KESSEL-Pumpstation Aqualift€F/Aqualift€F Duo For all wastewaters ...

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6. Commissioning 6.1 General instructions Please follow DIN 1986 Part 31 when commissioning pumps / lifting stations. Caution - Before commissioning the Aqualift F make sure that all inlet pipes as well Aqualift F storage chamber and the pump is free from metal, sand or any other potentially damaging debris. Only place the Aqualift F into operation after it has been thoroughly checked to assure that installation and pipe and electrical connection have been properly made. Make sure that all closure valves are fully open before starting Important: the commissioning of the Aqualift F must be handled by a licensed professional Make sure to follow all safety instructions in Part 1 of this User´s manual and do not place the Aqualift F in operation if the pump, control unit or cables show any signs of damage. Please make sure that the power requirements of the pumpstation match those of the power supply from the local power grid. Before placing the system in operation, re-check all electrical connections. Also, make sure that all local and international regulations have been followed – especially those pertaining to explosion proof wastewater pumping stations. Do not use this pumping station to pump mediums for which the pumps or the pumping chamber are not intended. . Pre-check: • Operation data • Pump oil level • Impeller rotation direction • All electrical connections • Proper installation of pump(s) on support feet The pump(s) must be completely filled with pumping medium (wastewater) to insure that an explosion risk atmosphere is prevented. The pump(s) can only be placed into operation when there is no chance of air entering the intake portion of the pump. Commissioning Before placing the pump(s) into operation, it must be confirmed that the wastewater level never falls below the „Minimal Level” (see Chapter 4.4.) During continuous operation of the pumps (S1), the pumps must remain completely submerged. Operating the pumps in non submerged conditions results in an increase wear and tear on the pumps. 6.1.1 Intake of floating matter Pumps with S-impellers are recommended for pumping wastewaters with floating matter. In these cases, it is recommended that the pumps run in a slightly tilted position. In addition, S-impellered pumps should run for an additional 10 seconds after the intake level has been reached. 6.1.2 Pumping medium temperature Max pumping medium temperature of explosion rated pumps – 40 deg C. The operator of this pumpstation must insure that the operational temperature of this system (pumping medium temperature) does not exceed this level. Do not operate this system with pumping mediums above the noted maximum temperature 6.1.3 Pump Starts The maximum pump starts per hour must not exceed 30. 6.1.4 Operating Voltage The highest allowable departure from operating voltage is: ± 10% with non explosion proof systems ± 10% with explosion proof systems The maximum allowable voltage difference between the phases is 1% 6.1.5 Density of Pumping Medium The max density of pumping medium is 1.1. Please contact the manufacturer for using this system with pumping mediums with a specific weight greater than 1.1. 6.2 Non-operating conditions / Storage 6.2.1 Storage of new pumps - Pumps should be stored in the vertical position in a dry location in their original packaging 6.2.2 Requirements for longer duration storage 6.2.2.1 Pump check without pump removal In order to insure proper pump operation, the pumps should be manually run 4 times per year for a short period of time (approx 1 minute). Pre-requisite to this check is that sufficient pumping medium is inside the pumping chamber (above Level 1 mark – see illustration on page 14) 6.2.2.2 Storage of removed pumps Before storing pumps that have already been in service, all check up and maintenance work should take place including lubricating the pumps as discussed in 6.2.1 20
6. Commissioning 6.3 Description of operation 6.3.1 „Auto“ mode Single pump unit The single pump Pumpstation Aqualift F is in standard operating mode when the control unit switch is set to „Auto„ and no failures or warnings are displayed (see Chapter 9 – Control Unit). As the wastewater level inside the Aqualift F storage chamber rises the level will reach the „Pump Off„ level and then reach the „Pump On„ level. After the wastewater level has reached the „Pump On„ level and after the pump start delay time (see Chapter 5.7) has elapsed the pump will begin operation. As the wastewater level decreases the „Pump Off„ float switch level will be reached and the motor will continue pumping until the pump stop delay time (see Chapter 5.7) has elapsed. After the pump stop delay time has elapsed, the pump will turn off. In the case that the pump has not run in the last 24 hours, the pump will automatically turn on for a period of 5 seconds if during this time the wastewater level inside the chamber is above the “Pump Off” level – this is a result of the antiblocking function. In the case that the wastewater inside the chamber is above the “Pump Off” level during this time, then the anti-blocking function will re-activate after the next 24 hours. In the case that the pump runs for longer than the set maximum pump run time, the pump will turn off and at this time the “Laufzeit” LED will turn on to let the operator know that the motor has run to its maximum run time. The warning will remain until the “Alarm Reset” button is pressed. Pressing the “Alarm Reset” button will then allow the pump to restart. Double pump unit The double pump Pumpstation Aqualift F is in standard operating mode when both control unit pump switches are set to “Auto” and no failures or warnings are displayed. Alternating operation The pumps in the double pump Pumpstation Aqualift F are designed to operate alternatingly. As the wastewater level inside the Aqualift F storage chamber rises the level will reach the „Pump Off„ level and then reach the „Pump On„ level. After the wastewater level has reached the „Pump On„ level and after the pump start delay time (see Chapter 5.7) has elapsed the pump will begin operation. As the wastewater level decreases the „Pump Off„ float switch level will be reached and the motor will continue pumping until the pump stop delay time (see Chapter 5.7) has elapsed. After the pump stop delay time has elapsed, the pump will turn off. The next time the wastewater reaches the `Pump On` height – the other pump will turn on and pump out the entire contents of the chamber. If one of the pump malfunctions or is improperly connected the other pump will handle all pumping of the wastewater. Parallel operation As the wastewater level inside the chamber rises, the float switch levels „Pump Off„ and then „Pump 1 On„ activate. After the pump start delay has elapsed, Pump 1 will activate and begin pumping wastewater (see Chapter 5.7). In the case that one pump cannot handle the incoming amounts of wastewater and the wastewater level continues to rise, the „Pump 2 On„ float switch will activate and second pump will begin running after the pump start delay period has elapsed. Both pumps will then continue to operate simultaneously until the „Pump Off„ level has been reached. The anti-blocking function for the double pump pumpstations functions exactly as it does for the single pump pumpstations. In the case that one or both of the pumps runs for longer than the set maximum pump run time, the pump(s) will turn off and at this time the “Laufzeit” LED will turn on to let the operator know that the motor has run to its maximum run time. The warning will remain until the “Alarm Reset” button is pressed. Pressing the “Alarm Reset” button will then allow the pump to restart. In the case that one of the two pumps no longer runs due to damage, exceeding the maximum pump run time or blockage, the remaining pump will function as a single pump unit. 6.3.2 “0“ Mode When the switch for a pump is set to the „0„ setting, this pump will not operate although the warning and failure displays on the control unit will continue to function. If both switches are set to „O„ neither of the pumps will operate 6.3.3 “Hand“ Mode When the control unit is set to the „Hand„ mode the pump will begin (or continue) to operate only if the wastewater level inside the chamber is above the „Pump Off„ level. During pump operation in this mode, the pump will continue to operate after the wastewater level has dropped below the „Pump Off„ level. Be sure not to leave the switch set to „Hand„ mode as this could cause continuous operation of the pump regardless of wastewater levels which could lead to over heating and potential damage to the pump(s). Attention: A pump running without water circulating through it causes increase temperatures and a drastic increase on the wear and tear of the motor. Excessive dry running of the pump(s) (above 5 minutes) can lead to irreparable damage to the pump(s). This damage is easily detectable and is not covered under the Pumpstation Aqualift F warranty. 21
Page 1 and 2: INSTALLATION AND OPERATING MANUAL K
Page 3 and 4: Contents 1. Safety precautions ....
Page 5 and 6: 1. Safety precautions Heavy weight
Page 7 and 8: 3. Technical Data 3.1 Explosion pro
Page 9 and 10: 3. Technical data Control unit powe
Page 11 and 12: 4. Installation Installing the cham
Page 13 and 14: 4.2 Pipe connections All pipes are
Page 15 and 16: 5. Electrical connections NOTICE -
Page 17 and 18: 5. Electrical connections On-site e
Page 19: 5. Electrical connections 5.6 Motor
Page 23 and 24: 7. Inspection and maintenance 7.1.3
Page 25 and 26: 8. Problems and Solutions Problem R
Page 27 and 28: 8. Problems and Solutions (with dou
Page 29 and 30: 9. Control unit 9.1.2 Interior of c
Page 31 and 32: 9. Control unit 9.2 Control unit fo
Page 33 and 34: 9. Control unit 9.2.3 Double unit P
Page 35 and 36: 11. Guarantee 1. In the case that a
Page 37 and 38: 37 Notice
Page 39 and 40: Important contacts / Info Separator

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