ATB AQUAmax PROFESSIONAL G Installation Instruction, Operating And Maintenance Manual

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AQUAmax® PROFESSIONAL G

Installation Instruction

Operating and Maintenance

Manual

Installation, operating and maintenance manual AQUAmax® PROFESSIONAL G

ATB WATER GmbH, Südstraße 2, D-32457 Porta Westfalica, www.atbwater.com / Art.-Nr.: 9060 XXXX / Stand: 08.01.2019 / Seite 2 von 56

Installation, operating and maintenance manual AQUAmax® PROFESSIONAL G

ATB WATER GmbH, Südstraße 2, D-32457 Porta Westfalica, www.atbwater.com / Art.-Nr.: 9060 XXXX / Stand: 08.01.2019 / Seite 3 von 56

Contents

General and safety information ................................................................................................4

Scope of delivery......................................................................................................................6

Functional description ............................................................................................................10

Services to be provided by the customer ...............................................................................12

Float switch ............................................................................................................................13

Tank preparation ....................................................................................................................14

Employment of the AQUAmax

..............................................................................................15

Employment of the charging pump.........................................................................................16

Sampling bottle, clarified water and charging hoses .............................................................. 17

AQUAmax

with pressure aeration (PROFESSIONAL GZB) ................................ 18

Cable connection and test run, closing operations.................................................................20

Check before commissioning .................................................................................................21

The control system proControl

2 ..........................................................................................23

General and safety information..........................................................................................23

Eqipment characteristics / Assembly.................................................................................24

Cycle process ....................................................................................................................25

Commissioning ..................................................................................................................27

Display information / Main menu / Logbook.......................................................................28

Settings..............................................................................................................................29

Service mode.....................................................................................................................31

Manual mode / Info / Date, time.........................................................................................36

Language / Error reset....................................................................................................... 37

List of pre-programmed parameters / current limits...........................................................38

Possible error messages ...................................................................................................39

Technical data ...................................................................................................................42

Terminal Box .....................................................................................................................43

Information on maintenance...................................................................................................44

Self-monitoring by the operator ..............................................................................................45

Information on disposal ..........................................................................................................46

Fault correction.......................................................................................................................47

Operators logbook..................................................................................................................50

Installation, operating and maintenance manual AQUAmax® PROFESSIONAL G

ATB WATER GmbH, Südstraße 2, D-32457 Porta Westfalica, www.atbwater.com / Art.-Nr.: 9060 XXXX / Stand: 08.01.2019 / Seite 4 von 56

Dear customer,

at this point we would like to thank you for the trust which you have shown in us by the purchase of this product.

On the following pages you will find everything necessary about the installation, operation and

maintenance requirements of your AQUAmax

small wastewater treatment plant.

Please note that the careful installation of the wastewater treatment plant and the later maintenance are very important for a good treatment performance.

Regular maintenance is laid down by the authorities. Through the conclusion of a maintenance contract the plant and its biological discharge values are monitored continuously.

General and safety information

With the AQUAmax

one is concerned with a technical system which, together with a multichamber, can be employed as small wastewater treatment plant for the aerobic biological treatment of domestic and comparable wastewater of up to 8 m³/d from individual or several buildings, collected using a separate system. Dimensioning, configuration and operation are to take place in accordance with DIN EN 12566-3 and the approval of the German Institute for Structural engineering (DIBt)!

With employment according to regulations no hazards whatsoever emanate from the plant. If the

AQUAmax

is used for other employment purposes without the express approval of ATB Umwelttechnologien GmbH and/or if the following safety information is disregard, this can lead to the hazarding or injury of persons and to malfunctions of or defects in the plant. In this case every liability is excluded. Modifications to the plant or unauthorised conversions are not permitted.

The AQUAmax

and accessories are not intended to be used by persons (including children) with limited physical, sensory or mental capabilities or without experience and/or knowledge, unless they are supervised by a person responsible for their safety or receive from him/her instruction on

how to use the AQUAmax

and accessories. Children are to be supervised in order that they do

not play with these.

Before use the AQUAmax

is to be installed correctly and in agreement with the installation instruction. Installation instructions, operation and maintenance instructions are to be read careful before assembly and commissioning and the instructions contained therein must be followed implicitly. With assembly and installation, commissioning and operation as well as, if necessary, decommissioning, the customary national standard specifications and provisions are to be observed. All tasks may be carried out by trained and qualified specialists with an appropriate certificate of qualification only. The operator of the plant is to be instructed by the service technician.

With the connection of the control system the national applicable provisions as well as the details on the specification plate are to be observed (mains voltage, frequency etc.). The equipment is to be operated only on network configurations which include a protective earth (PE) conductor.

Attention is to be paid to correct phase connection (even with ready-to-plug configurations)! Connection to the mains must be by means of separate fusing and earth leakage

circuit breaker (ELCB). Before commissioning the faultless function of the electrical safety measures must be checked! Installation tasks are to be carried out by electrically skilled persons only. With work on the equipment the mains plug must be disconnected. A separation or extension of the leads is not permitted. The electrical connection data is to be taken from the specification plate on the equipment.

Installation, operating and maintenance manual AQUAmax® PROFESSIONAL G

ATB WATER GmbH, Südstraße 2, D-32457 Porta Westfalica, www.atbwater.com / Art.-Nr.: 9060 XXXX / Stand: 08.01.2019 / Seite 5 von 56

Do not operate any equipment which has a damaged connection/connecting lead or plug, which exhibits a malfunction, has been dropped or is damaged in any way.

With all maintenance and repair tasks the plant is to be disconnected from the mains. The

AQUAmax

can be removed easily from the pit. If the plant has to be entered then this (fundamentally) may take place only with the presence of a second person. Particular care is to be taken. The applicable accident prevention regulations and the rules of technology are to be observed.

The AQUAmax

submersible aerator feeds the required air to the wastewater through a rapidly

rotating propeller. Never operate in the vicinity of the aerator as long as the AQUAmax

connected to the mains supply. Danger of injury!

Only with the use of original spare parts or with spare parts authorised by ATB can correct function be assured. Before commissioning all points of the operating instructions are to be checked again. Keep these instructions available at all times!

Explanation of the warning notices used:

ATTENTION! Hazard due to electrical voltage!

Rotating parts. Danger of crushing or ingestion in the area of the submersible aerator!

Installation, operating and maintenance manual AQUAmax® PROFESSIONAL G

ATB WATER GmbH, Südstraße 2, D-32457 Porta Westfalica, www.atbwater.com / Art.-Nr.: 9060 XXXX / Stand: 08.01.2019 / Seite 6 von 56

Scope of delivery

ATB goes to great lengths to ensure complete commissioning and product-matching packaging for all equipment and parts supplied. Nevertheless, please check the delivery for transport damage and completeness.

Technical data (all units 230 V AC, 50 Hz):

Submersible aerator AQUA 5: 0,56 kW / 2,5 A

Pumps ATBLift 2: 0,3 kW / 1,3 A FEKA 600: 1,0 kW / 4,3 A

More data for fault

diagnosis s.p. 49

AQUAmax® PROFESSIONAL

GZ 1-16

consisting of:

• 1 carrier frame made of PE/V2A for chain suspension

• 1 submersible aerator AQUA 5

• 1 submersible pump ATBlift 2

as clarified water pump

• 1 submersible pump ATBlift 2

as excess sludge pump

• 1 each float switch for H

W,min

und H

W,max

• 15 m connection cable 7x1,5 mm² with special plug

AQUAmax

PROFESSIONAL

GZ 17-50

bestehend aus:

• 1 carrier frame made of V2A for chain suspension

• 2 submersible aerators AQUA 5

• 1 submersible pump ATBlift 2

as clarified water pump

• 1 submersible pump ATBlift 2

as excess sludge pump

• 1 each float switch for H

W,min

und H

W,max

• 15 m connection cable 7x1,5 mm² with special plug

Accessories, loose:

• 1 control system proControl

230 V, for internal installation

• 1 submersible pump FEKA 600 as charging pump with a separate float switch as protection against dry running

• 1 sampling bottle made of PE with harness

• 5 m PVC-hose Ø 30 mm for discharge

• 10 m PVC-hose Ø 30 mm for charging

• 10 m PVC-hose Ø 30 mm for sludge return

• 1 set securing material

• 1 information plate

Zubehör, lose:

• 1 control system proControl

230 V, for internal installation

• 1 submersible pump FEKA 600 as charging pump with a separate float switch as protection against dry running

• 1 sampling bottle made of PE with harness

• 5 m PVC-hose Ø 30 mm for discharge

• 10 m PVC-hose Ø 30 mm for charging

• 10 m PVC-hose Ø 30 mm for sludge return

• 1 set securing material

• 1 information plate

Installation, operating and maintenance manual AQUAmax® PROFESSIONAL G

ATB WATER GmbH, Südstraße 2, D-32457 Porta Westfalica, www.atbwater.com / Art.-Nr.: 9060 XXXX / Stand: 08.01.2019 / Seite 7 von 56

AQUAmax

PROFESSIONAL

GZB 1-16

consisting of:

• 1 carrier frame made of PE/V2A for chain suspension

• 1 submersible pump ATBlift 2

as clarified water pump

• 1 submersible pump ATBlift 2

as excess sludge pump

• 1 each float switch for H

W,min

und H

W,max

• 15 m connection cable 7x1,5 mm² with special plug

AQUAmax

PROFESSIONAL

GZB 17-32

consisting of:

• 1 carrier frame made of PE/V2A for chain suspension

• 1 submersible pump ATBlift 2

as clarified water pump

• 1 submersible pump ATBlift 2

as excess sludge pump

• 1 each float switch for H

W,min

und H

W,max

• 15 m connection cable 7x1,5 mm² with special plug

Accessories, loose:

• 1 control system proControl

230 V, for internal installation

• 1 compressor JDK-S-120

• 1 submersible pump FEKA 600

as charging pump with a separate float switch as protection against dry running

• 1 sampling bottle made of PE with harness

• 5 m PVC-hose Ø 30 mm for discharge

• 10 m PVC-hose Ø 30 mm for charging

• 10 m PVC-hose Ø 30 mm for sludge return

• 2 tube aerators, 820 mm

• 1 set securing material

• 1 information plate

Accessories, loose:

• 1 control system proControl

230 V, for internal installation

• 1 compressor JDK 200

• 1 submersible pump FEKA 600

as charging pump with a separate float switch as protection against dry running

• 1 sampling bottle made of PE with harness

• 5 m PVC-hose Ø 30 mm for discharge

• 10 m PVC-hose Ø 30 mm for charging

• 10 m PVC-hose Ø 30 mm for sludge return

• 3 tube aerators, 1070 mm

• 1 set securing material

• 1 information plate

Technical data: All units 230 V AC, 50 Hz

Compressor:

JDK-S-120: 0,095 kW JDK 200: 0,18 kW

Pumps: ATBlift 2: 0,3 kW / 1,3 A FEKA 600: 1,0 kW / 4,3 A

Installation, operating and maintenance manual AQUAmax® PROFESSIONAL G

ATB WATER GmbH, Südstraße 2, D-32457 Porta Westfalica, www.atbwater.com / Art.-Nr.: 9060 XXXX / Stand: 08.01.2019 / Seite 8 von 56

AQUAmax

PROFESSIONAL

GZB 33-50

consisting of:

• 1 carrier frame made of PE/V2A for chain suspension

• 1 submersible pump ATBlift 2

as clarified water pump

• 1 submersible pump ATBlift 2

as excess sludge pump

• 1 each float switch for H

W,min

und H

W,max

• 15 m connection cable 7x1,5 mm² with special plug

AQUAmax

PROFESSIONAL

GZB 51-75

consisting of:

• 1 carrier frame made of V2A for chain suspension

• 1 submersible pump FEKA 600 as clarified water pump

• 1 submersible pump FEKA 600 as excess sludge pump

• 1 each float switch for H

W,min

und H

W,max

• 15 m connection cable 7x1,5 mm² with special plug

Accessories, loose:

• 1 control system proControl

230 V, for internal installation

• 2 compressors JDK 200

• 1 submersible pump FEKA 600

as charging pump with a separate float switch as protection against dry running

• 1 sampling bottle made of PE with harness

• 5 m PVC-hose Ø 30 mm for discharge

• 10 m PVC-hose Ø 30 mm for charging

• 10 m PVC-hose Ø 30 mm for sludge return

• 4 tube aerators, 107 mm

• 1 set securing material

• 1 information plate

Accessories, loose:

• 1 control system proControl

230 V, for internal installation

• 2 compressors JDK 300

• 1 submersible pump FEKA 600

as charging pump with a separate float switch as protection against dry running

• 1 sampling bottle made of PE with harness

• 5 m PVC-hose Ø 30 mm for discharge

• 10 m PVC-hose Ø 30 mm for charging

• 10 m PVC-hose Ø 30 mm for sludge return

• 4 tube aerators, 1070 mm

• 1 set securing material

• 1 information plate

Technische Daten: Alle Aggregate 230 V AC

Verdichter:

JDK 200: 0,18 kW JDK 300: 0,23 kW

Pumpen: ATBlift 2: 0,3 kW / 1,3 A FEKA 600: 1,0 kW / 4,3 A

Installation, operating and maintenance manual AQUAmax® PROFESSIONAL G

ATB WATER GmbH, Südstraße 2, D-32457 Porta Westfalica, www.atbwater.com / Art.-Nr.: 9060 XXXX / Stand: 08.01.2019 / Seite 9 von 56

Installation, operating and maintenance manual AQUAmax® PROFESSIONAL G

ATB WATER GmbH, Südstraße 2, D-32457 Porta Westfalica, www.atbwater.com / Art.-Nr.: 9060 XXXX / Stand: 08.01.2019 / Seite 10 von 56

Functional description

The sewage treatment plant operates according to the activated sludge principle in the back-up process (SBR plant). The pollutants from the waste water are absorbed by floating microorganisms (activated sludge) and converted into biomass.

A correspondingly large buffer volume is taken into account for buffering large quantities of waste water that occur at peak times (e.g. hall operation of restaurants on weekends, commercial operations).

The wastewater first enters the coarse trap/sludge storage tank and then into the buffer chamber. At regular intervals, the waste water is pumped into the SBR chamber. When a maximum water level is reached during revival, the pumping process is stopped. When a minimum water level is reached in the buffer tank or after the preset charging time has elapsed, the pumping process is terminated. Aeration occurs intermittently via a submersible motor aerator or a compressor and diaphragm tube aerator. After approx. 6 hours the aeration phase ends and the settling phase begins.

After a settling time of 1.5 hours, the treated wastewater is pumped off with the clear water pump. The switch-off point of the pump is set via a float switch. If this minimum water level cannot be reached due to a pump fault, an alarm is triggered. After approx. 8 hours the cycle ends with the end of the clear water discharge and a new cycle begins.

The system reaches its full cleaning performance after a start-up time of approx. one month. In the case of strong underload or temperatures below 12° C, it can also take longer for the biology to develop completely. In this case it is recommended to inoculate with activated sludge to accelerate this process.

The control system can be adapted to the particular case of need. During commissioning, the system is set to the maximum number of persons connected. It is not necessary to change this setting in the event of a short-time overload or underload.

Economic operation

If no wastewater flows into the system over a period of more than 4 hours, the system automatically switches to energy-saving economic operation. The aeration time is reduced to such an extent that the microorganisms have sufficient oxygen available. Under normal load, the system switches back to the set operating mode.

Installation, operating and maintenance manual AQUAmax® PROFESSIONAL G

ATB WATER GmbH, Südstraße 2, D-32457 Porta Westfalica, www.atbwater.com / Art.-Nr.: 9060 XXXX / Stand: 08.01.2019 / Seite 11 von 56

Sampling

Since the pumping process is of short duration, the purified water is collected in a suitable container in the clear water tank (accessory: 1.5 l sampling bottle). The vessel is placed near the cover and is therefore easily accessible from above. Alternatively, a vessel can also be placed in a separate sampling chamber.

Installation and dimensioning

The systems can be individually dimensioned according to requirements.

Operation and maintenance

Small sewage treatment plants must be checked by the operator at certain intervals and should maintained by a specialist for example twice a year. Both are important for the proper operation of the systems. Depending on capacity utilization, the sludge is removed once a year or as required. The machine technology can be pulled out through the system cover for maintenance purposes.

Application possibilities

The AQUAmax® PROFESSIONAL G is designed for the treatment of domestic wastewater. It is particularly suitable for objects with irregular waste water production, e.g. hotels, restaurants, butcher's shops, etc. For the treatment of waste water from e.g. apartments, other ATB sewage treatment plants can be used. The system must not be supplied with: commercial waste water (if not comparable with domestic waste water), external water (e.g. drainage water), cooling water, discharge water from swimming pools, rainwater.

Modular system

Phosphate removal and UV disinfection can be retrofitted.

Installation, operating and maintenance manual AQUAmax® PROFESSIONAL G

ATB WATER GmbH, Südstraße 2, D-32457 Porta Westfalica, www.atbwater.com / Art.-Nr.: 9060 XXXX / Stand: 08.01.2019 / Seite 12 von 56

Services to be provided by the customer

• The tanks are offset at the appropriate height and watertight.

• A watertightnesss test has been carried out and concluded successfully. For this, the

installation instructions of the tank manufacturer are to be observed.

• All chambers of the plant are accessible to persons (clear openings of at least 600mm diameter).

• A fully functioning aeration and ventilation of the plant must be assured. In normal cases this takes place via the roof ventilation and a cover with ventilation openings in the (last) tank or ventilation in the run-off pipe. The correct operation is to be documented and verified.

• The run-off pipeline is connected to the manhole and reaches ca. 15 cm into the shaft (do not cut off at the manhole wall).

• Behind the wastewater treatment plant is located a further distributor, control or percolation shaft. If this is not the case then a possibility for sampling is to be installed in the SBR tank.

• Should the buffer tank be divided into several chambers, then the partition wall must have openings at the bottom.

• A 230 V power line is laid to the location of the control unit and is fused separately as follows: B 16 A, and 25 A / 30 mA earth leakage circuit breaker (ELCB).

• Between the control unit and the wastewater treatment plant there are laid one (buffer and SBR in one tank) or two (buffer and SBR in separate tanks) cable conduits (≥ DN 100). There may be no bends laid with a greater curvature angle than 30°! The cable conduits are to be sealed odour-tight.

• Pull wires are included in the conduits. The maximum distance between control system and

AQUAmax

or buffer for the ready-to-plug variants is 35 m (for plants with compressor aeration

[GZB] 12 m).

• The tank is free of wastewater and cleaned.

• The AQUAmax

incl. accessories are on the construction site at the start of assembly.

• The inlet pipeline is connected to the primary settling stage. With retrofitting this, as a rule, has been laid (if necessary please take note of the project sketch).

• The connection pipeline between primary settling stage, buffer and aeration stage is carried out in DN 150. There may be no bend laid with a greater curvature angle than 45°.

Installation, operating and maintenance manual AQUAmax® PROFESSIONAL G

ATB WATER GmbH, Südstraße 2, D-32457 Porta Westfalica, www.atbwater.com / Art.-Nr.: 9060 XXXX / Stand: 08.01.2019 / Seite 13 von 56

Float switches

Open float switch

= 0 in the status display

(Float switch has dropped)

Closed float switch

= 1 in the status display

(Float switch has floated up)

ATTENTION! Switching action is noticeable through a distinct "clack". The switching situation changes relatively late (ca. +/- 50° related to the surface of the water), so that an apparently floated up float switch can still be open or an apparently dropped float switch can still be closed. Take note of status indicator!

Switch-OFF point (H

W,min

), all types

The switch-OFF point of the float switch, with all types, is located at the height of the partition edge between upper and lower part of the aerator housing. The difference (= H

W,min

) between this

point and the tank sole may not be undercut.

Please take the values for H

W,min

from data sheets

or the technical clarification calculations.

Installation, operating and maintenance manual AQUAmax® PROFESSIONAL G

ATB WATER GmbH, Südstraße 2, D-32457 Porta Westfalica, www.atbwater.com / Art.-Nr.: 9060 XXXX / Stand: 08.01.2019 / Seite 14 von 56

Tank preparation

A watertightness test must be carried out!

The openings between the primary settling chambers must remain.

Openings and jointing between primary settling stage and buffer or SBR as well as between buffer and SBR are to be closed and sealed.

It must be ensured that an emergency overflow (> 40 cm²) exists between buffer and SBR tanks.

Install T-piece for the overflow between (last) primary settling chamber and buffer tank as well as for the runout. The level should lie at one height

For the cable feed, plan one (buffer and SBR in one tank) or two (buffer and SBR in separate tanks) openings (≥ DN

100) per tank.

Installation, operating and maintenance manual AQUAmax® PROFESSIONAL G

ATB WATER GmbH, Südstraße 2, D-32457 Porta Westfalica, www.atbwater.com / Art.-Nr.: 9060 XXXX / Stand: 08.01.2019 / Seite 15 von 56

Employment of the AQUAmax

Please note with all connection work, that cables and hoses are long enough so that the AQUAmax® can be removed from the plant without problem. Furthermore, it is to be ensured that no cable is loaded under tension.

The stainless steel hooks provided are to be so fixed

to the tank cover, that the AQUAmax

is positioned as far as possible in the middle of the tank. See to it that the pipeline outlets for sludge and clarified water point approximately in the direction of the corresponding inlet and outlet pipelines (the outlets have limited capability for rotation).

Now hang the AQUAmax

to the chains provided so that the difference between the switch-OFF point of float switch SW1 and the tank sole must correspond at least with the value for H

W,min

from data sheet or technical clarification calculation. With this, the slope of the tensioned chain should not be more than 45°.

Float switch SW2

Mount a further stainless steel hook above the SBR tank. Form a loop from the cable of the float switch for the maximum water level in the SBR tank [H

W,max

/ SW2] with the aid of 2 cable straps. Following hanging up, the difference between the switch-ON point of the float switch and the switch-OFF point of the float switch for H

W,min

[SW1] must at least correspond to

the difference between H

W,min

and H

W,max

from technical clarification calculation/data sheets. Please do not forget the float weight (mount ca. 10 cm in front of the cable screw connection).

Please see that the switch-ON point of SW2 in each case lies below the outlet!

Installation, operating and maintenance manual AQUAmax® PROFESSIONAL G

ATB WATER GmbH, Südstraße 2, D-32457 Porta Westfalica, www.atbwater.com / Art.-Nr.: 9060 XXXX / Stand: 08.01.2019 / Seite 16 von 56

Employment of the charging pump

Mount a stainless steel hook above the buffer tank.

Prepare the charging pump with angled hose nozzle, PVC hose (40 mm) and chain. The chain is already secured to the pump handle using a shackle. The float switch is also attached to the handle using two cable clips. The switch-OFF point should lie approximately at the height of the centre of the pump. Please take care that the float switch moves freely upwards and downwards and cannot jam. For better handling hose, chain and cable are fixed using cable straps. Hang the pump ca. 5 cm above the sole in the buffer tank. Here also take care that the pump is not located to near the tank wall in order to ensure the free movement of the float switch.

Secure the distributor box with the connection cable to the cone. Roll up the freely hanging cable and hang it up in the OBO grip.

Pull the charging hose through the connecting pipe in the SBR tank and secure the end to the cover using a plastic clip.

Please ensure that you take care that the free end of the charging hose does not dip into the water in the SBR tank or can submerge in order to avoid a syphon effect (communicating pipes)!

Installation, operating and maintenance manual AQUAmax® PROFESSIONAL G

ATB WATER GmbH, Südstraße 2, D-32457 Porta Westfalica, www.atbwater.com / Art.-Nr.: 9060 XXXX / Stand: 08.01.2019 / Seite 17 von 56

Sampling bottle, clarified water and charging hoses

Up to 16 PT and from 51 PT red, from 17 to 50 PT blue connection cover!

Mount the sampling bottle on the cone so that the sampling is easily achieved and the sample can be easily removed. Screw the hose nozzle on to the prepared clarified water hose (DN 25) to the threaded connection on the pressure pipe of the clarified water pump and cut it to length so that it can be pushed on to

the hose nozzle of the sampling bottle. With this take

note of the direction of flow of the sampling bottle! Sampling bypass

A sampling bypass is included in the scope of delivery for variants from 51 EW. The sampling bottle represents a bottleneck, which means, that the clear water discharge takes an increasingly unfavourable period of time for larger systems. This is prevented by the bypass, because a part of the clear water flow is directed around the sampling bottle.

Push the remaining hose far enough into the outlet so that the clarified water cannot flow back (if necessary provide an elbow on the outlet). Secure the hose against slipping out using a pipe clip. If there is a nonreturn valve installed in the clarified water hose or if the sampling bottle is significantly higher than the outlet, further measures can be necessary. In these cases please contact our service department. A sufficient freedom of movement for the removal of the bottle is to be taken into account.

The pressureless outflow of the clarified water must be guaranteed!

Screw the prepared hose for the excess sludge return feed (DN 32) to the pressure pipe of the excess sludge pump.

Pull the hose through the connecting pipe into the coarse interceptor/sludge storage and secure the end thereto the cover using a plastic clip.

Immersion in the wastewater of the coarse interceptor/sludge storage is to be avoided at all costs!

from AQUAmax

outlet

Bypass

Installation, operating and maintenance manual AQUAmax® PROFESSIONAL G

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AQUAmax® with compressor and membrane tube diffusers

(AQUAmax® PROFESSIONAL GZB)

As an alternative to the submerged aerator, air can be blow in by one or two compressors and a corresponding number of membrane tube diffusers (GZB versions). The following figure shows an example of installation with two compressors

Using 25 mm hose compressor outputs are connected on preferably short distance to the air adapter (not required if only one compressor is provided). This is connected in the tank to the air allocator via 25 mm hose (empty pipe between compressor/adapter and tank). From here, the air is transferred to the membrane diffusers via a 16 mm hose. The air allocator is prepared for mounting in the tank above the water level or near the tank opening.

The membrane diffusers are to be arranged on the bottom of the SBR so that an optimal aeration is guaranteed. Due to their weight, they can be positioned without separate fixing.

Air adapter

Installation, operating and maintenance manual AQUAmax® PROFESSIONAL G

ATB WATER GmbH, Südstraße 2, D-32457 Porta Westfalica, www.atbwater.com / Art.-Nr.: 9060 XXXX / Stand: 08.01.2019 / Seite 19 von 56

The AQUAmax® PROFESSIONAL GZB 1-16 is supplied with air via a 16 mm fabric hose, which is laid directly from the compressor through the empty pipe into the tank. This is connected to the membrane tube diffusers via a Y-piece.

Installation, operating and maintenance manual AQUAmax® PROFESSIONAL G

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Cable connection and test run

Only for British standard plug system with earthing contact!

Take the adapter plug and the plug. Press the plug into the adapter plug The new plug is ready.

One-way assembly, to the unique and for fixed connection. Without destruction not solvable!

Pull the cable from the pit(s) through the empty

conduit(s) up to the proControl

2 control system (pull wire). Cable lengths longer than 15 m are to be considered when ordering. Insert the special plug into the appropriate socket

of the proControl

2 control system and hand

tighten (see next pages).

Still do not connect the control system to the mains.

The plant must now be filled be filled with water at least up to the switch-ON point of the lower float switch in the SBR [SW1].

Following connection of the control system to the mains it is activated and is in the program mode. Please continue with commissioning and functional check in accordance with the details

for the proControl

2 in the corresponding

chapter of this operating manual.

Installation, operating and maintenance manual AQUAmax® PROFESSIONAL G

ATB WATER GmbH, Südstraße 2, D-32457 Porta Westfalica, www.atbwater.com / Art.-Nr.: 9060 XXXX / Stand: 08.01.2019 / Seite 21 von 56

Check before commissioning,

whether the connection slits are present in the partition walls in the primary settling stages

whether the joints of the partiton wall and the connection slits to the aeration (SBR) and to the buffer are sealed

whether an overflow (T-piece) from the primary settling stage to the buffer and an emergency overflow from the buffer to the SBR tank are available

whether the outlet openings of the charging hose and of the hose for the removal of the excess sludge are above the maximum possible water level

whether the setting has been carried out according to the actually connected inhabitants

whether all units are connected correctly, the pumps deliver water and the aerator

introduces air (to check activate test run and/or manual operation Æ proControl

whether the switch-OFF points of float switch SW1 is at the height of the given minimum water level H

W, min

and ALL float switches are free moving

whether the switch-ON point of the float switch SW2 is at the height of the given maximum water level H

W, max

and lies below the outlet

whether the difference between the float switches SW1 and SW2 corresponds at least with the difference between H

W,min

and H

W,max

from the technical clarification calculation or the

datasheet

whether the instruction plate, which contains the disposal information, is clearly visible and correctly mounted

whether the outlet hose is secured correctly at the outlet elbow and the sampling bottle and a back-up from the percolation system, the receiving water or the through reverse slope is not to be feared

whether the cover of the plant has ventilation openings and the airing of the tanks is ensured via the roof ventilation or via another means

whether the wastewater treatment plant is safeguarded via a separate ELCB

whether with the employment of a cable extension with a screwed connection has been additionally protected against the penetration of water (shrinking hose is provided by ATB for cable extension)

whether for the case of continuous mode (power failure) is assured so that the air suction hose/air suction pipe cannot be flooded

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Danger of accident

The AQUAmax

may first be taken into operation when the plant is installed

and filled with water! No one may be any longer in the manhole.

Moving parts – danger of injury! Before working within the pit and/or the removal of the AQUAmax

the

power supply is to be disconnected!

Danger due to electrical voltage. With work on the AQUAmax

the plant is

without fail to be disconnected from the mains!

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The control system proControl© 2

Splashproof IP 54

7-figure backlight graphic display

4 short-stroke foil keys

2 LEDs green (Operation) / red (Error)

Separate 230V terminal space includes fine fuses 8 x T6.3A, 1 x 1A with replacement fuses.

Circular plug-in connectors for PROFESSIONAL G, BASIC and CLASSIC

Yellow = buffer Blue = aggregate SBR (GBZ: Clearwater pump / floatswitches SBR) Black = float switch SBR (GBZ: Compressor / sludge pump)

BASIC / CLASSIC

General and safety information

The proControl

2 control unit serves for the operation of SBR wastewater treatment plants

of the AQUAmax

series. The control unit – independent of plant type – is suitable for the connection of in each case up to two aeration units (or one aerator and one mixer), two charging, two clear water pumps, one sludge pump, one UV-disinfection plant, one system for phosphate precipitation and four float switches for level indication.

With employment in accordance with the intended use there are no hazards emanating from the equipment. National applicable regulations as well as technical data are to be observed.

Should the proControl

2 be used for other purposes without the express agreement of the firm of ATB Umwelttechnologien GmbH and/or if the following safety information is disregarded, then this can lead to malfunctions of or defects in the plant. In this case any liability is excluded. Modifications to the equipment are not permitted and lead to the loss of warranty claims.

Do not operate any equipment which shows malfunctions, has been dropped or has been damaged in any way.

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Equipment characteristics

• Controlled by microprocessor

• Protection marking for electrical enclosures IP54

• Wall mounting

• Undervoltage failure signalling (UVS)

• 2 potential-free contacts for alarm facility

• Activation of a dosing pump for phosphate removal

• Activation of a UV-system for disinfection

• Comprehensive logbook documentation

• Simple and rapid handling by 4 softkey operation

• Times for all parameters completely pre-programmed

• Automatic run-in phase with suppression of the excess sludge removal

• Parameter settings freely selectable

• Selection of 6 menu languages (German, English, French, Spanish, Rumanian and

Polish)

• Can be used for AQUAmax

BASIC, CLASSIC and PROFESSIONAL

• Ready-to-connect version for BASIC, CLASSIC und PROFESSIONAL G

• Following power failure (< 30 min) restart at the interrupted program point

• Wide range power supply 110 – 250V, 50/60Hz

Assembly

Using the mounting material provided, secure the proControl

2 to the cabinet brackets provided and at a suitable position, as far as possible not directly affected by weather conditions.

With temperatures below 0°C one has to reckon with a severely limited function of the LC display.

The proControl

2 is delivered as ready-to-connect model for the variants CLASSIC, BASIC and PROFESSIONAL G. Installation wiring in situ is dispensed with! For the PROFESSIONAL XL the control unit is wired complete, with a separate connection, to a common assembly plate. Opening of the control unit is dispensed with! An associated connection plan is provided.

For the AQUAmax® PROFESSIONAL GZB with pressure aeration, the control unit is already mounted on a mounting plate. This can be mounted directly on the wall or in an outdoor control cabinet.

Next to the control unit there is a distribution box on the mounting plate to which the excess sludge pump is connected, as well as the sockets for the control unit (and the mains supply line) and the compressor(s).

The remaining units and float switches are connected directly to the control unit (see pin assignment on the previous page).

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All tasks, which nevertheless require the opening of the control unit as well as the electrical connection of a PROFESSIONAL XL, are to be carried out by a qualified electrician!

ATTENTION! Before opening the proControl

2 and/or the connection box these MUST be disconnected from the mains supply. Work on open equipment may be carried out exclusively by qualified electricians! Pay attention to appropriate-phase connection (even with ready-to-connect models!

As one is concerned with an electrical plant with submersible motor pumps a separate 16 A fuse and a (separate) upstream 30 mA residual current (RCD) circuit breaker MUST be provided! Attention is to be paid to the correct laying of the protective ground wire up to the earthing of the building.

General notes on operation

Operation of proControl

2 via 4 short-stroke foil keys.

Depending on the type of plant, the displays can differ slightly from the displays in this manual.

Key functions ↑↓ Scroll upwards and downwards / to increase or decrease a value. OK Select a menu item / accept and save the input.

ESC Jump one level back within the menu structure or jump one number back within the number input.

Cycle process

The cycle starts with the charging, which is part of the denitrification phase. With a sufficient water level in the buffer tank (lower float switch in the buffer tank [SW3] closed) the wastewater is delivered into the SBR tank at regular intervals. Charging ends a) following the expiry of the preset time, b) when SW3 opens (minimum water level reached in the buffer tank) or c) the maximum water level in the SBR tank is achieved (H

W, max

, upper float switch in the

SBR tank [SW2] closed/ON). After the charging, the denitrification is running until the set time expires. During the denitrification phase the SBR tank is stirred, which is done either by briefly switching ON the aerator or by the agitator (mixer).

In the following aeration phase (nitrification) oxygenation of SBR is carried out by switching on the aerator unit(s) according to the time settings. In the case of the

- PROFESSIONAL G (1-50 PT): using submerged motor aerator or optionally using the compressor and string diffuser.

This is followed by the settling phase and clear water evacuation phase. The clear water discharge phase ends a) with the opening of the lower float switch in the SBR [SW1] or b ) after the preset max. pumping time. In this case, an alarm is emitted (CW-timeout).

The clear water removal can be extended by the CW follow-up time.

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The excess sludge removal takes place in the series PROFESSIONAL G during the treatment phase and in the series PROFESSIONAL XL after the follow-up time or after the clear water evacuation. With activated run-in phase - no sludge removal takes place (factory setting for PROFESSIONAL G 180 days and PROFESSIONAL XL 0 days).

High-water operation

(only possible with 4 float switches, not valid for XLn) If so much water runs into the sewage treatment plant that the maximum useful volume of the buffer and the SBR tank is exceeded (SW2 and SW4 are closed), the alarm message "high-water" appears and an immediate settling operation reduced to half takes place.

Economy mode

If after the last denitrification phase before settling the lower float switch in the SBR [SW1] has not floated up, the system switches to economy mode. Here, the air supply - and thus the energy consumption -is throttled (factory setting aeration time reduced to half).

Phosphate precipitation, UV irradiation, clear water discharge , follow-up time and sludge removal do not take place in the eco-mode!

A settling phase is, however, carried out in the AQUAmax

PROFESSIONAL series. Charging continues to take place at the set intervals even in eco-mode. The position of the float switch [SW1] is queried in each case after the end of denitrification. The economy mode ends with the

- AQUAmax

BASIC / CLASSIC: when the float switch [SW1] has floated up after a denitrification phase. A nitrification phase follows before the system goes into the settling phase.

- AQUAmax

PROFESSIONAL: when the lower float switch in the buffer [SW3] has floated up at the start of the charging / denitrification phase and a charging is carried out.

Power failure

After a power failure < 30 minute s the proControl

2 continue the program at the same point where the cycle has been interrupted. After a power failure > 30 minutes or after rebooting the control starts the cycle with the last denitrification phase (exception with the XLA cycle; here the restart begins with the central charging phase (i.e. with charging 5/10 with factory setting of 10 charges). Depending on the water level in the buffer tank [SW3] with this one charging takes place.

Flushing pulses

To keep pumps free from sludge and to have a short operation during longer downtimes, the charging, clear water, and sludge pumps are automatically switched on for the time of the flushing pulse. This takes place in the middle of the settling phase or with each feeding phase (independent of the position of the float switch [SW3]).

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Commissioning

With the first initiation of the control unit basic settings and tests are carried out. By entering the plant size all important parameters are preset. However, we recommend, after commissioning to enter into “settings” and check the parameters again. In the Service Mode you also have subsequently the opportunity to make changes.

Use the ↑↓-keys to select the desired language for the menus and display and press OK. Available are English, German, French, Spanish, Romanian or Polish.

With the input of the service code it is ensured that the commissioning is

carried out by a speciakist. Enter the 6 - digit code number using ↑ ↓ and OK.

Enter the data for date (display = dd.mm.yyyy) and time (display = hh:mm:ss). Warning: the date of commissioning cannot be changed later. This is important for the correct entries in the logbook!

Use the ↑↓-keys to select the type of plant and confirm with OK.

Use the ↑↓-keys to select the PT size of the plant and confirm with

OK.

Important for the correct preset parameters!

Enter the serial number which is located on the AQUAmax

frame (BASIC / CLASSIC / PROFESSIONAL G ) or inside the outdoor cabinet or on the mounting plate of the control (PROFESSIONAL XL). Not the serial number of the control unit! Please make sure to enter the serial number right justified.

With the confirmation of “new plant” to suppress sludge recirculation for the duration of run-in phase (preset to 180 days for BASIC, CLASSIC and PROFESSIONAL G).

Click OK to start the test run (with ↑↓ OK and you can cancel the operation

and exit the menu item). Here all active outputs are sequentially switched ON for about 5 seconds. Error messages are generated by current consumption outside the preset current limits.

Furthermore, function and allocation of the float switches will verify. Test run can be restarted by moving any float switch.

If your AQUAmax

is equipped with a float switch type AQUAswitch© (BASIC / CLASSIC), the float switch test can only be performed by dipping or pulling the AQUAmax

out of the water-filled tank.

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In the case of wrong settings, the commissioning may finally restart by

entering “no”. Confirm the correct entries with „yes“ and OK.

Display information

Info

Info display indicates the type of plant, the selected PT - number, the serial number, the software version number and the current time. (here installation type XL, 60 PT, serial number 654321, software version V0.02.04)

Runtimes

With ↑ and ↓ you can change the display from Info to runtimes, to current phase and to the main menu.

Actual phase

The display "actual phase" contains information about the plant type with PT number and active treatment phase. The switching state of the float switches 1 - 4 *, the time and possible existing errors on the bottom line. *

1 for closed float switch, 0 for opened float switch.

1. position = SW1 = SBR minimum level [H

W, min

]

2. position = SW2 = SBR maximum level [H

W, max

/ PROFESSIONAL only]

3. position = SW3 = buffer low level [PROFESSIONAL only]

4. position = SW4 = buffer high level [PROFESSIONAL XL and G optional]

Main menu

In the main menu you have the opportunity to request further information or to make changes to specific settings.

Logbook

In the logbook you will find entries for errors, runtimes, events and messages. Use the arrow keys ↑↓ to scroll to the next following or prior entry. Once the memory is full, the oldest entry is overwritten. Parameter details

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Errors

Recording the occurred error messages. For an explanation of the messages displayed, please refer to the appendix. Example: CW timeout for exceeded runtime of the clear water pump

Runtimes

Display of the weekly or accumulated run times (cumulative).

Events

Documentation of manual interventions. Example: acoustic alarm and subsequent manual reset of this alarm

Messages

Each change is documented in the message logbook. For example, when a float switch has switched, or when a pump switched ON or OFF.

Settings

Display of the set operating parameters and the current limits . These parameters can only be changed in the service mode. However, you have the opportunity here to make entries for alarm pause, the

sludge removal and the beep.

Operating parameters

An overview of the standard parameters can be found in the appendix. Changing of the default settings is possible in “service mode” only. There you will also find

a description of each parameter.

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Current limits

Preset current limits. A change of the default values ispossible in service mode only.

Alarm pause

If within the selected time period any error occurs (max. 12 hours), the audible alarm signal is issued after this alarm pause time.

Sludge evacuation

With the activation (YES and OK) the run time of the aerator will be reduced

by 20% for 6 weeks (no further reduction during the winter operation). Once activated, this feature is disabled for 6 months.

Signal sound

6 different sounds of the audible alarm signal. Alarm 6 = noiseless. Should only be selected if another alarm is present (flashing light or GSM transmission).

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Service Mode

In the “service mode” all relevant and necessary operating parameters for the wastewater treatment plant can be changed. Please note that incorrect settings can cause a faulty operation!

Access to the service mode via a 6 - digit code number, which is made

available exclusively to authorized service specialists.

The entries are not checked for plausibility!

In this case warranty claims are excluded by ATB

Umwelttechnologien GmbH!

The individual parameters are presented to you on the following pages. If you have questions please contact us at any time!

When exiting the service mode, the program continues at the same point, as before the entry.

Plant type

Select the plant type.

PT number

Entering the PT number will automatically load the default parameter set for this size. This means that, as a rule you need to carry outy no further actions. The pre-set parameters for the individual dimensions are given in the appendix.

Operating parameters

To enter and to change relevant parameters. The data displayed starting with „info“ emerge from the inputs and cannot be modified directly.

cycles per day Central specification of the desired number of cleaning cycles per day. From this, the maximum cycle time results (see following line).

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info cycle duration Maximum duration of one complete treatment cycle. This time can be shortened, for example by economy modes or shorter clear water evacuation times.

settling phase Duration of the sedimentation time before clear water evacuation takes place.

flushing pulse Short switch-on of the pumps for the time of the flushing pulse (see functional description)

CW evacuation Maximum time allowed for the clear water evacuation. If the lower float switch in the SBR [SW1] does not switch from ON to OFF during this time (display: 1 Æ

0), an alarm message will be generated.

SL removal Duration of the excess sludge removal. Occurs immediately after an aeration (CLASSIC, BASIC, PROFESSIONAL G) or at the end of a cycle (PROFESSIONAL XL). Only if run in phase is 0 days.

CW follow-up For systems that are equipped with a float switch

AquaSwitch

(BASIC, CLASSIC) the clear water evacuation time will be extended for this time setting after reaching the minimum water level HWmin. A new switching operation of the float by back running water after completion of the pumping is prevented..

info reaction ph. Info duration of the treatment phase. This time is calculated from the previously entered settings.

feed. p. cycle Number of the charges per cycle. The charging phases are divided equally between the reaction phases. With the feeding as well a denitrification phase starts.

feeding duration Run time of the feed pump (BASIC: number of feed batches), based on a flow rate of 150 l/PT/d and a cycle duration of 8h with 3 feedings per cycle.

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info feed pause Time between the end of one charging and the next charging (resp. end of reaction phase).

additional nitri

The last nitrification phase prior to settling phase may

be extended by a corresponding input. Caution: As a

result the other nitrification phases and the feed pause will be shorter.

info off-time feed. Information about the time span between the end of the last charging and the first charging at the beginning of the next cycle.

info no. deni

(not in the XLA system) Information about the number of denitrification phases for one cycle.

deniphase

(not in the XLA system) Duration of the denitrification phase (begins with a feeding, but is independent of it).

deni aer. ON/OFF

(not in the XLA/XLAM) Setting for the intermittent agitation of the aerator during deni phase. In PROFESSIONAL XLAM the mixer is automatically in continuous operation during deniphase.

info nitri duration Info display indicating the duration of a nitrification phase.

nitri aer. non-stop

(only PROFESSIONAL XLA/XLAM) Deciding whether the aerator operates continuously or intermittently during the nitrification.

When nitri aer. non-stop is OFF the intermittent operation can be parameterized (factory settings: 10min ON and 10min OFF).

With plant type XLAM the mixer is oriented to the aerator settings (aerator ON Æ mixer OFF, aerator OFF Æ mixer ON).

nitri aer. ON/OFF Setting parameter for the intermittent aeration during nitrification.

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eco aer. ON /OFF Setting parameter for the intermittent aeration during eco mode.

run in phase For the displayed time no excess sludge removal is carried out. In the first weeks of treatment plant operation, the activated sludge must arise. During this period the sludge removal is not useful. Depending on the type of plant the parameter is 0 days (for XL) or 180 days for (BASIC/CLASSIC/PROFESSIONAL G).

info P-precipit. / disinfection Info display if phosphate precipitation and UV disinfection is active or not. The setting of these parameters is carried out in separate menu items.

Current limits

With the current limits the allowable range between minimum and maximum current is set. Current values outside of Imin - Imax lead to corresponding over- or undercurrent alarms.

If the current consumption is below the minimum value, the unit will continue to be controlled. If you carry out no error reset (only acknowledged by OK) t,he same errorwill not cause an error message for the next 72 hours! If the current consumption is higher than the maximum value the

control of the unit is blocked until the error reset is done (automatic

reset after 72 hours).

Test run

(see commissioning)

Note: Test run during settling phase may have the consequence that with

next clear water evacuation activated sludge is pumped out.

Serial number (SID)

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Alarm contact

Activation / deactivation of the potential-free contact for alarm signal.

UV-disinfection

Activation / deactivation of UV disinfection. When enabled, the UV lamp is

controlled in accordance with the specified warm-up time before starting the

clear water pump. UV lamp is switched OFF at the end of the clear water

evacuation.

Imin / Imax UV: If the current consumption of the UV reactor is beyond the

current limits an alarm is generated.

Sensor: ON/OFF possible activation of the UV sensor.

P-precipitation

Activation / deactivation of phosphate precipitation. If this is activated, a

further phase (time = P - phase) is subsequently added to the final

nitrification before settling phase. Time settings for duration of P-phase,

dosing time, operation time of the aerator/mixer and min/max current limits

are selectable.

Winter operation

In activated winter mode, the aeration times are reduced by 20% in the

months of December, January and February.

Factory settings

All parameters are reset to standard factory settings (see appendix).

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Manual mode

The manual mode allows you to test all the units, the alarm contact and the float switches. The display informs you directly about the current consumption of the units and as well about the position of the float switches.

The various groups of units are interlocked. Thus, for example, aerators and

clear water pump(s) are not to be taken into operation at the same time.

Press OK button to start or stop the respective unit. With float switch ON an

alarm sounds by closed float switch.

If a unit has triggered an error due to overcurrent consumption, it can be

taken into operation only after resetting this error. (see troubleshooting).

The manual mode is independent of the switching status of the float switches! Even unused outputs can be connected.

After 10 minutes without pressing any button, an automatic reset from

manual mode into automatic mode takes place.

Following the manual operation, the control continue the program at the

same position where it was before entering into manual mode.

If a unit is manually switched to ON during the settling phase, the remaining

time in settling phase will be set to half settling time.

Info

Shows the actual plant type, the PT number set), the software version

number, the date of commissioning and the serial number (SID).

Date / time

Input / modification of date and time.

Important for correct logbook entries!

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Language

Input / modification of the display language. Available are German, English,

French, Spanish, Romanian or Polish.

Error reset

When during current operation an error occurs, it will be indicated visually

(display) and acoustically (plus any option on the potential-free contact). By

pressing the OK button you acknowledge the acoustic indication (plus the

optional alarm of the potential-free contact). The error message on the

display will continue and will be cancelled only after deleting the error

(delete Æ OK).

Time of occurrence and type of the error as well as the acknowledgment will

be listed in the error logbook.

If no manual error reset is performed, the recurrence of the

same error does not generate an alarm. A continuation of the same error is detected in this case only

after the

automatic error reset (72 hours after the error

acknowledgement)

Please inform your maintenance company immediately after an error

message occurs. This will take care about all necessary measures.

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List of pre-programmed parameters:

AQUAmax service mode unit operating parameters setting range PE

2 4 6 8 10 12 14 16 20 24 28 32 36 40 44 48 50 60** 75**

cycles per day 1 … 6 x 3333333333333333344 info cycle duration calculated h 8888888888888888866 settling phase 30 … 150 min 90 90 90 90 90 90 90 90 90 90 90 90 90 90 90 90 90 90 90 flush pulse 0,0 … 3,0 s 0,2 0,2 0,2 0,2 0,2 0,2 0,2 0,2 0,2 0,2 0,2 0,2 0,2 0,2 0,2 0,2 0,2 0,2 0,2 CW evacuation 0 … 240 min 15 15 15 15 15 18 21 24 30 36 42 48 54 60 66 72 75 20 25 SL-Abzug 0 … 999 sec 1 2 3 4 5 6 7 8 10 12 13 15 17 19 21 23 24 24 24 CW followup 0 … 120 s 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 0 0 info reaction ph. calculated min 375 375 375 375 375 372 369 366 360 354 348 342 336 330 324 318 315 250 245 feed. p. cycle 0 … 12 x 3333333333333333333 feeding duration 0,0 … 120,0 min 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,3 2,7 3,2 3,6 4,0 4,5 4,9 5,4 5,6 5,0 6,0 info feed pause calculated min 125 124 124 124 124 123 121 120 118 115 113 110 108 105 103 101 99 78 76 additional nitri* 0 … 120 min 0000000000000000000 info off-time feed. calculated min 230 230 229 229 229 231 233 234 238 242 245 249 252 256 260 263 265 189 191 info no. Deni 0 …12 x 3333333333333333333 deniphase 0 … 120 min 42 42 42 42 42 42 42 42 44 45 45 46 47 48 48 49 50 30 30 deni aer. ON 0 … 60 s 10101010101010101010101010101010101010 deni aer. OFF 0 … 120 min 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 info nitri duration calculated min 83838383838281807673716865626057555352 nitri aer. ON 0 … 999,9 min 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 1,0 1,3 1,6 1,9 2,2 2,5 2,8 3,1 3,3 10,0 15,0 nitri aer. OFF 0 … 120,0 min 7,5 7,5 7,5 7,5 7,5 7,5 7,5 7,5 7,5 7,5 7,5 7,5 7,5 7,5 7,5 7,5 7,5 7,5 7,5 eco aer. ON 0 … 120,0 min 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 0,5 0,7 0,8 1,0 1,1 1,3 1,4 1,6 1,7 5,0 7,5 eco aer. OFF 0 … 120,0 min 7,5 7,5 7,5 7,5 7,5 7,5 7,5 7,5 7,5 7,5 7,5 7,5 7,5 7,5 7,5 7,5 7,5 7,5 7,5 run in phase 0 … 180 d 180 180 180 180 180 180 180 180 180 180 180 180 180 180 180 180 180 180 180 info P-precipit. ON/OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF info disinfection ON/OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF

current limits

I min … I max aer. 1

- GZB**

I min … I max aer. 2

- GZB** I min … I max feed 2 I min … I max cw 1 I min … I max cw 2 I min … I max SL

0,8…2,5

0,6…2,0

0 - 9,9 A

0,0…5,0

0,5…2,0 2,2…5,4

0,0…5,0

2,2…5,4

0,5…3,7 2,0…5,8

0,5…2,0

PROFESSIONAL G

0,0…5,0

0,3…0,9 0,8…2,5

* additional.nitri = additional nitriphase is appended to the last nitriphase before settling phase. Time setting so that the whole last

nitriphase has a duration of one hour.

** For the GZB variants (pressure aeration) the current limits for aerator 1 (=compressor) must be changed manually! The parameters for 60 and 75 P.E. are only valid for the GZB variants and must be entered completely manually!

Installation, operating and maintenance manual AQUAmax® PROFESSIONAL G

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Possible error messages:

Attention! The acoustic and external (potential free contact) alarm will be acknowledged by

pressing the OK button. The optical error message (display) is cleared only with the error reset. A deleted error is seen only in the logbook.

No alarm will be triggered by a recurrence of the same error if the error is not deleted

! To ensure a safe and proper operation it is absolutely necessary to carry out an error reset in the main menu after acknowledging the error (Æ delete all errors? Æ OK)!

The automatic error reset will be performed 72 hours after acknowledging the error. Please inform your maintenance company about the occurred error message, so that it can carry

out the necessary measures.

Error messages on the display (+ acustic alarm)

A1 = aerator 1 A2 = aerator 2 / mixer F1 = feeding pump 1 F2 = feeding pump 2 C1 = clear water pump 1 C2 = clear water pump 2 SL = sludge pump UV = UV-lamp P = P-precipitation

Under current (A1/A2/F1/F2/C1/C2/SL/UV/P)

Possible causes

Troubleshooting

The unit or the entire AQUAmax

is not

connected to the control unit.

Connect the unit concerned.

A terminal in the cable distribution box or on the terminal strip of the control unit is not properly tightened, so that the connection is broken.

Call service or electrician to check the contact points and the wiring.

The cable connection from the electrical device to the control is interrupted.

See above

The micro-fuse of the corresponding device has been triggered.

Change the fuse (2 slow acting 6.3A fuses inside the cover of the connection box)

The water levelis so low that the pumps are running dry.

Check water level in the tanks and check the

float switch function. Current limits are not correct. Adjust the current limits. The corresponding unit is defective. Call service Air bubble in the pump (C1, C2, SL). Call service

Installation, operating and maintenance manual AQUAmax® PROFESSIONAL G

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Over current (A1/A2/F1/F2/C1/C2/SL/UV/P)

Possible causes

Troubleshooting

Current limits are not correctly set. Adjust the current limits. The corresponding unit is blocked or not running smoothly.

Check the current consumption. Take out the

defective device and remove the blockage.

ATTENTION! With the exceeding of the maximum current consumption the unit is locked and can only be put into operation error reset. Rotating parts: Ensure that the system is disconnected from power supply before removing parts!

Float switch SBR / buffer

Logicerror. The upper float switch closes and the lower float switch is still open (please note the float indication on the display)

Possible causes

Troubleshooting

Float switch defective. Call service. Float switch is stuck. Detect and eliminate the cause of the

sticking. A screw in the cable distribution box or on the terminal strip of the control unit is not properly tightened, so that the connection is broken. .

Call service or electrician to check the contact

points and the wiring.

The cable connection is broken. See above

CW timeout

The clear water evacuation takes longer than the maximum time setting allows without lower float in the SBR [SW1] is switching OFF (please note the float indication on the display).

Possible causes

Troubleshooting

Float switch [SW1] is defective. Call service. Float switch [SW1] is stuck. Detect and eliminate the cause of the

sticking. A terminal in the cable distribution box or on the terminal strip of the control unit is not properly tightened, so that the connection is interrupted.

Call service or electrician to check the contact

points and the wiring.

The cable connection is broken. See above Insufficient performance of the clear water pump.

Check the capacity and the current

consumption (manual mode). Clean the pump

or change the device. Leakage in the clear water pressure line / pressure line not properly connected to the outlet of the plant.

Change pressure line / fasten properly.

Backing-up Eliminate the cause of back-up. Exceptionally high sewage / infiltration water inflow.

Eliminate the cause for high sewage / seal

the leakage of infiltration water. Incorrect value for the max. pumping time. Change the setting.

Installation, operating and maintenance manual AQUAmax® PROFESSIONAL G

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High water

The maximum usable volume in the buffer and in the SBR is achieved. Float switches SW1 to SW4 are in up position (display fl-switch 1-4 1 1 1 1).

Possible causes

Troubleshooting

Backing-up Eliminate the cause of back-up. Exceptionally high sewage / infiltration water inflow.

Eliminate the cause for high sewage / seal

the leakage of infiltration water. Buffer volume not correct. Provide additional buffer volume.

Precipitant level

The level of the precipitant in the container has reached the minimum.

Possible causes

Troubleshooting

Precipitant is +expended. Refill with precipitant. A terminal in the cable distribution box or on the terminal strip of the control unit is not properly tightened, so that the connection is interrupted.

Call service or electrician to check the contact

points and the wiring.

The cable connection is broken. See above

UVS (Audible alarm, crossed-socket in the display)

The integrated UVS (power failure detection / Under Voltage Signaling) simplifies ensuring flawless

operation. If there is a power failure > 1 sec. In the power supply of the proControl

2 (and thus the

AQUAmax

), for example, by triggering the RCD or a fuse, an audible alarm is triggered. Once activated the pulse tone continues, depending on the charge level of the battery, up to 48 hours. Acknowledge the alarm by pressing the OK button. If power returns the audible signal automatically switches OFF after ca. 10 seconds, and the control continues with the cycle. NOTE: Press and hold the OK button after a power failure for more than 3 seconds to shut down the system.

Control without function (no display)

Pre-fuse 1 A of the power device is defective. (one spare fuse inside the cover of the connection box).

Installation, operating and maintenance manual AQUAmax® PROFESSIONAL G

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Technical data:

Case dimension: (H x B x T )220x260x125 mm Case protection class: IP54 Temperature range: 0°C ... +70°C (With the exception of batteries) Power supply: 110...250V, 50...60Hz Connection terminals: 4 x L (phase), 4 x N (neutral), 8 x PE (pot. earth) Graphic display 30.5 x 59mm (64 x 128 pixel) 7 outlets each with T6.3A slow acting microfuse: A1 – Aerator 1 A2 – Aerator 2 (mixer for XLAM) F1 – Feeding pump 1 F2 – Feedinging pump 2 C1 – Clear water pump 1 C2 – Clear water pump 2 SL – Sludge pump UV – UV-disinfection P – P-precipitation, dosing pump Maximum connected load per outlet: 1,450 VA at 230V Maximum total connected load: 3,680 VA at 230V

Inputs 12V DC, internal power supply: 4 x S1 – S4 for float switches 1 x US for UV-sensor 1 x PL for phosphate-precipitant level control Inputs 4 … 20 mA 2 x A+/A-, B+/B- analogue inputs 4 … 20 mA, max. 24V

Interfaces: CAN-Bus for networking of multiple control units USB-Host for software update and data exchange RS232 for remote data transmission e. g. via modem

2 x potential-free contact max. 250V AC, 5A 4 x monitoring relays (RR1...RR4) optional

Battery recharge.: 2 x AA Mignon NiMH, 1.2 V, 2100 mAh, charge time approx. 20h Real-time clock: Battery-buffered via 3V lithium battery Internal signal generator 4kHz with max. 80dB in 10cm distance

Installation, operating and maintenance manual AQUAmax® PROFESSIONAL G

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Terminal box

Terminal configuration: 4 x L, 4 x N, 8 x PE power supply 110...250V, 50...60Hz Outlets A1, N / A2, N Aerator 1 / 2 (Mixer for XLAM) Phase / Neutral F1, N / F2, N Feed pump 1 / 2 Phase / Neutral C1, N / C2, N Clear water pump 1 / 2 Phase / Neutral SL, N Sludgepump Phase / Neutral UV, N UV-lamp Phase / Neutral P, N Precipitant dosingpump Phase / Neutral Inputs 12 V DC S1 / G Float switch SW1 Phase / Ground S2 / G Float switch SW2 Phase / Ground S3 / G Float switch SW3 Phase / Ground S4 / G Float switch SW4 Phase / Ground

US / G UV-sensor Phase / Ground

PL / G Precipitant level control Phase / Ground Inputs 4-20 mA, max. 24V A+, A- /B+, B- Analog Inputs Plus / Minus CAN-Bus for networking of multiple control units 2 x 24V, GND, H, L Potential free contacts max. 250V AC, 5A NO1, CO1, NC1 Alert contact 1 potential free NO2, CO2, NC2 Alert contact 2 potential free

Aggregate no. no. Aggregate

sludgepump (SL) F1 F2 UV + dosingpump (UV+P)

clearwaterpump 1 (C1) F3 F4 clearwaterpump 2 (C2)

feedpump 1 (F1) F5 F6 feedpump 2 (F2)

aerator 1 (A1) F7 F8 aerator 2 (A2)

Assignment of microfuses T6.3A (see label in the terminal cover)

Installation, operating and maintenance manual AQUAmax® PROFESSIONAL G

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Notes on maintenance

With the maintenance tasks and examinations have to be carried out at greater time intervals by the service personnel. The number of and requirements on the maintenance are laid down by the lower water authorities, whereby, with this, the biological effectiveness is at the fore. The plant is equipped with a UVS

. As a rule, a twice/year maintenance is sufficient. The examination of the treated wastewater with regard to the various parameters is also laid down by the lower water authority.

We recommend that at least the following tasks are carried out:

• Inspection of the operator’s logbook or the electrical logbook and reading of the operating

hours count with establishment of regular operation (set-actual comparison).

• Removal of the AQUAmax

and removal of possibly existing tangles and sludge deposits or

similar in the units.

• Functional check of the operationally important mechanical, electrical engineering and other

plant components such as aerators, pump(s), float switches and control systems.

• Functional check of the roof ventilation.

• Setting of optimum operating values, e.g. oxygen supply (~ 2 mg/l), sludge volume (300-500

ml/l).

• Determination of the height of the sludge level in the sludge storage and, if required,

arrangement of sludge removal (with a maximum filling level of 70% of the useful volume).

• Implementation of general cleaning tasks such as, for example, removal of deposits, removal

of foreign bodies.

• Examination of the structural condition of the plant e.g. corrosion, accessibility, ventilation,

screw-type connections, hoses.

• As far as present, check UV lamp for dirt and, if necessary, clean.

Arrange for the carrying out of the maintenance tasks by firms whose staff hold a certificate of technical qualification and have been trained by ATB. The maintenance carried out is to be recorded in the operator’s logbook.

As a minimum the following wastewater examinations should be carried out within the scope of maintenance:

Examination of a grab sample from the discharge (sampling vessel

Inspections in the aeration tank

• COD

• pH

• Settleable solids

• Oxygen concentration

• Sludge volume

• Temperature

If the sample is taken from the sampling bottle this should have stood at rest for at least 15 minutes beforehand. Under no circumstances shaken! Through this a possible growth on the side of the bottle could become loosened and falsify the analysis result. At the end of maintenance the sampling bottle is to be cleaned or exchanged for a clean one.

The findings and tasks carried out must be documented in a maintenance report. This is handed or sent to the operator of the wastewater treatment plant with the results of the water sample. The responsible water authority can demand an inspection of the operator’s logbook and the maintenance report. Frequently, the lower water authority demands the transmission of the maintenance report by the operator or the maintenance firm. after each maintenance.

Installation, operating and maintenance manual AQUAmax® PROFESSIONAL G

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Self-monitoring by the operator

As operator of the wastewater treatment plant you are responsible to the water authority to ensure a smooth operation of the plant. Operating faults in biological small wastewater treatment plants in almost all cases reflects on the discharge quality of the treated water. These therefore must be recognized promptly and remedied by either him/herself or a qualified maintenance firm.

In order to document the self-monitoring you are obliged to keep an operator’s logbook. The form provided for this “Operator’s Logbook – Self-Monitoring by the Operator" can be found at the end of this manual. It is best to keep this near the control equipment. The water authority can demand an inspection of this operator‘s logbook.

In detail you are required to carry out regularly the following checks:

Daily:

• Function of the control unit and

• Inspection or unusual indications.

Monthly:

• Transfer of the operating times from the display into the operator’s logbook (with the presence

of an electronic logbook and in consultation with the responsible water authority, this can possibly be dispensed with).

• Visual check of the submersible aerator for thorough mixing and air bubble input.

• Visual check of the water level in the primary settling stage. No sludge may pass over

uncontrolled into the aeration chamber.

• Visual check of the discharging water for sludge driving.

• Examination of the free discharge in order to avoid a backing-up into the aeration chamber.

If you keep to the following recommendations you can save unnecessary repair costs and increase the service life of your plant:

• Infiltration water such as rainwater, groundwater, swimming pool water and aquarium water

may not be introduced.

• With domestic cleansing please note that no acids or alkaline reactions appear.

• The ventilation openings as well as inlet and outlet openings must always remain clear. The

cover of the plant must be capable of being opened.

• Ensure that the plant is maintained regularly by a specialist firm.

• Only the primary settling stage has to be dislodge regularly (ca. every 12 months) by a

disposal firm! Following consultation with the responsible authority and with conclusion of a maintenance contract desludging can also take place on an as required basis.

At the completion of desludge the primary settling stage is to be refilled with water so that the suction opening of the AQUAmax® is completely submerged!

Installation, operating and maintenance manual AQUAmax® PROFESSIONAL G

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Information on disposal

In your own interest please note the following information on disposal:

Solid or liquid substances which do not belong in the sink or in the toilet

What they cause Where they are well

taken care of

Adhesive plaster Blocks pipes Dustbins, garbage cans Ashes Do not decompose Dustbins, garbage cans Birdcage sand Blocks wastewater treatment plants Dustbins, garbage cans Cat litter Blocks pipes Dustbins, garbage cans Chemicals Poison wastewater, danger of explosion Collection points Cigarette butts Lodge in wastewater treatment plants Dustbins, garbage cans Cleaning materials (not general)

In part poison wastewater Collection points

Condoms blockages Dustbins, garbage cans Corks Lodge in wastewater treatment plants Dustbins, garbage cans Cottonwool sticks Block wastewater treatment plants Dustbins, garbage cans Deep frying fats Form deposits in pipes and lead to

blockages

Dustbins, garbage cans

Disinfectants Kill bacteria Do not use Drain cleaners Poison wastewater, corrode pipes Do not use Edible oils Block wastewater treatment plants Dustbins, garbage cans

/collection points Food scraps Block wastewater treatment plants Dustbins, garbage cans Hair Is deposited in the plant and leads to

blockages

Dustbins, garbage cans

Lacquer, varnish Poison wastewater Collection points Medicines Poison wastewater Collection points,

chemists Motor oil Poisons wastewater Collection points, petrol

stations Nappies, diapers Block wastewater treatment plants Dustbins, garbage cans Paintbrush cleaner Poison wastewater, danger of explosion Collection points Paints Poison wastewater Collection points Pesticides Poison wastewater Collection points Photographic chemicals Poison wastewater Collection points Plant protectants Poison wastewater Collection points Razor blades Block wastewater treatment plants and

case injury

Dustbins, garbage cans

Sanitary towels tampons, liners

Block wastewater treatment plants Dustbins, garbage cans

Textiles (e.g. nylons, cleaning cloths, handkerchiefs etc.)

Block wastewater treatment plants Old clothes collection,

dustbins, garbage cans Thinners (Paint) Poison wastewater Collection points Wallpaper glues Block wastewater treatment plants Collection points Wastes containing oil (oil filters, clothes etc.)

Poison wastewater Collection points

WC stones Poison wastewater Do not use

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Fault correction

Fault Possible cause Rectification

The water level in the primary settling stage is unusually high, whereby there is a normal water level in the activated sludge stage.

• The charging pipeline is leaking and draws in air.

• Check the threaded connection for tightness. If a hose is available as charging pipeline the hose fixture and the hose should be checked for tightness.

• The charging line is blocked.

• The passage of water can be checked though manual operation of the surplus sludge pump.

• The submersible motor pump is defective.

• Call Service support.

• There is air in the impeller

chamber. This condition can be detected by a gurgling noise. Removal of air from this chamber is enabled through a small drilling in the lower third of the pump casing.

• Remove AQUAmax and check the drilling, if necessary clean.

The water level in the primary settling stage and in the activated sludge stage is unusually high. The control system indicates “Flooding Alarm”.

• Unusually high infiltration inflow. With heavy rainfall due to surface water or sodden earth through leaking concrete tanks.

• Infiltration water may not get into wastewater treatment plants over a long period. If necessary seal the concrete tank or remove other causes.

• The submersible motor pump is blocked or defective.

• Check the pump through manual operation; if necessary call service support.

• There is backflow at the inflow point. The water conveyed by the pump flows back again.

• The inlet point must be again freed.

The water level in the activated sludge stage is unusually high. The control system indicates “Economic operation”.

• The float switch cannot rise as it is limited in its movement.

• Check the float switch (see manual mode).

• The float switch is defective or the cable lead is broken.

• Call service support.

The water levels of the primary settling stage and the aeration are always the same although water flows into the primary settling stage.

• The partition wall between aeration and primary settling stages is leaking.

• Close the separation wall slits and, if necessary reseal the joints.

• The hydraulic system in the AQUAmax for the interruption of the charging pipeline is impaired.

• Call service support.

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Fault Possible cause Rectification

There is no indication on the control system display.

• The plant has no electrical power.

• Check fuse and/or ELCB.

• The display is defective. • Call service support.

Acoustic alarm sounds. There is no indication present on the display.

Plant is without electrical power. UVS

has triggered.

• Check fuse and/or ELCB.

• The display is defective. • Call service support.

“Fault” appears on the display with indication of the electrical unit concerned.

• The unit or the complete

AQUAmax

is not connected to the control system.

• Connect the appropriate unit.

• A screwed terminal in the cable distribution box or on the terminal board of the control unit is not correctly tightened so that the connection is interrupted.

• Have an electrician check the contact point and the leads.

• The connecting cable from the electrical equipment to the control box is interrupted.

• Defect rectification see above.

• The micro-fuse of the equipment concerned has tripped.

• Change fuse.

• The water level in the

aeration stage is so low that the pumps run dry.

• Defect rectification see above.

• The unit concerned is blocked or runs rough (check power intake).

• Remove AQUAmax

and

remove blockages.

• The electrical unit concerned is defective.

• Call service support.

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Fault Possible cause Rectification

The treatment performance of the plant is unsatisfactory.

The majority of the above given defect cases can lead to a reduction of the treatment performance.

In addition, there can be many reasons for unsatisfactory effluent values such as, for example:

• insufficient air transfer

• wrong position of the

submersible aerator

• leaks in the tank

• introduction of too large

quantities of cleaning or disinfection agents as well as other banned substances (paints, solvents etc.)

• sludge disposal not carried out

• incorrect setting of number of inhabitants and population equivalents

• plant disconnected from the mains supply over a longer period.

In the interests of the environment you should contact your service firm in order to achieve an improvement to effluent values.

Important data for fault diagnosis of the electrical units

(All units 230 V AC)

Submersible aerators RHa [Ω] I

Load

[A]

AQUA 3 32 1.3

AQUA 5 14 2.5

AQUA 200 SV 27 1.1

Submersible motor pumps ATBLift 1 32 1.1

ATBLift 2 32 1.25

NOVA 180 SV 46 0.9 NOVA 200 SV 27 1.5

FEKA 600 8 4.3

Operations logbook – self-monitoring by operator

Date: Checks:

Operating times

Aerator [h/min] Feeding pump Clearw.pump Sludge pump

[h/min] [h/min] [h/min] [h/min]

As operator of the wastewater treatment plant you have the responsibility to the water authority of ensuring smooth operation of the plant.

Serial No.: ___________________________

Particular events:

e.g. power failure, defects, sludge removal...

Additional operator’s logbooks can be obtained from your installation partner or under

www.atbwater.com

Operations logbook – self-monitoring by operator

Date: Checks:

Operating times

Aerator [h/min] Feeding pump Clearw.pump Sludge pump

[h/min] [h/min] [h/min] [h/min]

As operator of the wastewater treatment plant you have the responsibility to the water authority of ensuring smooth operation of the plant.

Serial No.: ___________________________

Particular events:

e.g. power failure, defects, sludge removal...

Additional operator’s logbooks can be obtained from your installation partner or under

www.atbwater.com

Manual AQUAmax® PROFESSIONAL G / Art.-Nr.: 9060 XXXX / Stand: 08.01.2019

ATB AQUAmax PROFESSIONAL G Installation Instruction, Operating And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual