Graf oneAdvanced User manual

OPERATION MANUAL
Startup | Operation | Maintenance
oneAdvanced – KLcontrol

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Intended and safe use requires you to heed the instructions
and other information in this documentation.
Read carefully these instructions before installation, assembly,
and startup.
Keep these in a safe place for future reference.
Instructions for startup, operation, and maintenance
Issued for GRAF oneAdvanced wastewater treatment plant
Control unit KLcontrol.M
EAN no. 4023122286325
Date issued 30/01/2023
Original operating instructions
Original language: German
.
Otto Graf GmbH Kunststofferzeugnisse
Carl-Zeiss-Straße 2–6, 79331 Teningen
Germany
Tel. [phone]
[e-mail] www.graf.info

Contents
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Contents
1About these instructions .................................................................................................................. 6
1.1 Typeface conventions ......................................................................................................................... 7
1.2 Symbols and signal words .................................................................................................................. 7
2Safety.................................................................................................................................................. 8
2.1 General safety instructions.................................................................................................................. 8
2.1.1 Safety symbols and signal words...........................................................................................................8
2.1.2 Intended use .........................................................................................................................................9
2.1.3 Incorrect use..........................................................................................................................................9
2.2 Safety instructions for the operator ................................................................................................... 10
2.2.1 Personnel qualifications ......................................................................................................................10
2.3 General safety measures .................................................................................................................. 11
2.4 Safety measures for inspection and maintenance ............................................................................ 12
2.4.1 Safety measures for work inside the tank...........................................................................................12
3General ............................................................................................................................................. 14
3.1 Details about your plant .................................................................................................................... 14
3.2 Layout and functions ......................................................................................................................... 15
3.2.1 Layout of oneAdvanced 3–9 PE...........................................................................................................15
3.2.2 Layout of oneAdvanced 10–14 PE.......................................................................................................16
3.2.3 3.2.2 Layout of oneAdvanced 16–1000 PE..........................................................................................17
3.2.4 Function of the SBR plant....................................................................................................................18
3.3 Control and machine cabinet ............................................................................................................ 24
3.3.1 Technical setup....................................................................................................................................25
3.3.2 Siting....................................................................................................................................................26
3.3.3 Power supply.......................................................................................................................................26
4The wastewater treatment system’s control unit......................................................................... 28
4.1 Operating unit.................................................................................................................................... 29
4.2 Display information and menu navigation ......................................................................................... 30
4.2.1 Status bar symbols ..............................................................................................................................31
4.2.2 Menu bar symbols...............................................................................................................................31
4.3 Operating the controller..................................................................................................................... 33
4.3.1 Menu navigation .................................................................................................................................33
4.3.2 Editing config parameters ...................................................................................................................33
4.3.3 Auto return to auto .............................................................................................................................33
4.3.4 Control unit restart (hardware reset)..................................................................................................33
4.4 Operator menu .................................................................................................................................. 34
4.4.1 Information menu – show operating hours, settings, sensor values ..................................................34
4.4.2 Events menu – show events................................................................................................................35
4.4.3 Mode menu.........................................................................................................................................36
4.4.4 Times/date menu – set date, clock, holiday period ............................................................................38
4.4.5 Settings menu – languages, buzzer, display settings ..........................................................................39
4.4.6 Service menu – access for specialists ..................................................................................................40
4.4.7 USB menu – software update, maintenance manual..........................................................................41
4.5 Function of the power cut detector.................................................................................................... 43
4.6 Monitoring the mains voltage ............................................................................................................ 44
4.7 Hardware reset.................................................................................................................................. 44
5Initial use.......................................................................................................................................... 45
5.1 Charging the tanks ............................................................................................................................ 45
5.2 Switching ON the switch cabinet....................................................................................................... 45
5.3 Commissioning wizard ...................................................................................................................... 45
5.4 Function tests .................................................................................................................................... 46
5.5 Startup behaviour .............................................................................................................................. 47
6Operating instructions.................................................................................................................... 48
7Operation and maintenance........................................................................................................... 51

Contents
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7.1 General specifications for maintenance, inspections, and operation................................................ 52
7.2 Duties of the operator........................................................................................................................ 52
7.2.1 Daily check...........................................................................................................................................52
7.2.2 Monthly checks ...................................................................................................................................53
7.2.3 Yearly checks .......................................................................................................................................54
7.3 Care and maintenance by a maintenance specialist only................................................................. 54
7.3.1 Maintenance work ..............................................................................................................................54
7.4 Sludge measurements ...................................................................................................................... 55
7.4.1 Sludge measurements on oneAdvanced 3–9 PU (one-tank systems).................................................55
7.4.2 Sludge measurements on oneAdvanced larger than 10 PE (with preliminary cleaning / sludge
reservoir) .............................................................................................................................................57
7.5 Sludge must be removed by a specialist only ...................................................................................57
8Service menu for authorised specialist ........................................................................................59
8.1 Menu overview .................................................................................................................................. 59
8.2 Cycle settings .................................................................................................................................... 60
8.2.1 Overview of processes, systems, and discharge classes .....................................................................61
8.2.2 Outputs................................................................................................................................................64
8.2.3 Inputs ..................................................................................................................................................65
8.2.4 Pressure sensor ...................................................................................................................................66
8.2.5 Information .........................................................................................................................................69
8.2.6 Temperature sensor ............................................................................................................................70
8.2.7 Current limits.......................................................................................................................................71
8.2.8 Maintenance .......................................................................................................................................71
8.2.9 Modules...............................................................................................................................................72
8.2.10 Contactor monitoring..........................................................................................................................74
8.2.11 Exit menu.............................................................................................................................................74
9Additional controller functions...................................................................................................... 75
9.1 Underload detection .......................................................................................................................... 75
9.1.1 Function...............................................................................................................................................75
9.1.2 Cleaning cycle queries .........................................................................................................................76
9.1.3 Calibrating level measuring .................................................................................................................77
9.1.4 Starting level measuring......................................................................................................................77
9.1.5 Deactivating the level measurement ..................................................................................................80
9.1.6 Safety and fault messages...................................................................................................................80
9.2 Compressed air monitoring ............................................................................................................... 81
9.2.1 Technical requirements.......................................................................................................................81
9.2.2 Settings................................................................................................................................................81
9.2.3 Teach-in phase ....................................................................................................................................81
9.2.4 Monitoring phase ................................................................................................................................81
9.3 Dosing installations ........................................................................................................................... 81
9.3.1 Components ........................................................................................................................................82
9.3.2 Dosing pumps......................................................................................................................................83
9.3.3 Phosphate precipitation with P module..............................................................................................84
9.3.4 Pumped carbon dosing (C module).....................................................................................................87
9.3.5 Pumped chlorination (chlorination module).......................................................................................88
9.4 UV reactor (UV module) .................................................................................................................... 90
9.4.1 Function...............................................................................................................................................90
9.4.2 Control unit settings:...........................................................................................................................91
9.5 Submersible pumps........................................................................................................................... 91
9.5.1 Submersible pump in lieu of pneumatic lifters ...................................................................................92
9.5.2 Submersible pump for additional transport process ..........................................................................92
9.6 External warning indicator ................................................................................................................. 93
9.7 Actuate solenoid valves .................................................................................................................... 93
10 Electrical connections .................................................................................................................... 94
11 Fault messages and rectification .................................................................................................. 97

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11.1 Power failure ..................................................................................................................................... 97
11.2 events in tabular form........................................................................................................................ 98
11.2.1 Information messages .........................................................................................................................99
11.2.2 Fault messages ..................................................................................................................................100
11.2.3 Error messages ..................................................................................................................................101
11.3 Unusual water levels–remedying a fault ........................................................................................ 103
11.4 Possible faults on step motor valves............................................................................................... 104
11.5 Water quality ................................................................................................................................... 104
11.6 Odours............................................................................................................................................. 105
11.7 Noise levels ..................................................................................................................................... 105
12 Disposing of the controller .......................................................................................................... 106
13 Declarations of performance ....................................................................................................... 107
14 Maintenance log for KLARO wastewater treatment systems ................................................... 111
15 Circuit diagrams ............................................................................................................................ 114
15.1 PP cabinet with KLcontrol.S and KLcontrol.M ................................................................................ 114
15.2 I cabinet (steel) with KLcontrol.S and KLcontrol.M ......................................................................... 115
15.3 E column with KLcontrol.S and KLcontrol.M ................................................................................... 116
15.4 E cabinet with KLcontrol.S and KLcontrol.M ................................................................................... 117
16 Maintenance instructions for compressor ................................................................................. 118
16.1 Operating and maintenance instructions for LA compressor .......................................................... 118
16.2 Becker rotary multivane compressor............................................................................................... 124
Notes......................................................................................................................................................... 138

1. About these instructions
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1 About these instructions
This Technical Documentation for the wastewater treatment system is divided into several sec-
tions. This documentation forms an integral part of the product and must be handed over to the
new owner or at the new site. The full Technical Documentation consists of:
xinstallation instructions for the underground tank
xAssembly instructions for the installation kit
xinstructions for startup, operation, and maintenance
All persons coming into direct contact with the plant must have read and understood the con-
tents of this documentation.
This section contains the startup, operating, and maintenance instructions. These are intended
for all persons handling the plant, and are prefaced with a description of the plant and its func-
tions as well as details pertaining to its handling safety and potential residual risks. These are
followed by details on the available switch and machine cabinets and their positions; a descrip-
tion of the controller and its functions; and instructions for its startup. Concluding these are in-
structions on how to operate and service the plant and a description of the fault messages, to-
gether with troubleshooting instructions. We recommend keeping this section in the vicinity of
the plant.
Copyright
These instructions for use contain copyrighted information and figures. Otto Graf GmbH Kun-
ststofferzeugnisse reserves all rights. No part of these instructions for use may be duplicated,
reproduced, used for other purposes, or translated into any language without the prior, explicit
consent issued in writing by Otto Graf GmbH Kunststofferzeugnisse.

1. About these instructions
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1.1 Typeface conventions
These instructions make use of the following typeface conventions.
Format
Meaning
Italic text
This refers the reader to other contents in this document, other sections of
the instructions for use, or additional information.
Digitised media (e.g. PDFs) present links to the destinations that
the user
can click or tap directly.
»…«
This reproduces lettering or a label on the product or component.
[…]
This represents a key or switch.
1.2 Symbols and signal words
These instructions make use of the following symbols. An overview of the safety symbols and
signal words used can be found in Subsection 2.1.1.
Symbol
Signal word and meaning
IMPORTANT
/ TIP / INFO
This highlights important information, tips, and other particularly useful de-
tails

2. Safety
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2 Safety
Despite all safety precautions, the plant may nevertheless pose some degree of residual risk,
particularly when handled incorrectly or negligently. To protect yourself and others from all dan-
ger and to prevent damage and pollution as a result of incorrect handling, therefore, please read
and follow the safety and other instructions in both this and the other sections making up the in-
structions for use.
WARNING
Failure to heed the safety instructions may cause accidents
and damage.
The
consequences can extend to serious, and even fatal injury
and harm to health.
tRead and follow both the safety and the other instructions.
2.1 General safety instructions
2.1.1 Safety symbols and signal words
The following safety symbols and signal words are used in these instructions and on the plant’s
components:
DANGER
This highlights imminent danger. Failure to observe this will cause death or
grievous injury.
WARNING
This highlights a potentially hazardous situation. Failure to observe this
may cause
death or grievous injury.
CAUTION
This highlights a potentially hazardous situation. Failure to observe this
may cause slight or minor injury.
IMPORTANT
This highlights a scenario that may cause pollution to the environment or
damage to the
product or nearby property.

2. Safety
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This highlights potential risks from electricity.
This highlights a potential risk of falling.
This highlights potential risks from hot surfaces.
This highlights potential risks from optical radiation.
2.1.2 Intended use
The SBR plant has been designed to channel domestic wastewater from private homes. Domes-
tic wastewater contains faeces and other substances found in bath, washing, sink, and mop wa-
ter such as soap, detergent, and food scraps.
The SBR plant may also be used to channel other wastewater types (e.g. from restaurants, dair-
ies, winemakers, breweries, and other commercial establishments) when this purpose was
known at the time of and incorporated in the plant’s layout.
2.1.3 Incorrect use
The SBR plant may be used only for the purposes described in these instructions. The plant
may not be used for industrial wastewater. Under no circumstances may the plant be used to
channel biocides, toxic substances, or substances which are not biocompatible: these hinder
bacteria important to wastewater cleaning and cause problems in the biological process.
A detailed list of substances that may not be channelled through the plant can be found in Sub-
section 6.
WARNING
Failure to use the plant for its intended purpose may cause
harm to health, pollution to the environment, and damage to
property.

2. Safety
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2.2 Safety instructions for the operator
The operator of the plant is responsible for its correct installation and operation. He is also re-
sponsible for ensuring adherence to the safety and other instructions in this section, but also to
the laws, standards, rules, and regulations pertaining to the plant’s site. These include in particu-
lar the health and safety, accident prevention, and environmental protection regulations as well
as the inspection and maintenance specifications applying to the plant’s site.
To meet official cleaning requirements, it is essential that the plant is operated in accordance
with the operating and maintenance instructions.
Operator’s obligations
In order to maintain the plant’s operating safety, the operator must:
x(re)configure and inspect the plant at the prescribed regular intervals and maintain an
operating log book (see Subsection 7.2)
xcommission a specialist to service the plant at the prescribed regular intervals
xImmediately on signs of damage to the controller or wiring, the plant must be shut down and
disconnected from the power supply.
xMalfunctions and damage must be remedied immediately or repaired by a specialist
xAll safety labels on the plant must be maintained in an easily legible condition at all times.
2.2.1 Personnel qualifications
The operator must make sure that the installation, assembly, inspection, and maintenance per-
sonnel are adequately qualified or possess the adequate knowhow for their assigned tasks, and
all persons handling the product have received adequate instruction. The requisite qualifications
may be subject to additional regulations.
The plant must not be operated by anyone under the influence of alcohol, narcotics, or medica-
tion that limits cognitive ability or ability to react.
Installation, care, maintenance
Only specialists may perform care and maintenance work on the plant. Specialists are those
persons whose professional training and qualifications render them suitable for operating and
servicing wastewater treatment systems. Only specialised electricians may be assigned to work
on the electrical installations and to connect the plant to its power supply.

2. Safety
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2.3 General safety measures
fKeep tank covers closed at all times. Never leave open tank covers unattended.
Tank covers may be opened for inspection and maintenance purposes only. There is a
danger of persons or animals falling into the tank. This may result in serious injury or
drowning.
tKeep unassigned persons, in particular children, away from open tank covers.
tClosed tank covers must resist all attempts by a child to open them.
Before closing, make sure that there are no persons or animals in the tank.
fKeep switch cabinets closed at all times. Never leave an opened switch cabinet
unattended.
Switch cabinets house components that may be hot to the touch. Touching these may
cause burning injuries.
Unauthorised access to the controller may cause serious malfunctions.
tOpen the switch cabinet only for the purpose of operating or servicing the plant.
tAt the end of the work, close and lock the cabinet.
fOperate the controller only when it is in perfect working condition
Any damage, however slight, to the controller’s housing or the wiring insulation poses
a risk of electric shock.
tImmediately on signs of damage, shut down the plant, disconnect it from its power
supply, and commission a specialist for its repair.
fDo not place any receptacles containing liquids on the switch cabinet.
Spilled or discharging liquids may cause short circuits. Fire or electric shock may be
the consequence.
fDo not transport or deposit any substances hazardous to water near the tank
cover.
fWear personal protective equipment (PPE)
PPE (protective gloves, goggles, safety shoes, etc.) protects the wearer against injury
and harm to health.
tWhenever necessary, wear the prescribed protective equipment.
tDo not use damaged or defective protective equipment, which must be replaced
immediately with fully functional equivalents.

2. Safety
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2.4 Safety measures for inspection and maintenance
fDo not consume any food or drink when operating or working at or on the plant.
Edibles coming into contact with microbes may carry and cause infection.
fShutting down the plant’s installations and equipment.
Equipment may start to operate unexpectedly. Damaged wiring poses a risk of electric
shock.
tBefore all repair, maintenance, and cleaning work on the plant, shut it down
completely, including all of its installations, and secure it against reactivation.
tDisconnect the electrical installations from their power supplies.
fOnly specialised electricians may be assigned to work on the electrical
installations and to connect the plant to its power supply.
Danger from electric shock.
fHandle chemicals properly.
Chemicals can cause poisoning, harm to health, and caustic injuries.
tConsult their manufacturers’ safety data sheets for details.
tWhenever necessary, wear PPE.
tKeep chemicals safely away from children and unauthorised access.
2.4.1 Safety measures for work inside the tank
Harmful gases may form inside wastewater treatment systems. The wastewater may carry path-
ogens and substances harmful to health. The plant’s tanks and shafts may be accessed bodily
for repair and maintenance work only.
fVerify that work in the tank is necessary.
tAlways examine first whether this work may be performed from outside (e.g.
inspections with a remote controlled camera).
fAssign a second person to supervise all work.
This second person must remain at the access point. He must remain in constant
contact with the person in the tank and be in a position to fetch assistance
immediately.
tNever enter the tank without this second, supervising person.
fEmpty tank completely
An accident victim can also drown in shallow depths.
tNever enter a tank, even when it is only partially full.
fProvide a supply of healthy air to the tank.
tBefore being accessed, the tank must first be vented adequately to clear it of any
gases.
tIf adequate cross or diagonal venting (chimney effect) cannot be ensured, a supply of
air must be provided with equipment.
tWhenever necessary, measure and monitor constantly the air quality.

2. Safety
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fIncrease access safety and provide an escape route
tUse only suitable equipment, e.g. ladder, to access the tank.
tMake sure that the escape route remains unobstructed.
2.4.1.1 In the event of an accident in the tank
fIf the accident victim is unconscious, do not under any circumstances attempt to
climb in to his rescue.
There is danger of death from asphyxiation or noxious gases.
tCall the emergency services and follow their instructions.
tWhile you are waiting, vent the tank from outside, using e.g. a fan or similar.

3. General
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3 General
3.1 Details about your plant
In case you have any queries while operating the plant, please enter the details of your plant
here as follows. Should you encounter a fault, these details will enable our staff to find a remedy
faster.
Your plant’s specifications can be found on the type plate. This type plate is affixed to the exter-
nal housing of internal switch cabinets and inside external switch cabinets.
Figure 1: Example oneAdvanced type plate

3. General
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3.2 Layout and functions
The basic wastewater treatment plant consists of the following components:
xone or two tanks
xwastewater treatment installation kit
xcontrol cabinet
The wastewater treatment installations in the tanks are connected to the control cabinet via air
hoses laid in the ground.
In the control cabinet, you will find:
xa quiet, low-maintenance air compressor
xa valve unit
xa control unit
3.2.1 Layout of oneAdvanced 3–9 PE
Figure 2: oneAdvanced 3–9 PE in a Carat tank (example)
The tank houses:
xa scum guard
xtwo membrane pipe aerators
xoutflow lifter in the form of a mammoth pump with its own air supply
xan integrated water sampling point
Sampling unit
Inlet DN110
Outlet DN110
Clear water lifter

3. General
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3.2.2 Layout of oneAdvanced 10–14 PE
Figure 3: oneAdvanced 10–14 PE in a Carat tank (example)
The tank is split into two areas by a scum guard: a sludge reservoir and buffer in the inlet area
and an SBR reactor in the outlet area.
The wastewater treatment installation kit is fitted to the scum guard. This consists of:
on the sludge reservoir / buffer side:
xfeed lifter in the form of a mammoth pump with its own air supply (marked in red)
on the SBR reactor side.
xa stainless steel pipe with membrane plate aerator
xoutflow lifter in the form of a mammoth pump with its own air supply (marked in black)
xa secondary sludge lifter in the form of a mammoth pump with its own air supply (marked in
white)
above the scum guard:
xan integrated water sampling point
Membrane plate aerator
Feed lifter
Inlet DN110
Outlet DN110
Sampling unit
Clear water lifter
SBR reactor
Sludge reservoir
/ buffer

3. General
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3.2.3 3.2.2 Layout of oneAdvanced 16–1000 PE
Figure 4: Example multi tank system in two Carat tanks
The wastewater treatment plant is made up of several tanks. The preliminary cleaning tank inte-
grates the sludge reservoir, buffer, and SBR tank. Plants larger than 32 PE consist of multiple
preliminary cleaning and SBR tanks.
In the sludge reservoir / buffer you will find:
xfeed lifter in the form of a mammoth pump with its own air supply (marked in red)
In the SBR reactor you will find:
xa stainless steel air distributor system with membrane pipes or aerator plates
xoutflow lifter in the form of a mammoth pump with its own air supply (marked in black)
xa secondary sludge lifter in the form of a mammoth pump with its own air supply (marked in
white)
xoptionally, an integrated water sampling point
DN110
DN110
DN110
DN110
DN110
DN110
DN110
Sludge reservoir
/ buffer
SBR reactor
Sludge return
Feed lifter
SBR reactor
Membrane plate aerator
Sampling unit
Clear water lifter

3. General
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3.2.4 Function of the SBR plant
oneAdvanced is a fully biological wastewater treatment system, which functions on the princi-
ple of the SBR process (aeration system in retention process).
This fully biological treatment takes place with aerated sludge. Aerated sludge basically consists
of microorganisms that break down the pollutants dissolved in wastewaster
Plants larger than 10 PE feature upstream sludge reservoirs with integrated buffer that perform
the following functions:
xstorage of primary and secondary sludge,
xretention of deposited materials and floating solids,
xstorage of supply water,
xcompensation of fluctuations in the wastewater supply related to volume and concentration.
The SBR reactor provides the following functions:
xbiological cleaning with aerated slurry
xnitrification and denitrification
xphosphate precipitation
The wastewater treatment plant is operated using a microprocessor control, which controls the
air compressor and air distribution for the various lifters via magnetic valves / stepped motors.
3.2.4.1 Process flow of oneAdvanced larger than 3–9 PE
The SBR procedure is a series of three steps, undertaken one after another and twice a day.
Step 1: Aeration
In the first phase, the wastewater is put straight through aerobic treatment
for a fixed time. As a result, firstly the microorganisms (aerated sludge) are
supplied with the oxygen needed for the breakdown and secondly pressure
aeration causes mixing. The system's aeration equipment is supplied with
ambient air by a compressor. Aeration is intermittent so that targeted
wastewater cleaning is possible. Different ambient conditions can thereby
be achieved.

3. General
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Step 2: Settle
There is no aeration in the second phase. The aerated sludge and the re-
maining settleable solids can now settle with the aid of gravity. A clear wa-
ter zone
forms at the top and a sludge layer at the bottom. Any floating
sludge is on top of the clear water zone.
Step 3: Clear water extraction
In this phase, the biologically cleaned wastewater (clear water) is drawn out
of the SBR stage. It is pumped out by an air lift (or mammoth) pump, which
uses compressed air. The air lift pump is designed not to pump out any
floating sludge on top of the clear water layer. A minimum water level is
maintained in the system without any further components.
Once step is complete, the cleaning process starts again with step 1.
2 cycles are undertaken a day. The maintenance company can individually adapt the switching
times.
3.2.4.2 Process flow of oneAdvanced larger than 10 PE
The process is a series of 5 steps undertaken in turn and repeated several times a day (usually
four times).
Step 1: Feed
The raw wastewater held in the sludge reservoir is fed to the
SBR reactor via an air lift pump. This is arranged such that
only water free of solids is pumped. The special design of the
lifter guarantees a minimum water level in the sludge reser-
voir.
Duration: approx 5
–20 min

3. General
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Step 2: Aeration
In this step, the wastewater is aerated and mixed. Membrane
pipe or plate aerators fitted on the base of the chamber aerate
the wastewater.
The plant's aeration equipment is supplied with ambient air by
a control cabinet installed separately. An air compressor pro-
duces the compressed air needed. Aeration usually takes
place intermittently.
with two simultaneous outcomes:
xthe microorganisms in the activated sludge are supplied
with oxygen, which is needed for their metabolism and
therefore for the pollutants to be broken down.
xthere is intensive contact between the wastewater and
bacteria.
Duration: approx 240 min
Step 3: Sedimentation phase
This step is a rest phase in which no aeration takes place.
The activated sludge settles with gravity (sedimentation
phase). A clear water zone forms at the top and a sludge
layer at the bottom. Any floating sludge is on top of the clear
water zone.
Duration: approx 90 min
Step 4: Clear water extraction
In this phase, the biologically cleaned wastewater (clear wa-
ter) is drawn out of the SBR stage. It is pumped out by an air
lift (or mammoth) pump, which uses compressed air. The air
lift pump is designed not to pump out any floating sludge on
top of the cl
ear water layer.
Duration: 5
–20 min