Kessel Aqualift F Standard Assembly instructions

I STALLATIO , OPERATI G A D MAI TE A CE I STRUCTIO S
KESSEL-liftin station Aqualift
쏐
F(400V) Standard
for aste ater ith and ithout faeces for
free-standing installation in rooms protected from frost
Edition 07/2010
Name/Unterschrift atum Ort
I -Nr. 206-818EN
Subject to technical amendment
Aqualift
쏐
F
Aqualift
쏐
F Duo
Product advanta es
Simple connection throu h
moulded connectin pieces
Drillin surfaces for further
connections
Fully automatic operation
Maintenance-friendly
PE-tank
General technical approval
no. Z-53.2-424
Stempel Fachbetrieb
Installation
The installation and service of this unit should be carried out by
a licensed professional servicer
Commissionin Instruction
mitSicherheit
geprüfteQualität
BauartBauart
geprüftgeprüft
und überwachtund überwacht
Bauart
geprüft
und überwacht
L
GA
Landesgewerbeamt Bayern

2
General safety precautions
uring installation, operation, maintenance or repairs to the system, please observe the accident pre-
vention regulations, the applicable IN and V E standards and guidelines, and also the regulations of
the local energy and supply companies.
The systems may not be operated in explosive areas
Electrical hazards
This system contains electrical voltages and controls rotating mechanical parts. Non-observation of the
operating instructions could lead to serious damage, injury or even fatal accidents.
The system must be securely disconnected from the mains supply before commencing any work on it.
The local master switch and the cut-outs must be turned off, i.e. switch the system to zero-potential and
take precautions to ensure it cannot be switched on again. If only cut-outs are available, these must be
switched off and a sign attached to prevent third parties from switching the main fuse on again.
V E 0100 applies to all electrical work on the system.
The switchgear and the level control are under voltage and may not be opened. Only electricians may
work on the electrical equipment. The term 'electrician' is defined in the V E 0105.
Steps must be taken to ensure that the electrical cables and all other electrical system parts are in a
fully functional condition. If any parts are damaged, the system may not be operated and/or must be im-
mediately shut down.
Risk of burning fingers and hands
The driving engine may become very hot during operation
Risk of injury to fingers and hands
The pumps are equipped with a closed impeller. Therefore work on the pump may only be carried out if
the power supply has been disconnected and the rotating parts have stopped rotating.
Take care on sharp edges during maintenance or repair work.
Risk due to heavy weights
The lifting system models with one pump weigh around 45 kg, and with two pumps around 84 kg. The
systems may only be lifted or mounted by two persons with appropriate care wearing protective equip-
ment (e.g. protective shoes).
The pumps may only be removed slowly or placed in the pump flange opening by two persons (if sui-
table precautions to prevent slipping have been taken).
1. Safety information

Health risk
The wastewater system transports wastewater that contains faeces; in turn this faeces may contain
harmful substances. Whenever working on the system, always ensure that there is no direct contact
between the wastewater and/or soiled system parts and your eyes, mouth or skin. In the event of direct
contact, clean the affected part of your body thoroughly and disinfect if necessary. It is also possible that
the atmosphere in the tank may be harmful.
Therefore before opening the cleaning aperture (or removing the pump) ensure that the respective room
is adequately ventilated or provide for (forced) ventilation during the opening process.
Noise pollution
When the pump is operated, a noise level is created that may be a nuisance depending on how the pump
is installed. If there are maximum noise level stipulations that need to be observed, appropriate mea-
sures need to be taken. The sound damping set from KESSEL may also be helpful here.
Risk of explosion
The inside of the tank is considered to be explosive within the meaning of EN 12050 because the bio-
logical digestive process may create flammable gases (hydrogen sulphide, methane gas). Therefore,
when unscrewing the pump or the cleaning aperture lid or any other parts, ensure that the room is ade-
quately ventilated or provide for (forced) ventilation during the opening process. Whilst the tank is open,
it is forbidden to smoke or carry out any other activities in the respective room that could cause the gas
to ignite (e.g. operation of electrical devices without encapsulated motors, metalworking etc.).
1. Safety information
3

1. Safety information ...........................................................................................................Page 2
2. General 2.1 Area of application...............................................................Page 5
2.2 System description ..............................................................Page 5
3. Technical data 3.1 imensions..........................................................................Page 6
3.2 Pumps .................................................................................Page 7
3.3 Electric switch unit ...............................................................Page 8
4. Installation and assembly 4.1 Fitting the collecting tank .....................................................Page 9
4.2 Connecting the pipes...........................................................Page 9
4.3 Setting the pressure level switches .....................................Page 11
5. Electrical connections 5.1 General notes......................................................................Page 12
5.2 Installation of the switch unit................................................Page 12
5.3 Installation, wiring................................................................Page 13
5.4 Checks ................................................................................Page 16
5.5 Configuration of switch unit .................................................Page 17
6. Initial operation 6.1 General notes......................................................................Page 18
6.2 Pressure outlet connecting pieces.......................................Page 18
6.3 Operating the switch unit .....................................................Page 18
6.4 Functional description..........................................................Page 19
6.5 Functional test .....................................................................Page 19
7. Inspection and maintenance 7.1 Notes on the pump ..............................................................Page 20
7.2 Notes on aeration device.....................................................Page 20
7.3 Notes on the electrical switch unit .......................................Page 21
8. Malfunctions and 8.1 General malfunctions ..........................................................Page 22
troubleshooting 8.2 Malfunction messages.........................................................Page 24
8.2.1 Irregular level states ............................................................Page 26
8.2.2 Internal monitoring...............................................................Page 27
8.2.3 "Malfunction" message... .....................................................Page 27
8.2.4 "Alarm" message .................................................................Page 27
8.2.5 What to do when...… ...........................................................Page 27
9. Control unit 9.1 Switch unit (from model year 01/10) ....................................Page 28
9.2 Switch unit (up to model year 12/09) ...................................Page 29
10. Spare parts and accessories 10.1 Accessory parts...................................................................Page 34
10.2 Spare parts..........................................................................Page 35
11. Warranty ...........................................................................................................Page 40
12. Declaration of conformity ...........................................................................................................Page 41
13. Handover certificate ...........................................................................................................Page 42
4
Table of contents

2.1 Area of application
The lifting stations pump wastewater with and without se-
wage that occurs below the sewer and backwater level fully
automatically into the sewage system in accordance with the
requirements of IN 1986. They are only suitable for use for
domestic wastewater, for example in single family and multi-
family homes, business, hotels and restaurants, department
stores, hospitals, schools or similar cases.
If the feed to the lifting stations must not be interrupted du-
ring normal operation, the lifting station must be equipped
with a second pumping device of the same capacity which
switches on immediately when required (twin station instead
of single station).
The KESSEL lifting station Aqualift®Fhas been designed
for free-standing set-up in frost-protected rooms. The res-
pective switch unit must be installed in a flood-proof, dry and
frost-protected room. The wastewater submersible pumps
are equipped with a single-channel impeller and have a com-
pletely free passage of 40 mm. The pressure pipes must be
at least of the size N 80, the ventilation pipes at least N
70. Wearing media must be kept away from the pump im-
peller.
The systems are suitable for constant wastewater tempera-
tures up to 35°C. A maximum temperature of 60°C is per-
missible briefly (up to 10 minutes).
2. General
5
2.2 System description
The KESSEL pumping station Aqualift
®
F as a single or twin
system basically comprises the following assemblies:
1. Collecting tank made of PEHD
gas and watertight, with
1.1 One or two wastewater pumps, each of which has
a 5 m connection cable
1.2 Pneumatic level control with 5 m air hose each
1.3 Cleaning opening
1.4 Connection for N 100 inlet pipe
1.5 Connection for ventilation pipe
1.6 Connection for manual diaphragm pump
1.7 N 100 pressure outlet connecting pieces with
integrated backwater flap and aerating device
1.8 Pre-scored areas
2. Electric switch unit
(see illustrations in chapter 8)
3. Accessory parts (not illustrated) )
3.1 Brackets with screws and dowels for fixing the tank to
the floor
3.2 Rubber hose with hose clamps for the pressure pipe
connection
3.3 Sound-insulating underlay mat
Mono: Art. no. 28692
uo: Art. no. 28693
A detailed description of the system set-up can be found in
chapter 10, Spare parts.
1.1
1.3
1.8 1.3 1.5
1.7
1.4
1.6
1.2
1.1
1.4
1.6
1.2
1.5
1.9
1.8
1.7

6
3. Technical data
3.1 Dimensions
3.1.1 Single system 1.1 kW with pressure outlet N 100, order no. 28645 / 28644 (with non-return valve)
Single system 2.2 kW with pressure outlet N 100, order no. 28647 / 28649 (with non-return valve)
N100
Ø110 N70
Ø75
N32
Ø40 N100
Ø110
475
Zulaufhöhe
180
3.1.2 Twin system 1.1 kW with pressure outlet N 100, order no. 28652 / 28659 (with non-return valve)
Twin system 2.2 kW with pressure outlet N 100, order no. 28634 / 28631 (with non-return valve)
N100
Ø110
N100
Ø110
N70
Ø75
N32
Ø40 N100
Ø110
539
Zulaufhöhe
300
525
154
564
773
780
160

7
3. Technical data
3.2 Pumps (Aqualift F Mono, Duo)
Type 400 V - 1,1 kW 400 V - 2,2 kW
Nominal capacity (P2) 1,15 k 2,4 k
Rated capacity (P1) 1,6 k 3,1 k
Operating voltage 400 V DS
Rated frequency 50 Hz
Nominal current 3,2 A 5,4 A
Start-up current 14,4 A 30,8 A
Fuse 3 x 16 A slow-blow
Connection cable 5 m long, 7 x 1,5 mm2
Temperature of material pumped 35 °C
eight (pump) 30 kg 31 kg
Protective rating IP 68 ( 24h; 3m S)
Operating mode S1 S3
Max. period of perm. operation 240 Min. 30% duty cycler
Sound level < 70 db < 70 db
Pump volume 20 l (Mono), 50 l (Duo)
Pumping capacity diagram
Pumping height m
Pumping capacity Q (m3/ h)
2
0
10
1
4
3
6
5
8
7
9
11
12
13
14
15
08412162024283236404446485052545658
230 V
1,1 kW
400 V
1,1 kW
400 V
2,2 kW
Qmin nach IN 1986 für N 100
Qmin nach IN 1986 (vmin = 0,7m/s) für N 80

8
3. Technical data
3.3 Electric switch unit
3.3.1 General technical data
Ambient conditions
Permissible temperature range: 0 to 50 °C
Permissible air humidity: 10 to 80 %
non-condensing
Maximum operating height: 2000 m above sea level
Power consumption
max. ca. 11 VA for single, 15 VA for double system
(electronics without motor)
Protective class
Class 1 with function grounding of the secondary electronics
circuit (PELV)
Protective rating
IP 54 when fitted correctly
3.3.2 Supply
Mains supply
PE/N/L1/L2/L3 according to marking on terminal block for
single / twin system
Operating voltage
400 / 230 V 3~ 50 Hz ± 10% rotary current (L1=230V AC /
50Hz±10% for supplying the power packs for the electronics)
Pre-fuse required
max. 16 A / phase (to be provided on installation side)
3.3.3 Inputs
a) From model year 01/10
Level inputs each approx. 24 V output; approx. 5 mA input
Each pump has the circuit TF1 and TF2
b) Up to model year 01/10
Level inputs each 15.8 V input approx. 5 mA circuit TF (or TF1
and TF2) and E7 (or E7 and E8) for connecting the temperatu-
re switch of the pump motor, sensor supply input max. 18 mA
for TF and 9 mA for E7
3 .3.4 Outputs
"Malfunction" relay
Changeover contact; opening contact, centre contact,
closing contact each max. 2A
"Warning" relay
Changeover contact; opening contact, centre contact,
closing contact each max. 2A
Mains
2 x N, max. each 2A
2 x L, max. each 2A
for supplying malfunction/alarm warning devices, switched
through the "malfunction"/"warning" relays, without internal
fusing
Motor (single system)
Motor PE Mains connection
(grey double-deck terminals up to model year 01/10)
(spring terminal on board from model year 01/10)
Motor U T1 contactor
Motor V T2 contactor
Motor W T3 contactor
Motor 1/2 (twin system)
Motor 1/2 PE mains connection
(4-fold mains through terminals up to model year 01/10)
(spring terminal on board from model year 01/10)
Motor 1/2 U T1 contactor 1/2
Motor 1/2 V T2 contactor 1/2
Motor 1/2 W T3 contactor 1/2
}max. 4kW
}max. 4kW

9
4.2 Connecting the pipes
All pipes must be routed so that they can run empty auto-
matically. All pipe connections must be flexible and sound in-
sulated.
There are two types of connection possible:
I. Use of existing moulded connecting pieces on the
tank
(for connection of inlet pipe, ventilation and manual
diaphragm pump according to Fig. A and B) by cutting off
the "front cap" as shown in Fig. C.
The following parts are included in the scope of supply (see
section 2.2):
- Collecting tank with all components mounted
- Electric switch unit
- Accessory parts
IMPORTA T:
The electric switch unit must be stored frost-free and dry.
If the system is not connected directly to the power sup-
ply on installation, the switch unit inc. all electric parts
must be stored accordingly.
CAUTIO :
Hazard through heavy weights. The lifting stations weigh ap-
prox. 45 kg (single system) and approx 84 kg (twin system).
The parts may only be lifted and/or assembled using suita-
ble equipment and exercising appropriate caution. If the sy-
stems are dropped, this can lead to irreparable damage to
system parts (e.g. pump) or the whole system. Such dama-
ge is not covered by the warranty.
4.1 Fitting the collecting tank
Umaintenance work on the lifting stations, they must always
be installed in such a way that there is sufficient access to all
areas of the lifting station and replaceability of all compo-
nents is guaranteed. According to IN 1986, there must be
at least 60 cm space all round the system (on all sides and
above it) to meet this requirement.
The system must be set up at the appropriate spot in the
room, aligned horizontally and placed on practical sound-in-
sulating material (available as an accessory from KESSEL).
The brackets, screws and dowels must be used to fix the lif-
ting station to the floor to prevent movement or twisting.
I STALLATIO SITE:
The KESSEL lifting station Aqualift®Fhas been designed
for free-standing set-up in frost-protected rooms. The re-
spective switch unit must be installed in a flood-proof, dry
and frost-protected room.
Tank-lifting station
Insulation mat
(optional)
Floor
Attachment bracket
4. Installation and assembly
Ventilation N 70 ( a=75mm)
Closure manual diaphragm
pump N 32 ( a=40mm)
Inlet
connection
N 100
( a=110mm)
Abb. A: Single System
Ventilation N 70 ( a=75mm)
Inlet connection
N 100 ( a=110mm)
Closure manual diaphragm pump N 32 ( a=40mm)
Abb. B: Twin System
Floor
attachment

10
Tank-lifting station
Inlet connection
Saw off
connecting pieces
Transition
hose piece
Hose
clamp
Hose
clamps
Pipe connection
Supporting ring
4. Installation and assembly
Abb. C:
Abb. :
A standard plastic pipe muff can be pushed over the connec-
ting piece (see Fig. C).
Alternatively, the connection of a plastic pipe with N 100 for
the inlet or N 70 for ventilation can be carried out using
connection clamps or rubber hoses with hose clamps*. To
prevent the high tension forces leading to deformation at the
connecting piece, a suitable supporting ring* must be pus-
hed into the upper end of the connecting piece (see Fig. ).
II. Connections attached to the pre-scored areas at
the side (for inlet pipe or manual diaphragm pump) using
bore hole with saw cap*, fitting of a suitable greases seal*
and insertion of a suitable plastic pipe (see Fig. E)
* KESSEL accessory part
Tank-lifting station
Pipe duct seal
Pipe connection
Abb. E
Opening drilled
Saw off con-
necting pieces

11
4. Installation and assembly
lInlet pipe
The inlet pipe must be laid at a gradient to the KESSEL lif-
ting station in accordance with IN 1986 and be routed as
straight as possible.
Connection to the tank can be carried out as described under
section I or II above.
The ventilation pipe sets up pressure compensation to the
fresh air for the air flowing into or out of the system during
emptying or filling. According to IN 1986 it must be laid at
least as size N 70 for these lifting stations, and must be rou-
ted over the roof to avoid odour pollution.
Connection to the tank can be carried out as described under
section I or II above.
lPressure pipe
The pressure pipe for directing the soiled water into the se-
wage system must be connected directly to the respective
pressure pipe connection. According to the regulations of EN
12056, the pressure pipe must be routed above the back-
water level and connected to a ventilated basic or collecting
pipe.
The rubber hose included in the scope must be pushed about
4 cm over the pressure connecting piece at the pressure
connection and fixed in place using a hose clamp as a means
of acoustic insulation and to prevent transmission of forces.
Connection of the rubber hose is not an interlocking connec-
tion. It must be set up on site using brackets.
The pressure pipe must be connected (see above) in such a
way that no forces are transferred to the system and there is
no direct contact with the building (structure-borne noise). No
other draining elements may be connected to the pressure
pipe.
Air-tightness and material strength must be guaranteed
under pressure load, too. This must be checked during initi-
al operation.
The pressure pipe must not be connected firmly to the buil-
ding to prevent pressure blows. When cast metal or steel
pressure pipes with low absorption properties are used, a
pressure blow muffler must be included in the pressure pipe
from pumping heights from 5 m.
Backwater flaps to avoid pressure blows for installation in the
IMPORTA T
In the case of all the connections drilled at the side it must
be remembered that the level control is adjusted in such
a way that during normal operation the water level in the
container only reaches up to or just below the lower edge
of the moulded inlet pipe connecting piece on the side.
For this reason, a respective water level will result in all
pipes that are connected lower down. In the case of inlet
pipes this means that dirt deposits cannot be excluded
and may lead to the pipe becoming blocked in extreme
cases.
pressure pipe are available as accessories:
N 80 backwater flap made of cast iron (art. no.: 206-199)
N 100 backwater flap made of cast iron (art. no.: 206-198)
Aerating device (art. no. 206)
A shut-off valve must be installed in the pressure pipe on site
in accordance with EN 12056. For this, we recommend the
non-return valves for mono systems (art. no. 28683) and for
duo systems (art. no. 28694) from the KESSEL range of ac-
cessories.
4.3. Level measurement
4.3.1 Systems from model year 01/2010
Level measurement takes place using pressure sensor and
submersible pipe. The transparent air hose must always be
routed rising to the switch unit so that no condensation can
collect in the air hose.
Perfect function is only guaranteed when permanent pres-
sure compensation takes place between the switch unit and
lifting station. Excess air hose lengths must be shortened.
Extensions of the air hose up to 20 m are possible.
The switching levels are pre-set and can be changed using
the switch unit. More detailed information is available from
KESSEL Customer Services.
4.3.2 Systems up to model year 01/2010
Level measurement is carried out using a pressure dia-
phragm switch that is connected to the switch unit via an el-
ectric cable inc. air hose. Contact KESSEL Customer Servi-
ces for information about setting the switching level.
CAUTIO :
Before commencing any work on the switchgear, the
pump or the level control, the master switch and cut-outs
must be switched off and secured against being re-
connected.

12
Please heed national and local safety regulations. If these
are not observed, personal hazard may be the result. In ad-
dition, no liability or warranty will be granted. After work has
been completed, the housing cover must be sealed properly
again.
5.2 Mountin the switch unit
Screw the housing cover with max. 1 Nm. Install the switch
unit provided in a frost-free, dry, flood-proof and well-venti-
lated room. The switch unit has been designed for vertical
wall-mounting on a solid base. Sufficient air circulation must
ensure excessive inside temperatures develop. The unit is
mounted using 4 screws (Ø 6 mm) at the corners of the hou-
sing (drilling template in the packaging box). The attachment
holes are accessible after the cover has been opened.
IMPORTA T:
All the cables connected to the electrical switch unit must
be fixed in place using suitable measures (e.g. cable ties)
so that they do not cause a hazard in the 1-error case, i.e.
if a connection becomes loose..
5. Electrical connections
5.1 General instructions
An external main switch must be installed for the electric
switch unit that can be used in an emergency to switch off all
the downstream circuits independently of the control unit.
This must be assigned clearly to the switch unit.
All connected cables must be strain-relieved.
Screw connections not used must always be sealed properly.
CAUTIO :
Only qualified electricians may carry out the work on el-
ectrical equipment described below. Before any work is
carried out on the switch unit, the pump or level control,
the main switch and fuses must be switched off, i.e. be vol-
tage-free and secured against being switched back on
again
5.3 Installation, wirin
The pump cables and control cable have a standard length
of 5 m. Extension to max. 20 m is possible on site, but must
be done using a V E-conform connection.
OTE (applies to pressure diaphragm switches up to model
year 01/10)
The cable on the pressure level switch is a special cable with
an air hose in the centre for compensating pressure for the
pressure sensor in the lifting station to the atmosphere. The
following must always be observed:
– The cable may be cut off at any point but must never be
extended. Special lengths of this cable can be ordered di-
rectly from KESSEL.
– The cable must be routed at a constant gradient from the
switch unit to the lifting station.
For this reason, excess lengths must not be rolled up, the
cable has to be shortened to fit.
– The respective screw connection at the switch unit may be
tightened with a maximum torque of 2.5 Nm. Greater torques
can lead to the air hose being squeezed.
– Deviations from these instructions can lead to fun-
ctional failure of the pressure sensor and thus the
whole system!

13
The individual connection jobs are listed in the following table and in the connection diagrams on pages 27 and 29. The ex-
planations in chapter 8, Electric switch unit, must also be heeded (position of the control elements, view of the inside of the
switch unit).
5. Electrical connections
SI GLE SYSTEM- Heed safety instructions!
Work to be done Switch unit from model year 01/10 Switch unit up to model year 12/09
Mains connection
Motor supply cable
Motor temperature sensor
Battery connection
(rechargeable batteries up to year 12/09)
• The rechargeable battery (1 x 9V block) must
be inserted into rechargeable battery fixture.
• Connect the mains supply cable L1 / L2 / L3 /
N / PE to the upper level of the grey mains
connection terminal block, heeding markings
(printing on the board).
• N and PE always have to be connected.
• The mains supply cable must have an all-pole
main switch on the installation side that is
clearly assigned to the control.
• The pre-fuse prescribed on the installation side
must not exceed 16 A per phase.
• The control can be damaged or destroyed if
connection is not carried out correctly.
• Connect the motor supply cable U/V/W to the
ABB connector B6-30-10 left of the motor pro-
tection switch in the right direction in the lower
screw terminals T1 / T2 / T3. The direction of
rotation of the motor must be heeded.
• Connect PE to the lower level of the grey
mains connection terminal block, heeding the
markings (printing on the board).
• Input TF: Wire 4 of the motor supply cable
must be connected on the right at TF input,
wire 5 on the left at TF input.
• Input E7: The jumper must be left.
Level inputs (ON/ALARM)
• The cable must always be routed rising to the
switch unit.
• The cable ends of the pressure level switch
must be connected to the respectively marked
terminals (white wire on the right, brown wire
on the left to "on" input, green wire on the right
and yellow wire on the left to "alarm" input).
Level measurement
Connection to the pressure sensor
The transparent air hose must al-
ways be routed rising to the switch
unit. The air hose must be screwed
tight to the connection provided on
the switch
Both batteries (2 x 9V block) must
be connected on the board.
• Connect the mains supply cable L1
/ L2 / L3 / N / PE at the terminal
block using screw connection.
• N and PE always have to be
connected.
• The mains supply cable must have
an all-pole main switch on the in-
stallation side that is clearly assig-
ned to the control.
• The pre-fuse prescribed on the in-
stallation side must not exceed 16
A per phase.
• The control can be damaged or de-
stroyed if connection is not carried
out correctly.
•
Connect the motor supply cable
U/V/W to the connector in the right di-
rection in the lower screw terminals
T1 / T2 / T3. The direction of rotatio n
of the motor must be heeded.
• PE must be connected with TF1
and TF2 to the terminal block on
the board underneath the motor
protection switch.
• Wire 4 of the motor supply cable
must be connected to the lowest
terminal of the terminal block TF2
TF1.
Wire 5 of the motor supply cable
must be connected to the central
terminal of the terminal block TF2
TF1. The input TF2 is bridged using
a 2-pole jumper, i.e. the central ter-
minal is doubly occupied. Jumper
must not be removed!

14
SI GLE SYSTEM- Heed safety instructions!
Work to be done Switch unit from model year 01/10 Switch unit up to model year 12/09
5. Electrical connections
Outputs
"Malfunction" and
"alarm / warning"
• The terminal block of the level inputs must
not be connected with any other circuit.
• The terminals are marked with switch
symbols.
• The outputs N / L1 (2 each) are provided to
supply external warning devices/equipment
with power via the "malfunction" and "alarm"
relays. They must not be used for other pur-
poses.
• Maximum permissible current is 2A.
• The "malfunction" and "alarm" messages
are issued via a relay (changeover contact)
without protective circuit. Inductive loads
must be dejammed externally. The quies-
cent state (currentless) of the relays is prin-
ted on the board. It means "malfunction" and
"alarm" message is switched on.
• The relay contacts do not have any internal
connection to any kind of supply or operating
voltages of the control unit and are safely se-
parated from these up to a working voltage
of 300 V according to Table .10 of the stan-
dard EN 61010 (excess voltage category 2
and degree of soiling 2).
• The relays have been designed for switching
230 V / 2 A. Suitable measures must be
taken to restrict the current externally to this
value.
• The relays must not be used to switch diffe-
rent phases. The phase may deviate from L1
however.
The "malfunction" and "warning"
messages are issued via a relay
(changeover contact) without pro-
tective circuit. Inductive loads must
be dejammed externally. The quies-
cent state (currentless) of the relays
is printed on the board. It means
"malfunction" and "warning" messa-
ge is switched on.
• 42 V C/ 0.5 A

15
5. Electrical connections
TWI SYSTEM- HEED SAFETY I STRUCTIO S!
Work to be done Switch unit from model year 01/10 Switch unit up to model year 12/09
Mains connection
Motor supply cable
Battery connection
(rechargeable batteries up to 12/09)
• er Akku (1 x 9V-Block) ist in die Akku-
halterung einzustecken.
• Connect the mains supply cable L1 / L2 / L3
/ N / PE to the second level from the bottom
of the mains through terminals, heeding mar-
kings (printing on the board / colours).
• N and PE always have to be connected.
• The mains supply cable must have an all-
pole main switch on the installation side that
is clearly assigned to the control.
• The pre-fuse prescribed on the installation
side must not exceed 16 A per phase.
• The control can be damaged or destroyed if
connection is not carried out correctly.
• The motor supply cables 2 x U/V/W must be
connected to the ABB connector B6-30-10
below the motor protection switch in the right di-
rection in the lower screw-type terminals T1 / T2
/ T3 (pump 1 left, pump 2 right). The direction of
rotation of the motor must be heeded.
• Connect PE to the respective upper level of the
mains through terminals, heeding the markings
(printing on the board / colours).
• The motors must be dejammed externally if ne-
cessary.
• Input TF1: Wire 4 of the motor supply cable
of pump 1 must be connected on the right to
input TF1, wire 5 of the motor supply cable
on the left to input TF1.
• Input TF2: Wire 4 of the motor supply cable
of pump 2 must be connected on the right to
input TF2, wire 5 of the motor supply cable
on the left to input TF2.
• Input E7: The jumper must be left.
• Input E8: The jumper must be left.
Level inputs (ON/ALARM)
• The cable must always be routed rising to the
switch unit.
• The cable ends of the pressure level switch
must be connected to the respectively mar-
ked terminals (white wire on the right, brown
wire on the left to "on" input, green wire on
the right and yellow wire on the left to "alarm"
input)
• The terminal block of the level inputs must
not be connected with any other circuit.
• Both batteries (2 x 9V block) must
be connected on the board.
• Connect the mains supply cable L1 /
L2 / L3 / N / PE at the terminal block
L1 / L2 / L3 / N / PE using screw
connection.
•
N and PE always have to be connected.
• The mains supply cable must have
an all-pole main switch on the instal-
lation side that is clearly assigned to
the control.
• The pre-fuse prescribed on the in-
stallation side must not exceed 16 A
per phase.
• The control can be damaged or de-
stroyed if connection is not carried
out correctly.
• The motor supply cables 2 x U/V/W
must be connected to the connectors
in the right direction in the lower
screw-type terminals T1 / T2 / T3
(pump 1 left, pump 2 right). The di-
rection of rotation of the motor must
be heeded.
• PE must be connected with TF1 and
TF2 to the terminal block on the
board underneath the motor protec-
tion switch.
PUMP 1/2: Wire 4 of the motor sup-
ply cable of pump 1 must be connec-
ted to the lowest terminal of the ter-
minal block TF2 TF1. Wire 5 of the
motor supply cable must be connec-
ted to the central terminal of the ter-
minal block TF2 TF1.
• Input TF2 pump 1/2: The jumper
must be left.
Connection to the pressure sensor
The transparent air hose must always
be routed rising to the switch unit. The
air hose must be screwed tight to the
connection provided on the switch
unit.
Motor temperature sensor
Level measurement

16
5. Electrical connections
TWI SYSTEM- HEED SAFETY I STRUCTIO S!
Work to be done Switch unit from model year 01/10 Switch unit up to model year 12/09
Outputs
"Malfunction" and
"warning"
• The terminals are marked with switch symbols.
• The "malfunction" and "alarm" messages are is-
sued via a relay (changeover contact) without
protective circuit. Inductive loads must be de-
jammed externally. The quiescent state (current-
less) of the relays is printed on the board. It
means "malfunction" and "alarm" message is
switched on.
• The relay contacts do not have any internal connec-
tion to any kind of supply or operating voltages of
the control unit and are safely separated from these
up to a working voltage of 300 V according to Table
.10 of the standard EN 61010 (excess voltage ca-
tegory 2 and degree of soiling 2).
• The relays have been designed for switching 230 V
/ 2 A. Suitable measures must be taken to restrict
the current externally to this value.
• The relays must not be used to switch different pha-
ses. The phase may deviate from L1 however.
• The "malfunction" and "warning"
messages are issued via a relay
(changeover contact) without
protective circuit. Inductive loads
must be dejammed externally.
The quiescent state (current-
less) of the relays is printed on
the board. It means "malfunc-
tion" and "warning" message is
switched on.
•
42 V dc/ 0,5 A
5.4 Checks
- on the setting of the motor protection switches
The motor protection switches must be set to the
values for rated current of the respective pumps
as specified in section 3.
5.5. Confi uration of switch unit (from model year 01/10)
The IP switch is located at the top right of the PCB in the switch unit and has four setting possibilities
1. Switch: Sensor selection
- Switch up: Level measurement using float switcher
- Switch down: Level measurement using air pressure switch
2. Switch: Level heights
- Switch up: Underground pumping stations (with submersible pumps)
- Switch down: Lifting stations (using air pressure switch)
3. Switch: Configuration tables (only for service partners)
4. Switch: Anti-blocking system
- Switch up: Anti-blocking system off
- Switch down: Anti-blocking system on

17
5. Electrical connections
S604 / 1
S604 / 2
S604 / 3
S604 / 4
O
Run-time controlled System
(wastewater lifting system)
Submersible pump
without OFF level switch
Rotary field/phase monitoring
on
Anti-blocking function
on
Level-controlled system
(submersible pump system)
Submersible pump
with OFF level switch
Rotary field/phase failure monitoring
off
Anti-blocking function
off
OFF
up to year 12/09
5.6 Configuration of switch unit (up to model year 12/09)
Configuration of the control is carried out in the factory using switches S601 ... S604 between the terminal blocks of the level
inputs and thermal protection input. For safety reasons, these must be checked according to the following descriptions.
Pre-settings or reference settings are highlighted grey.
- Basic setting is carried out using switch S604 (4-way IP switches with 2 positions ON / OFF each).
- Deviatin settin s are not allowed.

18
6. Initial operation
6.1 General instructions
Initial operation
Initial operation must be carried out by a qualified expert, with
the direct supplier of the wastewater lifting station responsi-
ble for his availability. uring initial operation, a test run with
water is required over at least two switching cycles. uring
the test run, dry running must be avoided. Before, during and
after this test run, the following must be checked:
a) The electric fuse protection of the wastewater lifting stati-
on according to IEC or local regulations
b) The direction of rotation of the motor
c) The gate (actuation, open position, air-tightness)
d) The switching and setting of switching heights in the
collecting tank, in as far as these are not pre-set by the
manufacturer
e) Air-tightness of the system, fittings and pipes
f) Check on operating voltage and frequency
g) Functional test on the backflow preventer
h) Malfunction warning device
i) Attachment of the pressure pipe
j) Motor protection switch; check by briefly screwing indivi-
dual fuses out (two-phase run)
k) Oil level (if oil chamber exists)
l) Pilot lamps and counters
m) Functional test for any manual pump that may be instal-
led.
Initial operation must be documented in writing, whereby im-
portant data e.g. setting of the motor protection switch and
status of operating hours counter must be noted.
This initial operation may only be carried out by authorised
specialist staff.
IN 1986, part 3, must be heeded during the initial operati-
on of lifting stations.
CAUTIO :
Before initial operation the inlet pipes and the pumps must
be cleaned of solid materials such as metal, sand etc.
Before initial operation the pump must be filled with pumping
fluid up to the height of the ventilation bore hole of the pump
housing.
The pump must not suck in any air!
After the complete and correct installation of the complete sy-
stem and all the additional parts as well as the pipe and el-
ectrical installations, the system can be put into operation.
Any shut-off valves must be opened.
Make sure before you put the system into operation that the
nominal voltage and type of current specified for the system
correspond to the nominal voltage and type of current on site.
Check the system installation/cabling carefully before you
put the system into operation. Is the protective earthed con-
ductor working? Have the relevant standards/guidelines
been heeded, particularly with a view to the potentially ex-
plosive area?
o not put the system into operation if there is any damage
to the motor, switch unit or cables visible.
Always follow the safety instructions in chapter 1 of this ma-
nual.
IMPORTA T:
All screw connections must be checked for a tight fit.
6.2 Pressure outlet connecting pieces
The pressure outlet connecting pieces of the lifting stations
are equipped with a backwater flap with aerating device as
standard for each pump. The aerating device must always be
in operating position (see Fig. 1).
The flap (dotted line) is opened exclusively by the pumping
flow of the pump.
6.3 Operatin the switch unit (from model year 01/10)
As soon as the network connection has been set up, initiali-
sation takes place immediately, i.e. the system undertakes a
self-test. After this test, the system is ready for operation
(mains LE lights up).
The acoustic alarm can be switched off by pressing the alarm
LE . The pump(s) can be switched on manually by pressing
the pump key twice.
Fig. 1

19
6.4.1 Operatin the switch unit ( up to model year 12/09)
6.4.1 "Automatic" operating model
a) Single system
The basic function is carried out when the operating mode
switch is set to "auto" and there is no indication of a malfun-
ction (see chapter 9, Switch unit). As the (soiled water) level
rises in the tank, the level switch "on" closes. After the "on"
switched has closed, the switch-on delay time begins (see
section 5.7, Configuration of switch unit), after which the
pump is switched on. The level in the tank decreases through
the pump operation so that the "on" level switch opens again.
After the "on" switched has opened, the run-on time begins
(see section 5.7, Configuration of switch unit), after which the
pump is switched off.
If the current pump running time exceeds the configured
value of the maximum running time limit, the pump is swit-
ched off. At the same time, a malfunction message is issued
by the red LE "run time" lighting up permanently and via the
"malfunction" relay output. The malfunction message (LE
and relay) remain stored until the "alarm reset" key is actua-
ted, and the pump can only be restarted once this has taken
place.
b) Twin system
The basic function is carried out when both operating mode
switches are set to "auto" and there is no indication of a mal-
function (see chapter 9, Switch unit).
Alternating operation
As the (soiled water) level rises in the tank, the level switch
"on 1" closes. After the "on 1" switched has closed, the
switch-on delay time begins (see section 5.7, Configuration
of switch unit), after which one pump is switched on. The
level in the tank decreases through the pump operation so
that the "on 1" level switch opens again. After the "on 1" swit-
ched has opened, the run-on time begins (see section 5.7,
Configuration of switch unit), after which this pump is swit-
ched off. Next time the "on 1" level is reached, the other
pump is switched on.
Parallel operation
As the (soiled water) level rises in the tank, the level switch
"on 1" closes. After the "on 1" switched has closed, the
switch-on delay time begins (see section 5.7, Configuration
of switch unit), after which one pump is switched on. If the
water level continues to rise, the second pump is switched
on (after the delay time) in addition if the "on 2" level is ex-
ceeded. This parallel pump operation continues until the "on
1" level switch opens again and the run-on time has expired.
When the maximum running time limit has been exceeded,
the malfunction message and switch-off of the respective
pump take place as with the single system. The respective
pump can only return to operation when the "alarm reset" key
has been actuated.
In as far as one pump leaves "auto" control (on account of
the running time limit being exceeded, a malfunction, through
respective position of the operating mode switch), the re-
maining second pump is operated analogue to the "auto"
control of a single system, independently of the other pump.
6.4.2 Operating mode "0" (up to model year 12/09)
When the operating mode switch is in the "0" position, the
(respective) pump is switched off, independently of all input
signals. The display elements remain ready for operation.
6.4.3 Operating mode "manual" (up to model year 12/09)
In the "manual" operating mode the (respective) pump is or
remains switched on, independently of the existing water
level in the tank, until this operating mode is switched off
again.
CAUTIO :
Running the pump(s) without water will lead to redu-
ced cooling and increased wear of the pump motor.
Excessive dry running of the pump(s) longer than 5
minutes can thus lead to irreparable damage to the
pump. Such damage is not covered by the warranty.
6.5 Functional test
The different functions of the overall system depending on
the ater level in the tank must be checked in a one-off test
using the corresponding ater filling levels in the tank. The
tank must be filled via the connected inlet pipe.
6. Initial operation

20
The system must be checked once every month by the ope-
rator through observation of the switching routine for opera-
tional ability and leaks.
CAUTIO :
Disconnect the unit from the mains during all mainte-
nance work! Heed safety instructions!
All the servicing and maintenance work described
below may only be carried out by authorised qualified
personnel.
Repairs may only be carried out by the manufacturer
or his authorised service partner.
IN 1986, part 3, must be heeded during maintenance work
on lifting stations. Maintenance work must be carried out re-
gularly by authorised qualified staff.
IMPORTA T:
All screws may only be tightened with a maximum torque
of 3 Nm.
The followin tasks have to be carried out:
• Visual inspection of the complete system, pumps and fitting
parts
• Thorough cleaning of the complete system and the pump
• Check on the complete system and pump housing for ex-
ternal damage and visible wear
• Check on the pump for free movement, wear and deposits
• Check the connection cables for mechanical damage and
wear
• Check the seal connections for air-tightness and replace
the seal (e.g. O-ring) if there any indications of wear
• Insulation test on the pump motor
• Check non-return valve for function if appropriate
• The backwater flap must be replaced after 2 years of ope-
ration.
7.1 otes on the pump
The pump should be checked at regular intervals. If opera-
tional noises increase, pumping capacity decreases or there
are vibrations in the pipeline system, the pump housing and
impeller must be checked for any stubborn soiling or wear.
To do this, the motor unit must be loosened at the four attach-
ment screws (refer also to section 10.2.1 or 10.2.2) and re-
moved from the pump housing.
When checking the pump housing, care must be taken that
the ventilation bore hole is kept open under all operating con-
ditions.
7.2 otes on the aerating device
The aerating device can be used to completely empty the
pressure pipe through manual lifting of the backwater flap on
the lifting system. To do this, an Allen key size 8 or open-
ended spanner size 15 must be used to hold the flap opener
turned (see Fig. 2) as long as necessary until the pressure
pipe is empty. Then the flap opener must always be returned
to its initial position or the marked operating position (see
Fig. 3).
ote:
The complete flap housing can be removed for cleaning
and maintenance purposes (see Fig. 4+5) by loosening
the screw connections on the lower and upper flange of
the flap housing. The pressure pipe must have been
blocked off and emptied first, of course.
7. Inspection and maintenance
Fig. 2
Fig. 3