schmalenberger fluvo CG700 rondo User manual

CG700 rondo
Operating Instructions
D
D
F
GB
I
E
27202 - D.1
Translation of the original

Contents
3CG700 rondo
Version: 27202 - D
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
Contents
1General ............................................................................................. 4
1.1 Guarantee notice .......................................................................................................... 4
1.2 General......................................................................................................................... 4
1.3 Usage Instructions........................................................................................................ 4
2Safety Instructions .......................................................................... 4
2.1 General......................................................................................................................... 4
2.2 Symbols........................................................................................................................ 5
3Unit Description / General Technical Data.................................... 5
3.1 Technical Data.............................................................................................................. 5
3.2 Device Units.................................................................................................................. 6
4Installation Site Specifications / Installation................................. 8
4.1 Base frames for the installation .................................................................................... 8
4.2 Planning the pump pit................................................................................................... 9
4.3 Installation preparations / Concrete pool ...................................................................... 10
4.4 Installation preparations / Pre-fabricated pool .............................................................. 11
4.5 Installation preparations / Wooden-liner pool .............................................................. 11
4.6 Installation - general ..................................................................................................... 12
4.7 Mounting the installation kit / Pre-fabricated pool......................................................... 12
4.8 Mounting the installation kit / Wooden-liner pool .......................................................... 13
4.9 Pump Kit Installation..................................................................................................... 14
4.10 Connection to the pool.................................................................................................. 14
4.11 Connection to the pump................................................................................................ 15
4.12 Installing the switchgear cabinet................................................................................... 15
4.13 Non-return air valve installation .................................................................................... 16
4.14 Installation of the face plate assembly - general........................................................... 16
5Electrical connections .....................................................................18
5.1 Electrical Connections - general................................................................................... .18
5.2 Electrical connections AC............................................................................................. .19
5.3 Electrical connections three-phase current................................................................... .20
6Start-up / Operating......................................................................... .21
7Fault Assistance.............................................................................. .22
8Shutdown / Overwintering.............................................................. .23
8.1 Empty the pool.............................................................................................................. .23
8.2 Face plate assembly overwintering .............................................................................. 23
8.3 Draining the pump ........................................................................................................ 24
9Maintenance and Repair ................................................................. .24
9.1 General......................................................................................................................... .24
9.2 Maintenance ................................................................................................................. .24
9.3 Repairs ......................................................................................................................... .24
10 Spare parts....................................................................................... .24
11 Spare parts list an drawing...............................................................25
11.1 Spare parts list............................................................................................................. ...28

OPERATING INSTRUCTIONS
4 CG700 rondo
Version:27202 - D
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
1 General
1.1 Guarantee notice
If the instructions contained in this operator’s manual are not observed then any claims
under guarantee shall be void.
1.2 General
All parts coming into contact with media are designed for water quality to DIN 19643.
The counter-current swimming unit (counter-current unit) is of state-of-the-art technology.
It has been manufactured with great care and is subject to constant quality checks. It has
been approved by the German Technical Inspectorate (TÜV) and awarded the TÜV-GS
(safety standard) mark.
The operator’s manual contains important instructions on how to use the counter-current
unit safely, properly and economically. The instructions must be strictly adhered to in order
to avoid danger and to ensure that the counter-current unit has a long useful life.
This manual does not take into account local regulations, the observance of which is the
responsibility of the operator – also on behalf of installation personnel that may be
involved.
The performance label specifies the machine series, the frame size, the most important
operating data and the serial number. Please be sure to quote it in case you require more
information and also when placing subsequent orders or ordering spare parts.
1.3 Usage Instructions
The counter-current unit was designed for use in private swimming pools. Consequently it
must not be installed in public swimming pools. Neither the entire unit nor parts thereof
must be used in other systems. You are expressly directed to use it only in accordance with
these instructions.
The counter-current unit must not be operated beyond the parameters stated in the
technical data (3.1) . In case of doubt, please contact your customer service or the
manufacturer.
2 Safety Instructions
2.1 General
• Make sure that the relevant safety regulations and laws are observed in the operating
company and / or country where the counter-current systems are to be used.
• Use the counter-current system only if it is in perfect technical condition, in accordance
with the regulations, observing safety requirements and danger conditions and strictly
adhering to all the instructions in the operator’s manual!
• Promptly remedy any faults that could influence safety.
• The details on the type plate must correspond to the electrical supply being connected
to.
• Prior to carrying out repairs to the counter-current system it must be isolated from the
electrical supply and protected from unintentional switching on.
• Regardless of what nature they may be, repairs must only be carried out by qualified
persons and the counter-current system must be emptied first.

OPERATING INSTRUCTIONS
5CG700 rondo
Version: 27202 - D
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
• The operator must ensure that
- the operator’s manual is always available for users to read,
- instructions in the operator’s manual are being observed,
- the counter-current system is immediately stopped if abnormal electrical voltages,
temperatures, noises, vibrations, leakages or other faults should arise.
2.2 Symbols
In these operating instructions the following symbols are used to draw your special
attention to dangers:
Notices attached directly to the counter-current system , e.g. the arrow indicating the
direction of rotation, must always be observed and maintained in a clearly legible condition.
3 Unit Description / General Technical Data
•Thefluvo counter-current system CG700 rondo complies with VDE (Association of
German Engineers) regulations.
• The electric motor and the water conducting plastic pump are electrically separated.
• The electric motor complies with protection class IP 55.
• The entire counter-current system complies with protection class I.
The counter-current system is delivered as 3 assemblies:
1. Pump kit 2. Assembly kit 3. Installation kit
3.1 Technical Data
*WS = AC = Alternating current
For more details of safety instructions please see the operator´s manual
WK (27220).
Warning! Risk of injury! / Warning! Risk of damage!
This symbol warns you of dangers through mechanical effects and also warns
of handling that could damage the product.
Warning! Mortal danger!
This sign warns you of the danger from electric shocks.
System type: CG700 1.5 CG700 1.5 WS* CG700 1.9 CG700 1.9 WS* CG700 3.0
Capacity 1.5 kW 1.5 kW 1.9 kW 1.9 kW 3 kW
Voltage [V] 400 V Y /
230 V ∆
230 V ~ 400 V Y /
230 V ∆
230 V ~ 400 V Y /
230 V ∆
Frequency 50 Hz 50 Hz 50 Hz 50 Hz 50 Hz
Current 2,86 A 9.5 A 3.6 A 11.5A 5,75 A
Speed 2840 rpm 2790 rpm 2850 rpm 2820 rpm 2810 rpm
Delivery capacity 42 m³/h 42 m³/h 48 m³/h 48 m³/h 60 m³/h
Delivery pressure 1.2 bar 1.2 bar 1.4 bar 1.4 bar 1.9 bar
Max. speed 2 m from the nozzle 1.15 m/sec. 1.15 m/sec. 1.3 m/sec. 1.3 m/sec. 1.6 m/sec.
Max. water temperature 50 °C 50 °C 50 °C 50 °C 50 °C
Expected sound pressure level 65 + 2 dB (A) 65 + 2 dB (A) 67 + 2 dB (A) 67 + 2 dB (A) 70 + 2 dB (A)
Weight 26 kg 26 kg 27kg 27kg39 kg

OPERATING INSTRUCTIONS
6CG700 rondo
Version:27202 - D
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
3.2 Device Units
* The item numbers correspond to the numbers in the parts list.
fig. 1
Overview of the Counter-current unit
The counter-current unit consists of:
1. Pump kit
2. Assembly kit (face plate assembly)
3. Installation kit
The installation kit is always different
depending on the pool type.
There are 4 kinds of pool:
- Concrete-tile pool
- Concrete-liner pool
- Pre-fabricated pool
(steel, plastic or similar)
- Wooden-liner pool
fig. 2 fig. 3
I - Pump kit
The pump kit consists of:
1. Pump assembly Item 01*
2. Suction hose Item 16
3. Pressure hose Item 13
4. Switching tube ø 4 mm Item 31
5. Switchgear cabinet Item 02
6. Protective hose Item K
*The pump kit is always identical no
matter what sort of pool it is intended for.
II - Assembly kit
The assembly kit includes:
1. Face plate assembly Item 35
2. Mounting screws Item 90
3. Air line fixing bracket Item 56
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OPERATING INSTRUCTIONS
7CG700 rondo
Version: 27202 - D
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
fig. 4
III - Installation kit for concrete-tile
pools
The installation kit consists of:
1. Housing Item 20
Note: The housing is concreted into the
concrete wall of the pool. Details of this
can be found in section 4 of this manual.
fig. 5 fig. 6
III - Installation kit for concrete-tile
pools
The installation kit + assembly
components (Item 73) consists of:
1. Installation kit Item 20
Note: The housing is concreted into the
concrete wall of the pool. Details of this
can be found in section 4 of this manual.
2. Clamp ring Item 72
3. Clamp gasket Item 32
4. Mounting screws Item 74
Note: Parts 2 to 4 are delivered with the
face plate assembly.
III - Installation kit for pre-fabricated
pools
The installation kit (Item 91) consists of:
1. Housing Item 20
2. Clamp ring Item 22
3. Clamp gasket Item 39
4. Hold-ring Item 62
5. Mounting screws Item 74
6. Nuts and washers Items 26+83
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OPERATING INSTRUCTIONS
8CG700 rondo
Version:27202 - D
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
4 Installation Site Specifications / Installation
4.1 Base frames for the installation
fig. 7
III - Installation kit for wooden-liner
pool
The installation kit (Item 92) consists of:
1. Housing Item 20
2. Clamp ring Item 22
3. Clamp gasket Item 39
4. Hold-ring Item 68
5. Hold-ring Item 67
6. Mounting screws Items 63+74
7. Nuts and washers Items 64/65 +
26/83
Warning! Risk of damage!
As the pumps are not self-priming, the installation must be under water level.
Make sure you take this into account during the installation planning phase.
fig. 8:
There are two base frames available that
must be ordered separately to suit local
circumstances.
1. W = for wall mounting
2. B = for floor mounting
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OPERATING INSTRUCTIONS
9CG700 rondo
Version: 27202 - D
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
4.2 Planning the pump pit
When planning a pump duct take into account:
1. Clear dimensions min. 1000 x 600 x 600
2. Return connection min. 300 mm under the pool water level
3. Leakage water discharge pipe-end min. DN 40
4. Cooling air supply for the motor min. 2x DN 125. Minimum clearance of the motor
cooling air inlet to the wall = 200 mm.
5. Be sure to cover the pump pit if it is installed in the open air.
6. The position of the non-return air valve (L) must always be over the pool water level
(BWSP).
7. The position of the switchgear cabinet (S) must always be over the pool water level
(BWSP).
8. In case of leakage from the pump, a suitable water drainage must be provided!
fig. 9: Cross-sectional view of the pump
pit
fig. 10: Top view of the pump pit
BWSP Pool water level
L Air valve
S Switchgear cabinet
Warning! Mortal danger!
The mains power supply cable must be equipped with an all-pole separator
with a contact opening of 3 mm.
8216 8217

OPERATING INSTRUCTIONS
1 0CG700 rondo
Version:27202 - D
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
4.3 Installation preparations / Concrete pool
Tailor the installation kit:
Place the installation kit on the formwork board and transfer the bore holes. Bore the holes
into the pool-side formwork board (D). Mark out and cut holes into the outer formwork
board (P) for the suction and pressure supplies and the two hoses.
Screw the installation kit complete with the mounting protection film (C) tightly to the pool-
side formwork board.
fig. 11 fig. 12: Rear view of the installation kit
BWSP Pool water level
C Mounting protection film
D Pool-side formwork board
P Outer formwork board
1 Pressure pipe DN 50
2 Suction pipe DN 65
3 Switching tube
4 Air supply to the non-return
air valve
Warning! Risk of damage!
• The installation kit must be horizontal.
• The distance between the centre of the installation kit and the water level
(BWSP) must be 275 mm.
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OPERATING INSTRUCTIONS
11CG700 rondo
Version: 27202 - D
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
4.4 Installation preparations / Pre-fabricated pool
4.5 Installation preparations / Wooden-liner pool
fig. 13: Boring diagram
Tailor the installation kit:
Cut the cavity Ø 205 and the mounting
holes Ø9into the pool wall.
Warning! Risk of damage!
The hold-ring (62) must be used as a
template.
For rear filling the pool ensure that there
is a cavity at least the size of the dotted
lines.
fig. 14: Boring diagram
Tailor the installation kit:
Cut the cavity Ø 260 and the mounting
holes Ø 12 into the pool wall.
Warning! Risk of damage!
The hold-ring (68) must be used as a
template.
Take note of the asymmetrical position of
the holes!
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OPERATING INSTRUCTIONS
1 2CG700 rondo
Version:27202 - D
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
4.6 Installation - general
4.7 Mounting the installation kit / Pre-fabricated pool
fig. 15
Place the base frame in the desired
position. Fasten the base frame with 4
screws (S).
Warning!
The base frame should be installed in
such a way that it is insulated from the
floor and the wall (I) to avoid the
possibility of external voltage
transmissions.
I Insulation
SScrew
fig. 16
B Pool wall
20 Housing
22 Clamp ring
32 Clamp gasket
62 Hold-ring
74 Hexagon screw
Mount the clamp ring (22) with the clamp
gasket (32) and the hold-ring (62) to the
pool wall. The sealing contact faces
must be clean and smooth.
Then mount the housing (20) on the
clamp ring (22) with the screws (74).
Warning!
The housing (20) must be mounted so
that the connection for the membrane
switch (MS) is at the top.
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OPERATING INSTRUCTIONS
13CG700 rondo
Version: 27202 - D
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
4.8 Mounting the installation kit / Wooden-liner pool
Mount the hold-ring (67) with the hold-ring (68) to the pool wall.
Hang in the liner. Fasten the liner and the clamp gasket (39) together with the clamp ring
(22) and cut out the liner.
Then mount the housing (20) on the clamp ring (22) with the screws (74).
fig. 17 fig. 18: Detail from fig. 17
B Pool wall
N For details see fig. 18
BWSP Pool water level
20 Housing
22 Clamp ring
39 Clamp gasket
67 Hold-ring
68 Hold-ring
74 Screw
Warning!
The housing (20) must be mounted so that the connection for the membrane
switch (MS) is at the top.
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OPERATING INSTRUCTIONS
14CG700 rondo
Version:27202 - D
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
4.9 Pump Kit Installation
4.10 Connection to the pool
fig. 19
R Pipework
S Hexagon screws
V Adaptor
Mount the pump free of all tension with
the hexagon screws M8 (S) on the base
frame.
Warning!
1. Do not use any vibration dampers
between the pump and the base
frame.
2. If the pipework (R) to the pump is
longer than 6 m then the nominal
width must be increased.
- Suction side from DN 65 to a
min. of DN 80
- Pressure side from DN 50 to a
min. of DN 65.
3. Then always mount the adaptors (V)
on the pump body.
fig. 20
14 Return connection DN 50
17 Suction connection DN 65
20 Housing
Stick the adaptors (14+17) onto the pipe
connections on the housing (20).
Alternatively, by using pipework, stick to
the pump-side end of the pipework.
Warning!
Always be sure to lay the pipework using
bends and not angles to keep the pipe
resistance to a minimum.
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OPERATING INSTRUCTIONS
15CG700 rondo
Version: 27202 - D
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
4.11 Connection to the pump
4.12 Installing the switchgear cabinet
fig. 21
01 Motor
12 Air pipe clamp
13 Hose line pressure side
16 Hose line suction side
Connect the hose lines (13 pressure side
+ 16 suction side) to the pump body. Use
the corresponding air pipe clamps (12)
on both sides for this.
Warning!
Make sure that the connections from the
body of the pump to the installation kit /
pipework are as nearly aligned as is
possible.
The hose lines must always be attached
to the pump on the one side
(compensator function), see diagram.
fig. 22
K Protective hose
02 Switchgear cabinet
31 Switching tube
Mount the switchgear cabinet (02) as
close as possible to the installation kit.
Also please observe the instructions in
chapter 4.2.
Fix the switching tube (31) onto the
nipple in the protective hose (K).
Warning!
Be careful not to put a kink in the
switching tube and keep it as short as
possible, maximum length 8 m.
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OPERATING INSTRUCTIONS
1 6CG700 rondo
Version:27202 - D
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
4.13 Non-return air valve installation
4.14 Installation of the face plate assembly - general
fig. 23
28 Non-return air valve
29 Air line hose tail
56 Fixing bracket
Stick the air line hose tail (29) to the air
hose (L). Screw the non-return air valve
(28) onto the air line hose tail (29).
Fasten the non-return air valve with the
fixing bracket (56) to the pool wall or
similar. In the case of a ground level
overflow, place the non-return air valve in
the duct, see detail “B”.
Warning!
To position the non-return air valve also please observe the information under
chapter 4.2.
fig. 24
A Hose coupling
B Plug sleeve
D Face plate assembly
21 Hose
Drain the pool water, if already filled, to
below the installation kit. Firmly place the
hose (21) with the hose coupling (A) onto
the plug sleeve (B) on the face plate
assembly (D). With that the air button is
connected to the switchgear cabinet.
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OPERATING INSTRUCTIONS
17CG700 rondo
Version: 27202 - D
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
4.14.1 Face plate assembly installation / Concrete-tile pool
4.14.2 Face plate assembly installation / Concrete-liner pool
After connecting the air button, put on the face plate assembly (35/35.1), this allows the
pressure connection and air connection to slide into one another (refer to fig. 24). Fasten
to the clamp ring (72) with the screws (90).
fig. 25
C Mounting protection film
20 Housing
21 Switching tube
35/35.1 Face plate assembly
90 Screw
Remove the mounting protection film (C).
After connecting the air button, put on the
face plate assembly (35/35.1), this allows
the pressure connection and air
connection to slide into one another.
Fasten to the housing (20) with the
screws (90.1).
Warning!
Make sure that there is not a kink in the
switching tube (21), do not lay it in a loop
and do not shorten it!
fig. 26
C Mounting protection film
20 Housing
21 Switching tube
35/35.1 Face plate assembly
39 Clamp gasket
72 Clamp ring
74 Screw
90 Screw
Remove the mounting protection film (C).
Place the clamp gasket (39) between the
installation housing (20) and the liner and
screw the clamp ring (72) to the
installation housing using the screws
(74). The sealing contact faces must be
clean and smooth. Now cut out the pool
liner.
Warning!
Make sure that there is not a kink in the switching tube (21), do not lay it in a
loop and do not shorten it!
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OPERATING INSTRUCTIONS
1 8CG700 rondo
Version:27202 - D
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
4.14.3 Face plate assembly installation / Pre-fabricated pool and
Wooden-liner pool
After connecting the air button, put on the face plate assembly (35/35.1), this allows the
pressure connection and air connection to slide into one another. Fasten to the clamp ring
(22) with the screws (90).
5 Electrical connections
5.1 Electrical Connections - general
The electrical connections to the counter-current swimming system must be carried out by
a specialised company in the electrical engineering branch approved by the local energy
provider, taking into account the technical connection requirements.
fig. 27: Pre-fabricated pool fig. 28: Wooden-liner pool
20 Housing
21 Switching tube
22 Clamp ring
35/35.1 Face plate assembly
90 Screw
Warning!
Make sure that there is not a kink in the switching tube (21), do not lay it in a
loop and do not shorten it!
Warning! Mortal danger!
The connections must be carried out by a qualified electrician. For this see for
example the Technical Connection Conditions for heavy current from the
local power supply company , the Regulations of the Electrical Trade
VBG (§3) and DIN VDE 1000-10 / 1995-5. The relevant DIN VDE directives
0100 and where there is a risk of explosion 0165 must also be observed. If the
installation is not carried out properly, there is a risk of getting electric shocks!
Warning!
Compare the available power supply voltage with the details on the motor’s
factory plate and select the appropriate switching.
We recommend the use of a motor protection facility. Connect the motor in
accordance with the circuit diagrams in the following chapters.
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OPERATING INSTRUCTIONS
19CG700 rondo
Version: 27202 - D
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
Please observe:
• The mains power connection must be a fixed connection.
• Under no circumstances must there be any conducting connection between the metal
parts of the motor and the water.
• The mains power supply cable must be equipped with an all-pole separator with a
contact opening of 3 mm.
• At the marked connection terminal (at the foot of the motor or next to the terminal box)
an equalising potential with a cross-section of 10 mm² must be fitted.
5.2 Electrical connections AC
Protective measures:
fig. 29
Mains voltage: 230 V for 1 ~ AC
Mains power supply cable: 3 x 2.5 mm²
Pump connection cable: 3 x 2.5 mm²
Fuse: 16 A passive
B = Control unit in the pool
M = Motor of the circulation pump
N = Mains power supply
(230 V for 1~)
S = Switchgear cabinet
C B= Capacitor
Connection cable, for example,
HO7RNF, all further details required for
making connections can be found in
chapter 3.1.
fig. 30: Basic circuit diagram for 230 V
for 1 ~ AC
An earth leakage circuit breaker
(nominal fault current ≤30 mA) must be
fitted to the mains power supply!
Important! Watch the order of the
terminal bridges!
See the inside of the terminal box lid or
enclosed circuit diagram. Please be sure
to observe instructions from the motor
manufacturer!
L External conductor
N Neutral conductor
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OPERATING INSTRUCTIONS
20CG700 rondo
Version:27202 - D
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
5.3 Electrical connections three-phase current
Protective measures:
fig. 31: Basic circuit diagram for 400/
230 V three-phase current
Mains voltage: 400/230 V
for 3~ AC
Mains power supply
connection cable: 5 x 2.5 mm²
Pump connection cable: 4 x 2.5 mm²
Fuse: 16 A passive
B = Control unit in the pool
M = Motor of the circulation pump
N = Mains power supply
(400/230 V 3 ~)
S = Switchgear cabinet
Connection cable, for example,
HO7RNF, all further details required for
making connections can be found in
chapter 3.1.
fig. 32: Basic circuit diagram for 400/
230 V three-phase current
An earth leakage circuit breaker
(nominal fault current ≤30 mA) must be
fitted to the mains power supply!
Important! Watch the order of the
terminal bridges!
See the inside of the terminal box lid or
enclosed circuit diagram. Please be sure
to observe instructions from the motor
manufacturer!
L External conductor
N Neutral conductor
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8239