Graf one2clean+, one2clean+ XXL Instruction For Operation And Maintenance
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Instructions for
start-up, operation and maintenance
one2clean+
one2clean+ XXL
Small wastewater treatment
systems
Control unit version KL24plus
The points described in these instructions must be observed in all
cases. Failure to do so shall invalidate the warranty. For any additional items purchased through
GRAF, you will receive separate
installation instructions in the
transport packaging.
The components must be checked
for any damage before the system
is transferred to the pit.
You will receive separate instructions for installation of the system.
Be sure to read before starting
up!
Contents
1. General information 2
2. Safety 3
3. Description of function 6
4. Control unit 8
5. Start-up 18
6. Level measurement 19
7. Operation and maintenance 22
8. Fault messages and rectification 28
9. EC conformity declaration 31
10. Technical data 32
11. Template for weekly / monthly check notes 34
12. Maintenance log for GRAF small wastewater
treatment systems 37
13. Notes 39
1. General information
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1. General information
Below you will find some important information for safely operating your system for a long time to come.
• The SBR system is designed to receive all domestic wastewater. Other wastewater, e.g. from restau-
rants and / or commercial premises etc., may only be received if this was specified and taken into
account in the system's design.
• Biocides, toxic substances or substances which are not biocompatible must not enter this system
because they hinder bacteria important to wastewater cleaning and cause problems in the biological
process (detailed information is provided on the following pages).
To meet official cleaning requirements, it is essential that the system is operated in accordance
with our operating and maintenance instructions. You will find these instructions on the following
pages.
We also ask you to read the following information carefully:
The External control cabinets should be located as much in the shade as possible to prevent
them from overheating in the summer.
At all times ensure that the cabinet, especially its ventilation apertures, are not covered and are
freely accessible for maintenance work.
External control cabinet: Ventilation apertures on the rear
The power supply must be ensured at all times. Please ensure that the fuse on the control cabi-
net is sufficient (16 A). Additional electrical fixtures on the same fuse may disrupt operation.
2. Safety
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2. Safety
This chapter contains details relating to safety measures and residual risks. Read this chapter through
carefully before using the system to ensure that it is used as safely as possible.
Intended use 2.1
The control unit was specifically developed for use in SBR small wastewater treatment systems. The control unit must not be used in areas representing a danger to life and limb:
control of machinery, vehicles and safety processes,
research technology involving hazardous substances,
medical technology,
nuclear power technology,
etc.
Explanation of warning notices and prohibitions 2.2
Warning of danger
Warning of dangerous voltage
Warning of tripping risk
Warning of hot surface
Warning of hand injuries
Warning of explosive atmospheres
Fire, naked flames and smoking prohibited
2. Safety
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Danger notices 2.3
1. To ensure safety, everyone who comes into direct contact with the system must note the content of
this documentation.
2. The system must not be used for any purpose other than that described by the manufacturer.
3. Local operating and safety requirements and legislation must be followed at all times, even if they
are not explicitly mentioned in these instructions. The same applies to environmental requirements.
4. If the operator becomes aware of mistakes or dangers, the manufacturer or responsible maintenance company must be informed immediately.
5. Safety precautions must never be removed or bypassed during normal operation of the wastewater
treatment system. Safety precautions may only be temporarily bypassed or deactivated by the
maintenance fitter during repairs and maintenance.
6. When working with chemical substances, contact with the chemicals should be avoided Before these substances may be used, the instructions for use on the packaging must be read and followed.
7. If the use of personal protective equipment (safety shoes, protective glasses, gloves, ear defenders,
etc.) is prescribed, ensure that they are used. Defective or damaged protective equipment must be
immediately replaced with fully functional equipment.
8. Work on electrical equipment may only be undertaken by specialists.
9. All safety and danger notices on the machine should always be kept fully legible.
10. Hot parts must not come into contact with explosive or highly flammable chemicals.
11. Do not put vessels containing liquids on electric switch cabinets; short circuits may occur if the liquid
is spilled.
12. The system must not be operated by anyone under the influence of alcohol or medication which limits cognitive ability or ability to react.
13. The system must be de-energised before any maintenance or cleaning work takes place.
14. Other than for maintenance purposes, the system should always be left switched on, otherwise correct wastewater cleaning cannot be guaranteed.
2. Safety
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Warning notices 2.4
Be sure to observe this information. Failure to do so may result in personal injury or damage to property!
Installation loca-
tion
Ensure that the machine cabinet is not installed above or in the direct vicinity of water
vessels. There is a risk of electric shock if improperly installed.
Mains connection
Only connect the machine cabinet to a correctly installed 230 V socket or earth cable
which is fused with an upstream 16 A fuse.
Electrical equipment connected to the mains may be damaged during a storm. We
would recommend fitting surge protection in the building to protect against this.
The connection cable must be laid in a way it won’t represent a tripping hazard.
Explosive atmos-
pheres
The control unit must not be fitted or activated in environments with potential explosive atmospheres or in places where there are flammable materials. Sparks in such
environments may cause an explosion or fire and this may result in physical injuries
or even death.
Interferences
The control unit may cause medical equipment to malfunction. This device should
therefore not be used in close proximity to medical equipment.
Damage
The control unit must not be operated if the housing or cable insulation is damaged or
crushed.
Service work
Service work on the machine cabinet may only be undertaken by authorised specialists / electricians.
Voltage supply
The power supply must be ensured at all times. Please ensure that the fuse on the
control cabinet is sufficient (16 A). Additional electrical fixtures on the same fuse may
disrupt operation.
3. Description of function
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3. Description of function
Description of the wastewater treatment process 3.1
The one2clean+ wastewater treatment system is a fully biological system and functions on the principle of
the retention process with extended aeration (Sequencing Batch Reactor). The system basically consists
of an aerobic stage, which is split into a rest and an aeration zone, linked together in the lower section.
This process therefore subjects all the domestic wastewater directly to aerobic wastewater treatment.
Blowing in compressed air aerates the entire system and the resultant aerated sludge biologically cleans
the wastewater.
The coarse materials and floating solids in the wastewater are initially retained using a scum guard in the
rest zone. Then the wastewater passes into the aeration zone via an aperture under the scum guard.
The rest zone is aerated too, so the retained solids are also aerobically broken down over the course of
time. In the one2clean+, the wastewater is treated without pre-treatment so no anaerobic putrefaction
processes can occur.
The SBR procedure is a series of different steps, undertaken one after another and at least once a day.
Step 1: Aeration
In the first phase, the wastewater is put straight through aerobic treatment for a fixed
time. As a result, the microorganisms (aerated sludge) are supplied with the oxygen
needed for the breakdown and then pressure aeration causes mixing. The system's
aeration equipment is supplied with ambient air by a compressor. Aeration is intermittent so that targeted wastewater cleaning is possible. Different ambient conditions can
thereby be achieved.
Step 2: Settle
There is no aeration in the second phase. The aerated sludge and the remaining settleable solids can now settle with the aid of gravity. A clear water zone forms at the top
and a sludge layer at the bottom. Any floating sludge is on top of the clear water zone.
Step 3: Clear water extraction
In this phase, the biologically cleaned wastewater (clear water) is drawn out of the SBR
stage. It is pumped out by an air lift (or mammoth) pump, which uses compressed air.
The air lift pump is designed not to pump out any floating sludge on top of the clear
water layer. A minimum water level is maintained in the system without any further
components.
In multi-tank systems, there is also a phase in which the sludge is returned to the system.
Once step is complete, the cleaning process starts again with step 1.
Two cycles are undertaken a day. The maintenance company can individually adapt the switching times.
3. Description of function
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Structure of one-tank systems 3.2
Figure 1: One-tank system
Structure of multi-tank systems 3.3
Figure 2: Two-tank system
Sampling point
Clear water lifter
Scum baffle
Pipediffusors
Sampling point
Clear water lifter
Pipe Diffusors
Pipediffusors
Sludge return
Connection pipe
4. Control unit
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4. Control unit
Connections to the KL24plus control unit 4.1
The figures below show the basic structure of the switch cabinet of a two-tank system.
Figure 3: EPP cabinet with 3-way air distributor
The following connections can be found on the switch cabinet:
1. 230V AV ~ 50 Hz mains connection, for connecting the control unit to a socket
2. Compressor connection, for connecting the
compressor to the control unit via an integrated two pin plug
3. Compressor's air connection. This is used to
connect the strip of valves integrated in the
switch box to the compressor
4. Hose connection (19 mm) for connecting the
aeration unit
5. Hose connection (13 mm) for connecting the
discharge lifter
6. Hose connection (13 mm) for connecting the
sludge lifter
7. One unused hose connection
Figure 4: Air distributor with stepped motors
Y4
Y3 Y2
Compressor
Compressor connection
Connection for power supply
Connection 6 mm
for level sensor
aeration
sludge lifter
discharge lifter
(two tank systems)
Control unit
4. Control unit
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Connections on the rear of the control unit 4.2
Figure 5: Rear of KL24plus control unit
Connections:
1 Connection for mains cable
230 V AC ~ 50 Hz
2 X1: Pre-assembled valve cable
3 X2: two pin plugs for the air compressor connection
4 COM: Connection for communication module (optional) and/or port for PC
5 F1: T6.3A main fuse, slow blow
6 F2: T2A fuse for UV module, slow blow
7 Connection for temperature sensor, "must be plugged in!"
9 X3: Connection for UV module
10 P: Connection for pressure measuring hose
Connections on the air distributor/valve block 4.3
When delivered, the control unit is already correctly connected to the corresponding connection on the air
distributor/valve block.
A distinction is made between three different air distributor variants:
1. 4-way air distributor (4 separate valves Y1 …Y4)
2. 3-way air distributor (3 separate valves Y2 …Y4) and
3. 2-way air distributor (2 separate valves Y3 and Y4)
To allow you to correctly connect up at a later date, the connectors of the control unit (X1.1 …X1.4), their
function (aeration, clear water extraction or sludge extraction) and the connections on the air distributor in
a matrix are shown in detail in the table below.
Control unit
Air distributor connections
Functions
Valves
Connectors
3-way
Y2
Y3
Y4
Aeration
Valve 1
X1.1
X
Clear water extraction
Valve 2
X1.2
X
Sludge Return
Valve 3
X1.3
X
-----
Valve 4
X1.4
4. Control unit
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Starting up the control unit 4.4
Once the system has been connected to the power supply, perform a brief system test. The system test
takes a few seconds and checks the real-time buffering. During this time, the LED lights up red. Then the
LED switches to green and the start phase is complete. During the system test the words "SYSTEM TEST
... OK" appear. The program version and the control unit's serial number are displayed briefly. The system's current operating mode is then displayed in the liquid crystal display. Once the system test is complete, the date and current time should be checked and adjusted if necessary.
After checking the date/time, the function of the installed parts should be checked. The check can only
take place as soon as the installed parts are connected to the control cabinet via the air hoses needed.
The check should be carried out via the "Manual operation" menu item in the control unit. The individual
installed parts should be activated and checked in turn.
The system should be reset to automatic mode once the check is completed successfully.
PLEASE NOTE: The clear water lifter will only work if the tanks are filled.
If the time and date are not set correctly, operating faults are saved with the wrong times.
4. Control unit
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Instructions for operating the wastewater treatment system 4.5
The system is operated using a microprocessor in the control unit. The microprocessor allows operating
parameters to be set, operating statuses to be displayed, system parameters to be queried and operating
times to be programmed by a specialist.
Settings are entered by scrolling through numerical values using the and arrow keys.
The setting is then confirmed by pressing the key.
The individual dialogues can be closed prematurely by pressing or close automatically after 2
minutes.
The control unit is divided into the following display screens:
1. Basic level: Status of cycle process with remaining time elapsing and fault message display.
2. Operator level: By pressing the key, the operator can enter the operator level and undertake
operator-specific settings.
3. Service level: A password-protected service level is accessed from the operator level via an additional
code. This level is reserved for trained staff. Settings and/or changes can be undertaken here and diagnosis data called up.
4.5.1 Control programs
The control unit switches the outputs for air compressors and valves at specific times.
The times are defined by the set sequence tables.
In accordance with the sequence table selected, a complete cleaning cycle is started at each start time.
Setting holiday times at operator level enables all cleaning cycles to be suppressed for the set time period. Only a holiday cycle with greatly reduced activity occurs during this time. No treated wastewater is
extracted during this time because no water should be fed in.
The current sequence table can be modified by trained staff in the service level. Depending on the size of
the wastewater treatment system, another sequence table can be selected. The current sequence table
and other settings are stored resistant to zero voltage. The current sequence table is only modified or a
new sequence table selected in the cycle pause. This ensures that the current extraction is always undertaken at the end of a complete cleaning cycle.
If this is not necessary, the user can perform a "Cycle restart" to immediately adopt the modified parameters.
A sequence table consists of:
• table name - comprising max. 16 characters, e.g. one2clean+ 4PE C
• number of start times (cycles) - max. 24
• cycles - with cycle times and the consumers to be switched
4. Control unit
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4.5.2 Operating status display
Figure 6 View of KL24plus operating unit
The system's operating status is indicated by the LEDs (Green = Operation / Red = Fault) and by text on
the screen.
In normal operating mode (aeration mode), the display looks like this:
In automatic mode, the liquid crystal display shows the current operating phase and time remaining in this
stage of operation.
If a fault occurs, the red LED switches on. A message appears in the liquid crystal display indicating
which component is faulty (e.g. compressor 0.0A fault).
The following operating phases are displayed:
KL24plus
Control unit
Process undertaken
Denitrification
Aeration is activated intermittently, the aerated sludge is briefly mixed. There are
long pauses in between (reaction times).
Aeration
Aeration is activated, the system is aerated at intervals.
Settling phase
Rest phase; the aerated sludge settles.
Discharge phase
Discharge lifter is activated, the clear water is pumped into the discharge.
Sludge removal
Sludge lifter is activated, the excess sludge is pumped out of the last tank back
into the first one.
ONLY with multi-tank systems
Cycle pause
Aeration is activated, the system is aerated at intervals (considerably less than in
the "aeration" phase).
Holiday mode
Aeration is activated, the system is aerated at intervals, no cleaning cycles are
undertaken.
Remaining: XXX.XX
min
Display showing time remaining.
Aeration
Remaining:
120:10min
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