AQUATO K-PILOT 9.7 User manual

AQUATO®K-PILOT
9.7 Control
PLEASE NOTE THE FOLLOWING:
The installation manual and the operating diary must be kept di-
rectly at the facility, so that both operators and qualied personnel
can inspect it at any time.
› Operation Manual

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Manufacturer
AQUATO®Umwelttechnologien GmbH
Ernstmeierstr. 24
D-32052 Herford
All rights reserved.
Infringements will lead to compensation.
Duplication and passing on to third parties is only allowed with the consent of the manufacturer.

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I Table of contents
I Table of contents ................................................................................................3
II List of abbreviations..........................................................................................8
1Manufacturer’s declaration ..........................................................................9
2Important information.................................................................................10
2.1 General information ..............................................................................10
2.2 Important information ............................................................................10
3Safety instructions......................................................................................13
3.1 General information on the safety information......................................13
3.2 Definition of Terms ................................................................................13
3.3 Hazard analysis.....................................................................................13
3.4 Warning symbols used..........................................................................14
3.5 Duty of care of the operator ..................................................................14
3.6 General safety instructions ...................................................................15
3.7 Safety instructions for qualified personnel ............................................16
3.8 Rescue measures .................................................................................16
4Area of application of the controller .........................................................17
4.1 Standard settings ..................................................................................17
4.2 Further operating modes.......................................................................18
4.2.1 Operation with UV lamp for hygienisation.....................................18
4.2.2 Operation with precipitant dosing for phosphate precipitation ......18
4.2.3 Operation with hygienisation and phosphate precipitation ...........18
4.2.4 Operation with double float ...........................................................18

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4.2.5 Operation with additional pump ....................................................18
5Installation manual for the controller .......................................................19
5.1 Safety instructions.................................................................................19
5.2 Installation of the K-Pilot 9.7 controller .................................................20
5.3 Solenoid valve block .............................................................................21
6Connections on the controller...................................................................22
6.1 Overview ...............................................................................................22
6.2 Air connections......................................................................................24
6.3 Pressure monitoring..............................................................................25
6.4 Electrical connections ...........................................................................26
6.4.1 Arrangement and function of the outputs and inputs ....................27
6.4.2 Mains connection of the controller ................................................29
6.4.3 Compressor...................................................................................29
6.4.4 Potential-free contact ....................................................................31
6.4.5 Solenoid valves .............................................................................33
6.4.6 Float switch ...................................................................................34
6.4.7 Further assignments of the outputs ..............................................39
7Commissioning of the plant.......................................................................44
7.1 Prior to commissioning..........................................................................44
7.2 Commissioning......................................................................................45
8Operation and displays of the controller..................................................46
8.1 Operation ..............................................................................................46
8.2 Faults ....................................................................................................47
8.3 Power failure alarm ...............................................................................48

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9Operation as an SSB plant.........................................................................49
9.1 Commissioning of the controller............................................................49
9.2 Main display ..........................................................................................52
9.3 Menu .....................................................................................................53
9.3.1 Menu structure ..............................................................................53
9.3.2 "Service" menu..............................................................................54
9.3.3 "Settings" menu.............................................................................66
9.3.4 Other menus with displays or settings ..........................................69
9.4 Presets ..................................................................................................78
9.5 Switching times – Basic settings...........................................................78
10 Operation as an SBR plant.........................................................................79
10.1 Commissioning of the controller............................................................79
10.2 Main display ..........................................................................................82
10.3 Menu .....................................................................................................83
10.3.1 Menu structure ..............................................................................83
10.3.2 "Service" menu..............................................................................84
10.3.3 "Settings" menu.............................................................................96
10.3.4 Other menus with displays or settings ..........................................99
10.4 Presets ................................................................................................108
10.5 Switching times – Basic settings.........................................................108
11 Operation as fluidised or fixed bed plant ...............................................109
11.1 Commissioning of the controller..........................................................109
11.2 Main display ........................................................................................111
11.3 Menu ...................................................................................................112

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11.3.1 Menu structure ............................................................................112
11.3.2 "Service" menu............................................................................113
11.3.3 "Settings" menu...........................................................................124
11.3.4 Other menus with displays or settings ........................................127
11.4 Presets ................................................................................................132
11.5 Switching times – Basic settings.........................................................132
12 Operation as a trickling filter plant..........................................................133
12.1 Commissioning of the controller..........................................................137
12.2 Main display ........................................................................................139
12.3 Menu ...................................................................................................140
12.3.1 Menu structure ............................................................................140
12.3.2 "Service" menu............................................................................141
12.3.3 "Settings" menu...........................................................................146
12.3.4 Other menus with displays or settings ........................................149
12.4 Presets ................................................................................................151
13 Operation as a constructed wetland plant .............................................152
13.1 Commissioning of the controller..........................................................153
13.2 Main display ........................................................................................155
13.3 Menu ...................................................................................................156
13.3.1 Menu structure ............................................................................156
13.3.2 "Service" menu............................................................................157
13.3.3 "Settings" menu...........................................................................162
13.3.4 Other menus with displays or settings ........................................165
13.4 Presets ................................................................................................167

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14 Operation with UV lamp for hygienisation .............................................168
15 Operation with precipitant dosing for phosphate precipitation...........171
16 Error messages and troubleshooting.....................................................174
17 Technical Data...........................................................................................177
18 Operation log.............................................................................................178
19 Decommissioning and disposal ..............................................................179
19.1 Temporary decommissioning..............................................................179
19.2 Disassembly of the whole plant ..........................................................179
19.3 Disposal ..............................................................................................179
20 Addresses..................................................................................................180

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II List of figures
Figure 1: K-Pilot 9.7 controller............................................................................................................22
Figure 2: K-Pilot 9.7 controller opened ...............................................................................................23
Figure 3: Connection for pressure measurement on and in the controller........................................... 24
Figure 4: Hose connection for pressure monitoring ............................................................................ 25
Figure 5: Electrical connections of the K-Pilot 9.7 controller .............................................................. 26
Figure 6: 9.7 controller – terminal strip ...............................................................................................27
Figure 7: K-Pilot 9.7 controller with socket for compressor ................................................................. 30
Figure 8: Potential-free contact ..........................................................................................................31
Figure 9: Potential-free contact with error indication – power supplied by controller ........................... 32
Figure 10: Potential-free contact with error indication even in case of power failure ........................... 32
Figure 11: K-Pilot 9.7 controller – connection of solenoid valves ........................................................33
Figure 12: K-Pilot 9.7 controller – float switch connection...................................................................35
Figure 13: Connection of 2nd float switch as flood detector................................................................ 36
Figure 14: Connection of double float switch to K-Pilot 9.7 controller ................................................. 37
Figure 15: K-Pilot 9.7 controller – connection of second and third compressor................................... 40
Figure 16: Clear water pump with external float switch.......................................................................41
Figure 17: K-Pilot 9.7 controller – clear water pump connection......................................................... 42
Figure 18: Control buttons..................................................................................................................46
Figure 19: Menu structure for SSB.....................................................................................................53
Figure 20: Menu structure for SBR.....................................................................................................83
Figure 21: Menu structure for fluidised/fixed bed plant ..................................................................... 112
Figure 22: Trickling filter plant with pumps ....................................................................................... 133
Figure 23: Menu structure of Trickling Filter C and Trickling Filter N................................................. 140
Figure 24: Menu structure of Trickling Filter C and Trickling Filter N................................................. 156
Figure 25: K-Pilot 9.7 controller – UV lamp connection .................................................................... 168
Figure 26: K-Pilot 9.7 controller – phosphate precipitation connection.............................................. 171

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1Manufacturer’s declaration
Declaration of Conformity
This certifies the conformity of the AQUATO®K-Pilot 9.7 controller with the EC directives for CE marking.
Device type:
Electronic control devices for the automatic operation of a fully
biological small wastewater treatment plant according to DIN
4261-2
AQUATO®K-Pilot 9.7
Directives:
1. EMC Directive 89 / 336 / EEC
2. Low Voltage Directive 73 / 23 / EEC
3. RoHS Directive
Applied standards:
for 1.
EN 61000 - 6 - 3 (2006)
EN 61000 - 6 - 1 (2007)
EN 61000 - 3 - 2 (2014)
for 2.
EN 6 204 - 1 (2007)
for 3.
- not applicable -
Special notes:
- none -
Date:
03/02/2020
Nils Homburg, Technical Manager
Manufacturer:
AQUATO®
Umwelttechnologien GmbH
Ernstmeierstraße 24
32052 Herford
Germany

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2Important information
2.1 General information
This manual describes the operation of the K-Pilot 9.7 controller.
With the AQUATO®K-Pilot 9.7 controller, you receive a quality product that is designed for controlling
small wastewater treatment plants. In addition, it automatically controls compressors and pumps. During
operation, the units are current- and pressure-controlled in order to ensure operational safety.
The K-Pilot 9.7 controller can be used to operate SSB, SBR, fixed bed and fluidised bed wastewater
treatment plants.
Please read this information in advance to ensure proper operation and compliance with the required
discharge values.
The complete operation manual must be kept directly at the plant so that
both the operator and qualified personnel can inspect it at any time.
2.2 Important information
The AQUATO® K-Pilot 9.7 controller indicates faults acoustically and optically. It features a mains-
independent power failure monitoring system.
After commissioning, please receive instruction in the plant engineering and functioning of the
AQUATO®K-Pilot 9.7 controller.
The warranty shall become void in the event of improper use!
In the case of repairs, the proper functioning of the plant and the continued validity of the warranty can
only be guaranteed if original spare parts or spare parts approved by AQUATO®are used.
The small wastewater treatment plant must always remain in operation!
It must not be switched off.
If you have any problems with your controller, please consult your maintenance company. They will be
happy to help you solve any problem you might have.

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If the AQUATO®controller is used for other purposes without the express consent of AQUATO
Umwelttechnologien GmbH and/or if the safety instructions are disregarded, this may result in danger
or injury to persons and malfunctions or defects in the plant.
In this case, all liability shall be excluded.
The relevant accident prevention regulations must be observed!
Modifications to the controller and unauthorised conversions are not permitted.
The AQUATO®K-Pilot 9.7 controller must be installed properly and in accordance with the
installation instructions (see Chapter 5).
The Controller Operation Manual must be read carefully before installation and commissioning and the
instructions contained therein must be strictly followed!
During assembly and installation, commissioning and operation, as well as, if applicable,
decommissioning, the applicable standards and regulations must be observed.
All work may only be carried out by trained specialists with an appropriate certificate of qualification.
The operator of the plant must be instructed in its operation by the fitter.
When connecting the controller, national regulations and the specifications on the nameplate must be
observed. The device may only be operated on mains types which contain a protective conductor (PE).
Connection to the mains must be made by means of a separate fuse and an RCD fuse. Before
commissioning, the electrical protective measures must be checked to verify their proper functioning!

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Installation work may only be carried out by qualified electricians.
When working on the device, always pull out the power plug.
Never operate a device that
►has a malfunction,
►was dropped or
►was otherwise damaged,
►apparently has a damaged connection cable or
►apparently has a damaged plug.
The plant must be disconnected from the mains supply for all maintenance and repair work.
If it is necessary to enter the plant, this may only be done in the presence of a second person
with appropriate safeguards (gas detector, safety ropes)!
The applicable accident prevention regulations and the accepted rules of technology must be
observed!

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3Safety instructions
3.1 General information on the safety information
This manual contains basic instructions that must be observed during installation, commissioning and
maintenance.
The complete manual must be kept directly at the plant so that both the
operator and qualified personnel can inspect it at any time.
The safety instructions contained in this operation manual, the applicable national accident prevention
regulations and any internal work, operating and safety regulations must be observed at all times.
Non-observance of the safety instructions may endanger both persons and the environment and result
in the loss of any claims for damages.
3.2 Definition of Terms
Operator
The operator of the plant is considered to be the person who ensures that the plant is kept in proper
operation.
Qualified personnel
Qualified personnel are in a position to assess and perform work assigned to them and to recognize and
assess dangers on the basis of the technical training and the knowledge and skills imparted to them.
3.3 Hazard analysis
The AQUATO®plants were developed according to the state of the art and subjected to a risk analysis.
To eliminate or minimize risks, please follow the instructions below.

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3.4 Warning symbols used
Below you will find an overview of the symbols used in this manual and their meanings:
Warning of a danger point
Warning of dangerous electrical voltage
3.5 Duty of care of the operator
Make sure that
•the plant is used only in accordance with its intended purpose (see Chapter 4),
•the plant is only operated in perfect condition,
•the self-checks are carried out by the operator,
•the maintenance intervals are complied with,
•maintenance and repairs are only carried out by qualified personnel,
•the Controller Operation Manual, the Installation, Operation and Maintenance Manual and the
operation log can be inspected at any time,
•and only wear and spare parts approved by the manufacturer are used.

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3.6 General safety instructions
The accident prevention regulations for work on wastewater plants (DGUV regulation 21 and DGUV
regulation 22, formerly: BGV C5) must be observed. The relevant applicable regulations (EN, VDE, etc.)
as well as the regulations of local energy suppliers must be strictly complied with. The work should only
be carried out by skilled personnel. The following safety instructions must always be observed for your
own safety when working and coming into contact with the small wastewater treatment plant:
1. Disconnect the small wastewater treatment plant from the mains!
Special care should be taken when performing maintenance work in the pit. In
this case, the plant technology must always be disconnected from the mains
and secured against unintentional reconnection of the power supply!
Risk of electric shock in case of defective compressor or defective power
cables.
The fine-bubble aeration of AQUATO ®diffuser systems causes a water-air
bubble mixture with a lower density than pure water. This reduces the
buoyancy in the water. Should a person accidentally fall into the reactor, he/she
would not be able to swim. (Danger of drowning!)
2. Ventilate the plant well, access to the pit only with safeguard and
supervisor!
Biological processes produce gases that are dangerous to humans. These can
lead to fainting and/or death by suffocation, even if they cannot be detected by
smell. For this reason, access to the small wastewater treatment plant is only
permitted under the supervision of a person keeping watch outdoors and after
a good ventilation with appropriate safeguards (gas detector, safety ropes).
A rescue/safety harness must be worn by each person entering the v
Never climb in after unconscious persons. Instead, get help immediately!
3. Electrical fuse protection, RCD fuse!
Die AQUATO®operate with 230 V / 50 Hz alternating voltage or with 400 V /
50 Hz alternating voltage. When operating the controller, the personnel must
also not be exposed to the risk of electric shock due to carelessness (e.g. wet
fingers). The socket provided for t
he control device must be separately
protected by an RCD fuse (DIN VDE 0100-410:2018-10) and connected to the
mains supply by electrically qualified personnel. Before commissioning the
plant, a qualified electrician must check the proper functioning of the electrical
protective measures.

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3.7 Safety instructions for qualified personnel
Installation, maintenance and repairs may only be carried out by qualified personnel. Before carrying
out the work, it must be ensured that
•the knowledge and skills of the personnel are adequate to the intended use,
•the personnel have received instruction,
•have read and understood the operation manual.
Before beginning and while carrying out work in the tank, ventilation must be
provided to ensure that neither gases in concentrations dangerous to health
nor a potentially explosive atmosphere or oxygen deficiency can occur.
Before beginning and while carrying out work, it must be ensured that the plant
is disconnected from the mains and secured against being switched on again.
Working in tanks requires protective measures even at low heights.
Appropriate measures must therefore be taken against the risk of falling.
If technical measures are not possible, personal protective measures against
falling should be taken.
Always wear suitable protective clothing as well as hand, foot and face
protection.
Avoid contact with wastewater.
It should be pointed out that, despite all the safety measures taken, residual risks at the installation site
cannot be ruled out:
•Danger of slipping and tripping
•Danger due to electrical voltage
•Risk of infection by germs and bacteria
3.8 Rescue measures
Ensure that a second person is always available for protection when working in the tank. Never climb in
after an unconscious person. Instead, get help.

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4Area of application of the controller
4.1 Standard settings
The K-Pilot 9.7 controller is used for the operation of small wastewater treatment plants. The K-Pilot 9.7
controller has seven electrical outputs as well as three float switch inputs, an integrated power failure
warning and current and pressure monitoring. This controller allows various combinations of units.
This controller can be used to operate SBR, SSB, fixed bed, fluidised bed as well as trickling filter and
constructed wetland wastewater treatment plants.
For the standard operating modes, it is equipped with a compressor and compressed air lifters that are
controlled via solenoid valves.
In the standard version, cleaning classes C and D are provided for SSB and SBR plants, and cleaning
class C for the other plant types.
The controller can also be operated with a float switch, in which case the clear water draw-off time is –
if possible – shortened and a flood alarm triggered, if necessary. In addition, an economy mode with
somewhat shorter running times is possible for SBR and SSB plants.
In the standard version, all necessary pumping operations are carried out with compressed air lifters.
However, when operated with the K-Pilot 9.7 controller, one or more lifters can also be replaced by
submersible motor pumps.
The K-Pilot 9.7 controller allow allows the use of a float switch purely as a flood detector – with no effect
on the cycle.
Additional compressors can also be connected. A three-phase compressor (400 V) can also be operated
via an intermediate ORKA-S module instead of a single-phase compressor. If necessary, one or more
additional 230 V compressors can also be connected via an ORKA-S module.

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4.2 Further operating modes
In addition to the standard operating modes, other functions can also be controlled with the controller.
In order to implement all these different operating modes, the electrical outputs of the K-Pilot 9.7
controller can be configured freely.
4.2.1 Operation with UV lamp for hygienisation
In order to achieve effluent classes C+H and D+H, hygienisation can be implemented downstream with
the aid of a UV lamp.
4.2.2 Operation with precipitant dosing for phosphate precipitation
For phosphate elimination, the dosing of a precipitant can be activated to cover effluent classes C+P,
D+P.
4.2.3 Operation with hygienisation and phosphate precipitation
A plant with phosphate precipitation and hygienisation (i.e. +P +H) can also be operated with the K-Pilot
9.7 controller to cover effluent classes C+P+H or D+P+H.
4.2.4 Operation with double float
With the K-Pilot 9.7 controller, it is possible to work with double float switches, i.e. to use one float switch
for the lower switching point and another for the upper switching point, thereby increasing the buffer. In
this case, however, it is not possible to use another float switch for an additional buffer.
4.2.5 Operation with additional pump
With the K-Pilot 9.7 controller, an additional cycle-independent pump can also be operated in addition
to the standard functions.

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5Installation manual for the controller
5.1 Safety instructions
Non-compliance with the following safety instructions may result in a limitation
or complete loss of liability on the part of the manufacturer.
The controller is intended for cabinet mounting.
Commissioning is carried out by connecting the controller to the mains.
Only plug in the power plug after the existing units have been connected to the
appropriate devices in the controller (see Chapter 6.4).
Only allow qualified personnel to carry out the electrical installation. The
manufacturer accepts no liability for any damage caused as a result of carrying
out the installation on one's own.
Only specialists may perform any actions on the device or repairs of any kind.
Before beginning and while carrying out work, it must be ensured that the plant
is disconnected from the mains and secured against being switched on again.
Before commissioning and switching on the mains voltage, it must be ensured that:
•there is no visible damage to the device and the connection cables,
•in particular the mains connection and the connections of the units are properly connected,
•all connections have been made properly and professionally,
•the laying / routing of all cables and lines comply with the applicable regulations,
•the device is closed properly,
•the plant is properly secured. Fuse protection on grid side: max. 1 x 16 A G.
Before working on the controller, please note the following important instructions:
•Disconnect the plant from the mains before opening the device.
•Replace individual fuses only in a de-energised state.
•Never use fuses with currents higher than those specified.
•Do not manipulate the circuitry of the system in any way.
•The relevant applicable regulations (EN, VDE, etc.) as well as the regulations of local energy
suppliers must be strictly complied with.
•If a fuse is defective, it may only be replaced by a microfuse of the same type. In the standard case
with one compressor, a fuse of the following type is installed at the factory: microfuse, slow-blow,

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type 3.15 A, 5 x 20 mm according to EN 60127-2/III with a maximum power loss of 1.5 W. With a
2-compressor plant, the following type is used: microfuse, slow-blow, type 5 A, 5 x 20 mm.
Note:
For larger plants, a stronger fuse may be installed (max. 6.3
A T). Always
replace fuses with a fuse of the same current rating.
The cables to the device must be laid correctly. In particular, it is important to prevent high mechanical
stress on the cables, e.g. due to insufficiently fixed cables, as otherwise protection class IP 54 cannot
be guaranteed.
5.2 Installation of the K-Pilot 9.7 controller
The controller allows you to control different treatment processes with different equipment. The valves
required for this are arranged outside the housing.
The controller can be mounted on a wall bracket or directly on a mounting plate.
When installed in the wall cabinet, the controller is mounted on the rear wall of the wall cabinet. The
compressor is installed (on site) in the wall cabinet.
If an outside wall cabinet or outdoor cabinet is used, place it in a shady and wind-protected location. In
climatically unfavourable locations, it may be necessary to install a heater and/or cooling fan. The use
of a larger diaphragm compressor or a rotary vane or side channel compressor requires a cooling fan.
•Before commissioning the controller, please read this manual carefully as well as the manual
for the respective process, especially the chapters "Safety instructions", "Commissioning of
the controller" and "Selecting plant types".
•When selecting the installation location, the weight of the finished unit (e.g. approx. 20 kg as in this
example) must be taken into account.
•A structure that transmits sound or vibrations is unsuitable for installation.
•The installation site must be dry, clean and well-ventilated – high dust accumulation must be
avoided, as otherwise the air filter of the compressor can become clogged.
•Mount the wall cabinet plumb and level to the wall.
•Place the compressor on the floor of the wall cabinet and connect the air outlet to the valve block.
•Connect the required units to the controller.
•Plug the plug for the power supply of the compressor into the 230 V socket on the bottom of the
controller.
If the controller has to be opened, disconnect the plant from the mains before opening the controller. To
prevent tearing or damaging cables or hoses, open it carefully and do not simply drop the cover.