Kessel Aqualift F Standard, Aqualift F Duo Standard Installation, Operating And Maintenance Instructions

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

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Landesgewerbeamt Bayern

KESSEL-lifting station Aqualift쏐F (400V) Standard

for wastewater with and without faeces for
free-standing installation in rooms protected from frost

Aqualift쏐F

Aqualift쏐F Duo

Product advantages

Simple connection through
moulded connecting pieces

Drilling surfaces for further
connections

Fully automatic operation

Maintenance-friendly
PE-tank

General technical approval
no. Z-53.2-424

Installation

Commissioning Instruction

The installation and service of this unit should be carried out by
a licensed professional servicer

Name/Unterschrift Datum Ort

Edition 07/2010

Stempel Fachbetrieb

Subject to technical amendment

ID-Nr. 206-818EN

1. Safety information

eneral safety precautions

G

uring installation, operation, maintenance or repairs to the system, please observe the accident pre-

D
vention regulations, the applicable DIN and VDE standards and guidelines, and also the regulations of
the local energy and supply companies.

he systems may not be operated in explosive areas

T

lectrical hazards

E

This system contains electrical voltages and controls rotating mechanical parts. Non-observation of the
operating instructions could lead to serious damage, injury or even fatal accidents.

The system must be securely disconnected from the mains supply before commencing any work on it.
The local master switch and the cut-outs must be turned off, i.e. switch the system to zero-potential and
take precautions to ensure it cannot be switched on again. If only cut-outs are available, these must be
switched off and a sign attached to prevent third parties from switching the main fuse on again.
VDE 0100 applies to all electrical work on the system.

The switchgear and the level control are under voltage and may not be opened. Only electricians may
work on the electrical equipment. The term 'electrician' is defined in the VDE 0105.

Steps must be taken to ensure that the electrical cables and all other electrical system parts are in a
fully functional condition. If any parts are damaged, the system may not be operated and/or must be im­mediately shut down.

Risk of burning fingers and hands

The driving engine may become very hot during operation

Risk of injury to fingers and hands

The pumps are equipped with a closed impeller. Therefore work on the pump may only be carried out if
the power supply has been disconnected and the rotating parts have stopped rotating.
Take care on sharp edges during maintenance or repair work.

Risk due to heavy weights

The lifting system models with one pump weigh around 45 kg, and with two pumps around 84 kg. The
systems may only be lifted or mounted by two persons with appropriate care wearing protective equip­ment (e.g. protective shoes).
The pumps may only be removed slowly or placed in the pump flange opening by two persons (if sui­table precautions to prevent slipping have been taken).

2

1. Safety information

ealth risk

H

he wastewater system transports wastewater that contains faeces; in turn this faeces may contain

T
harmful substances. Whenever working on the system, always ensure that there is no direct contact
between the wastewater and/or soiled system parts and your eyes, mouth or skin. In the event of direct
contact, clean the affected part of your body thoroughly and disinfect if necessary. It is also possible that

he atmosphere in the tank may be harmful.

t

Therefore before opening the cleaning aperture (or removing the pump) ensure that the respective room

s adequately ventilated or provide for (forced) ventilation during the opening process.

i

Noise pollution

When the pump is operated, a noise level is created that may be a nuisance depending on how the pump
is installed. If there are maximum noise level stipulations that need to be observed, appropriate mea­sures need to be taken. The sound damping set from KESSEL may also be helpful here.

Risk of explosion

The inside of the tank is considered to be explosive within the meaning of EN 12050 because the bio­logical digestive process may create flammable gases (hydrogen sulphide, methane gas). Therefore,
when unscrewing the pump or the cleaning aperture lid or any other parts, ensure that the room is ade­quately ventilated or provide for (forced) ventilation during the opening process. Whilst the tank is open,
it is forbidden to smoke or carry out any other activities in the respective room that could cause the gas
to ignite (e.g. operation of electrical devices without encapsulated motors, metalworking etc.).

3

Table of contents

1. Safety information

2. General

3. Technical data

. Installation and assembly

4

5. Electrical connections

6. Initial operation

...........................................................................................................Page 2

2.1 Area of application...............................................................Page 5

2.2 System description ..............................................................Page 5

3.1 Dimensions..........................................................................Page 6

3.2 Pumps .................................................................................Page 7

3.3 Electric switch unit...............................................................Page 8

.1 Fitting the collecting tank.....................................................Page 9

4

4.2 Connecting the pipes...........................................................Page 9

4.3 Setting the pressure level switches .....................................Page 11

5.1 General notes......................................................................Page 12

5.2 Installation of the switch unit................................................Page 12

5.3 Installation, wiring................................................................Page 13

5.4 Checks ................................................................................Page 16

5.5 Configuration of switch unit .................................................Page 17

6.1 General notes......................................................................Page 18

6.2 Pressure outlet connecting pieces.......................................Page 18

6.3 Operating the switch unit.....................................................Page 18

7. Inspection and maintenance

8. Malfunctions and

troubleshooting

9. Control unit

10. Spare parts and accessories

11. Warranty

6.4 Functional description..........................................................Page 19

6.5 Functional test .....................................................................Page 19

7.1 Notes on the pump ..............................................................Page 20

7.2 Notes on aeration device.....................................................Page 20

7.3 Notes on the electrical switch unit .......................................Page 21

8.1 General malfunctions ..........................................................Page 22

8.2 Malfunction messages.........................................................Page 24

8.2.1 Irregular level states ............................................................Page 26

8.2.2 Internal monitoring...............................................................Page 27

8.2.3 "Malfunction" message... .....................................................Page 27

8.2.4 "Alarm" message .................................................................Page 27

8.2.5 What to do when...…...........................................................Page 27

9.1 Switch unit (from model year 01/10) ....................................Page 28

9.2 Switch unit (up to model year 12/09) ...................................Page 29

10.1 Accessory parts...................................................................Page 34

10.2 Spare parts..........................................................................Page 35

...........................................................................................................Page 40

12. Declaration of conformity

13. Handover certificate

...........................................................................................................Page 41

...........................................................................................................Page 42

4

.1 Area of application

2

2. General

he lifting stations pump wastewater with and without se-

T
wage that occurs below the sewer and backwater level fully
automatically into the sewage system in accordance with the
requirements of DIN 1986. They are only suitable for use for

omestic wastewater, for example in single family and multi-

d
family homes, business, hotels and restaurants, department

tores, hospitals, schools or similar cases.

s
If the feed to the lifting stations must not be interrupted du­ring normal operation, the lifting station must be equipped
with a second pumping device of the same capacity which
switches on immediately when required (twin station instead
of single station).

2.2 System description

The KESSEL pumping station
system basically comprises the following assemblies:

Aqualift®F

1.8 1.3 1.5

as a single or twin

1.4

®

he KESSEL lifting station Aqualift

T
for free-standing set-up in frost-protected rooms. The res­pective switch unit must be installed in a flood-proof, dry and
frost-protected room. The wastewater submersible pumps

re equipped with a single-channel impeller and have a com-

a
pletely free passage of 40 mm. The pressure pipes must be

t least of the size DN 80, the ventilation pipes at least DN

a

70. Wearing media must be kept away from the pump im­peller.
The systems are suitable for constant wastewater tempera­tures up to 35°C. A maximum temperature of 60°C is per­missible briefly (up to 10 minutes).

1.4

1.9

1.6

1.3

has been designed

F

1.5

1.6

1.2

1.7

1. Collecting tank made of PEHD

gas and watertight, with

1.1 One or two wastewater pumps, each of which has
a 5 m connection cable

1.2 Pneumatic level control with 5 m air hose each

1.3 Cleaning opening

1.4 Connection for DN 100 inlet pipe

1.5 Connection for ventilation pipe

1.6 Connection for manual diaphragm pump

1.7 DN 100 pressure outlet connecting pieces with

integrated backwater flap and aerating device

1.8 Pre-scored areas

1.1

1.2

1.8

1.7

1.1

2. Electric switch unit

(see illustrations in chapter 8)

3. Accessory parts (not illustrated)

3.1 Brackets with screws and dowels for fixing the tank to
the floor

3.2 Rubber hose with hose clamps for the pressure pipe
connection

3.3 Sound-insulating underlay mat
Mono: Art. no. 28692
Duo: Art. no. 28693

A detailed description of the system set-up can be found in
chapter 10, Spare parts.

)

5

3. Technical data

3.1 Dimensions

3.1.1 Single system 1.1 kW with pressure outlet DN 100, order no. 28645 / 28644 (with non-return valve)
ingle system 2.2 kW with pressure outlet DN 100, order no. 28647 / 28649 (with non-return valve)

S

DN100

Ø110

DN70

Ø75

Ø110

DN100

475

180

Zulaufhöhe

Ø40

DN32

773

3.1.2 Twin system 1.1 kW with pressure outlet DN 100, order no. 28652 / 28659 (with non-return valve)

Twin system 2.2 kW with pressure outlet DN 100, order no. 28634 / 28631 (with non-return valve)

DN100

Ø110

DN70

Ø75

DN100

Ø110

Ø110

DN100

780

160

539

300

Zulaufhöhe

Ø40

DN32

564

525

154

6

3. Technical data

2

0

10

1

4
3

6
5

8
7

9

11

12

13

14

15

0

8412162024283236404446485052545658

3.2 Pumps (Aqualift F Mono, Duo)

Type 400 V - 1,1 kW 400 V - 2,2 kW

ominal capacity (P2) 1,15 kW 2,4 kW

N
Rated capacity (P1) 1,6 kW 3,1 kW
Operating voltage 400 V DS
Rated frequency 50 Hz
Nominal current 3,2 A 5,4 A
Start-up current 14,4 A 30,8 A
Fuse 3 x 16 A slow-blow
Connection cable 5 m long, 7 x 1,5 mm
Temperature of material pumped 35 °C
Weight (pump) 30 kg 31 kg
Protective rating IP 68 ( 24h; 3m WS)
Operating mode

Max. period of perm. operation 240 Min. 30% duty cycler

Sound level < 70 db < 70 db
Pump volume 20 l (Mono), 50 l (Duo)

S1 S3

2

Pumping capacity diagram

Pumping height m

Q min nach DIN 1986 (vmin = 0,7m/s) für DN 80

Q min nach DIN 1986 für DN 100

400 V

230 V

1,1 kW

1,1 kW

400 V
2,2 kW

Pumping capacity Q (m3/ h)

7

3. Technical data

3.3 Electric switch unit

3.3.1 General technical data

Ambient conditions

Permissible temperature range: 0 to 50 °C

ermissible air humidity: 10 to 80 %

P

non-condensing

Maximum operating height: 2000 m above sea level

Power consumption

max. ca. 11 VA for single, 15 VA for double system
(electronics without motor)

Protective class

Class 1 with function grounding of the secondary electronics
circuit (PELV)

Protective rating

IP 54 when fitted correctly

3.3.2 Supply

Mains supply

PE/N/L1/L2/L3 according to marking on terminal block for
single / twin system

Operating voltage

400 / 230 V 3~ 50 Hz ± 10% rotary current (L1=230V AC /
50Hz±10% for supplying the power packs for the electronics)

3.4 Outputs

3

.

Malfunction" relay

"

Changeover contact; opening contact, centre contact,
closing contact each max. 2A

Warning" relay

"

Changeover contact; opening contact, centre contact,
closing contact each max. 2A

Mains

2 x N, max. each 2A
2 x L, max. each 2A
for supplying malfunction/alarm warning devices, switched
through the "malfunction"/"warning" relays, without internal
fusing

Motor (single system)

Motor PE Mains connection
(grey double-deck terminals up to model year 01/10)
(spring terminal on board from model year 01/10)
Motor U T1 contactor
Motor V T2 contactor
Motor W T3 contactor

max. 4kW

}

Pre-fuse required

max. 16 A / phase (to be provided on installation side)

3.3.3 Inputs

a) From model year 01/10
Level inputs each approx. 24 V output; approx. 5 mA input
Each pump has the circuit TF1 and TF2

b) Up to model year 01/10
Level inputs each 15.8 V input approx. 5 mA circuit TF (or TF1
and TF2) and E7 (or E7 and E8) for connecting the temperatu­re switch of the pump motor, sensor supply input max. 18 mA
for TF and 9 mA for E7

Motor 1/2 (twin system)

Motor 1/2 PE mains connection
(4-fold mains through terminals up to model year 01/10)
(spring terminal on board from model year 01/10)
Motor 1/2 U T1 contactor 1/2
Motor 1/2 V T2 contactor 1/2
Motor 1/2 W T3 contactor 1/2

max. 4kW

}

8

4. Installation and assembly

he following parts are included in the scope of supply (see

T
section 2.2):

Collecting tank with all components mounted

-

- Electric switch unit

- Accessory parts

MPORTANT:

I

The electric switch unit must be stored frost-free and dry.
If the system is not connected directly to the power sup­ply on installation, the switch unit inc. all electric parts

ust be stored accordingly.

m

CAUTION:

Hazard through heavy weights. The lifting stations weigh ap­prox. 45 kg (single system) and approx 84 kg (twin system).
The parts may only be lifted and/or assembled using suita­ble equipment and exercising appropriate caution. If the sy­stems are dropped, this can lead to irreparable damage to
system parts (e.g. pump) or the whole system. Such dama­ge is not covered by the warranty.

INSTALLATION SITE:

The KESSEL lifting station Aqualift®F has been designed
for free-standing set-up in frost-protected rooms. The re­spective switch unit must be installed in a flood-proof, dry
and frost-protected room.

.2 Connecting the pipes

4

ll pipes must be routed so that they can run empty auto-

A
matically. All pipe connections must be flexible and sound in­sulated.

here are two types of connection possible:

T

. Use of existing moulded connecting pieces on the

I

tank

(for connection of inlet pipe, ventilation and manual
diaphragm pump according to Fig. A and B) by cutting off
the "front cap" as shown in Fig. C.

Ventilation DN 70 (Da=75mm)

Inlet
connection
DN 100

(Da=110mm)

4.1 Fitting the collecting tank

Umaintenance work on the lifting stations, they must always
be installed in such a way that there is sufficient access to all
areas of the lifting station and replaceability of all compo­nents is guaranteed. According to DIN 1986, there must be
at least 60 cm space all round the system (on all sides and
above it) to meet this requirement.

The system must be set up at the appropriate spot in the
room, aligned horizontally and placed on practical sound-in­sulating material (available as an accessory from KESSEL).
The brackets, screws and dowels must be used to fix the lif­ting station to the floor to prevent movement or twisting.

Attachment bracket

Tank-lifting station

attachment

Insulation mat
(optional)

Floor

Closure manual diaphragm
pump DN 32 (Da=40mm)

Abb. A: Single System

Inlet connection
DN 100 (D

a

=110mm)

Ventilation DN 70 (Da=75mm)

Closure manual diaphragm pump DN 32 (Da=40mm)

Abb. B: Twin System

Floor

9

4. Installation and assembly

A standard plastic pipe muff can be pushed over the connec­ting piece (see Fig. C).

Alternatively, the connection of a plastic pipe with DN 100 for
the inlet or DN 70 for ventilation can be carried out using
connection clamps or rubber hoses with hose clamps*. To

revent the high tension forces leading to deformation at the

p
connecting piece, a suitable supporting ring* must be pus­hed into the upper end of the connecting piece (see Fig. D).

Saw off
connecting pieces

Transition
hose piece

Supporting ring

ipe connection

P

H

clamps

Saw off con-

necting pieces

Hose

clamp

ose

Inlet connection

Tank-lifting station

Abb. C:

Abb. D:

II. Connections attached to the pre-scored areas at

the side (for inlet pipe or manual diaphragm pump) using

bore hole with saw cap*, fitting of a suitable greases seal*
and insertion of a suitable plastic pipe (see Fig. E)

Pipe duct seal

Pipe connection

Opening drilled

Tank-lifting station

Abb. E

* KESSEL accessory part

10

4. Installation and assembly

IMPORTANT

In the case of all the connections drilled at the side it must
be remembered that the level control is adjusted in such
a way that during normal operation the water level in the

ontainer only reaches up to or just below the lower edge

c
of the moulded inlet pipe connecting piece on the side.
For this reason, a respective water level will result in all
pipes that are connected lower down. In the case of inlet

ipes this means that dirt deposits cannot be excluded

p
and may lead to the pipe becoming blocked in extreme
cases.

ressure pipe are available as accessories:

p
DN 80 backwater flap made of cast iron (art. no.: 206-199)

N 100 backwater flap made of cast iron (art. no.: 206-198)

D
Aerating device (art. no. 206)
A shut-off valve must be installed in the pressure pipe on site
in accordance with EN 12056. For this, we recommend the

on-return valves for mono systems (art. no. 28683) and for

n
duo systems (art. no. 28694) from the KESSEL range of ac-

essories.

c

4.3. Level measurement

l Inlet pipe
The inlet pipe must be laid at a gradient to the KESSEL lif­ting station in accordance with DIN 1986 and be routed as
straight as possible.
Connection to the tank can be carried out as described under
section I or II above.
The ventilation pipe sets up pressure compensation to the
fresh air for the air flowing into or out of the system during
emptying or filling. According to DIN 1986 it must be laid at
least as size DN 70 for these lifting stations, and must be rou­ted over the roof to avoid odour pollution.
Connection to the tank can be carried out as described under
section I or II above.

l Pressure pipe
The pressure pipe for directing the soiled water into the se­wage system must be connected directly to the respective
pressure pipe connection. According to the regulations of EN
12056, the pressure pipe must be routed above the back­water level and connected to a ventilated basic or collecting
pipe.
The rubber hose included in the scope must be pushed about
4 cm over the pressure connecting piece at the pressure
connection and fixed in place using a hose clamp as a means
of acoustic insulation and to prevent transmission of forces.
Connection of the rubber hose is not an interlocking connec­tion. It must be set up on site using brackets.
The pressure pipe must be connected (see above) in such a
way that no forces are transferred to the system and there is
no direct contact with the building (structure-borne noise). No
other draining elements may be connected to the pressure
pipe.
Air-tightness and material strength must be guaranteed
under pressure load, too. This must be checked during initi­al operation.
The pressure pipe must not be connected firmly to the buil­ding to prevent pressure blows. When cast metal or steel
pressure pipes with low absorption properties are used, a
pressure blow muffler must be included in the pressure pipe
from pumping heights from 5 m.
Backwater flaps to avoid pressure blows for installation in the

CAUTION:

Before commencing any work on the switchgear, the
pump or the level control, the master switch and cut-outs
must be switched off and secured against being re­connected.

4.3.1 Systems from model year 01/2010

Level measurement takes place using pressure sensor and
submersible pipe. The transparent air hose must always be
routed rising to the switch unit so that no condensation can
collect in the air hose.
Perfect function is only guaranteed when permanent pres­sure compensation takes place between the switch unit and
lifting station. Excess air hose lengths must be shortened.
Extensions of the air hose up to 20 m are possible.
The switching levels are pre-set and can be changed using
the switch unit. More detailed information is available from
KESSEL Customer Services.

4.3.2 Systems up to model year 01/2010

Level measurement is carried out using a pressure dia­phragm switch that is connected to the switch unit via an el­ectric cable inc. air hose. Contact KESSEL Customer Servi­ces for information about setting the switching level.

11

5. Electrical connections

CAUTION:

Only qualified electricians may carry out the work on el­ectrical equipment described below. Before any work is
carried out on the switch unit, the pump or level control,
the main switch and fuses must be switched off, i.e. be vol­tage-free and secured against being switched back on
again

.1 General instructions

5

An external main switch must be installed for the electric
switch unit that can be used in an emergency to switch off all
the downstream circuits independently of the control unit.
This must be assigned clearly to the switch unit.
All connected cables must be strain-relieved.
Screw connections not used must always be sealed properly.

IMPORTANT:

All the cables connected to the electrical switch unit must
be fixed in place using suitable measures (e.g. cable ties)
so that they do not cause a hazard in the 1-error case, i.e.
if a connection becomes loose..

.3 Installation, wiring

5

he pump cables and control cable have a standard length

T
of 5 m. Extension to max. 20 m is possible on site, but must
be done using a VDE-conform connection.

NOTE (applies to pressure diaphragm switches up to model

ear 01/10)

y
The cable on the pressure level switch is a special cable with
an air hose in the centre for compensating pressure for the
pressure sensor in the lifting station to the atmosphere. The
following must always be observed:
– The cable may be cut off at any point but must never be
extended. Special lengths of this cable can be ordered di­rectly from KESSEL.
– The cable must be routed at a constant gradient from the
switch unit to the lifting station.

For this reason, excess lengths must not be rolled up, the

cable has to be shortened to fit.
– The respective screw connection at the switch unit may be
tightened with a maximum torque of 2.5 Nm. Greater torques
can lead to the air hose being squeezed.

– Deviations from these instructions can lead to fun­ctional failure of the pressure sensor and thus the
whole system!

Please heed national and local safety regulations. If these
are not observed, personal hazard may be the result. In ad­dition, no liability or warranty will be granted. After work has
been completed, the housing cover must be sealed properly
again.

5.2 Mounting the switch unit

Screw the housing cover with max. 1 Nm. Install the switch
unit provided in a frost-free, dry, flood-proof and well-venti­lated room. The switch unit has been designed for vertical
wall-mounting on a solid base. Sufficient air circulation must
ensure excessive inside temperatures develop. The unit is
mounted using 4 screws (Ø 6 mm) at the corners of the hou­sing (drilling template in the packaging box). The attachment
holes are accessible after the cover has been opened.

12

5. Electrical connections

he individual connection jobs are listed in the following table and in the connection diagrams on pages 27 and 29. The ex-

T
planations in chapter 8, Electric switch unit, must also be heeded (position of the control elements, view of the inside of the

witch unit).

s

INGLE SYSTEM- Heed safety instructions!

S
Work to be done Switch unit

oth batteries (2 x 9V block) must

attery connection

B

(rechargeable batteries up to year 12/09)

Mains connection

B
be connected on the board.

• Connect the mains supply cable L1
/ L2 / L3 / N / PE at the terminal
block using screw connection.

• N and PE always have to be
connected.

• The mains supply cable must have
an all-pole main switch on the in­stallation side that is clearly assig­ned to the control.

• The pre-fuse prescribed on the in­stallation side must not exceed 16
A per phase.

• The control can be damaged or de­stroyed if connection is not carried
out correctly.

from model year 01/10 Switch unit up to model year 12/09

The rechargeable battery (1 x 9V block) must

•
e inserted into rechargeable battery fixture.

b

• Connect the mains supply cable L1 / L2 / L3 /

N / PE to the upper level of the grey mains
connection terminal block, heeding markings
(printing on the board).

• N and PE always have to be connected.

• The mains supply cable must have an all-pole

main switch on the installation side that is
clearly assigned to the control.

• The pre-fuse prescribed on the installation side

must not exceed 16 A per phase.

• The control can be damaged or destroyed if

connection is not carried out correctly.

Motor supply cable

Motor temperature sensor

Level measurement

Connect the motor supply cable

•
U/V/W to the connector in the right di­rection in the lower screw terminals
T1 / T2 / T3. The direction of rotatio
of the motor must be heeded.

• PE must be connected with TF1
and TF2 to the terminal block on
the board underneath the motor
protection switch.

• Wire 4 of the motor supply cable
must be connected to the lowest
terminal of the terminal block TF2
TF1.

Wire 5 of the motor supply cable
must be connected to the central
terminal of the terminal block TF2
TF1. The input TF2 is bridged using
a 2-pole jumper, i.e. the central ter­minal is doubly occupied. Jumper
must not be removed!

Connection to the pressure sensor
The transparent air hose must al­ways be routed rising to the switch
unit. The air hose must be screwed
tight to the connection provided on
the switch

• Connect the motor supply cable U/V/W to the
ABB connector B6-30-10 left of the motor pro­tection switch in the right direction in the lower

n

screw terminals T1 / T2 / T3. The direction of
rotation of the motor must be heeded.

• Connect PE to the lower level of the grey
mains connection terminal block, heeding the
markings (printing on the board).

• Input TF: Wire 4 of the motor supply cable
must be connected on the right at TF input,
wire 5 on the left at TF input.

• Input E7: The jumper must be left.

Level inputs (ON/ALARM)

• The cable must always be routed rising to the

switch unit.

• The cable ends of the pressure level switch
must be connected to the respectively marked
terminals (white wire on the right, brown wire
on the left to "on" input, green wire on the right
and yellow wire on the left to "alarm" input).

13

5. Electrical connections

SINGLE SYSTEM- Heed safety instructions!
Work to be done Switch unit from model year 01/10 Switch unit up to model year 12/09

• The terminal block of the level inputs must
not be connected with any other circuit.

• The terminals are marked with switch

ymbols.

s

• The outputs N / L1 (2 each) are provided to
supply external warning devices/equipment
with power via the "malfunction" and "alarm"
relays. They must not be used for other pur­poses.

• Maximum permissible current is 2A.

Outputs
"Malfunction" and
"alarm / warning"

The "malfunction" and "warning"
messages are issued via a relay
(changeover contact) without pro­tective circuit. Inductive loads must
be dejammed externally. The quies­cent state (currentless) of the relays
is printed on the board. It means
"malfunction" and "warning" messa­ge is switched on.

• 42 V DC/ 0.5 A

• The "malfunction" and "alarm" messages
are issued via a relay (changeover contact)
without protective circuit. Inductive loads
must be dejammed externally. The quies­cent state (currentless) of the relays is prin­ted on the board. It means "malfunction" and
"alarm" message is switched on.

• The relay contacts do not have any internal
connection to any kind of supply or operating
voltages of the control unit and are safely se­parated from these up to a working voltage
of 300 V according to Table D.10 of the stan­dard EN 61010 (excess voltage category 2
and degree of soiling 2).

• The relays have been designed for switching
230 V / 2 A. Suitable measures must be
taken to restrict the current externally to this
value.

• The relays must not be used to switch diffe­rent phases. The phase may deviate from L1
however.

14

5. Electrical connections

TWIN SYSTEM- HEED SAFETY INSTRUCTIONS!

ork to be done Switch unit

W

from model year 01/10 S

witch unit

up to model year 12/09

Battery connection

rechargeable batteries up to 12/09)

(

Mains connection

Motor supply cable

• Both batteries (2 x 9V block) must
be connected on the board.

Connect the mains supply cable L1 /

•
L2 / L3 / N / PE at the terminal block
L1 / L2 / L3 / N / PE using screw
connection.

•

N and PE always have to be connected.

• The mains supply cable must have
an all-pole main switch on the instal­lation side that is clearly assigned to
the control.

• The pre-fuse prescribed on the in­stallation side must not exceed 16 A
per phase.

• The control can be damaged or de­stroyed if connection is not carried
out correctly.

• The motor supply cables 2 x U/V/W
must be connected to the connectors
in the right direction in the lower
screw-type terminals T1 / T2 / T3
(pump 1 left, pump 2 right). The di­rection of rotation of the motor must
be heeded.

• PE must be connected with TF1 and
TF2 to the terminal block on the
board underneath the motor protec­tion switch.

• Der Akku (1 x 9V-Block) ist in die Akku­halterung einzustecken.

• Connect the mains supply cable L1 / L2 / L3
/ N / PE to the second level from the bottom
of the mains through terminals, heeding mar-

ings (printing on the board / colours).

k

• N and PE always have to be connected.

• The mains supply cable must have an all­pole main switch on the installation side that
is clearly assigned to the control.

• The pre-fuse prescribed on the installation
side must not exceed 16 A per phase.

• The control can be damaged or destroyed if
connection is not carried out correctly.

• The motor supply cables 2 x U/V/W must be

connected to the ABB connector B6-30-10
below the motor protection switch in the right di­rection in the lower screw-type terminals T1 / T2
/ T3 (pump 1 left, pump 2 right). The direction of
rotation of the motor must be heeded.

• Connect PE to the respective upper level of the

mains through terminals, heeding the markings
(printing on the board / colours).

• The motors must be dejammed externally if ne-

cessary.

Motor temperature sensor

Level measurement

PUMP 1/2: Wire 4 of the motor sup­ply cable of pump 1 must be connec­ted to the lowest terminal of the ter­minal block TF2 TF1. Wire 5 of the
motor supply cable must be connec­ted to the central terminal of the ter­minal block TF2 TF1.

• Input TF2 pump 1/2: The jumper
must be left.

Connection to the pressure sensor

The transparent air hose must always
be routed rising to the switch unit. The
air hose must be screwed tight to the
connection provided on the switch
unit.

• Input TF1: Wire 4 of the motor supply cable
of pump 1 must be connected on the right to
input TF1, wire 5 of the motor supply cable
on the left to input TF1.

• Input TF2: Wire 4 of the motor supply cable
of pump 2 must be connected on the right to
input TF2, wire 5 of the motor supply cable
on the left to input TF2.

• Input E7: The jumper must be left.

• Input E8: The jumper must be left.

Level inputs (ON/ALARM)

• The cable must always be routed rising to the
switch unit.

• The cable ends of the pressure level switch
must be connected to the respectively mar­ked terminals (white wire on the right, brown
wire on the left to "on" input, green wire on
the right and yellow wire on the left to "alarm"
input)

• The terminal block of the level inputs must
not be connected with any other circuit.

15

5. Electrical connections

TWIN SYSTEM- HEED SAFETY INSTRUCTIONS!
Work to be done Switch unit from model year 01/10 Switch unit up to model year 12/09

The terminals are marked with switch symbols.

•

Outputs

Malfunction" and

"
"warning"

5.4 Checks

- on the setting of the motor protection switches

• The "malfunction" and "warning"
messages are issued via a relay
(changeover contact) without
protective circuit. Inductive loads
must be dejammed externally.
The quiescent state (current­less) of the relays is printed on
the board. It means "malfunc­tion" and "warning" message is
switched on.

42 V dc/ 0,5 A

• The "malfunction" and "alarm" messages are is­sued via a relay (changeover contact) without
protective circuit. Inductive loads must be de­jammed externally. The quiescent state (current­less) of the relays is printed on the board. It
means "malfunction" and "alarm" message is
switched on.

• The relay contacts do not have any internal connec­tion to any kind of supply or operating voltages of
the control unit and are safely separated from these
up to a working voltage of 300 V according to Table

•
D.10 of the standard EN 61010 (excess voltage ca­tegory 2 and degree of soiling 2).

•

The relays have been designed for switching 230 V
/ 2 A. Suitable measures must be taken to restrict
the current externally to this value.

• The relays must not be used to switch different pha­ses. The phase may deviate from L1 however.

The motor protection switches must be set to the
values for rated current of the respective pumps

as specified in section 3.

5.5. Configuration of switch unit (from model year 01/10)

The DIP switch is located at the top right of the PCB in the switch unit and has four setting possibilities

1. Switch: Sensor selection

- Switch up: Level measurement using float switcher

- Switch down: Level measurement using air pressure switch

2. Switch: Level heights

- Switch up: Underground pumping stations (with submersible pumps)

- Switch down: Lifting stations (using air pressure switch)

3. Switch: Configuration tables (only for service partners)

4. Switch: Anti-blocking system

- Switch up: Anti-blocking system off

- Switch down: Anti-blocking system on

16

5. Electrical connections

5.6 Configuration of switch unit (up to model year 12/09)

Configuration of the control is carried out in the factory using switches S601 ... S604 between the terminal blocks of the level
inputs and thermal protection input. For safety reasons, these must be checked according to the following descriptions.
Pre-settings or reference settings are highlighted grey.

- Basic setting is carried out using switch S604 (4-way DIP switches with 2 positions ON / OFF each).

- Deviating settings are not allowed.

up to year 12/09

S604 / 1

S604 / 2

S604 / 3

S604 / 4

ON

Run-time controlled System

(wastewater lifting system)

Submersible pump

without OFF level switch

Rotary field/phase monitoring

on

Anti-blocking function

on

OFF

Level-controlled

(submersible pump system)

Submersible pump

with OFF level switch

Rotary field/phase failure monitoring

off

Anti-blocking function

off

system

17

6. Initial operation

.1 General instructions

6

nitial operation

I

Initial operation must be carried out by a qualified expert, with
the direct supplier of the wastewater lifting station responsi­ble for his availability. During initial operation, a test run with

ater is required over at least two switching cycles. During

w
the test run, dry running must be avoided. Before, during and

fter this test run, the following must be checked:

a
a) The electric fuse protection of the wastewater lifting stati-

on according to IEC or local regulations
b) The direction of rotation of the motor
c) The gate (actuation, open position, air-tightness)
d) The switching and setting of switching heights in the

collecting tank, in as far as these are not pre-set by the

manufacturer
e) Air-tightness of the system, fittings and pipes
f) Check on operating voltage and frequency
g) Functional test on the backflow preventer
h) Malfunction warning device
i) Attachment of the pressure pipe
j) Motor protection switch; check by briefly screwing indivi-

dual fuses out (two-phase run)
k) Oil level (if oil chamber exists)
l) Pilot lamps and counters
m) Functional test for any manual pump that may be instal-

led.
Initial operation must be documented in writing, whereby im­portant data e.g. setting of the motor protection switch and
status of operating hours counter must be noted.

heck the system installation/cabling carefully before you

C
put the system into operation. Is the protective earthed con-

uctor working? Have the relevant standards/guidelines

d
been heeded, particularly with a view to the potentially ex­plosive area?
Do not put the system into operation if there is any damage

o the motor, switch unit or cables visible.

t
Always follow the safety instructions in chapter 1 of this ma-

ual.

n

IMPORTANT:

All screw connections must be checked for a tight fit.

6.2 Pressure outlet connecting pieces

The pressure outlet connecting pieces of the lifting stations
are equipped with a backwater flap with aerating device as
standard for each pump. The aerating device must always be
in operating position (see Fig. 1).

This initial operation may only be carried out by authorised
specialist staff.

DIN 1986, part 3, must be heeded during the initial operati­on of lifting stations.

CAUTION:

Before initial operation the inlet pipes and the pumps must
be cleaned of solid materials such as metal, sand etc.

Before initial operation the pump must be filled with pumping
fluid up to the height of the ventilation bore hole of the pump
housing.

The pump must not suck in any air!

After the complete and correct installation of the complete sy­stem and all the additional parts as well as the pipe and el­ectrical installations, the system can be put into operation.
Any shut-off valves must be opened.
Make sure before you put the system into operation that the
nominal voltage and type of current specified for the system
correspond to the nominal voltage and type of current on site.

Fig. 1

The flap (dotted line) is opened exclusively by the pumping
flow of the pump.

6.3 Operating the switch unit (from model year 01/10)

As soon as the network connection has been set up, initiali­sation takes place immediately, i.e. the system undertakes a
self-test. After this test, the system is ready for operation
(mains LED lights up).
The acoustic alarm can be switched off by pressing the alarm
LED. The pump(s) can be switched on manually by pressing
the pump key twice.

18

6. Initial operation

.4.1 Operating the switch unit

6

6.4.1 "Automatic" operating model

) Single system

a

The basic function is carried out when the operating mode
switch is set to "auto" and there is no indication of a malfun­ction (see chapter 9, Switch unit). As the (soiled water) level

ises in the tank, the level switch "on" closes. After the "on"

r
switched has closed, the switch-on delay time begins (see
section 5.7, Configuration of switch unit), after which the
pump is switched on. The level in the tank decreases through
the pump operation so that the "on" level switch opens again.
After the "on" switched has opened, the run-on time begins
(see section 5.7, Configuration of switch unit), after which the
pump is switched off.

If the current pump running time exceeds the configured
value of the maximum running time limit, the pump is swit­ched off. At the same time, a malfunction message is issued
by the red LED "run time" lighting up permanently and via the
"malfunction" relay output. The malfunction message (LED
and relay) remain stored until the "alarm reset" key is actua­ted, and the pump can only be restarted once this has taken
place.

b) Twin system

The basic function is carried out when both operating mode
switches are set to "auto" and there is no indication of a mal­function (see chapter 9, Switch unit).

p to model year 12/09)

(

u

hen the maximum running time limit has been exceeded,

W
the malfunction message and switch-off of the respective
pump take place as with the single system. The respective
pump can only return to operation when the "alarm reset" key
has been actuated.

n as far as one pump leaves "auto" control (on account of

I
the running time limit being exceeded, a malfunction, through
respective position of the operating mode switch), the re­maining second pump is operated analogue to the "auto"
control of a single system, independently of the other pump.

6.4.2 Operating mode "0" (up to model year 12/09)

When the operating mode switch is in the "0" position, the
(respective) pump is switched off, independently of all input
signals. The display elements remain ready for operation.

6.4.3 Operating mode "manual" (up to model year 12/09)

In the "manual" operating mode the (respective) pump is or
remains switched on, independently of the existing water
level in the tank, until this operating mode is switched off
again.

CAUTION:
Running the pump(s) without water will lead to redu­ced cooling and increased wear of the pump motor.
Excessive dry running of the pump(s) longer than 5
minutes can thus lead to irreparable damage to the
pump. Such damage is not covered by the warranty.

Alternating operation

As the (soiled water) level rises in the tank, the level switch
"on 1" closes. After the "on 1" switched has closed, the
switch-on delay time begins (see section 5.7, Configuration
of switch unit), after which one pump is switched on. The
level in the tank decreases through the pump operation so
that the "on 1" level switch opens again. After the "on 1" swit­ched has opened, the run-on time begins (see section 5.7,
Configuration of switch unit), after which this pump is swit­ched off. Next time the "on 1" level is reached, the other
pump is switched on.

Parallel operation

As the (soiled water) level rises in the tank, the level switch
"on 1" closes. After the "on 1" switched has closed, the
switch-on delay time begins (see section 5.7, Configuration
of switch unit), after which one pump is switched on. If the
water level continues to rise, the second pump is switched
on (after the delay time) in addition if the "on 2" level is ex­ceeded. This parallel pump operation continues until the "on
1" level switch opens again and the run-on time has expired.

6.5 Functional test

The different functions of the overall system depending on
the water level in the tank must be checked in a one-off test
using the corresponding water filling levels in the tank. The
tank must be filled via the connected inlet pipe.

19

7. Inspection and maintenance

he system must be checked once every month by the ope-

T
rator through observation of the switching routine for opera-

ional ability and leaks.

t

CAUTION:
Disconnect the unit from the mains during all mainte-

ance work! Heed safety instructions!

n

ll the servicing and maintenance work described

A
below may only be carried out by authorised qualified
personnel.
Repairs may only be carried out by the manufacturer
or his authorised service partner.

DIN 1986, part 3, must be heeded during maintenance work
on lifting stations. Maintenance work must be carried out re­gularly by authorised qualified staff.

IMPORTANT:

All screws may only be tightened with a maximum torque
of 3 Nm.

.2 Notes on the aerating device

7

he aerating device can be used to completely empty the

T
pressure pipe through manual lifting of the backwater flap on
the lifting system. To do this, an Allen key size 8 or open­ended spanner size 15 must be used to hold the flap opener

urned (see Fig. 2) as long as necessary until the pressure

t
pipe is empty. Then the flap opener must always be returned

o its initial position or the marked operating position (see

t
Fig. 3).

The following tasks have to be carried out:

• Visual inspection of the complete system, pumps and fitting

parts

• Thorough cleaning of the complete system and the pump

• Check on the complete system and pump housing for ex-

ternal damage and visible wear

• Check on the pump for free movement, wear and deposits

• Check the connection cables for mechanical damage and

wear

• Check the seal connections for air-tightness and replace

the seal (e.g. O-ring) if there any indications of wear

• Insulation test on the pump motor

• Check non-return valve for function if appropriate

• The backwater flap must be replaced after 2 years of ope-

ration.

7.1 Notes on the pump

The pump should be checked at regular intervals. If opera­tional noises increase, pumping capacity decreases or there
are vibrations in the pipeline system, the pump housing and
impeller must be checked for any stubborn soiling or wear.
To do this, the motor unit must be loosened at the four attach­ment screws (refer also to section 10.2.1 or 10.2.2) and re­moved from the pump housing.
When checking the pump housing, care must be taken that
the ventilation bore hole is kept open under all operating con­ditions.

Fig. 2

Fig. 3

Note:

The complete flap housing can be removed for cleaning
and maintenance purposes (see Fig. 4+5) by loosening
the screw connections on the lower and upper flange of
the flap housing. The pressure pipe must have been
blocked off and emptied first, of course.

20

7. Inspection and maintenance

Fig. 4 Fig. 5

7.3 Notes on the electric switch unit

• The battery / rechargeable battery is a wearing part and

should be checked and changed if necessary once a year
if possible. When changing the batteries, make sure you
dispose of them properly, with the environment in mind.
They may only be replaced by batteries of the same type.

• The contactor is a wearing part and should be checked and

changed if necessary once a year if possible. When chan­ging the batteries, make sure you dispose of them properly,

with the environment in mind. They may only be replaced
by batteries of the same type.

• After maintenance work, the cover plate and transparent
housing cover (up to model year 12/09) must be attached
properly again (contact protection!).

• Repairs may only be carried out by the manufacturer/ser­vice partner.

21

8. Malfunctions and troubleshooting

he system must be checked once every month by the operator through observation of the switching routine for operatio-

T
nal ability and leaks.

8.1 General malfunctions

Malfunction Cause Remedial measure

Pumps do not start

1

perating mode switch is not set to

O
"auto" (only up to model year 12/09)

Motor protection switch has trigge­red, motor is blocked

Motor turns sluggishly

1 or 2 phases have no current

Control fails on account of heavy
fluctuations in the mains power
supply

et switch to "auto"

S

Remove pump; eliminate blockage (object) in
the impeller or housing area

Maintenance / repair by Customer Services

Check fuses and power supply
cables
Retrofit battery in the switch unit and
inform power supply company.

2 Pumps are running,

Alarm level is reached /
is indicated

3 Pumps run roughly or loud

and LED "phase/rotary field"
lights up (only up to model
year 12/09))

3 Pumps run roughly or loud

and LED "phase/rotary
field" does not light up (only

up to model year 12/09)

Pressure sensor not airtight or PE
hose not connected

System is overloaded

Too little pumping capacity.

Aeration device not in operating position

Wrong direction of rotation for
motor

In the case of twin systems, both
motors are rotating the wrong way

Reduced capacity through
damage

Wrong direction of rotation for
motor

In the case of twin systems, both
motors are rotating the wrong way

Check all screw connections for air-tightness

Check whether there is a short-term increase in
wastewater occurrence; if possible do not use
drainage points temporarily or divert wastewa­ter elsewhere if possible

• Eliminate object in the impeller or housing
area

• Remove the object from the pressure fitting or
pressure pipe

• Pumps are worn, have them replaced

• Wrong lifting station design, clarification
through KESSEL Customer Services

Put aeration device into operating position

Check direction of rotation, if incorrect swap
2 phases of the supply cable

Swap 2 phases in the supply cable of the
switch unit

Check pump(s) and motor(s); have damaged
parts replaced by Customer Services

Check the direction of rotation, if incorrect swap
2 phases of the motor supply cable (see sec­tion 5.5)

Swap 2 phases of the motor supply cables of
the switch unit

4 Wastewater is not drained

off, backwater at the lowest
draining points

Systems not switched on

Power supply cable to the switch
unit without current

Level control malfunction

Inlet pipe to the system blocked

Set switch to automatic

Check fuse. Check current supply.

Check soiling, switching points and function of
the level control

Clean inlet pipe

22

8. Malfunctions and troubleshooting

törung Ursache Abhilfemaßnahme

S

5 System suddenly

runs loudly

6 Putrid smell

Acrid smell

Inlet gate to the system (if existent) not
opened or not opened completely

Wastewater temperature too high

ver a longer period (15 min), lea-

o
ding to restricted suction capacity
of the system

Phases switched through work on

he domestic power supply

t

Damage to the pump parts through
objects

Object in the pump

Leaks in the lifting station

Pump not airtight

Motor(s) too hot, overloaded

Open inlet gate completely

Reduce wastewater temperature

checking the direction of rotation

Check pump, have it repaired or replaced by
Customer Services if necessary

Remove the object, check pump for damage
and replace if necessary

Check ventilation, inlet and pressure lines as
well as covers for air-tightness and eliminate
leaks
Check pump, have it repaired or replaced by
Customer Services if necessary

Check motor and pump to make sure they are
running easily, check system for switching mal­functions (particularly motor protection switch)

7 System runs too often, swit-

ches on for no reason

8 System does not switch or

has a variety of different
switching malfunctions

9 Pumping capacity too low

Contactors too hot on account of
switching malfunctions

Supply quantity too high through
external water or similar

Backwater flap faulty, wastewater
runs out of the pressure pipe back
into the system

Foam formation in the system

Tank or pumps are blocked by
grease being discharged in large
quantities

Level control ventilation blocked

Level control soiled; level pressu­re switch set incorrectly or faulty

Rotary field incorrect

System switched on and off too often on ac­count of high inlet quantities, clarification with
KESSEL customer services

Check system for switching malfunctions.

Find and eliminate the causes

Check backwater flap (integrated in the pres­sure outlet connecting piece on every pump),
clean it and replace any damaged parts

Reduce amounts of washing powder and de­tergents used
Clean the whole system, check grease
discharge

Check cables between the switch unit and level
control for kinks and correct routing (even gra­dient), correct or replace if necessary

Remove the level control, clean submersible
pipe, check pressure switch and adjust if ne­cessary

Swap mains wires (malfunction message at the
switch unit)

Wrong direction of pump rotation

23

Check pump wires for correct connection

8. Malfunctions and troubleshooting

alfunction messages / remedial measures (from model year 01/10)

M

= lit = off

Battery fault

Power failure (battery operation)

l =

= flashing slowly ❍ = flashing quickly

- Acknowledge alarm and alarm key

- Check if batteries are connected
Replace discharged batteries

-

- After acknowledging the signal tone, press the alarm key again

--> Switch unit continues to work without batteries

--> No protection function during power failure

- Check whether power has failed in the whole room / building

- Check fuses / check fault-current circuit breaker

- Check mains cable for fault

- Check microfuse in the switch unit

(only use fuses with the same nominal capacity and triggering characteristics).

Motor fault

Cause: TF1, TF2, MSS
Remedy: --> Check motor protection switch 1/2

--> Lower winding temperature switch has triggered

--> Automatic reset when motor has cooled must be acknowledged

Duo Pump 1

Duo Pump 2

Running time limit fault/ running frequency limit fault

- Running frequency limit fault: one pump starts up more often than 20 times in 3 minutes

--> Check air hose between submersible pipe/plunger and switch unit
for water inclusions

--> Check submersible pipe/plunger for blockage

Duo Pump 1

--> Check supply pipe, check pumping capacity

--> Check backwater flap

using the alarm key.

--> In the case of lifting stations jumper TF2 faulty/not installed
Replace/install jumper

Duo Pump 2

- Running time limit fault: Pump has been running for longer than 240 minutes at a time

--> Check air hose between submersible pipe/plunger and switch unit for water inclusions

--> Check submersible pipe/plunger for blockage

--> Check supply pipe, check pumping capacity

--> Check backwater flap

24

Sensor fault

Duo Pump 1/2

8. Malfunctions and troubleshooting

- Drop in pressure:
Water level has fallen by 12 mm without the pump having been running

--> Pump the submersible pipe/plunger free by hand

-> Check the air hose for leaks

-

Rotary field / phase fault

Duo Pump 1/2

Relay switching cycles

Duo Pump 1

Duo Pump 1

- Rotary field fault:
Wrong rotary field for mains connection of switch unit

--> Swap 2 phases

- Phase fault:
Phase L1 or L2, L3 not available

--> Check connection on the switch unit, mains cable, fuses,
check fault-current circuit breaker

--> If L1 has failed, direction of rotary field cannot be recognised.

--> If L1 has failed, the switch unit goes into battery-operated mode

Power contactor has exceeded 100,000 switching cycles

--> Can be acknowledged, power contactor makes another 1,000 switching cycles
before the message is repeated

--> Replace contactor --> Contact Customer Services

--> The fault "relay switching cycles" is recurring

Alarm level exceeded

Alarm level is reached by water level

--> Alarm goes out automatically when the level drops below the alarm level again

--> LED only goes out after manual acknowledgement has taken place

--> Check inlet

--> Check level measurement and switching points

25

Relay fault

Duo Pump 1

Duo Pump 2

Level fault

Duo Pump 1/2

8. Malfunctions and troubleshooting

ower contactor no longer switches off

P

--> Disconnect switch unit from the mains

--> Replace contactor --> Contact Customer Services

Level fault (only with pressure diaphragm switch): Control cable to the switch unit is not
laid on a continual gradient

--> Check cable route, shorten any excess lengths if appropriate.

The switches ON and ALARM switch in the wrong order

--> Pressure control unit faulty, replacement necessary

8.2.1 Irregular level states (up to 12/09)

Malfunctions of level switches can be recognised in part and
trigger a meaningful emergency control in "automatic" ope­rating mode. If the control unit recognises an implausible
level switch state, the malfunction message "level" is indica­ted by the red "running time/level" LED flashing and the
"malfunction" relay. The malfunction message can be dele­ted using the "alarm reset" key when the fault has been re­medied or when no level fault can be detected on account of
pending level signals. Generally speaking it is not possible
to distinguish between non-closing "alarm" level switches
and non-opening "on" level switches.

Irregular level states usually indicate a fault in the level
switches or wiring. Maintenance may only be carried out
by a qualified electrician.

a) Single system

No distinction can be made between a non-closing "on" level
switch and a non-opening "alarm" level switch. If "alarm"
level is pending without "on" level, a level fault is indicated.
The motor is not switched on. If the "on" level switch closes
in this state, however, the pump is switched on. Opening the
"on" level switch switches the pump off.

b) Twin system

• Non-closing "on 1" level switch
Malfunction message follows the "on 2" level being excee­ded. If the "alarm" level is exceeded, both pumps switch on.
If the level drops below the "on 2" level, the pumps switch off.

• Non-closing "on 2" level switch
Malfunction message follows the "alarm" level being excee­ded. At the same time, the second pump is switched on. Both
pumps remain in operation until the level falls below "on 1"
again.

• Permanently closed "on 2" level switch
Malfunction message follows the "on 1" level not being rea­ched. One pump switches on when the "on 1" level is ex­ceeded, the second pump when the "alarm" level is excee­ded.

• Permanently closed "alarm" level switch
Malfunction message follows when "alarm" level is indicated
but at least "on 2" level is not reached. A permanent "alarm"
message is then sent. The alarm message via the internal
signal sensor can be deleted by actuating the "alarm reset"
key. The "alarm" relay remains active, however, until the fault
has been eliminated. One pump is switched on when the "on
1" level is exceeded, the second pump when the "on 2" level
is exceeded. Both pumps are switched off after the level falls
below "on 1".

26

.2.2 Internal monitoring

8

8. Malfunctions and troubleshooting

The control unit evaluates the signals of the phase/rotary field
monitoring, motor protection switch and motor temperature

ensor regardless of the configuration. In the event of a mal-

s
function or non-readiness for operation, the pump is switched

ff or the switch-on suppressed. In addition, a fault is indica-

o
ted by the respective display LED and the malfunction relay
switching.

hase/rotary field monitoring

P
If L2 and/or L3 fail, the "phase/rotary field" LED is perma­nently lit, and the "malfunction" relay becomes active. (In this
case the control unit can no longer recognise rotary field
faults.) Since the control unit is supplied by L1, failure of L1
cannot be indicated. If L1 fails, however, the built-in signal
sensor is switched on provided the rechargeable battery is
inserted in the control unit and charged.
In the case of false rotary field (anti-clockwise rotary field) the
"phase/rotary field" LED flashes. The contactor for the motor
output is disabled by the control unit.

Motor protection switch
One auxiliary contact (each) of the motor protection switch is
evaluated. If a motor protection switch has triggered on ac­count of manual actuation, short-circuit or exceed load, a
malfunction is indicated by the "motor protection switch" LED
(or LED "pump ... MSS/temp" is permanently lit) and the
"malfunction" relay. In addition, the contactor for the motor
output is disabled by the control unit.

or on twin systems with
– Phase/rotary field

Pump 2 MSS/temp

–
– Pump 1 MSS/temp

Running time/level

–
The conditions for the malfunction messages are described
in detail in the previous chapters.

.2.4 "Alarm" message

8

Alarm messages are sent through:

• Activation of the "alarm" relay and thus through the war-

ning device connected to this.

• The internal signal sensor
Two conditions can lead to an alarm message.

1. An alarm message is issued if the level exceeds the

"alarm" level. The internal acoustic alarm can be switched
off again by pressing the "alarm reset" key. As soon as the
level falls below the "alarm" level, both alarm messages
(signal sensor and relay) are reset.

2. If a replaceable battery (battery) is inserted and charged,

an alarm message is also issued if there is a power failu­re, i.e. the mains power failure is indicated by an acoustic
signal triggered by the internal signal sensor. The rechar­geable battery supplies the internal signal sensor for a few
hours depending on the charge state. The internal acou­stic alarm can be switched off again by pressing the "alarm
reset" key.

Motor temperature
In every motor, there is a temperature sensor which indica­tes excess temperature to the control unit:
When excess temperature has been reached (approx. 110
°C) this is indicated (flashing) by the "motor temperature"
LED (or "pump ... MSS/temp" LED in the case of a twin sy­stem) and the "malfunction" relay drops out. In addition, the
contactor for the respective motor output is disabled by the
control unit. When the motor has cooled down again, the
pump is automatically ready for operation as soon as the
temperature sensor indicates this.

8.2.3 "Malfunction" message

SMalfunction messages are sent through:

• Activation of the "malfunction" relay and thus through the
warning device connected to this.

• Display of the type of malfunction by the malfunction LEDs
on individual systems with

– Phase/rotary field
– Motor protection switch
– Motor temperature
– Running time/level

8.2.5 What to do when...

... the motor protection switch has triggered.

Remove the transparent housing cover (heed instruc­tions!) and press the black "START" switch on the motor pro­tection switch. If the motor protection switch triggers again,
please contact a qualified electrician.

... another malfunction message occurs.

If the malfunction cannot be eliminated within the con­text of the operating instructions, please contact a qualified
electrician.

... the control unit no longer reacts to input signals, but sig­nalises readiness for operation through the "operation" dis­play.

Disconnect the control unit completely from the mains
for about 10 seconds using the mains switch on the installa­tion side. If the control unit still does not work, please contact
a qualified electrician.

27

Aqualift F Mono 400V

N

IVEAU

L

EVEL

PUMPE

P

UMP

K

urzbedienungsanleitung:

Netzverbindung herstellen

grüne Netzanzeige

Automatikbetrieb

Niveau-Anzeige leuchtet

Pumpniveau erreicht

Pumpen-Anzeige leuchtet

Pumpe läuft

U

nterdrücken des
akustischen
A

larms mit - Taste

A

usschalten/Handbetätigen
der Pumpe mit - Taste

g

g

g

g









134,8 mm

R 3 -0,2mm

Pumpe I

Pump I

Pumpe II

Pump II

Aqualift F Duo 400V

Kurzbedienungsanleitung:

N

etzverbindung herstellen

grüne Netzanzeige
Automatikbetrieb

Pumpe I läuft

Pumpe II läuft

U

nterdrücken des
akustischen
Alarms mit - Taste

Ausschalten/Handbetätigen
der Pumpe mit - Taste

Pumpe I-Anzeige leuchtet

P

umpe II-Anzeige leuchtet

g

g

g

g









134,8

mm

R3-0,2mm

.1 Switch unit (from model year 01/10)

9

9. Control unit

















 Display/indicator panel

Pilot lamp indicating readiness for operation



 c Pilot lamp for alarm message (the activated

alarm can be switched off by acknowledging
the alarm key)

 Pump can be switched on manually by

pressing this twice

 e Switch-on level reached

(pump automatically starts up once
switch-on delay has expired)



9.1.1 Circuit diagram single system (from model year 01/10)

28

9. Control unit

9.1.2 Circuit diagram twin system (from model year 01/10)

9.2 Switch unit (up to model year 12/09)

9.2.1 Switch unit for single system (up to model year 12/09)

Description of the display and control elements

Display elements (LED’s)
Normal mode Operation

(for information Level „Alarm“ yellow "Alarm" level reached
for the operator) Level „On“ yellow On" level reached

Level „Off“ yellow no function
Pump yellow Pump output activated

Malfunction

(for information for the Flashing: Rotary field fault
fitter, motor protection Motor protection switch red Motor protection switch has triggered
switch also for the operator) Motor temperature red Flashing: "Temperature A" (TF)

Control elements
Manual - 0 - Auto
Alarm Reset

Motor protection switch

Phase/rotary field red Permanently lit: Phase failure (has display priority)

Running time / Level red Permanently lit: Running time fault

Sliding switch Choice of operating mode
Key Reset / alarm signal sensor test

Switch Triggered when pump has excess current

yellow

Voltage supply OK

Flashing: Level fault

saving - priority treatment

Reset of a level fault display
Reset of excess motor temperature

29

9. Control unit

• The operating elements can be accessed once the trans­arent housing cover has been removed. The housing

p
cover may be removed for operational purposes, but it only
makes sense for service work.

• The protective rating given is reduced when the cover is

removed (water-tightness). Before removal, it must be
checked whether there is a hazard through high humidity

r splashwater. In this case, the control unit must be swit-

o

View of the inside of the switch unit (schematic, not to scale) up to model year 12/09

ched voltage-free first. In case of doubt, a qualified elec-

rician must always be consulted.

t

• The current set at the motor protection switch must corre­spond with the rated current of the connected motor and
must not be adjusted by the operator.

• Following operation, the housing cover must be sealed
properly again to guarantee the

1. Holes for on-site M6 screws for wall

2. Mains supply

3. Slot for rechargeable battery (rechar-

4.1 Connection of supply for pump motor

4.2 Connection of temperature monitoring

5. Connection for level inputs

attachment

geable battery available as accessory)

for pump motor

6. Connection for external malfunction
and alarm message

30

9. Control unit

.2.2 Switch unit for single system (from model year 12/09)

9

Edition 04.99 / Du / EINZ-F

31

9. Control unit

.3 Switch unit for double system (up to model year 12/09)

9

.3.1 Description of the display and control elements

9

Display elements (LEDs)
Normal mode

(for information for the user Level „Alarm“ yellow "Alarm" level reached

Malfunction

(for information for the Flashing: Rotary field fault
fitter, motor protection switch Pump 2 MSS/Temp red Permanently lit: Motor protection switch
also for the operator) hat ausgelöst

Bedienelemente
Manual - 0 - Auto (Pump 1)
Manual - 0 - Auto (Pump 2)
Alarm Reset

Motor protection 1
Motor protection 2

Operation green Voltage supply OK

evel „On2“ yellow "On 2" level reached

L
Level „On1“ yellow "On 1" level reached

evel „Off“ yellow no function

L
Pump 1 green Pump output 1 activated
Pump 2 green Pump output 2 activated
Phase / rotary field red Permanently lit: Phase failure (has display priority)

Flashing: Excessive motor temperature Pump 2

Pump 1 MSS/Temp red Permanently lit: Motor protection switch pump 1

has triggered

Flashing: Excessive motor temperature pump 1

Running time/level red Permanently lit: Running time fault

Flashing: Level fault

saving - priority treatment

Sliding switch Choice of operating mode for pump 1
Sliding switch Choice of operating mode for pump 2
Key Reset / alarm signal sensor test

Reset of a level fault display

Reset of excess motor temperature
Switch Triggered when pump 1 has excess current
Switch Triggered when pump 2 has excess current

• The operating elements can be accessed
once the transparent housing cover has
been removed. The housing cover may be
removed for operational purposes, but it
only makes sense for service work.

• The protective rating given is reduced

when the cover is removed (water-tightn­ess). Before removal, it must be checked

whether there is a hazard through high
humidity or splashwater. In this case, the
control unit must be switched voltage-free
first. In case of doubt, a qualified electrici­an must be consulted.

• The current set at the motor protection
switch must correspond with the rated cur­rent of the connected motor and must not
be adjusted by the operator.

• Following operation, the housing cover
must be sealed properly again to guaran­tee the protective rating (water-tightness).

View of the inside of the switch unit (schematic, not to scale)

1. -

2. Mains supply

3. Slot for rechargeable bat­tery (rechargeable battery
available as accessory)

4.1 Connection of supply for
pump motor

4.2 Connection of temperature
monitoring for pump motor

5. Connection of level inputs

6. Connection for external
malfunction and alarm mes-

4.1

4.1

sage

32

9. Control unit

.3.2 Switch unit for double system (Aqualift Duo) (up to model year 12/09)

9

Edition 04.99 / Du / DUO-F

33

10. Spare parts and accessories

0.1 Accessory parts

1

Designation Article-Nr.

Manual diaphragm pump 28680

Shut-off valve for manual diaphragm pump 28681

Elastic hose connection

with 2 hose clamps DN 40 28660

N 70 28661

D

DN 100 28663

Flange-hose connection DN 80 28655

DN 150 28658

Plastic shut-off valve for pressureless installation DN 100 28698

DN 150 28699

Sound insulation (underlay mat) Single system 28692

Twin system 28693

Seal for pipe duct DN 50 850114

DN 70 850116

DN 100 850117

DN 125 850118

DN 150 850119

Saw cap DN 50 - DN 150 50100

Battery (1 unit) from model year 01/2010 197-081

Rechargeable battery up to model year 12/2009 20230

Non-return valve for mono systems DN 100 28683

Non-return valve for duo systems DN 100 28694

Compressor set for bubble formation

for greater operational safety with grease discharge and hygiene articles 28048

Air filter for compressor motor protection (28048) 363-140

Motor protection switch 2,5 -4 Amp. 363-134

Motor protection switch r 4-6,3 Amp. 363-135

Motor protection switch 6,3-10 Amp. 363-136

Contactor 363-151

Refer to Kessel catalogue

34

0.2 Spare parts

1

0.2.1 Single system

1

10. Spare parts and accessories

14





10

15

15

12

11

16

7

1

13

9

9



Position Units Part no. Description

11206-004 Mono tank
21206-161 Pump flange complete (F)
3a 1 367-002 Motor complete 1.1 kW / 400 V
3b 1 367-003 Motor complete 2.2 kW / 400 V
41240-051 Mono flap housing DN 100
5a (up to 12/09) 1 206-017 Mono pressure control unit complete
5b (up to 01/10) 1 206-208 Mono submersible pipe
61206-018 Cleaning cover
7a (up to 12/09) 1 206-048 Mono switch unit 1,1 kW
7a (up to 12/09) 1 206-116 Mono switch unit 2,2 kW
7b (up to 01/10) 1 363-100 Mono switch unit 1,1 kW
7b (up to 01/10) 1 363-101 Mono switch unit 2,2 kW
8128663 Elastic hose connection DN 100
92206-054 BG attachment bracket
10 1 206-042 Profile seal
11 1 049-010 Lip seal
12 1 049-011 Lip seal
13 1 049-005 Rolling ring
14 4 017-095 Cylinder head screw
15 8 206-074 PT screw
16 8 017-199 Cylinder head screw M8x25
17 8 017-012 Washer
18 1 367-007 Seal

19 1 206-228 PE-hose 6 x 4 mm (5m)
19 1 206-227 PE-hoses 6 x 4 mm (10m)

35

10.2.2 Twin system

10. Spare parts and accessories

22



15

20

2



6

1

1

Position Units Part no. Description

11206-005 Duo tank
22206-161 Pump flange complete (F)
3a 2 367-002 Motor complete t 1,1 kW / 400 V
3b 2 367-003 Motor complete 2,2 kW / 400 V
41240-056 Duo return flow lock complete DN 100
5a (up to 12/09) 1 206-022 Duo pressure control unit complete
5b (from 01/10) 1 206-224 Duo submersible pipe (from model year 01/10)
61206-018 Cleaning cover
7a (up to 12/09)1 206-049 Duo switch unit 1.1 kW 400 V
7a (up to 12/09)1 206-117 Duo switch unit 2.2 kW 400 V
7b (from 01/10) 1 363-117 Duo switch unit 1.1 kW 400 V
7b (from 01/10) 1 363-118 Duo switch unit 2.2 kW 400 V
8128663 Pressure hose D = 110 x 6 for DN 100
92003-144 Pipe clamp D = 120 for DN 100
10 2 206-054 BG attachment bracket
11 2 206-042 Profile seal
12 1 049-010 Lip seal
13 1 049-011 Lip seal
14 2 049-005 Rolling ring
15 8 017-095 Cylinder head screw
16 4 206-074 PT screw
17 14 017-199 Cylinder head screw M8x25
18 14 017-012 Washer
20 4 017-213 Lens head screw M6
21 1 367-007 Seal
22 1 206-228 PE hose 6 x 4 mm (5m)
22 1 206-227 PE hose 6 x 4 mm (10m)

36

10. Spare parts and accessories

0.2.3 Submersible pipe L = 175 mm

1

➂

➁

➀

Single system (206-208)
Double system (206-224)

Pos. Unit Part-No. Description

11 197-333 Bulkhead fitting
21 197-340 Clamping ring for bulkhead fitting
31 197-339 Closing nut for bulkhead fitting

1 206-228 PE hose 6 x 4 mm (5m)
1 206-227 PE hose 6 x 4 mm (10m)

10.2.4 Pressure control unit (up to model year 01/10)

➄

➁

➀

➂

Single system (206-017)

Pos. Unit Part-No. Description

11 28045 Pressure control unit mono
21 206-014 Upper part of pressure control unit
31 206-045 Cable screw connection
4 5m 206-047 Cable
52 017-153 PT screw

Double system (206-022)

Pos. Unit Part-No. Description

11 28046 Pressure control unit duo
21 206-014 Upper part of pressure control unit
31 206-045 Cable screw connection
4 5m 206-047 Cable
52 017-153 PT screw

➃

37

10. Spare parts and accessories

10.2.5 Mono flap housing DN 100 (part no. 240-051)

➂

➄

➃

➀

➁

Pos. Unit Part-No. Description

11 240-046 Flap housing
21 240-048 Hose connection 110

1 240-038 Hex. locknut M8

3

1 240-037 O-Ring

4
5a 1 240-068 Backwater flap for 1,1 kW

inc. flap stay

5b 1 240-069 Backwater flap for 2.2 kW

inc. flap stay

38

10. Spare parts and accessories

0.2.7 Mono flap housing DN 100 (part no. 240-056)

1

Pos. Units Part no. Description

12240-007 Duo RS housing
22240-045 Pressure cover closed
31240-009 T-piece DN 100
4a 2 240-068 Backwater flap for 1.1 kW inc. flap stay
4b 2 240-069 Backwater flap for 2.2 kW inc. flap stay
64240-027 O-Ring
78240-058 Hexagon safety screw M6
88240-059 Hexagon safety screw M6
98240-038 Hexagon safety screw M8
10 8 240-039 Hexagon safety screw M8
11 2 049-005 Rolling ring DN 125

39

11. Warranty

1. In the case that a KESSEL product is defective, KESSEL has
the option of repairing or replacing the product. If the product
remains defective after the second attempt to repair or repla­ce the product or it is economically unfeasible to repair or re­place the product, the customer has the right to cancel the
order / contract or reduce payment accordingly. KESSEL
must be notified immediately in writing of defects in a product.
In the case that the defect is not visible or difficult to detect,

ESSEL must be notified immediately in writing of the defect

K
as soon as it is discovered. If the product is repaired or re­placed, the newly repaired or replaced product shall receive
a new warranty identical to that which the original (defective)
product was granted. The term defective product refers only
to the product or part needing repair or replacement and not
necessarily to the entire product or unit. KESSEL products are
warranted for a period of 24 month. This warranty period be-

ins on the day the product is shipped form KESSEL to its cu-

g
stomer. The warranty only applies to newly manufactured
products. Additional information can be found in section 377
of the HGB.
In addition to the standard warranty, KESSEL offers an addi­tional 20 year warranty on the polymer bodies of class I / II
fuel separators, grease separators, inspection chambers, wa-

stewater treatment systems and rainwater storage tanks. This
additional warranty applies to the watertightness, usability
and structural soundness of the product.
A requirement of this additional warranty is that the product is
properly installed and operated in accordance with the valid
installation and user's manual as well as the corresponding
norms / regulations.

. Wear and tear on a product will not be considered a defect.

2

Problems with products resulting from improper installation,
handling or maintenance will also be considered a defect.

Note: Only the manufacturer may open sealed components or
screw connections. Otherwise, the warranty may become null
and void

1.06.2010

0

40

41

Handover-Ceritficate

Handover certificate (copy for the company carrying out the installation)

❏ T

he initial operation and instruction was carried out in the presence of the person authorised to perform the

acceptance and the system operator.

❏ The system operator/person authorised to perform the acceptance was informed about the obligation to ser-

vice the product according to the enclosed operating instructions.

❏ Initial operation and instruction were not carried out.

The client/ person responsible for initial operation was handed the following components and/or product components

Initial operation and instruction is being carried out by (company, address, contact, phone)

The exact coordination of the dates for initial operation/instruction is being carried out by the system operator and per­son responsible for initial operation.

Place, date Signature of person Signature of system operator Signature of the company

authorised to perform acceptance carrying out the installation work



42

Important contacts / Info

Separator Type: __________________________________________________________

Day / Hour __________________________________________________________

roject description / Building services

P

supervisor __________________________________________________________

Address __________________________________________________________

Telephone / Fax __________________________________________________________

Builder __________________________________________________________

Address __________________________________________________________

Telephone / Fax __________________________________________________________

Planner __________________________________________________________

Address __________________________________________________________

Telephone / Fax __________________________________________________________

Contracted plumbing company __________________________________________________________

Address __________________________________________________________

Telephone / Fax __________________________________________________________

Commissioning no. KESSEL

System operator / owner __________________________________________________________

Address __________________________________________________________

Telephone / Fax __________________________________________________________

Other remarks __________________________________________________________

__________________________________________________________

__________________________________________________________

__________________________________________________________

The system operator, and those responsible, were present during the commissioning of this system.

____________________________ ____________________________ ____________________________

Place and Date Signature Builder Unterschrift Anlagenbetreiber



K

Backwater protection

K

Lifting Stations and pumps

K

Drains and shower channels

K

Separators

-Grease Separators

-Oil-/ Fuel-/Coalescence
Separators

-Starch Separators

-SedimentSeparators

K

Septic Systems

K

Inspection Chambers

K

Rainwater Management
Systems