Kessel aqualift f Programming manual

INSTRUCTIONS FOR INSTALLATION, OPERATION
AND MAINTENANCE
KESSEL Lifting station Aqualift F Basic
Status 2017/11 Part no. 010-974
Installation Commissioning Instructional brieng
for the system was carried out by your specialist company:
Name/signature Date City
The economical way to
discharge wastewater for
the private sector
With oat switch to detect
switching and alarm levels
Flexible and fast thanks
to a variety of connecting
muffs
DIN EN 12050-1
Product advantages
Stamp of specialist company
Subject to technical modications

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1 Introduction 34
1.1 Product description, general ............................................................................................. 34
1.2 General instructions on using these operating and maintenance instructions.................. 35
1.3 How it works...................................................................................................................... 35
1.4 Type plate ......................................................................................................................... 36
1.5 Scope of delivery .............................................................................................................. 37
1.6 Displays, operating keys and their functions .................................................................... 37
1.7 Component assemblies and functional properties............................................................ 38
2 Safety 39
2.1 Correct use ....................................................................................................................... 39
2.2 Staff selection and qualication ........................................................................................ 39
2.3 Organisational safety measures ....................................................................................... 39
2.4 Risks caused by the product............................................................................................. 40
2.4.1 Risk caused by special location / ambient conditions....................................................... 40
2.4.2 Health risks ....................................................................................................................... 40
2.4.3 Risk caused by noise........................................................................................................ 40
2.4.4 Explosion hazard .............................................................................................................. 40
2.4.5 Risk caused by heat ......................................................................................................... 40
2.4.6 Risk caused by unexpected wastewater pump start-up ................................................... 40
3 Installation 41
3.1 General points related to installation ................................................................................ 41
3.2 Fasten system tank to the oor......................................................................................... 41
3.3 Fitting the inlet and outlet.................................................................................................. 42
3.4 Connecting the ventilation pipe......................................................................................... 43
3.5 Planning a connection for manual diaphragm pump ........................................................ 43
3.6 Installing the control unit ................................................................................................... 44
3.7 Connection of a potential-free contact .............................................................................. 46
3.8 Connection of the audible alarm ....................................................................................... 46
3.9 Initial operation ................................................................................................................. 47
3.9.1 Initialising the control unit ................................................................................................. 47
3.9.2 Functional check............................................................................................................... 47
4 Operation 48
4.1 Automatic operation.......................................................................................................... 48
4.2 Alarm statuses .................................................................................................................. 48
4.2.1 System tank too full alarm ................................................................................................ 48
Table of contents

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4.2.2 Power supply failure alarm ............................................................................................... 48
4.3 Overview of LED displays / information ............................................................................ 49
4.4 Acknowledging the alarm.................................................................................................. 50
4.5 Switching off the lifting station .......................................................................................... 50
4.6 Manual operation .............................................................................................................. 50
5 Maintenance 51
5.1 Maintenance safety notes................................................................................................. 51
5.2 Maintenance intervals....................................................................................................... 51
5.3 Preparing for maintenance work....................................................................................... 52
5.4 Maintenance jobs.............................................................................................................. 52
5.4.1 Replace battery................................................................................................................. 52
5.4.2 Cleaning the lifting station................................................................................................. 52
6 Troubleshooting 55
7 Technical data 56
7.1 Control unit ....................................................................................................................... 56
7.2 Pump ................................................................................................................................ 56
7.3 Pumping ow .................................................................................................................... 57
7.4 Tightening torques for screw connections ........................................................................ 57
7.5 Dimensions, volume ......................................................................................................... 58
8 Spare Parts 59

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Introduction
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1 Introduction
Dear customer,
customer,
We are pleased that you have decided to buy one of our products. This will certainly completely match your
requirements. We wish you smooth and successful installation.
In trying to keep our quality standard as high as possible, we rely on your help of course. Please let us know of
any possible improvements we could make to our product.
Have you got any questions? We look forward to you getting in touch.
1.1 Product description, general
The KESSEL lifting station Aqualift F Basic (referred to as „lifting station“ from here onwards) has been designed
for pumping off wastewater with and without sewage. The system tank houses the pump and the level sensor
(oat switch). All the assemblies have been matched to the KESSEL control unit included.
The level sensor switching signals for the wastewater level are processed electronically in the control unit. When
the switch-on level has been reached, the pump-off function is activated. When the level has fallen accordingly
again, pumping off is ended.
The pipe connections on the system tank have been prepared for different nominal widths and inlet directions.
The connection for a ventilation pipe has been prepared.

Introduction
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1.2 General instructions on using these operating and maintenance instructions
Symbols and legends used
<1> Reference in the text to a legend number in an illustration
[2] Reference to an illustration
•Working step
3. Working step in numbered sequence
–List
Italics Italic case design: Reference to a section / item in the control menu
CAUTION: Warns of a risk to persons and material. Ignoring the instructions marked with this
symbol can lead to serious injuries and material damage.
Note: Technical notes which must be given particular attention.
1.3 How it works
Ill. [1]

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Introduction
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1.4 Type plate
Information on the type plate
1Name of the system
2Article number
3Connection voltage and connection frequency, current consumption
range
4Maximum pumping ow / pumping height
5Protective rating (IP) + mode of operation
6Serial number
7QR code
10 Hardware revision status
Hebeanlage Aqualift F Basic
XXXXX
XXXV XXHz X,XA X,XkW
XXm³/h XXm
S3 XX% ED IP XX (XmWS/xh)
RevStd.: X.X MM/JJ DIN-EN 1
Ser. Nr. XXXXXXXXX
Bahnhofstraße 31
D-85101 Lenting
www.kessel.com
Aqualift F
Mono/Duo
XXXXX
www.kessel.de/info
XXXXXXXXXX
1
6
2
7
1
6
2
10
5
4
3
Ill. [2]

Introduction
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1.5 Scope of delivery
14 Control unit
16 Operating and maintenance instructions
18 Fastening material for the control unit
19 Drilling template for the control unit
20 System tank with wastewater pump and level sensor
1.6 Displays, operating keys and their functions
Control unit
1LED Ready for operation
2LED Alarm
3LED system tank, switch-on level reached
4LED, wastewater pump running
5Operation symbol
6Switch off (acknowledge) alarm button
7System tank symbol
8Wastewater pump on (manual) button
Lifting station
1Ventilation device: see position 25A in Fig. [5]
16 20
14
19 18
17
Ill. [3]
Aqualift Basic Mono
PUMP
1234
5678
Ill. [4]

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Introduction
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1.7 Component assemblies and functional properties
10 Flap, backwater preventer
14 Control unit
20 System tank
22 Type plate
23 Wastewater pump
24 Connection for pressure pipe
25 Backwater preventer housing
25A Ventilation device
26 Inlet (various options, see 3.3)
27 Level sensor (oat switch)*
28 Connection for vent pipe
29 Manual diaphragm pump connection
30 Servicing opening*
*mutually replaced depending on the type of use (see 3.4)
14
24
25
10
27
23
28
26
29
20
22
30
25A
Ill. [5]

Safety
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2 Safety
2.1 Correct use
The lifting station is to be used exclusively for pumping domestic wastewater with and without sewage.
The system must not be used in a potentially explosive environment.
Any
• conversions or attachments
• use of non-genuine spare parts
• carrying out of repairs by companies or persons not
approved by the manufacturer
• use under conditions other than those required in the current guidelines and standards
which has been carried out without the express and written permission of the manufacturer can lead to a loss of
warranty.
Note:
In order to protect the system‘s electrical components from damage, the control unit must be equipped with a
protective circuit. This does not serve as lightning protection. If such requirements are made, an appropriate
protective device must be installed on site.
2.2 Staff selection and qualication
Persons who install the lifting station must
– be at least 18 years old.
– have been sufciently trained and be sufciently qualied for the respective tasks.
– be familiar with and follow the respective technical rules and safety regulations.
Qualied staff are members of staff who, on the basis of their training and experience as well as their knowledge
of the relevant instructions, valid standards and accident prevention regulations, can carry out the required tasks
and both recognise and avoid any possible hazards.
Work on electrical components may only be carried out by specially trained specialist staff and under adherence
to all the valid accident prevention regulations (UVV).
2.3 Organisational safety measures
The operating and maintenance instructions must always be kept available.

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Safety
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2.4 Risks caused by the product
2.4.1 Risk caused by special location / ambient conditions
Risk caused by toxic and hazardous vapours, gases and substances (e. g. bacteria, viruses). If the lifting
station is located in an inspection chamber, any necessary work must always be done by specialist staff (see
2.2).
2.4.2 Health risks
The lifting station pumps wastewater with sewage which can contain hazardous substances. Make sure eyes,
mouth or skin do not come into direct contact with the wastewater or parts of the system soiled by it. In the
case of direct contact, the part of the body affected must be washed thoroughly immediately and disinfected if
necessary. Wear personal protective equipment.
2.4.3 Risk caused by noise
Operation of the lifting station can cause a high noise level. Wear appropriate protective equipment if
necessary and take sound-insulating measures.
2.4.4 Explosion hazard
In accordance with DIN EN 12050-1: 2015-05 the inside of the system tank in a sewage lifting station can be
classied as a potentially explosive area. The operator of the system is responsible for this classication within
the scope of a risk assessment. A classication of zones is only required if potentially
– explosive gases occur simultaneously, e.g. through the introduction or formation
– of sewer gas, and measures to prevent a hazardous concentration of hazardous gases such as
aeration and ventilation prove inadequate.
The formation of a hazardous, potentially explosive atmosphere can be avoided during normal operation with
a standard-compliant installation and operation in accordance with EN 12056-4 and sufcient exchange of the
atmosphere in the system tank.
Notwithstanding this, the operator of the system must guarantee adequate occupational safety during all work
on the system. Special risks arise through toxic gases such as hydrogen sulphide as well as a lack of oxygen.
This is why appropriate safety measures such as measuring safe levels or forced ventilation in accordance with
occupational safety regulations have to be carried out.
2.4.5 Risk caused by heat
Risk of burning by touching hot surfaces. When in operation for longer periods, wastewater pumps develop a
high temperature on the housing surface. Wear protective equipment (gloves) or allow the pumps to cool down
accordingly.
2.4.6 Risk caused by unexpected wastewater pump start-up
The wastewater pump can start up at any time if the lifting station is not disconnected from the power supply.
Always have specialist staff remove the wastewater pump and only after the system has been cleared and
secured against being switched on again unintentionally.

Installation
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3 Installation
Risk caused by toxic and hazardous vapours, gases and substances (e. g. bacteria, viruses). Always have any
necessary work on the lifting station done by specialist staff (see 2.2).
Before housing covers, plugs and cables (including those on potential-free contacts) are opened they must be
switched voltage-free. Work on electrical components may only be carried out by specialist staff (page 2.2).
3.1 General points related to installation
– A fault current circuit breaker must be provided as electrical protection for the lifting station.
– The lifting station‘s control unit should be positioned to prevent any unauthorised use. Consequential damage
can occur in the building if the lifting station is switched off accidentally.
The lifting station is installed and put into operation at different times according to the usual construction phases
on a building site.
1. Installation of the system tank with connection of wastewater inlet, ventilation and the pressure pipe via which
the wastewater is pumped off (Chapter 3.2 to 3.5)
2. Installation of the control unit and connection of the electrical components (chapter 3.6)
3. Initial operation (chapter 3.7).
3.2 Fasten system tank to the oor
We recommend using a sound-absorbent mat as acoustic insulation
(to minimise the transmission of sound on the support surface).
This is available as an accessory from KESSEL.
• Position the system tank correctly and screw to the oor at the two
fastening points <21>. Screws maximum M8.
Choose the fastening elements such that a tensile load of at least
200 N can be borne by each fastening point.
21
Ill. [6]

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3.3 Fitting the inlet and outlet
Preparation
Risk of functional problems due to suspended matter and solids
deposited on the level sensor.
If the inlet is to be at the muffs <26B > or <26C>, the respective
muff must be sawn off at the given cutting edge.
If the inlet to the system tank is to be via position <26C>, the level
sensor <27> has to be exchanged with the cover of the service
opening <30> . To do so, proceed as described below
• Unscrew each of the 4 fastening screws <1> and dismantle the
two assemblies accordingly. Position the anti-twist protection
device <2> correctly
The inlet can be mounted at various positions on the system tank:
24 DN 80
26A DN 50 or DN 100
26B DN 100
26C DN 100
26D Scoring surface, maximal DN 100. Make sure that no
backwater enters the inlet pipe
Installing the inlet
• Dismantle the level sensor if necessary
• Mount the inlet on the system tank
Installing the outlet
• Connect the pressure pipe to the connection <24>.
26C
30
27
1
2
Ill. [7]
26A
26D
26C 26B
27
30
24
Ill. [8]

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3.4 Connecting the ventilation pipe
• Connect the venting pipe to the venting connection <28>
A separate venting pipe has to be routed via the roof in
accordance with DIN EN 12056-4
• Saw off the muff for the vent pipe <28> at the given cutting edge.
3.5 Planning a connection for manual diaphragm pump
• Provide for a connection for a manual diaphragm pump at the connection muff <29> Fig [5], DN 40) if
necessary.)
28
Ill. [9]

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3.6 Installing the control unit
• Select the mounting position making sure that:
– there is a safety socket in the direct vicinity of the control units.
– The connecting cable from the wastewater pump and oat
switch can be installed correctly and routed to the control unit.
– The control unit can be fastened safely and sufciently.
• Unscrew the housing cover <5>
• Break out the cable ducts <1> with a suitable tool
• If an external potential-free contact (external alarm signal)
connection is provided for this installation, break out the cable duct
<1B>
• Press the rubber grommets <2> into the openings <1>
• Fit all three fastening screws (drilling template included in the
scope of delivery). Make sure that the gap <4> between the screw
heads and fastening area is approx. 3 to 4 mm
• Suspend the control unit on the three fastening screws and press
down lightly
1
1
1B
5
2
Ill. [10]
32
4
Ill. [11]

Installation
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Danger through incorrectly dimensioned connection cables. The lifting station is only designed for operation
with the enclosed connection cables (or equivalent). If in doubt, consult the manufacturer / supplier.
• Fit end sleeves (length 8 mm) to the ends of the cables
• Lay the connecting cable safely from the system tank to the control unit (e.g. conduit pipe, cable duct)
• Attach connecting cable to the terminal strip acc. to the
circuit diagram (next page). To do so, keep the relevant cable
terminal <3> pressed down against the spring pressure with a
suitable screwdriver until the end of the cable has been inserted
• Attach strain relief ttings for all connecting cables
• Connect battery plug to battery
• Fit and fasten the housing cover,
tightening torque 1.2 Nm
• Route the battery‘s cable (32) so that it does not cover
the LEDs or is clamped.
3
Ill. [12]
32
Ill. [13]

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• Connection diagram
1 Mains connection
Abrown
Bblue
Cgreen/yellow
2 Wastewater pump
Dgreen/yellow
Eblue
Fbrown
3 Float switch
Gyellow
Hwhite
Jpink
Kbrown
Lgrey
Mgreen
Nnot occupied
4 Alarm
OConnection for external
audible alarm/
potential-free contact
P
3.7 Connection of a potential-free contact
A potential-free contact can be connected to the control unit, available from Busch-Jäger (art. no. 1515 U-12)
• For this purpose the alarm key <6> and the pump key <8> must be pressed simultaneously for 5 seconds
after the control unit has been connected to the mains power supply
• The control unit bleeps briey twice as conrmation that the potential-free contact can be connected.
• Connect the potential-free contact to O P in accordance with the circuit diagram Fig. [14].
3.8 Connection of the audible alarm
• To connect the audible alarm again, keep the alarm key <6> and the pump key <8> simultaneously
for 5 seconds
• The control unit bleeps briey 3 times as conrmation that the audible alarm can be connected.
I2I1 -I3 +
--
-
1234
ABCDEF GHJKLMN OP
Ill. [14]

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3.9 Initial operation
Avoid the wastewater pump(s) running dry for a longer period (>30 seconds) at all costs, it/they could become
damaged. Never switch wastewater pumps on if the system tank is not lled at least to the minimum level.
3.9.1 Initialising the control unit
• Connect the control unit to the mains supply, initialisation begins. The 4 LEDs come on in succession, an
acoustic signal is heard and the wastewater pump is switched on for a few seconds. Following successful
initialisation, the control unit is ready for operation, the green LED <1> comes on
3.9.2 Functional check
• Switch off the lifting station (see 4.5)
• Open the service opening <30> (Fig. [5], page 38)
• Fill the system tank fully with water. The water level must be up to
the opening of the access cover
• Re-connect the control unit‘s power supply (plug in mains plug),
the control unit is initialised (see 3.7.1). The functional check is
has been successful if the following procedures are performed as
described:
– Level alarm is triggered, the Alarm LED <2> ashes red, an acoustic signal is heard and the wastewater
pump begins to evacuate the system tank
– Once the level falls below the alarm level, the alarm LED <2> goes out and the two orange LEDs
(level <3> and pump operation <4>) come on until the system tank has been evacuated by the wastewater
pump
– Visual inspection: The system tank may only contain a few centimetres of water when the wastewater pump
no longer runs
• Screw the service opening <30> (Fig. [5], page 38) down again, the lifting station is ready for operation
Aqualift Basic Mono
PUMP
1234
5678
Ill. [15]

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Operation
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4 Operation
The backwater preventer must be functional during operation, see <25> in Fig. [5], page 38
4.1 Automatic operation
The lifting station is in automatic mode if no fault has been detected
and the green operating LED <1> comes on The wastewater pump is
switched on an off according to the wastewater level.
4.2 Alarm statuses
4.2.1 System tank too full alarm
If the level in the system tank exceeds the alarm level (oat switch)
an alarm is triggered, the alarm LED <2> ashes and an acoustic
signal is heard. The wastewater pump is running.
This alarm status cannot be acknowledged, it is only switched off after successful pumping off.
The acoustic tone can be deactivated (press the alarm button briey).
4.2.2 Power supply failure alarm
If the power supply fails, the green operating LED <1> goes out after one second, the alarm LED <2> ashes
and a repeated acoustic signal is heard. The wastewater pump can no longer be switched on.
* Temporary interruptions in the power supply do not trigger the alarm.
When the power supply is restored the control unit no longer shows this alarm status, the lifting station again
works in the automatic mode.
See chapter 4.3 for further alarm statuses
Aqualift Basic Mono
PUMP
1234
5678
Ill. [16]

Operation
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4.3 Overview of LED displays / information
ey
Flashing
Lights up / switched on
Switched off
Flashing alternately
ashing simultaneously
LED Acoustic
signal
(interval)
Description Action
1 2 3 4
Operating states
- Ready for operation
- System tank full, will be pumped out
shortly
No action necessary, wastewater
pump can be switched off with button
<8> (see manual operation 4.6)
- Pumping system tank to empty
Alarm statuses / faults
x Battery fault Replace battery
x Power outage, no mains voltage, lifting
station has no function
Restore mains voltage, acknowledge
alarm (see 4.4)
x Level fault, illogical sequence of levels
detected
Acknowledging the alarm (4.4)*
x Running time / number limit, wastewater
pump switch on to often or too long
x Running time limit, maximum running
time for wastewater pump exceeded
x Alarm level exceeded Wait until the level drops below the
alarm level again
Exceeded maximum switching cycles Acknowledge alarm (4.4) and replace
control unit
* If the fault occurs again, inform the Customer Services department
Aqualift Basic Mono
PUMP
1234
5678
Ill. [17]

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Operation
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4.4 Acknowledging the alarm
If a state occurs which triggers an alarm (e.g. fault on the pump, power failure), this is indicated by the alarm
LED <2> coming on and possibly one of the other LEDs (see 4.3). After the cause of the alarm has been
eliminated, the alarm can be acknowledged by pressing key <6>.
– To switch the alarm sound off: Press key <6> 1x
– To acknowledge the alarm: Keep button <6> pressed for >5 seconds, the alarm display goes out and the
alarm has been acknowledged
4.5 Switching off the lifting station
• Disconnect the control unit‘s mains plug and wait a few seconds until the power failure alarm is triggered
(short, repeated acoustic signal and alarm LED <2> ashes)
• Press and hold down the alarm <6> push-button until the alarm LED <2> no longer ashes, four short
acoustic signals are heard, the control unit is switched off
If the control unit is switched off, the battery connection is deactivated. The battery can remain connected
since it will not be discharged. Mains voltage is required for initialisation since this re-activates the battery
connection.
4.6 Manual operation
Manual operation can be activated with the push-button switch <8>. The wastewater pump is no longer switched
on automatically. If manual operation is activated during pumping-off, the wastewater pump is switched off.
Activate manual operation
• Press push-button switch <8>, the manual operation LED <4> ashes orange
Switch on wastewater pump
The wastewater pump can be switched on as follows when manual operation is activated:
Switching on briey Press the push-button switch <8> 1x , the wastewater pump is switched on for a
short time.
Switching on for longer Press and hold down the push-button switch <8> for as long as the wastewater
pump is to be switched on.
If manual operation is not used for a certain period of time (5 minutes), the control unit re-activates the automatic
mode.