Kessel aqualift f User manual

A LEITU G FÜR EI BAU, BEDIE U G U D WARTU G
KESSEL-Pumping s a ion
AqualiftF/AqualiftF Duo Komfor
For all wastewaters (with / without sewage)
For underground / sub-surface installation.
dition 2010/06
Company Date / Town
ID-Nr.. 328-199 N
(Subject to technical amendment)
AqualiftF Aqualift F Duo Produc advan ages
Quick and easy ins alla ion
due o ligh weigh chamber
Long-life / durable due o
wa er igh chamber and
resis ance o aggressive
soils/fluids
Addi ional inle s easily
connec ed on-si e.
Ver ically adjus able and
il able upper sec ion
Company stamp
Ins alla ion
The ins alla ion and service of his uni should be carried
ou by a licensed professional servicer
Service

Dear Customer,
thank you for choosing a K SS L pumping station.
This entire system has passed a strict quality control inspection before leaving K SS L headquarters. Upon delivery of
the lifting station please thoroughly inspect it to make sure that it has not been damaged during shipping and that the de-
livery is complete. In case damage has occurred to the lifting station during shipping, please contact the shipping com-
pany. In case any parts are missing please follow the instructions listed in the ´Guarantee` section of this user´s manual.
Before the K SS L - Aqualift F Pumpstation is installed and placed into operation please carefully read and follow all of
the instructions contained in this Installation, Maintenance and User´s Manual.
K SS L AG
This User´s Manual should always remain with the Pumpstation Aqualift F.
This Installation Manual contains safety instructions for the installation, operation and maintenance of this system. Please be
aware of the following symbols:
Danger symbol for people / personnel according to ISO 3864-B-3-1
Danger symbol for electrical current according to ISO 3864-B-3-6
Safety symbol according to DIN 4844-W8 for marking instructions which need to be followed in order
to maintain the explosion proof rating according to RL 94/9/ G (AT X 100a)
This word denotes safety instructions which if not followed could result in damage to the
system and negatively effect its function
CAUTION

1. Safety instructions ....................................................................................Page 4
2. General 2.1 Application / Installation ..............................................Page 6
2.2 Aqualift F description...................................................Page 6
3. Technical Data 3.1 Pumps.........................................................................Page 7
3.2 Switching levels...........................................................Page 8
3.3 lectrical control unit ..................................................Page 8
4. Installation 4.1 Assembly of the pump chamber..................................Page 10
4.2 Pipe connections ........................................................Page 13
4.3 Installation of the submersible pump(s) ......................Page 14
4.4 Setting the float switches ...........................................Page 14
5. Electrical Connections 5.1 General instructions ....................................................Page 15
5.2 Mounting the control unit ............................................Page 15
5.3 Information concerning explosion protection ..............Page 15
5.4 IInstallation – cable connection ..................................Page 15
5.5 lectrical connections .................................................Page 15
5.6 Checking the motor protection switches .....................Page 18
5.7 Completion of electrical work ......................................Page 18
6. Commissioning 6.1 General instructions ....................................................Page 19
6.2 Storage / non-operation ..............................................Page 19
6.3 Description of operation ..............................................Page 20
6.4 Operational test ..........................................................Page 20
6.4.1 System menu .............................................................Page 22
6.4.2 Information menu .......................................................Page 22
6.4.3 Maintenance menu .....................................................Page 23
6.4.4 Settings menu ............................................................Page 23
7. Inspection and Maintenance 7.1 Pumps.........................................................................Page 24
7.2 lectrical control unit ..................................................Page 25
7.3 Dissassembly of the pumps .......................................Page 25
7.4 Pump ventilation information.......................................Page 25
8. Problems and Solutions 8.1 General problems........................................................Page 26
8.2 Irregular level conditions .............................................Page 27
8.3 Disturbances / Internal controls ..................................Page 28
8.4 Malfunction warnings .................................................Page 29
8.5 Alarm warnings ...........................................................Page 29
8.6 What to do when.... .....................................................Page 29
9. Control Unit 9.1 Control unit connections for single pump ....................Page 33
9.2 Control unit connections for double pump ..................Page 33
10. Replacement parts ....................................................................................Page 34
11. Warranty ....................................................................................Page 35
12. Conformity statement ....................................................................................Page 36
13. Hand-over certificate ....................................................................................Page 37
3
Table of Contents

General Safety Precautions
During installation, operation, maintenance and repair of this system it is important to follow all appropriate DIN
and VDE safety precautions as well as any applicable precautions in your area.
Additionally the safety precautions relating to explosion risks in wastewater pumping systems must be followed.
In danger areas, such as pump stations or septic systems, it is important that systems with explosion proof ra-
tings are installed. Installation and connection of these units should only be handled by licensed, professional in-
stallers.
Qualified Personnel
Personnel responsible for the operation, maintenance, inspection and repair of this system must be fully trained
and licensed. It is the responsibility of the owner or operator of this system to insure that the person(s) responsi-
ble for this system are fully trained and licensed. If this is not the case the existing personnel must be immedia-
tely trained or replaced with trained and licensed personnel. It is also the responsibility of the owner or operator
to make sure that the responsible personnel have read through and are completely familiar with this User´s and
Maintenance Manual.
Electrical voltage / current danger
The Aqualift F uses electricity to operate rotating and mechanical parts. Not following the User´s Manual can re-
sult in damage to the unit as well as injury or a possible fatal accident.
Before maintaining or servicing the Aqualift F make sure to disconnect it from ALL power sources and secure that
power cannot be re-connected during maintenance / servicing. The main fuse for the system should be also swit-
ched off. In the case that only a fuse is available for cut off – then this fuse must be clearly marked during main-
tenance work to avoid a third party from accidentally activating the fuse during servicing or maintenance.
During any service or maintenance work, VDE 0100 regulations apply
The system must be connected to a 30mA RCD (Residual Current Device)
The control unit and float switches / level controls are electrically powered systems which should not be opened
or serviced except by licensed professional electricians. Licensed professional electrician is defined in VDE 0105.
It is important that all electrical cables and units relating to the Aqualift F are always in perfect operating conditi-
on. If damage to any of the electrical cables or systems of the Aqualift F is noticed, the Aqualift F unit must be
immediately disconnected and taken off line.
Danger - hot surfaces
During operation, the Aqualift F pumps can develop high temperatures. Take caution before touching or coming
into contact with the pump body.
Danger for hands and fingers
The Aqualift F pump is equipped with external macerating blades. In order for the system to operate properly the
blades are exposed and unprotected. Any inspection or maintenance work must take place after the Aqualift F
has been fully disconnected from its power source. Also, during maintenance and inspection take caution of any
sharp surfaces or edges.
Slip / Crush / Fall dangers
When entering the chamber there is a risk of slipping / falling. An appropriate access / entry aide should be avai-
lable. In addition, it is important that a second party remain outside of the chamber and oversee the person ente-
ring and performing work on the pumping system.
4
1. Safety Instructions
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Caution - Heavy weight
The pre-assembled chamber base sections (excluding pump(s)) of the KE EL Aqualift F weigh bet-
ween 40 and 60 kg depending on the model, the manhole covers weigh between 38 and 58 kg and an
individual pump weighs approximately 39 kg. The Aqualift F components should be handled by at least
two people equipped with appropriate equipment (e.g. safety shoes, back support, winching devices).
Health Safety
The Aqualift F is designed to pump wastewater containing untreated raw sewage which may pose a
health hazard. It is important that no direct or indirect contact between the Aqualift F and skin, eyes or
mouth occurs. If contact does occur it is important to immediately wash and disinfect the contamina-
ted area. In addition, the atmosphere inside the pump station chamber can also pose a health risk. Be-
fore entering the chamber be sure to properly vent the entire chamber. During access an active ventila-
tion system must also be in place and operating. It is recommended that anyone entering the chamber
is equipped with a portable multi-warning device with audible and optical alarm. This person should be
harnessed to a hoisting device set up above the cover of the chamber – this hoisting device should be
operated by a second individual. KE EL recommends that an approved portable multi gas warning
device with optical and acoustic alarm is worn by the party entering the pumping station.
Noise
During operation of the Aqualift F pumps emit noise. Based on the installation of the Aqualift F this could
present a nuisance. If on-site noise regulations come into effect, appropriate actions may need to be
taken. Take care in selecting the installation location of the system.
Pump operation / commissioning of the pumps
Before placing the pump(s) into operation please observe the conditions on site. The use and operation
of the pumps must be in accordance with explosion proof regulations.
• Dry-running or semi-submersion of the pumps must not occur!
The cutting blades, impeller and pump housing must always be submerged underwater
• The minimal submersion level must always be maintained!
• The pump(s) may not be placed into operation when people are located in the wastewater storage area
of the pumping systems.
• During operation, the pump(s) build up a pressure inside the storage tank
Surrounding conditions / lighting
• Any additional equipment brought into the pumping station (such as external lighting or power tools)
must be equipped with the explosion proof rating.
xplosion protected components of the pumping system are identified by the and AT X symbols on
the identification stickers of the pump and control unit.
Information concerning the Explosion Proof Rating
The set up of systems in an explosion risk area must follow the 94/9/ G (AT X 100a).
The motors can be connected to low voltage with nominal voltage and voltage tolerance according to
I C 38 or other power sources with a supply tolerance of plus / minus 10%.
The pump(s) are to be secured with an overload breaker. This is controlled inside the system´s control
unit by:
- Current limiter (motor protection switch according to N 60 974-2). Motor will turn itself off with a fac-
tor 1.15 rated current within 15 minutes.
- Temperature limiter within an integrated bimetallic switch in the stator.
The motors can also be operated with a frequency converter. In this case the pump ratings must be con-
sidered and not exceeded. In order to prevent overheating, pumps operating with a frequency converter
must be equipped with an internally installed bimetallic switch in the stator. The pump must be capable
of shutting off when the temperature limit has been reached in order to conform with AT X 100a regula-
tions. This shut off system must be connected to the intended measurement switch to assure that the sy-
stem complies with the required temperature class.
1. Safety precautions
5
EX
EX

2.1 Application / Installation
The Aqualift F Pumpstation is designed to automatically
pump wastewater (with or without sewage collected below
the outgoing sewer level) into a septic system or public sewer
piping. This system is only for use with wastewater draining
from single and multi-family homes, commercial buildings,
hotels, restaurants, hospitals, schools or similar buildings. In
circumstances where the interruption of
wastewater flow is not allowed or desired, a twin pump sy-
stem (Pumpstation Aqualift F Duo) is required in which the
second pump will activate during times of heavy flow or if the
second pump is not operating for any reason.
The K SS L Pumpstation Aqualift F is designed for outdo-
or / underground installation. Pumps are equipped with ma-
cerating blades which cut all soft objects into smaller pumpa-
ble pieces. Due to the cutting blades, outlet pipes of DN 40
or larger may be connected to the outlet of the Pumpstation
Aqualift F. Objects in the wastewater which could damage or
cause wear and tear on the cutting / macerating blades
should not come in contact with the pumps. The system is
designed to handle continuous wastewater temperatures up
to 40 deg C (104 deg F).
2.2 Aqualift F description
The K SS L Pumpstation Aqualift F in single or twin pump
variations is comprised of the following components:
1. Single or double sewage pumps with cutting assembly
2. K SS L Inspection Chamber System 800 or System
1000 (mm diameter)
3. Curve pump support base
4. Closure valve for each pump
5. Backflow prevention flap
6. Pressure pipe outlet connection PN 10 from P HD DN
50 (Outside Diameter – 63 mm) or DN 80
(Outside Diameter – 90 mm)
7. Connection for ventilation pipe (DN 100)
8. DN 100 conduit connection for power / control cables (DN
100)
9. Connection for inlet DN 100/150
10. Float switches
11. lectrical control unit (See Chapter 8)
Options for the K SS L Pumpstation Aqualift F include:
• Single (1 pump) or Twin (2 pumps)
• Pumps available with various power ratings
• In K SS L 800 or 1000mm diameter Inspection Chamber
• Installation depths from 1.5 to 5 meters.
The pump support bases, closure valve, backflow preventi-
on
flap, outlet pressure pipe and float switches have already
been installed in the base of the chamber. The pump(s), ad-
ditional
chamber sections and the electrical control unit are
shipped separately with the system. The pumps, depending
on their size, are shipped either in the chamber upper sec-
tion
or on a separate pallet. The pumps are to be installed
only after the complete chamber has been completely as-
sembled
and installed. In order to prevent the build up of dangerous
gases in the chamber which can cause an explosion
risk, the system must be ventilated appropriately.
6
2. General
9
7
8
4
6
5
3
10
Illustration shows:
KESSEL Pumpstation Aqualift F twin pumping unit
2
1
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7
3.1 Explosion proof pumps according to ATEX
Type TPF 1,3 TPF 1,9
Rated input (P1) 1,75 kW 2,6 kW
Rated output (P2) 1,3 kW 1,9 kW
Operating voltage 400 V DS
Frequency 50 Hz
Current 3,56 A 4,5 A
Fusing 3 x 16 A träge
Protection Class IP 68
Pump cable length 10 m Länge, 7 x 1,5 mm210 m Length 7 x 1,5 mm2
Allowable wastewater temp. 40 °C
Max running time at 40 deg C 640 minutes (see settings in chapter 5.7)
Pump weights 39 kg 39 kg
Pumping height (meters)
Flow Q
(cubic meters / hour)
(liters / second)
3. Technical Data
35
30
25
20
15
10
5
00510 15 20
012345
Performance Curve
Q
min
according to DIN 1986 (v
min
= 0,7m/s)
for DN 50 for DN 80
0081 II 2G x d IIB T4 LCI 06 AT X 6043X
Classifications:
• Operating modes: Pump submerged – Continuous operation S1
• Pumps with the TPF . . . ex identification according to Unit Group II, Unit Category 2G ( xplosion endangered
areas Zone 1 and 2) are designed for installation in atmospheres containing dangerous gases which require the
xplosion Group IIB and the Temperature Class T4. Pumps constructed according to this designation comply with
the ignition protection type ‘pressure protection encapsuled’.
TPF 1,9 kW
TPF 1,3 kW
EX

3.3 Electrical control unit
3.3.1 General technical data
Required Fuse
max 16 Amp / phase (provided on-site)
+ FI with 30mA rating
3.3.2 Control Unit Protection
IP 54 based on appropriate installation and securely closed
cover
3.3.3 Appropriate use
Information concerning the appropriate use of the
control unit in areas at risk of explosion
The control unit is designed to operate KE EL single or
twin pump wastewater lifting station. Float switches or other
level controls are used to monitor the wastewater levels in-
side the chamber.
The control is to be installed outside of the area designated
as at risk of explosion.
Classifications
II (1) GD [EEx ia] IIC (Group II, Category (1)G, designa-
ted for use in gaseous atmosphe-
res)
The requirements of Norms N 50014:1997 + A1 – A2, N
50020:2002 have been fulfilled.
G – Certification
BAS 01 ATEX 7217
Identification
II (1) G [EEx ia] IIC 1180 Ta = -20°C..+ 60°C
Installation / Commissioning
The lifting station must be installed, connected and commissioned
only by a licensed professional. This professional must be trained
and certified in areas including types of ignition, regulations and
work in areas at risk of explosion. Check to make sure that the
pump classification (listed above) satisfies the requirements of the
installation area.
• Temperatures in the immediate area of the pumping stati-
on must remain between
0 – 50 deg Celsius (32 – 122 deg F).
Electrical data / Connections
Power supply –
3 x 400 Volt (AC) / 50 Hz +- 10% 3-Phase
(Jacks – N, L1, L2, L3 P ) 230 V (AC) / 50 Hz +- 10% to supply
electronics
ntry electrical circuit
Thermal entry Un = 230V
Connection jacks TF1, TF2a, TF1b, TF2b)
Output electrical circuit
U = 42 V AC DC / 0.5 Amp
Relay malfunction and warning
Power contactor
Switching contact U = 400V +- 10% <= 4 kW, 50 Hz
Single pump type
lectrical circuit x ia IIC – protection type
Connection jacks AUS, ON, ALARM
8
3. Technical Data
Alarm levels are slightly below the wastewater inlet height to the pumping chamber
3.2 Activation levels of the float switches
System 800 inspection chamber System 1000 inspection chamber
Volume diff. liters (approx) Height difference [cm] Volume diff. liters (approx) Height difference [cm]
Single pump
Off – On 150 31 230 31
On – Alarm 90 20 150 20
Twin pumps
Off – On1 --200 31
On1 – On2 --70 10
On2 – Alarm --70 10
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3. Technical Data
9
Electrical explosion protective shield MTL 7787+
Highest value: Uo = 15,8 V
Io = 93 mA
Ro = 300 Ω
Po = 0,65 W
Co = 0,083 µF
Lo = 3,5 mH
Lo/Ro = 56 µH/Ω
Electrical explosion protective shield MTL 7789+
Highest value: Uo = 28 V
Io = 93 mA
Ro = 300 Ω
Po = 0,33 W
Co = 0,083 µF
Lo = 16 mH
Lo/Ro = 106 µH/Ω
Twin pump
lectrical circuit x ia IIC – protection type
Connection jacks AUS, ON1, ON2, ALARM
Highest value: Uo = 28 V
Io = 93 mA
Ro = 300 Ω
Po = 0,33 W
Co = 0,083 µF
Lo = 16 mH
Lo/Ro = 106 µH/Ω
Installation / Assembly
• All appropriate local and national codes must be followed
• Regulations (including safety regulations) concerning the installa-
tion must be followed
• Also consider the installation and assembly instruction of non-
AT X relevant units
Specific conditions for safe operation
none
Upkeep / Maintenance
• Removal of the control unit cover reduces the water / moisture
proof effectiveness of the control unit. In the case that the control
unit is in a very moist, humid or splash endangered area, make
sure to disconnect power to the control unit before handling or
maintenance work is attempted. Removing the cover of the con-
trol unit should only be done by a licensed service professional.
• After maintenance is completed on the control unit, it is important
that the control unit cover is properly closed and secured.
• No changes should be made to the control unit – such as removal
of the protective cover. Control unit repairs are not possible. In the
case that the control unit does not function or is damaged, please
contact the manufacturer.
• If required, data sheets, G – certifications, User´s Manuals and
G conformity certifications can be requested form the manufac-
turer.
3.3.4 Control unit outputs
„Malfunction” relay
Change over contact; opener, middle contact, closer each
with max 42 Volt ac dc / 0.5 Amp
„Alarm” relay
Change over contact; opener, middle contact, closer each
with max 42 Volt ac dc / 0.5 Amp
Motor (single pump unit)
Motor P mains power connection (grey double jacks)
Motor U T1 protection
Motor V T2 protection max 4kW
Motor W T3 protection
Motor1/2 (twin pump unit)
Motor ½ P main power connection (4 x power jacks)
Motor ½ U T1 protection ½
Motor ½ V T2 protection ½ max 4kW
Motor ½ W T3 protection ½
}
}

10
The delivered shipment should include the following (see
section 2.2):
- K SS L Inspection Chamber delivered in sections (for as-
sembly on-site)
- Sewage pump(s)
- lectrical Control Unit
4.1 Installation
The base / bottom of the excavation in which the Aqualift F
is to be installed should be prepared with 30 cm even layer
of compacted gravel. On top of this layer of gravel should be
a 10 cm thick evenly compacted layer of fine stones. Now
place the bottom section of the pumping chamber into the ex-
cavation making sure that inlets / outlet, ventilation and pipe
cable outlets are in the correct location (see Section 4.2)
The excavation is then to be backfilled in 30 cm layers with
gravel (gravel to be group G1 according to ATV-A127). ach
of these 30 cm layers is to be compacted with a light duty
compactor. Make sure to connect any necessary inlets / ou-
tlet or other pipes before these areas are backfilled (see the
section ‘connection of pipes’.
4. Installation and Assembly
Important:
The electrical control unit should be stored in a dry, frost
free area until time of connection. The cable ends of the
float switches must not come in contact with water or moi-
sture during storage or installation.
CAUTIO :
- Caution- Heavy weight
The base of the inspection chamber as well as the pumps
and chamber cover each way over 30 kg! Be sure that ap-
propriate personnel and equipment (e.g. safety shoes, back
support, etc.) are used when moving or handling these
heavy parts. The pumps should be placed into the chamber
after the chamber is installed and lowered into the chamber
only with an appropriate winch / pully assembly.
- Caution - Danger of slipping
While entering or working in or around a chamber the dan-
ger of slipping is always present. Due to this it is mandatory
that a second worker always remains outside of the cham-
ber to aide / observe the other.
- Caution – Danger of tipping
Before the trench / hole is backfilled with soil, the possibili-
ty that the chamber tips or falls is always present. Due to
this, entry into the chamber should only take place after the
hole, in which the chamber is installed, is backfilled.
Einbau Bodenteil
Soil
Soil
Soil
Granite
4-6 cm grit
Concrete
4-6 cm grit
Concrete
30 cm Gravel, 30 cm Gravel
 The installation of the chamber needs to take into con-
sideration the appropriate load class. Installations in
pedestrian areas (Load Class A – 1.5 tons) and stan-
dard traffic areas (Load Class B - 12.5 metric tons) re-
quire that the upper section is firmly compacted into the
surrounding backfill (see illustration)
 For installation on fully access roadways (Class D –
40.0 ton), a concrete load distribution plate is required
on the surface (height of plate 150mm, 2x2 meters)
which should be poured around the upper section of
the chamber. This plate needs to be steel reinforced –
a plan for this is available upon reques).
 For installation in areas with high groundwater, the
chamber needs to be secured against floatation. In ad-
dition to this a re-enforced, groundwater resistant
chamber base is available at an additional cost.
 All inlet and outlet connections to the chamber must be
checked to assure they are secure and watertight.

11
ach chamber section is connected using a gasket (the size
of this gasket will vary depending on if an 800 or 1000 cham-
ber is being installed and on the specific section being in-
stalled). The recessed area for the gasket (located on the top
of each section as seen in the illustration) should be clean
and free from all debris / sand. Firmly place the gasket into
the recessed area of the chamber. The upper exposed por-
tion of the gasket should now be lubricated with a standard
gasket lubricant.
Installing the chamber seals / gaskets Installing chamber sections
Installing the vertically adjustable upper sections
Access step installation
Access steps (included with K SS L 1000 chamber) (Avai-
lable as accessory with K SS L 800 chamber). Access
steps may be installed prior to assembling the individual
chamber sections. Steps are installed as shown in the dia-
gram below.
Now place the next chamber section on top of the other ma-
king sure that the location for access steps are in line with
the lower portion. The steps should be in a left / right / left /
right pattern to aide in accessing the chamber after installa-
tion is complete. If connected properly the 600mm open ac-
cess to the chamber in the cone section should be directly
above the access steps. Connect the two chambers sections
with the supplied clipping systems as seen in the illustrations.
• Firmly insert cu-
stom gasket into
recessed area of
cone section -
using hammer if
required
• Final elevation /
slope adjust-
ments can be
made with the 3
adjustment scr-
ews which should
be upside down
(screws heads
should be at bot-
tom – threads on
top)
4. Installation and Assembly
• Lubricate interior
exposed portion
of the gasket, in-
sert upper sec-
tion and secure
with clamping
ring

12
After the upper section has been set to its final elevation and
slope, it is important to note the following:
• Cobble stone / pavers installation
•In the case that the upper section and cover will be instal-
led in a stone / paver surface, it is important that the top of
the upper section is installed approx 2 cm higher than that
of the pavers. When the cobble stones are compacted the
upper section (with installed cover) should also be com-
pacted (be sure to tighten cover screws before compacting)
until it is level with the surrounding stones
• Installation in traffic areas
•In the case that the upper section and cover will be instal-
led in a surface which is to handle Class D (40.0 metric ton
load classes), a 18cm thick, 2m x 2m B25 concrete load dis-
tributiont plate must be poured around the upper section.
The concrete support plate should be steel re-enforced
and comply with any local regulations. A drawing of this load
support plate is available from K SS L upon request.
• In some instances it may be required that the lower sec-
tion of the upper section be sawed off in order to obtain the
correct installation depth. This cut should be made as
evenly as possible and any remaining loose edges should
be filed away. The included manhole cover removal key as
well as the User´s Manual for the pumping system should
be stored in a protected dry area in the vacinity of the con-
trol unit.
4. Installation and Assembly
K SS L – Pumpstation Aqualift F in System 800 Inspection Chamber
Installation depths from 1.46 to 1.96 meters
K SS L – Pumpstation Aqualift F in System 1000 Inspection Chamber
Installation depths from 1.63 to 5.13 meters
Possible installation depths

13
4.2 Pipe connections
All pipes are to be laid with negative slope into the Pump-
station Aqualift F Chamber – meaning that wastewater will
flow with gravity out of the pipes and into the pumpstation.
All pipe connections must be flexible connections and be in-
stalled with sound dampening accessories. The DN 100/150
pipe connections for the inlets, ventilation and cable supply
can be made with standard DN 100 or DN 150 KG piping.
According to DIN N 12056 the DN 150 wastewater pipe
must have a minimum 2 % slope into the pumpstation and
should be laid as straight as possible. Bends and fittings
should be used only when necessary. The connection to the
DN 150 inlet to the pumpstation can be made with a female
/ female fitting or a DN 100 inlet pipe with reduction.
All electrical cable going to or from the pumpstation should
be installed in one DN 100 conduit pipe. This cable supply
pipe may be used for no other purpose other than running
cables. Curves / Bends in the cable supply pipe should be
handled with 30 or 45 degree fittings (no 67 or 90 degree
bends should be used which could complicate running ca-
bles at a later date).
After all electrical installations have been completed it is im-
portant that the cable supply pipe is completely air and water
tight. This can be accomplished with special cable sealing in-
serts or with special expansion foams which will prevent
odour transfer into the building as well as water / moisture
entering the basement.
The ventilation pipe serves to compensate negative or posi-
tive pressure build-ups which can occur inside the pumpsta-
tion as it is filled with wastewater or as wastewater is pum-
ped out of the system. Since these systems are normally in-
stalled close to the building which they serve, it is recom-
mended that the pumpstation´s ventilation pipe be run to the
roof of the building – this will prevent odour nuisances in the
future. If the opportunity exists, the pumpstation´s ventilati-
on pipe can be connected to the building´s existing ventilati-
on pipe.
The pumpstation is shipped with gaskets
for securing any connecting pipes such
as the ventilation
pipe and the cable access pipe. These
gaskets should be lubricated before KG
inlet and ventilation piping is attached.
The outlet pressure pipe (DN 50 /
80)(connected to a private or public
sewer system) should be connected to
the supplied outlet using PN 10 P HD
DN 50 (OD 63mm) or DN 80 (OD 90mm)
piping. In the case that the DN 80 pres-
sure outlet is to be used, the DN 50 pres-
sure pipe reduction should be cut off on-
site. This connection can by welding the
P pressure pipes together
or by using appropriate heavy duty pipe
connection couplings.
According to DIN N 12056, it is important that this outlet
pipe be plumbed over the local backwater level and then
down into a ventilated wastewater pipe and into the private
or public sewer (this outlet piping must be protected against
freezing) – this can be accomplished by:
• Running the outlet pressure pipe back into the building and
then running the pipe up and above the backwater level and
then down into the main drainage pipe to the sewer, or
• Running the outlet pressure pipe outdoors above the back-
water level and then back into the main drainage pipe (this
option requires the pipe to be protected against freezing
temperatures by either burying if in a soil mound / wall or in
a heated exterior enclosure
A direct solid connection from the pressure pipe outlet to the
building should not exist – this will prevent noise /vibrations
being transferred to the building. No other drainage or pres-
sure pipes can be connected to the pressure outlet pipe.
After the pressure pipe outlet connections have been com-
pleted, it should be pressure tested to assure that the piping
is securely fastened and is 100% watertight.
Pressure pipe (connection muff DA
40 mm) must be routed above the
backwater level in accordance
with DI 1986!
Inlet pipe (connection muff
DN 100/150)
Switch unit
Cable conduit
(connection DN 100)
Ventilation pipe
(connection DN 100)
4. Installation and Assembly

14
4.3 Installation of the submersible sewage pump(s)
CAUTIO :
the Aqualift F submersible TPF 1.3 kW and 1.9 kW pumps
weigh 39 kg. These pumps should only be lifted and in-
stalled in the pumpstation using appropriate lifting and pul-
ley devices. If an installation or maintenance worker
needs to enter the pumpstation this worker should be
equipped with the appropriate safety devices to prevent
slipping and falling and there should always be at least
one observer who remains outside of the chamber
Before installing the submersible pumps(s) check the inside
of the pumpstation to make sure it is free of any debris or
waste. Once the chamber is cleaned, the pump(s) should be
lowered with the aide of a mechanical lowering device (pul-
ley) onto the steel guide rail bars and to the bottom of the
chamber making sure that the pump(s) make firm contact with
the base of the guides. Remove the lowering chain from the
pulley and attach it to the hook located in the upper section of
the chamber so the chain is accessible without entering the
chamber the next time pump service work needs to be done.
Important:
After installing the pump(s) make sure that the closure val-
ves are in the open position (lever should be in the verti-
cal position).
4.4 Setting the float switches
The float switches are set in their appropriate positions at the
factory (see illustration 3.2). It is recommended that the po-
sition of these float switches is not changed as it may nega-
tively effect the operation of the pumps. Please note that the
minimum float switch cable length is 20 mm (see illustration
below).
Single Pump Unit
This pumping station is equipped with one submersible se-
wage pump. The system is controlled by 3 float switches. The
function of these 3 float switches are Pump OFF, Pump ON
and ALARM. The float switches have been installed and set
at the factory. The float switches have been set so that the
ALARM float switch will activate when the wastewater level
inside the chamber reaches the bottom of the inlet pipe level
of the pumpstation. If other pumping levels are desired, the
float switches must
be changed on-site. Important is that the ALARM float switch
activation point is not set above the inlet pipe elevation and
that the Pump OFF float switch is not set too low – this will
prevent the pump from intaking air. Ideally, the submersible
pump should be totally underwater before pumping begins.
Double Pump Unit
This pumping station is equipped with two identical submer-
sible sewage pumps. The system is controlled by 4 float swit-
ches. The function of the 4 float switches are Pump OFF,
Pump 1 ON, Pump 2 ON and ALARM. The float switches
have been installed and set at the factory. The float switches
have been set so that the ALARM float switch will activate
when the wastewater level inside the chamber reaches the
bottom of the inlet pipe level of the pumpstation. If other pum-
ping levels are desired, the float switches must be changed
on-site. Important is that the ALARM float switch activation
point is not set above the inlet pipe elevation and that the
Pump OFF float switch is not set too low – this will prevent
the pump(s) from intaking air. Ideally, the submersible pumps
should be totally underwater before pumping begins.
4. Installation and Assembly

15
NOTIC – only certified licensed professionals should
conduct the following electrical connections.
5.1 General instructions
The control unit for the Pumpstation Aqualift F must be
connected to a separate main switch so that if required
theentire system can be switched off line. This main switch
should be clearly visible and located in the immediate vicini-
ty of the control unit. All cables entering the control unit must
be secured to the control unit using the supplied plastic strain
relief nuts. Cable inlet openings into the control unit which are
not used must be properly closed.
Important:
All electrical cables must be properly secured (with tie
wraps for example) so that in the case that the cable re-
leases from the control unit that the bare ends of the ca-
bles do not come in contact with any other cables (for ex-
ample in the case that cable L1 comes out of the input
jacks it will physically be impossible for this cable to
contact the P LV or the X switching portion of the con-
trol unit).
All local and national safety regulation should be followed. If
these codes are not strictly followed, a danger to people and
maintenance workers could exist. After any work on the con-
trol unit has been completed, the see-thru cover must be pro-
perly secured in order that the control unit remains splash
proof.
Float switch cables should be run separately from the pump
power cables and main power cables in order to prevent el-
ectrical interference which could negatively affect operation
of the system.
5.2 Mounting of control unit
The control unit for this pumping station is to be installed in
a frost-free, dry and well-ventilated area. The control unit
may not be installed in an explosion endangered area. To
prevent overheating of the inside of the control unit, sufficient
air circulation in the immediate vicinity of the control unit
should be provided. The control unit is to be installed verti-
cally on a solid wall with the supplied 4 screws – a template
is provided to aid in drilling holes in the wall. To access the
control unit mounting screws first remove the see-thru cover.
The cables for the pump(s) and the float switches should be
run through an conduit pipe to the control unit. To connect
these cables please follow the instructions in Section 5.4 “In-
stallation – Cable connections”.
5.3 Information concerning explosion protection
Only the float switches can be installed in the explosion risk
areas. When connected cables inside the control unit make
sure that the cables are connected to their appropriate jacks.
Float switch cables must be connected to float switch jacks
and power and pump cables must be connected to their ap-
propriate jacks. Improper connection of cables could dama-
ge the system as well as nullify the explosion proof rating of
the system. No external power may be supplied to the float
switch Off, On, On1/On2 or alarm connection jacks. As re-
quired by the connection plan, the float switch cables should
only be connected to the connection jacks on the HAZARD
section inside the control unit which is connected to the el-
ectrically shielded / protected control unit area.
5.4 Installation – Cable connection
The cables for the pump(s) and the float switches are 10me-
ters in length. The cables between pumping station and buil-
ding must be run in a dedicated conduit pipe (as discussed
in Chapter 4.2 – Pipe Connections). In the case that the 10
meter cable lengths are not sufficient, the cables may be ex-
tending following VD codes..
Important:
All electrical cables must be installed so that they do not
come in contact with the submersible pump(s) and are clear
of the access steps as well as not hindering access to the
chamber. The cable lengths must also assure that the remo-
val of one or both of the submersible pumps for inspection
and / or maintenance purposes is possible.
5.5 Electrical connections
( X) All electrical connections should be handled by
a licensed professional only and should follow all local
and international codes and regulations. The power
supplied to the control unit must match that listed on
the control unit.
Cable Identification
5. Elektroanschluss
green/yellow green/yellow green/yellow green/yellow
black
black
black
black
black
blue
Connect
Switch
cupboard

16
5. Elektroanschluss
The individual cables of the main pumps cables are marked.
In the case that the cable is shortened, the marking should
be left or the cable should be re-marked in the case that the
original marked portion of the cable is cut off. The electrical
system must meet I C 364 requirements.
In an explosion risk area, all electrical cable connec-
tions to the power supply cable must be carried out to
meet all explosion proof requirements.
5.5.1 Pumpstation Monitoring Systems
Temperature monitoring
Function description of the thermal monito-
ring for Ex protected pumps.
The pump windings are monitored by twin independent ther-
mal monitors. The first monitoring system (Bimetal tempera-
ture monitor – cables 20 and 21) will shut down the pump
when a certain temperature has been reached. This monitor
will also restart the pump after the pump has cooled.
In the case that the first monitoring system malfunctions, a
second monitoring system (Bimetal temperature alarm – ca-
bles 21 and 22) will shut down the pump before it exceeds
the maximum allowable explosion proof rated temperature.
The pumps will not restart after they cool down if the second
monitor shuts down the system. In this case the pumpstati-
on must be inspected.
The explosion proof protection for the pumpstation is only
functionable when the integrated temperature monitor and
temperature alarm are properly connected to the control unit
– as described later in the manual.
Max operating voltage of the switch is 250 V, max switching
current is 2 Amp cos phi = 1
Cable identification 20, 21 and 22.
5.5.2 Securing of electrical connection cables
The pump power cables must be taught and firmly connec-
ted in the chamber to prevent these cables from being
sucked into the pumps
5.5.3 Overload Protection System
The motor(s) are protected from overloading by a thermal de-
layed overload protection according to VD 0660. This is set
to the motor´s current – this is displayed on the control unit´s
shield.
5.5.4 Float Switches
The automatic operation of the pumps is controlled by the in-
cluded float switches. The lowest pump off level is set to a
level above the minimal level – see Section 4.4.
5.5.5 Pump Rotation Checkg
ever place hands or any objects near the im-
peller of the pump
The control unit includes a pump rotation monitor. In the case
that the phases are improperly connected, an alarm will
sound. Properly connecting power cables as described in
Section 5.5 will guarantee proper pump rotation.
5.5.6 Potential equalling connection
N 60 204 regulations regulate potential equalling. Pumps
with an explosion proof rating are equipped with an internal
threaded connection for a M8x20 bolt.
Special requirement for chemically corrosive fluids
If the pump unit is used in chemically corrosive fluids
and is the subject to explosion protection require-
ments, the terminal provided on the outside of the
pump unit must not be used.
Instead, the P conductor shall be connected to a
flange of the discharge pipe which is not in contact
with the fluid handled. Make sure that electrical
contact is established between the newly created
potential equalization connection and the pump.

17
5. Electrical Connections
On-site electrical connection work is described in the table below as well as on the control unit connection plan (see pages
27 and 29). Please take note of instructions listed in Chapter 8 – lectrical Control Unit (position of the operating panel and
an interior view of the control unit).
Single Pump Systems – Follow all safety regulations!
Connection Instructions
Power connection • Power cables L1, L2, L3, N and P should be connected to their appropriate
jacks.
• It is mandatory that cables N and P are connected and connected properly.
• The power supply cable to the control unit must be equipped with a main On /
Off switch
• ach phase of the main power cable must be equipped with a fuse with a max
rating of 16 Amps
• Improper cable connection (Phase and N reversed) will cause the internal fuse
(315 mAT) to blow.
Motor / pump cables • The motor / pump cables U/V/W should be connected to the T1 / T2 / T3 connec-
tion jacks.
• The P cable is to be connected to the TF1 and TF2 jacks on the connection
block located below the motor protection switch.
Motor temperature sensors • Cable number 4 on the motor supply cable should be connected to lowest jack
on the TF2 TF1 connection area.
• Cable 5 on the motor supply cable should be connected to the middle jack on
the TF2 TF1 connection area.
• Cable 6 on the motor supply cable should be connected to the top jack on the
TF2 TF1 connection area. The 2 polar ‘bridge’ must be removed if present.
Warning and Alarm outputs • The ‘Störung’ (malfunction) and ‘Alarm’ (alarm) control unit signals are control-
led by a relay. Inductive loads must be externally eliminated. The stand by (po-
werless) position of the relays is printed on the board. This means the ‘Warning’
and ‘Alarm’ signals are activated
• 42 V ac dc / 0.5
Battery connection • both 9-volt batteries located inside the control unit must be connected.
Float switch connections The cable ends of the float switches are to be connected to the appropriate
connection jacks in the HAZARD area inside the control unit which are protec-
ted by the electrical shield.

18
5. Electrical Connections
Double Pump Systems – Follow all safety regulations!
Connection Instructions
Power connection • Power cables L1, L2, L3, N and P should be connected to their appropriate jacks.
• It is mandatory that cables N and P are connected and connected properly.
• The power supply cable to the control unit must be equipped with a main On / Off switch
• ach phase of the main power cable must be equipped with a fuse with a max rating
of 16 Amps
• Improper cable connection (Phase and N reversed) will cause the internal fuse (315
mAT) to blow.
Motor / pump cables • The 2 x motor / pump cables U/V/W should be connected to the T1 / T2 / T3 connection
jacks. Pump 1 connections are on the left, Pump 2 connections are on the right.
• The P cable is to be connected to the TF1 and TF2 jacks on the connection block lo-
cated below the motor protection switch. Pump 1 connections are on the left, Pump 2
connections are on the right.
Motor temperature sensors • Pump 1 and Pump 2
• Cable number 4 on the motor supply cable should be connected to lowest jack on the
TF2 TF1 connection area.
• Cable 5 on the motor supply cable should be connected to the middle jack on the TF2
TF1 connection area.
• Cable 6 on the motor supply cable should be connected to the top jack on the TF2 TF1
connection area. The 2 polar ‘bridge’ must be removed if present.
Warning and Alarm outputs • The ‘Störung’ (malfunction) and ‘Alarm’ (alarm) control unit signals are controlled by a
relay. Inductive loads must be externally eliminated. The stand by (powerless) position
of the relays is printed on the board. This means the ‘Warning’ and ‘Alarm’ signals are
activated.
• 42 V ac dc / 0,5 A
Battery connection • both 9-volt batteries located inside the control unit must be connected.
Float switch connections The cable ends of the float switches are to be connected to the appropriate connec-
tion jacks in the HAZARD area inside the control unit which are protected by the elec-
trical shield.
5.6 Controls
Checking the motor protection switches
The motor protection switch must be set for the
appropriate rated current of the pumps – as descri-
bed in Section 3 of this manual
5.7 Completion of electrical work
After all electrical connection work has been completed in the
control unit, the control unit cover must be closed and pro-
perly secured. In order to eliminate odour nuisances in the
area where the control unit is installed, the conduit pipe to the
control unit should be sealed with a special gaskets or sim-
ply with insulation foam.

19
6.1 General instructions
Commissioning
The commissioning of the Aqualift F should be handled by a
licensed professional. The system should be filled with water
(by draining a drainage fixture connected to the Aqualift F)
and the pump should be allowed to activate twice. During this
text be sure that the pump does not run dry. The following
should be checked prior, during and after the tests:
a) lectrical connections and fuses of the wastewater lifting
station all meet the I C requirements
b) The direction of rotation of the motor / impeller is correct
c) The gate closure valve is watertight and working properly
d) The settings and activation levels of the float switches is
correct
e) The entire system, valves, fittings and pipes are properly
connected and watertight
f) Check frequency and voltage of the system
g) Check of the non-return valve
h) Warning and malfunction alarms are in working order
i) Outlet pressure pipe is watertight and securely connected
j) Motor protection switches
k) Check of the emergency manual pump if available
l) Controlling lamps and counters;
m) Functional check of the perhaps installed hand pump.
The commissioning of the system should be protocolled in writ-
ing, data such as motor settings and hours of operation should
be entered into this document. Commissioning should only be
handled by a licensed professional. DIN 1986 Part 3 should be
followed during the commissioning
E amination:
- of the company data
- of the oil state
- the rotation direction
- of the electric connections
- of the correct installation of the pump
The pump must be completely filled with the pum-
ping medium in order to prevent an explosive at-
mosphere from developing. The pump can only be
operated so that air cannot enter the pump housing.
Commissioning
Before commissioning it must be checked that the
wastewater level is not below the ‘Minimum Waste-
water Level’ (See Section 4.4).
During S1 operation of the pump, the pump should be com-
pletely submersed. Operating the pump not submerged will
cause premature wear and tear on the pump.
6.1.1 Intake of floating matter
Pumps with S-impellers are recommended for pumping wa-
stewaters with floating matter. In these cases, it is recom-
mended that the pumps run in a slightly tilted position. In ad-
dition, S-impellered pumps should run for an additional 10
seconds after the intake level has been reached.
6.1.2 Pumping medium temperature
Max pumping medium temperature of explosion rated
pumps – 40 deg C.
The operator of this pumpstation must ensure that the ope-
rational temperature of this system (pumping medium
temperature) does not exceed this level.
Do not operate this system with pumping mediums
above the noted maximum temperature.
6.1.3 Pump Starts
The maximum pump starts per hour must not exceed 30.
6.1.4 Operating Voltage
Die höchstzulässige Abweichung der Betriebsspannung be-
trägt:
The highest allowable departure from operating voltage is:
± 10% with non explosion proof systems
± 10% with explosion proof systems
The maximum allowable voltage difference between the pha-
ses is 1%
6.1.5 Density of Pumping Medium
The max specific weight of the pumping medium is 1.1. Plea-
se contact the manufacturer for using this system with pum-
ping mediums with a specific weight greater than 1.1.
6.2 on-operating conditions / Storage
6.2.1 Storage of new pumps
- Pumps should be stored in the vertical position in a dry
location in their original packaging
- Spray the interior side of the pump housing with oil.
6.2.2 Requirements for longer duration storage
6.2.2.1 Pump check without pump removal
In order to insure proper pump operation, the pumps should
be manually run 4 times per year for a short period of time
(approx 1 minute). Pre-requisite to this check is that sufficient
pumping medium is inside the pumping chamber (above
Level 1 mark – see illustration on page 15)
6.2.2.2 Storage of removed pumps
Before storing pumps that have already been in service, all
check up and maintenance work should take place including
lubricating the pumps as discussed in 6.2.1.
6. Commissioning

20
6. Commissioning
6.3 Description of operation (for units built in January 2010
and newer)
The Pumpstation Aqualift F is in standard operating mode
when the POW R L D on the control unit is lit and no failu-
res or warnings are displayed. As the wastewater level insi-
de the Aqualift F storage chamber rises the level will reach
the ‘Pump On’ level and the pump will activate. The pump will
pump out the wastewater causing the wastewater level to
sink and eventually fall below the ‘Pump Off’ level. When this
level is reached the pump will stop after the pump post run
time has expired.
In the case that the pump runs for longer than the set maxi-
mum pump run time, the pump will turn off and at this time
the “Laufzeit” L D will turn on to let the operator know that
the motor has run to its maximum run time – in this case a
malfunction alarm will sound and be displayed by an orange
L D. This alarm and L D warning will remain until the ‘Alarm’
button has been pressed to acknowledge the problem – only
after this will the pumps resume operation. The pump can be
manually tested by pressing the Pump button on the control
unit twice
6.4 Control unit operation
 Control unit digital display
 Display navigation buttons
 Confirmation / OK button
 Return / SC (escape) button
 POW R L D signalling operation
 Alarm warning lamp
 Activate pump by pressing pump button twice
In order to open the control unit covers, the
mains power switch to the control unit must first
be turned off, regardless of the current opera-
tion of the system.
 




Aqualift F Mono 400V
Niveau
Level
Pumpe
Pump
ESC OK
Pumpe I
Pump I
Pumpe II
Pump II
Aqualift F Duo 400V
ESC OK







