listed below should be handled by an authorized service professional Repairs should only be handled by the manufacturer Maintenance DIN 1986 31 should be followed when maintaining this unit Maintenance should be handled by an
29. hr Anschlu DN 100 Entl ftungsleitung Anschlu DN 100 ich DIN 1986 ber die ne gef hrt werden tau IE 15 4 Installation 4 3 Installation of the submersible pump s Caution the Aqualift F submersible pumps weigh between 49 and 59 kg These pumps should only be lifted and installed in the Pumpstation using appropriate lifting and pully devices If an installation or maintenance worker needs to enter the Pumpstation there should always be at least one observer who remains outside of the chamber Before installing the submersible pumps s check the inside of the Pumpstation to make sure it is free of any debris or waste Once the chamber is cleaned the pump s should be lowered with the aide of a mechanical lowering device pulley onto the steel guide bars and to the bottom of the chamber making sure that the pump s make firm contact with the bottom of the guides Remove the lowering chain from the pulley and attach it to the hook located in the upper section of the chamber Important After installing the pump s make sure that the closure valves are in the open position lever should be in the vertical position 4 4 Setting the float switches Single pump unit This Pumping station is equipped with one submersible sewage pump The system is controlled by 3 float switches The function of these 3 float switches are Pump OFF Pump ON and ALARM The float switches have been installed and set at the facto
30. ing switch Chooses Pump 2 operating type Alarm reset button Turns off alarm from level switch Turns off level failure alarm Turns of motor temperature alarm Motor protection switch 1 switch Activated when pump overloads Motor protection switch 2 switch Activated when pump overloads The control buttons can be accessed by removing the transparent cover of the Aqualift F control unit The cover should only be removed and the control buttons accessed by a licensed professional During the time that the transparent control unit cover is removed the control units protection class is reduced In the case that a humid condition or splashing water may be present first unplug the control unit before removing the transparent cover e The current for the motor protection switch must be set appropriately according to the requirements of the motor and must not be set or changed by the operator owner Be sure that the transparent cover is properly replaced and secured so that the proper protection class is ensured IE 32 9 Control unit OJ SIOLIOLT I OOLUO PIOLIOL AOLO p OUO I OOO JOI S401 S403 402 NIVEAUE INGANGE A OA 1 2 Jacks for power connection 3 Location for battery available as accessory 4 1Jacks for motor pump 4 2 Jacks for temperature control cables for motor pump 5 Jacks for float switches 6 Jacks for warning and alarm connections Text fro
31. ioning wastewater flowing back into chamber Check and clean backflow preventer replace if necessary Connection between base of pump and outlet pipe not watertight Remove pump check sealing gasket properly replace pump and check for proper connection Replace gasket if necessary 8 Pump s run continuously Foam build up inside system Grease fats coating tank and pump s Float switch set incorrectly or broken Float switches jammed by obstruction or dirty grease Reduce use of dishwashing clotheswashing detergents Completely clean system check source of incoming greases fats and reduce or remove source Check float switch connections clean and remove and obstructions 8 2 Irregular level conditions Problems or failures with the level switches can often be detected by the control unit and be displayed while in the Auto mode If the control unit detects an impossible level switch situation the Laufzeit Niveau LED will begin to blink This can be confirmed and cancelled by pressing the Alarm Reset button if the problem has been fixed or the wastewater level has changed and this impossible level is no longer present Problems with the Alarm closure switch and the opening of the On level switch cannot be detected IK 26 8 Problems and solutions Single pump Aqualift F Pump Off float switch which does not shut off In the case that the
32. ions Cable connections for pumpstation Aqualift F single pump unit Power cable connections 1 Power cables L1 L2 L3 N and PE should be connected to their appropriate jacks grey color jacks located on above level Please see the color coded installation help located near the connection area 2 Itis mandatory that cables N and PE are connected and connected properly 3 The power supply cable to the control unit must be equipped with a main On Off switch 4 Each phase of the main power cable must be equipped with a fuse with a max rating of 16 Amps 5 Improper electrical installation connection of the control unit and or pumps can damage or destroy the control system Motor pump cables e The motor pump cables U V W should be connected to the ABB Sch tze B6 30 10 jacks T1 T2 T3 which are to the left of the motor protection switches The direction of rotation of the motors is to be noted e The PE cable is to be connected to the lower level of grey jacks according to the coded installation help located near the connection area The motor cables must be connected so that removal of the pump s for repair or maintenance is possible Motor temperature sensors v Entry TF Cable 4 from Pump 1 should be connected on the right in entry TF Cable 5 should be connected to the left of entry TF Entry TF Cable 4 from Pump 1 should be connected on the right in entry TF Cable 5 should be connected to the left of entry T
33. lectrical company Address Telephone Fax System operator Address Telephone Fax Other remarks The system operator and those responsible were present during the commissioning of this system Place and Date IE 37 Declaration of EC Conformity according to machine guide line 89 392 EWG of 14 06 1989 and modification guidelines 91 368 EWG of 20 06 1991 93 44 EWG of 19 07 1993 and 93 68 EWG of 22 07 1993 low voltage guideline 73 23 EWG and guideline regarding electromagnetic compatibility 93 97 EWG of 29 10 1993 The producer KESSEL GmbH D 85101 Lenting confirms that the product KESSEL Aqualift F pumping station for underground sub surface installation was developed and produced in accordance with the following norms EN 292 VDE 31001 VDE 0113 EN 55082 2 EN 55011 EN 55014 EN 60335 Lenting 01 01 1999 I B Kessel G Vanetta IE 38 Everything for drainage gt Backwater valves and cleanouts gt Grease separators gt Polymer and cast iron drains gt Oil fuel and coalescence separators gt Volatile liquid traps gt Inspection chambers gt Lifting stations pumps warning and gt Custom projects for industrial control units applications gt Rainwater management systems IK KESSEL 39
34. m the illustrations Motorschutzschalter Motor protection switch Alarm Ein2 Ein1 Aus Alarm On2 On1 Off Niveueing nge Float switch inputs Thermoschutz Thermal switch Ausgang Outlet St rung Warning Alarm Alarm Installationsseitige Vorsicherung Max 25A On site fuse Max 25 Amp BE 33 9 Control unit Text from the illustrations Pumpe Pump St rmeldung Warning Notice Pot freier Kontakt potential free contact Achtung Caution Connection only to be made by a licensed professional electrician Follow VDE and EVU protection guidelines Control units should not be installed in rooms araeas with explosion risks before starting set overload switch to Inenn Setting chech rotation of pumpfs wS av tuvvovwwenc 5su8a 138 UOJ 49194 hod waeiy AL 1U0OY A9la4r4 100 Bbunpisw4ors duyz xew NOEZ Bunp jaw 403g N No uv an EO 2 gt ag T kku Ha ter 42080 DS 58 Hz 12 mA Accumulator nach IEC 6F22 jeweils 3x 1mn 9U 11 mA od Ei nschal tver zoger ung Grenzlaufzert 681 6802 683 Nachlaufzeit Voralarm Schwimmer schalter Accumulator nach IEC Accumulator according to IEC 6F22 Akku Halter Battery housing Einschaltverz gerung Pump start delay time Grenzlaufzeit Max running time Nachlaufzeit Pump stop delay time Alarm Alarm Voralarm Pre Alarm Schwimmerschalter Float switches Ein Aus On Off IK 34 10 Replacement part
35. mp is created by two floating ring seals which have a oil holding chamber between them The condition of the floating seal on the bottom of the pump the pumping medium side can be checked by examining the oil In order to complete this check the two oil outlet plug screws have to be removed see illustration After removing the two oil outlet plug screws the oil can be poured into a clear glass container If the oil is clean and clear then the lower floating ring seal is still in good condition If the oil is milky and cloudy or this chamber contains dirty water then this lower floating ring seal needs to be replaced The replacement of this seal should only be handled by a qualified professional While replacing the lower seal the professional should also check the condition of the above seal If the oil needs to be changed replace with DEA SERA 32 MINOLR 32 or SHELL TELLUS 29 oil The quantity of replacement oil need is 1 6 liters for the 120KE pumps and 1 8 liters for the 154KE pumps 7 1 2 Macerating blades cutting blades The cutting blades of the pump should be checked during the 6 month inspection or if operation of the pump becomes louder The distance between the rotating surface and the cutting blades should be 0 1 to 0 2 mm Setting this distance can be accomplished by loosening the 4 holding screws on the cutting blades and then adjusting the distance between the rotating surface and the cutting blades by using the cutting blade adjustm
36. n Danger of tipping Before the trench hole is backfilled with soil the possibility that the chamber tips or falls is always present Due to this entry into the chamber should only take place after the hole in which the chamber is installed is backfilled 4 1 Installation The base bottom of the hole in which the Aqualift F is to be installed should be prepared with 30 cm even layer of compacted gravel On top of this layer of gravel should be a 10 cm thick evenly compacted layer of fine gravel Now place the bottom section of the pumping chamber into the excavation making sure that inlets outlet ventilation and pipe cable outlets are in the correct location The excavation is then to be backfilled in 30 cm layers with gravel no sharp stones allowed gravel to be group G1 according to ATV A127 Each of these 30 cm layers is to be compacted Make sure to connect any necessary inlets outlet or other pipes before these areas are backfilled In the case that the chamber is to be installed in an area that is subject to rising groundwater the chamber must be protected against floatation To protect the chamber against groundwater the entire lower portion of the chamber including the bottom of the chamber up to a height that is higher than the highest possible groundwater level must be covered surrounded by concrete To help anchor the chamber 10 mm steel anchor rods hooks as seen in the illustration must be installed Einbau Bai
37. nit Text from Illustrations Rillenkugellager Deep groove ball bearing Schragkugellager Bearings slanted Wellen Gleitringdichtung Rotor seals upper motor side Wellen Gleitringdichtung Rotor seals lower medium side Laufrad Impeller Justierschraube cutting blade adjustment screws quantity 4 OlablaBschraube oil outlet plug screws quantity 2 Befestigungsschrauben Cutting blade holding screws quantity 4 Schneideinrichtung Exterior positioned cutting surface and interior positioned rotating cutting 11 The batteries inside the control unit should be inspected at least once per year and replaced if necessary Replacement batteries should be identical to the originals Dispose of old batteries properly 12 The motor protection switch is a wear and tear part and should be checked every year and replaced if necessary Please replace with the identical switch and dispose of the old switch properly 13 Please make sure the see thru cover of the control unit is properly closed and tightened 14 Repairs of the control unit should be undertaken by the manufacturer IK 24 8 Problems and solutions The following problems and solutions should only be checked and handled by a licensed professional serviceman woman 8 1 General problems Problem Reason Solution 1 Pump does not start Control unit switch not on Auto mode Set switch to Auto settin
38. on If the motor protection switch reactivated immediately after being pressed please contact a licensed electrician The Aqualift F no longer reacts to incoming signals for example from the float switches unplug the control unit of the Aqualift F for at least 10 seconds and then plug back in In the case that the Aqualift still no longer response to incoming signal please contact a licensed professional IE 28 9 Control unit 9 1 Control unit for single pump pumpstation Aqualift F 9 1 1 Description of displays and operational button on control unit Normal operation Betrieb green power supply functioning Information for User Alarm level yellow Alarm level reached On 2 level yellow pump 2 on level reached On 1 level yellow pump 1 on level reached Off level yellow Pump off level reached Pump1 green pump outlet 1 activated Warnings Phase red constant phase not active Information for Tradesman blinking rotating field problem Motor protection red Motor protection switch has switch been acitivated Motor temperature red onstant Temperature B E7 Blinking emperature A TF Running time level red onstant running time ailure blinking level failure Buttons Hand 0 Auto Pump 1 Rotating switch Chooses mode of operation Alarm reset button Turns off alarm from level switch Turns off level failure alarm Turns of motor temperature alarm Motor
39. on a separate pallet The pumps are to be installed only after the complete chamber has been completely assembled and installed In order to prevent the build up of dangerous gases in the chamber which can cause an explosion risk the system must be ventilated appropriately IK 3 Technical data 3 1 Explosion proof pumps according to ATEX Type TPF 120 KE TPF 154 KE Power consumption P1 1 33 kW 2 63 kW Power consumption P1 1 05 kW 2 13 kW Operating voltage 400 V DS 400 VDS Frequency 50 Hz 50 Hz Current 2 5 Amps 4 4 Amps Cables 10 m Length 10 m Length 7 x 1 5 mm 7 x 1 5 mm Fuses 3 x 16 Amps 3 x 16 Amps Protection IP 68 IP 68 Wastewater temp 40 C 40 C Protection IP 68 IP 68 Max running time at 40 deg C 640 minutes see settings 640 minutes see settings in chapter 5 7 In chapter 5 7 Pump weight 49 kg 59 kg CE oto2 Il 2G EEx d IIB T4 PTB 03 ATEX 1140 Classifications Operating modes Pump submerged Continuous run S1 Pump not submerged Periodic run S3 25 2 5 minute run 7 5 minute pause with ambient temperature of 40 deg C 104 deg F Pumps with the TES ex identification according to Unit Group Il Unit Category 2G Explosion endangered areas Zone 1 and 2 are designed for installation in atmospheres containing dangerous gases which require the Explosion Group IIB and the Temperature Class T4 Pumps constructed according to this designation comply with the
40. opriate jacks the second row of jacks from the bottom Please see the color coded installation help located near the connection area 7 It is mandatory that cables N and PE are connected and connected properly 8 The power supply cable to the control unit must be equipped with a main On Off switch 9 Each phase of the main power cable must be equipped with a fuse with a max rating of 25 Amps 10 Improper electrical installation connection of the control unit and or pumps can damage or destroy the control system Motor Pump cables e The motor pump cables U V W x 2 should be connected to the ABB Sch tze B6 30 10 screw jacks T1 T2 T3 Pump 1 left Pump 2 right The direction of rotation of the motors is to be noted e The PE cable is to be connected to the upper of jacks according to the coded installation help located near the connection area The motor cables must be connected so that removal of the pump s for repair or maintenance is possible Motor temperature sensors v Entry TF1 Cable 4 from Pump 1 should be connected on the right in entry TF1 Cable 5 should be connected to the left of entry TF1 v Entry TF2 Cable 4 from Pump 2 should be connected on the right in entry TF2 Cable 5 should be connected to the left of entry TF2 Entry E7 Cable 6 from Pump 1 should be connected on the left in entry E7 remove the bridge if necessary Entry E8 Cable 6 from Pump 2 should be connected on the left in entry E8 remo
41. ore changing batteries Schutz Protection Motorschutzschalter Motor protection switch Alarm ein aus Alarm on off Niveaueingange Float switch cabler Thermoschutz Thermal protection Ausgang Output Max St rung Problem Alarm Alarm Installationsseitige Vorsicherung On site fuse Max 16 Amp T lt 30 9 Control unit 9 1 3 Single unit ver den Inbetr 1ebnahme ber str om ausloeser auf Imen s nd nach Vorschriften der VOE einstellen digen Evy richtung der Motoren hutzmassnahmen Or eh prueten schutzschalter 5 den Motor siehe Typenschild Achtung Anschluss nur durch e nen Elektrofachmann explosionsgef aehr deten Raeumen installiert Netzanschluss 400V DS 5 Hz Abs cherung bzu des zu dur chzuf vel Vor Ae 1U0 49134 od wae y 142 UOY 491944 100 Bunp sw 401g duyz xew NOEZ Bunp ew 401s Pumpe 1 4 U OS 50 Hz C u E E Q p a I c uU u 9 N U Zz co SLE I N she he 1 3x Imm E nschaltver z ger ung jeweils Grenzlaufzeit Nachlaufzeit 601 602 623 Schwimmer schalter Stand 05 99 Du EINZ F Text from the illustrations 601 Pump start delay time Pot Freier Kontakt potential free contact 602 Max running time Netzanschluss Power Connection 603 Pump stop delay time Absicherung siehe Typenschild Safety Fuse see Alarm Ein Aus On Off Achtung Caution Connection only to be made by a Jeweils 2x
42. p s may not be placed into operation when people are located in the wastewater storage area of the pumping systems Surrounding conditions lighting Any additional equipment brought into the pumping station such as external lighting or power tools must be equipped with the explosion proof rating Marking codes of explosion proof items such as the pump and control unit are labelled as follows EX 2 1 Application Installation The Aqualift F is designed to pump wastewater with or without sewage collected below the outgoing sewer level up to the sewer level so that it may flow with gravity out of the building and into a septic system public sewer piping Installation examples of the Aqualift F would be single and multi family homes commercial buildings hotels restaurants hospitals schools or similar buildings In circumstances where the interruption of wastewater is not allowed or desired a twin pump system Pumpstation Aqualift F Duo is required for installation The KESSEL Pumpstation Aqualift F is designed for outdoor underground installation Pumps are equipped with cutting blades which macerate all soft objects into smaller pumpable pieces Due to the cutting blades outlet pipes of DN 40 or larger may be connected to the outlet of the Pumpstation Aqualift F Objects foreign to wastewater piping such as utensiles wood plastics should not come in contact with the pump s cutting assembly The system is designed to h
43. peller turns in the wrong direction either switch L1 with L2 or switch L2 with L3 5 6 Motor protection switch The motor protection switch must be set to handle the appropriate power rating listed in Chapter 3 1 of this User s Manual 5 7 Pump configuration control The control of the pump configuration is set at the factory using switches S601 S604 located between the jacks for the float switches and the motor thermal protection entry ports The configurations should be checked to make sure they are properly set The configuration can be set by adjusting the S604 switch 4 way DIP switch each with ON OFF setting Different settings are not permitted S604 1 level controlled OFF OFF S604 2 with OFF level switch OFF OFF S604 3 rotation monitor on ON ON S604 4 anti blocking function on ONON S604 1 level controlled OFF OFF 604 2 without OFF level switch ONON S604 3 rotation monitor on ON on 604 4 anti blocking function ON ON The pump start delay time can be custom sci vy auyu gt ung the S601 switch This delay can be set Lace 2 REVERE Eee foo 02 MOM os oe 1o 12 1a se xe 20 22 24 26 20 20 between 0 and 3 seconds in 0 2 second increments tolerance 0 1 seconds The maximum running time can be custom set by adjusting the S602 switch This can be set between 40 and 640 minutes in 40 minute increments tolerance 4 minutes sez fo fat 2 3 4 rte etatetct ole r tatmini 40 20 120 160
44. professionals should conduct the following electrical connections 5 1 General instructions The control unit for the Pumpstation Aqualift F must be connected to a separator main switch so that if required the entire system can be switched off line All cables enterring the control unit must be secured to the control unit using the supplied plastic strain relief nuts Cable inlet openings into the control unit which are not used must be properly closed Important All electrical cables must be properly secured with tie wraps for example so that in the case that the cable releases from the control unit that the bare ends of the cables do not come in contact with any other cables for example in the case that cable L1 comes out of the input jacks it will physically be impossible for this cable to contact the PELV All local and national safety regulation should be followed If these codes are not strictly followed a danger to people and maintenance worker could exist After any work on the control unit has been completed the see thru cover must be properly secured touch and spray water proof The cable for the control unit especially the float switch cables must be kept separate from the power and pump cables to prevent interference 5 2 Mounting of control unit The control unit for this pumping station is to be installed in a frost free dry and well ventilated area The control unit may not be installed in an explosion endangered are
45. protection switch1 switch Activated when pump overloads The control buttons can be accessed by removing the transparent cover of the Aqualift F control unit The cover should only be removed and the control buttons accessed by a licensed professional During the time that the transparent control unit cover is removed the control units protection class is reduced In the case that a humid condition or splashing water may be present first unplug the control unit before removing the transparent cover The current for the motor protection switch must be set appropriately according to the requirements of the motor and must not be set or changed by the operator owner Be sure that the transparent cover is properly replaced and secured so that the proper protection class is ensured IE 29 9 Control unit 9 1 2 Interior of control unit for single pump pumpstation Aqualift F schematic not dimensioned 602 604 S nene 1 at YI YI OD SCHUTZ AUSGANG MAX ST RUNG ALARM YD INSTALLATIONSSEITIGE VORSICHERUNG MAx 15 1 Holes in interior of control unit for wall mounting with screws 2 Jacks for power connection 3 Location for battery available as accessory 4 1 Jacks for motor pump 4 2 Jacks for temperature control cables for motor pump 5 Jacks for float switches 6 Jacks for warning and alarm connections Text from the illustration Bei Akkuwechsel Ger t spannungsfrei schalten Unplug control unit bef
46. ry The float switches have been set so that the ALARM float switch will activate when the wastewater level inside the chamber reaches the bottom of the inlet pipe level of the pumpstation If other pumping levels are desired the float switches must be changed on site Important is that the ALARM float switch activation point is not set above the inlet pipe elevation and that the Pump OFF float switch is not set too low this will prevent the pump from intaking air Ideally the submersible pump should be totally underwater before pumping begins Double pump unit This Pumping station is equipped with two identical submersible sewage pumps The system is controlled by 4 float switches The function of these 3 float switches are Pump OFF Pump 1 ON Pump 2 ON and ALARM The float switches have been installed and set at the factory The float switches have been set so that the ALARM float switch will activate when the wastewater level inside the chamber reaches the bottom of the inlet pipe level of the pumpstation If other pumping levels are desired the float switches must be changed on site Important is that the ALARM float switch activation point is not set above the inlet pipe elevation and that the Pump OFF float switch is not set too low this will prevent the pump s from intaking air Ideally the submersible pump should be totally underwater before pumping begins IE 16 5 Electrical connections NOTICE Only certified licensed
47. s Replacement part Group Part Number Sewage pump Type TPF 120 KE 185 172 Type TPF 154 KE 185 173 Pressure outlet 90mm OD single pump pressure fitting 185 174 63mm OD single pump pressure fitting 185 238 90mm OD double pump pressure fitting 185 196 63mm OD double pump pressure fitting 185 239 Pump seal 185 183 Lead pipe holder clip end piece 185 216 Lead pipe double holder middle piece 185 264 PEHD holder for lead pipe extension 185 194 Lead pipe sold per meter 185 273 Anti return ball valve 185 179 Ball valve 185 217 Float switch 185 164 Float switch holder clamp 185 169 Steal chain sold per meter 185 182 Hook for chain 185 181 Electical control unit Control unit for single pump TPF 120 KE 185 178 Control unit for single pump TPF 154 KE 185 186 Control unit for double pump TPF 120 KE 185 187 Control unit for double pump TPE 154 KE 185 188 Control unit single pump no motor protection Switch 185 189 Control unit double pump no motor protection switch 185 190 Motor protection switch for TPF 120 KE 2 5 Amps 185 269 Motor protection switch for TPF 154 KE 4 4 Amps 185 270 Protection 185 271 Batteries accessorie 20230 Pump chamber parts see KESSEL sales catalog IE 35 11 Guarantee 1 In the case that a KESSEL product is defective KESSEL has the option of repairing or replacing the product If the product remains defective after the second attempt to repair or replace the product or it is economically unfeasible to repair
48. seatehendem Dr ndvemuner BE 11 4 Installation Installing the chamber seals gaskets Each of chamber sections is connect using a gasket the size of this gasket will vary depending on if an 800 or 1000 chamber is being installed and on the specific section being installed The recessed area for the gasket located on the top of each section as seen in the illustration should be clean and free from all debris sand Firmly place the gasket into the recessed area of the chamber After the entire gasket has been installed grease the gasket with a standard gasket lubricant Insert an access step if desired KESSEL 1000 chambers come standard with access steps steps for the 800 chambers are available upon request BE 12 4 Installation Installing chamber sections Now place the next chamber section on top of the other making sure that the location for access steps are in line with the lower portion The sections are secured with another with the supplied connection clips which should be installed as illustrated A a Installing the vertically adjustable upper sections Firmly insert custom gasket into cone section using hammer if required Grease custom gasket insert upper section and secure with clamping ring Final elevation slope adjustments can be made with the 3 adjustment screws T4 13 4 Installation After the upper section has been set to its final elevation and slope it is important to note
49. ter not being pumped out of system backwater from connected fixtures With double pump system both motors Impellers rotating in System not turn on Switch two phases from the main motor cable on control unit wrong direction Place control unit switch on Auto mode Power cables to control unit not receiving power Check fuses Check power supply Inlet pipe s to Aqualift F blocked Check and clean inlet pipes Inlet closure valves closed or not completely open Make sure any inlet valves or locks are completely open IK 25 8 Problems and solutions 5 System suddenly Operation very loud Phases have been switched accidentally Check rotation and switch rotation if necessary Pump s damage or cutting assembly damage Check pump s and replace any damage parts Foreign object in pump Check pump s impeller s and remove and obstruction 6 Bad odor Pumping chamber has a leak and is no longer water air tight Check chamber inlet outlet cable pipe for leaks Sharp biting odor Motor s operating too hot Check for free rotation of motor s impeller s Pump s starting and stopping to frequently Check with customer service 7 Pump s running too much starting for not reason Incoming volume of wastewater exceeding systems capacity Reduce incoming wastewater volume Aqualift F s backflow preventer malfunct
50. th pumps will turn on when the wastewater level rises above the Pump 2 On level and will turn off when the level falls below the Pump 1 On level Pump On float switch which does not shut off The alarm will activate and both pumps will start when the wastewater rises above the Alarm On level Both pumps will turn off when the level falls below the Pumps Off level Pump 2 On float switch which does not shut off An alarm will activate after the wastewater level has risen above the Alarm level At the same time the second pump will start Both pumps will continue to run until the Pumps off level has been reached Constantly closed Pump 1 On level switch An alarm will activate after the wastewater level has fallen below the Pumps Off level Both pumps will start again when the level reached the Pump 2 On level and will both turn off when the level falls below the Pumps Off level Constantly closed Pump 2 On level switch An alarm will activate after the wastewater level has fallen below the Pump 1 On level One pump will activate after the level rises above the Pump 1 On level and the second pump will activate after the Alarm level has been reached Both pumps will turn off after the level falls below the Pump Off level e Constantly closed Alarm level switch The Level alarm will activate when the Alarm level is activated AND the Pump 2 On level has been reached One pump will activate when t
51. the following e Cobble stone installation in the case that the upper section and cover will be installed in a stone cobble stone surface it is important that the top of the upper section is placed approx 2 cm higher than that of the cobble stones When the cobble stones are compacted the upper section and cover should also be compacted be sure to tighten cover screws before compacting until it is level with the surrounding stones Installation in automobile traffic areas in the case that the upper section and cover will be installed in a surface which is to handle Class D 40 0 metric ton load classes a 18cm thick 2m x 2m concrete support plate must be poured around the upper section The concrete support plate should be steel re enforced and comply with any local regulations A sample drawing of this load support plate is available from KESSEL In some instances it may be required that the lower section of the upper section be sawed off in order to obtain the correct installation depth This cut should be made as evenly as possible and any remaining loose edges should be filed away The included manhole cover removal key as well as the User s Manual for the pumping system should be stored in a protected dry area in the near vacinity of the control unit KESSEL Pumpstation Aqualift F in 1000 Inspection Chamber Installation depths from 1 63 to 5 13 meters KESSEL Pumpstation Aquailift F im Schachtsystem 1000 Einbautiefen
52. ve the bridge if necessary Float switch connections Off On 1 On 2 and Alarm gt The cable ends of the float switches are to be connected to their corresponding marked jacks gt No other cables or power sources should be connected in the jacks for the float switches gt The connection jacks are marked with switching symbols Outputs L1 N 230 Volt 50 Hz The L1 and N outputs 2 each are designed for an external extra warning for the Malfunction and Alarm functions These outputs may not be used for any other purposes Rechargeable battery 9 A NiCd 9V Block rechargeable battery Type IEC 6F22 is to be used inside the control unit The purpose of this battery is to power the alarm and notification devices on the control unit during power outages failures 10 Only remove or replace the battery in the control unit when the power to the entire control unit has been turned off disconnected 11 In the case that a dead or power less rechargeable battery is placed in the control unit the unit will require approximately 36 hours to completely re charge the battery After this 36 hours the battery and the control unit will be fully operational IE 19 5 Electrical connections 5 5 Impeller Motor rotation Before placing the Aqualift F into operation check to make sure that the rotation of the motor impeller is correct An arrow on the pump housing shows the correct direction of rotation If the im
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