Insallation instruction
ACO Building Drainage
Operating instructions
Issued: 23/06/2014
Muli Pro
Waste water lifting plants > Waste water containing faeces >
Freestanding installation
Type -PE K duo
Type -PE V duo
PE PE-LLD_K Pumps with channel impeller_duo
System comprising 2 pumps
PE PE-LLD_V Pumps with free flow impeller_duo
System comprising 2 pumps
Type -PE K parallel
Type -PE V parallel
PE PE-LLD_K Pumps with channel impeller_
parallel 2 containers (linked)
PE PE-LLD_V Pumps with free flow impeller_
parallel 2 containers (linked)
Type -1.x VA duo
Type -2.x VA duo
1.x container size 1/pump size_
VA 1.4571_
duo System comprising 2 pumps
2.x container size 2/pump size_
VA 1.4571_
duo System comprising 2 pumps
Please read this documentation and other product-related literature carefully to ensure
safe and correct use.
Give to end users and keep safely until the product is disposed of.
0150.54.40_V1.101_GB
Translation of the original German operating instructions
 elcome
W
Welcome
ACO Passavant GmbH (hereafter referred to as ACO) would like to thank you for placing your
confidence in us. We have supplied you with a waste water lifting plant (hereafter referred to
as the plant), which is state of the art and whose proper condition has been checked prior to
delivery as part of a quality control process.
Images in these operating instructions are intended to help with basic understanding and
details may vary slightly from the components supplied.
The following hints will help you to work with these operating instructions.
■■
A list of tables and illustrations can be found as an appendix.
■■
The following general abbreviations are used in this manual:
……
Illus
=
Illustration
……
Chap.= Chapter
……
max.= Maximum
……
min. =
Minimum
……
mins =
Minutes
……
secs =
Seconds
……
hrs
=
Hours
……
Tab. =
Table
……
e.g. =
for example
……
■■
The following specific abbreviations are used in this manual:
……
BL =
……
BL OFF =
Base load OFF/Switch on for the after-running time for the pump
……
PL Peak load ON/Switch on point for the second pump
……
PL OFF =
Peak load OFF/Switch off point for the second pump
……
ARP OFF =
After-running period OFF/Switch off point for the pump
……
AL Overflow alarm
=
=
Base load ON/Switch on point for the first pump
ACO Passavant GmbH
Im Gewerbepark 11c
D 36457 Stadtlengsfeld
Tel: + 49 36965 819-0
Fax: + 49 36965 819-361
www.aco-haustechnik.de
2
Table of Contents
Table of Contents
1Introduction........................................................................................................ 6
1.1
ACO Service................................................................................................... 6
1.2
Warranty........................................................................................................ 6
1.3
Declaration of Performance............................................................................. 6
1.4
Owners, Users................................................................................................ 6
1.5
Product Identification....................................................................................... 7
1.6
Symbols used in the operating instructions....................................................... 8
2 For your Safety................................................................................................... 9
2.1
Appropriate Usage.......................................................................................... 9
2.1.1
Field of Application............................................................................. 9
2.1.2
Improper Applications...................................................................... 10
2.2
Qualification of Personnel.............................................................................. 11
2.3
Personal Protective Equipment....................................................................... 11
2.4
Warnings...................................................................................................... 12
2.5
Non-approved Parts...................................................................................... 13
2.6
Basic Potential Risks..................................................................................... 13
2.7
2.6.1
Thermal Risks.................................................................................. 13
2.6.2
Risks Relating to Materials/Substances............................................. 13
Owner's Responsibility................................................................................... 14
3 Transport and Storage........................................................................................ 15
3.1
Safety during Transport and Storage.............................................................. 15
3.2Transport..................................................................................................... 16
3.3Storage........................................................................................................ 17
4 Product Description........................................................................................... 18
4.1
Scope of Supply........................................................................................... 18
4.2
Product Features.......................................................................................... 19
4.2.1
Technical Terms Used...................................................................... 19
4.2.2
Short Description of the Plant........................................................... 20
4.2.3
Features of the Plant Parts............................................................... 21
4.3Components................................................................................................. 24
4.4
Operating Principle........................................................................................ 25
4.5
Type Plate.................................................................................................... 27
4.6Accessories................................................................................................. 27
4.7
Recommendations for Installation................................................................... 28
3
Table of Contents
4.8
Pump Control -duo........................................................................................ 29
4.8.1
Overview of Operating and Display Elements...................................... 29
4.8.2
Operating Elements......................................................................... 30
4.8.3
Display Elements............................................................................. 31
4.8.4
Messages in the Display Field........................................................... 32
4.8.5Settings.......................................................................................... 32
4.8.6Settings.......................................................................................... 33
4.8.7
Setting Options................................................................................ 33
5 Technical Data.................................................................................................. 36
5.1
Plant Technical Data ..................................................................................... 36
5.2
Plant Performance Data................................................................................. 40
5.3
Technical Data for the Pump Control -duo........................................................ 43
6Installation....................................................................................................... 47
6.1
Safety during Installation................................................................................ 47
6.2
Sanitary Installation....................................................................................... 48
6.2.1
Assembling the Tank........................................................................ 49
6.2.2
General Requirements for Pipework Systems..................................... 51
6.2.3
Install the stop valve in the discharge pressure line ............................ 52
6.2.4
Assemble the stop valves and Y-branch pipe (type -parallel)................. 53
6.2.5
Connecting the Inlet Line.................................................................. 54
6.2.6
Installing the Stop Valve in the Inlet Line (Optional).............................. 60
6.2.7
Connecting Vent Stack..................................................................... 60
6.2.8
Installing and Connecting the Discharge Pressure Line........................ 62
6.2.9
Connecting the Drain Line (Optional).................................................. 64
6.2.10 Connecting the Manual Membrane Pump (Optional on Type -PE)........... 65
6.2.11 Securing the Tank............................................................................ 65
6.3
Checking the Seal......................................................................................... 67
6.4
Electrical Installation...................................................................................... 68
6.4.1
Attaching the Pump Control -duo....................................................... 69
6.4.2
Attaching the mini compressor.......................................................... 69
6.4.3
Attaching the CEE Socket................................................................. 70
6.4.4 Installing and Connecting Cable for Transmitting the Group Alarm
(Optional)...................................................................................................... 70
4
6.4.5
Installing and Connecting the Connecting Cables of the Pumps............ 71
6.4.6
Installing the Control Line and Connecting it to the Pump Control -duo.. 72
6.4.7
Connecting the Connecting Cable for the Mini Compressor ................ 73
6.4.8
Connecting the Air Bubble Injection Line ............................................ 73
6.4.9
Connecting the Potential Compensation............................................. 75
Table of Contents
7 Commissioning and Operation............................................................................ 76
7.1
Safety during Commissioning and Operation................................................... 76
7.2Commissioning............................................................................................. 76
7.3
Inserting the Battery in the Pump Control -duo................................................. 77
7.4
Automatic Venting of the Volute...................................................................... 77
7.5
Setting the Pump Control -duo........................................................................ 78
7.6
Setting the Pump Control -duo to Soft Start the Pumps (Types K-55 and K-75)... 79
7.7
Test Run....................................................................................................... 81
7.7.1
Specifications.................................................................................. 81
7.7.2
Carry out test run............................................................................ 82
7.8
Adjusting Air Bubble Injection......................................................................... 86
7.9
Control Checks............................................................................................. 86
7.10 Setting Automatic Operation.......................................................................... 86
7.11 Handing over Plant to User............................................................................ 87
7.12 ACO Maintenance Contract............................................................................ 87
7.13Operation..................................................................................................... 88
8Servicing.......................................................................................................... 89
8.1
Safety during Installation................................................................................ 89
8.2
Plant Log...................................................................................................... 90
8.3
Servicing Tasks for Users.............................................................................. 90
8.4
8.3.1
Daily Checks................................................................................... 90
8.3.2
Servicing Tasks as Needed............................................................... 90
8.3.3
Annual Servicing Work...................................................................... 91
Servicing Tasks for Skilled Professionals......................................................... 92
9 Troubleshooting and Repairs............................................................................... 93
9.1
Safety during Troubleshooting and Repairs...................................................... 93
9.2Troubleshooting............................................................................................ 94
9.3
Repairs and Spares....................................................................................... 95
10 Decommissioning and Disposal .......................................................................... 96
10.1 Safety during Decommissioning and Disposal.................................................. 96
10.2Decommissioning......................................................................................... 97
10.3Stopping...................................................................................................... 97
10.4Disposal....................................................................................................... 97
Appendix ............................................................................................................... 98
Index of Tables and Illustrations................................................................................ 98
Notes .................................................................................................................... 99
5
Introduction
1
Introduction
The greatest care has been taken when preparing these operating instructions for the Muli
Pro, and they contain information which ensures its safe operation over a long working life.
If errors have nevertheless occurred, or if information has been omitted, please do let us
know.
1.1 ACO Service
If you have any questions about the plant and the operating instructions, our ACO Service
team will be happy to help.
ACO Service
Im Gewerbepark 11c
D 36457 Stadtlengsfeld
Tel: + 49 (0) 3 69 65 / 81 9 -4 44
Fax: + 49 (0) 3 69 65 / 81 9 -3 67
[email protected]
1.2 Warranty
For information on warranties see our "General Terms and Conditions", at
http://www.aco-haustechnik.de/agb
1.3 Declaration of Performance
The Declaration of Performance for the plant can be downloaded from the following Internet
address by entering the "DoP number",
Chap. 4.5 "Type Plate":
http://www.aco-haustechnik.de/DoP
1.4 Owners, Users
The owner is responsible for the layout (planning and dimensions) of the plant.
If the plant is not operated by the owner, the following points must be agreed with the user:
6
■■
Who is responsible for day-to-day operations?
■■
Who is responsible for initiating servicing or repairs for the plant?
Introduction
■■
Who will react when there is a malfunction, for example?
■■
...
1.5 Product Identification
Identify the supplied plant using the characteristic data from the type plate,
Chap. 4.5 "Type Plate" and mark these on the following table.
Tab. 1:
Key data for product identification
Item number
Type
P2/Motor
performance
[kW]
0175.13.17
PE K-15 duo
0175.13.18
Illus.
Year of
construction
Serial no.
1.5
_________
_________
PE K-22 duo
2.2
_________
_________
0175.13.19
PE K-30 duo
3.0
_________
_________
0175.13.20
PE K-55 duo
5.5
_________
_________
0175.13.21
PE K-75 duo
7.5
_________
_________
0175.12.89
PE V-15 duo
1.5
_________
_________
0175.12.90
PE V-22 duo
2.2
_________
_________
0175.12.91
PE V-30 duo
3.0
_________
_________
0175.12.92
PE V-40 duo
4.0
_________
_________
0175.13.23
PE K-15 parallel
1.5
_________
_________
0175.13.24
PE K-22 parallel
2.2
_________
_________
0175.13.25
PE K-30 parallel
3.0
_________
_________
0175.13.26
PE K-55 parallel
5.5
_________
_________
0175.13.27
PE K-75 parallel
7.5
_________
_________
0175.12.94
PE V-15 parallel
1.5
_________
_________
0175.12.95
PE V-22 parallel
2.2
_________
_________
0175.12.96
PE V-30 parallel
3.0
_________
_________
0175.12.97
PE V-40 parallel
4.0
_________
_________
0175.06.69
1.1 VA duo
1.5
_________
_________
0175.06.70
1.2 VA duo
2.2
_________
_________
0175.06.71
1.3 VA duo
3.0
_________
_________
0175.06.72
1.4 VA duo
4.0
_________
_________
0175.06.74
2.1 VA duo
1.5
_________
_________
0175.06.75
2.2 VA duo
2.2
_________
_________
0175.06.76
2.3 VA duo
3.0
_________
_________
0175.06.77
2.4 VA duo
4.0
_________
_________
7
Introduction
1.6 Symbols used in the operating instructions
To aid understanding, information in these operating instructions has been marked with the
following symbols:
Useful tips and other information to make working with it easier

Steps to be carried out in the prescribed sequence
References to additional information in these operating instructions or in other documents
Warnings,
8
Chap. 2.4 "Warnings"
For your Safety
2
For your Safety
In order to avoid injury to people or damage to property, read the safety instructions before
installing or using the plant.
2.1 Appropriate Usage
2.1.1
Field of Application
This plant is used to collect and automatically raise waste water containing faeces above the
backflow level. The waste water is fed into the waste water drain without any risk to humans
or any threat to structures.
Fields of application of the various types:
Tab. 2:
Fields of application
Type
PE K duo
Fields of application
■■
■■
■■
■■
PE V duo
■■
■■
■■
■■
PE K parallel
■■
■■
PE V parallel
■■
■■
■■
■■
1.x VA duo
■■
■■
■■
■■
2.x VA duo
■■
■■
■■
Apartment buildings
Small business premises with a high level of waste water
Downstream of grease separators up to NS 20
Where there are long discharge pressure lines with a large difference in height
Apartment buildings
Small business premises with a high level of waste water
For waste water containing long fibres
Downstream of grease separators up to NS 15
Commercial or industrial units with high level of waste water
Where there are long discharge pressure lines with a large difference in height
Commercial or industrial units with high level of waste water
Apartment buildings
Downstream of grease separators up to NS 20
For waste water containing long fibres
Apartment buildings
Small business premises with a high level of waste water
For waste water containing long fibres
Downstream of grease separators up to NS 10
Apartment buildings
Downstream of grease separators up to NS 20
For public and industrial waste water
Other possible uses and applications, and modifications, are not permitted.
9
For your Safety
2.1.2
Improper Applications
Some examples of incorrect applications are e.g.:
■■
Using the plant outside the scope of its application,
Chap. 5 "Technical Data".
■■
Letting the plant or the centrifugal pumps run dry.
■■
Using worn components (neglecting servicing)
■■
Ignoring these operating instructions and other documentation supplied with the product.
■■
Use in areas where there is a risk of explosion.
Never put dangerous substances into the plant which could injure people, pollute the water or
affect the proper functioning of the plant.
This includes in particular:
10
■■
Waste water containing mineral oils and grease
■■
Heavy metals, e.g. zinc, lead, cadmium, nickel, chrome
■■
Corrosive substances, e.g. acids (pipe cleaning agents with a pH-value below 4), alkalines,
lyes, and condensates
■■
Cleaning and disinfecting, rinsing and washing agents in large quantities or any which
generate excessive quantities of foam.
■■
Inflammable or explosive substances e.g. petrol, benzene, oil, phenols, solvent-based
paints, white spirit
■■
Solids, e.g. kitchen scraps, glass, sand, ashes, fibres, synthetic resins, tar, cardboard,
textiles, grease (oils), paint
■■
Fluids which can set into solids, e.g. plaster of Paris, cement, lime
■■
Biocides, e.g. plant protection products and pest control products
■■
Waste water from manure pits and animal husbandry, e.g. swill, slurry, manure
For your Safety
2.2 Qualification of Personnel
Any activities which affect the plant must be carried out by qualified personnel, unless they
are explicitly designated as suitable for other people (owners, users).
The immediate supplier of the plant is responsible for making these people available.
Qualified personnel must be able to provide proof of several years of professional experience
and specific knowledge of the following:
Tab. 3:
Personnel qualifications
Activities
Person
Knowledge
Design
Functional changes
New type of use
Planner
■■
Transport/storage
Dispatchers, dealers
■■
■■
■■
Plumbing/electrical installation
Commissioning, maintenance,
Repair,
Decommissioning,
Dismantling,
Checking
Qualified personnel
Use, operation
Monitoring operations,
Simple maintenance and
troubleshooting
Disposal
Knowledge of sanitary engineering
Assessment of applications for waste water
technology and correct planning of waste water lifting
plants
Proof of training in loading safely
Safe handling of lifting and fixing accessories
■■
Working safely with tools
Installing and connecting pipelines and connectors
Installing electrical wiring
Mounting distributors, earth circuit breakers, other
circuit breakers, electrical machinery, switches,
buttons, mains sockets, etc.
Measuring effectiveness of electrical safeguards
Product-specific knowledge
Owners, users
■■
No specific requirements
Qualified personnel
■■
Correct and environmentally-friendly disposal of
materials and substances
Decontamination of dangerous substances
Knowledge of recycling
■■
■■
■■
■■
■■
■■
■■
2.3 Personal Protective Equipment
Personal protective equipment is required for various activities relating to the plant.
Personal protective equipment must be provided to staff and its use must be enforced by
supervisors.
11
For your Safety
Tab. 4:
Personal Protective Equipment
Mandatory
Meaning
signs
Explanation
Wear safety
shoes
Safety shoes offer good non-slip protection, especially in wet areas, and
resistance to piercing, e.g. by nails, and also protect the feet from falling
objects, e.g. when moving items.
Wear a safety
helmet
Safety helmets protect you from head injuries, e.g. from falling objects or
blows.
Wear protective
gloves
Protective gloves protect the hands from minor bruises, cuts, infections and
hot surfaces, particularly during transport, commissioning, maintenance,
repairs and dismantling
Wear protective
clothing
Protective clothing protects the skin from minor mechanical effects and from
infections due to exposure to waste water
Wear protective
goggles or
glasses
Protective eye-gear will protect the eyes against exposure to waste water,
especially during commissioning, maintenance, repairs and decommissioning
2.4 Warnings
To make them stand out, risks and dangers are indicated using the following warning
symbols and words in these operating instructions:
Tab. 5:
Levels of Risks
Warning symbols and
words
Meaning
Indicates a dangerous situation which, if not prevented, will lead to death or
serious injuries.
WARNING
Injuries
DANGER
Indicates a dangerous situation which, if not prevented, may lead to minor
or moderate injuries.
12
Damage to
property
BEWARE
CAUTION
Indicates a dangerous situation which, if not prevented, may lead to death
or serious injuries.
Indicates a situation which, if not prevented, may damage components, the
plant and/or its functions, or an item close by.
For your Safety
Examples of warning messages:
KEY WORD
Cause of risk
Results of risk
Description/list of protective measure(s)
2.5 Non-approved Parts
The plant underwent a large number of quality control steps prior to market launch, and all
components were tested at maximum load.
Installing unapproved parts can compromise safety, and voids any warranty from ACO.
Only original parts from ACO, or ACO approved spares, may be used when replacing components.
2.6 Basic Potential Risks
This chapter lists the basic risks relating to the plant.
2.6.1
Thermal Risks
The centrifugal pumps work intermittently. Thermal risks do not exist in relation to the electric
motor of the centrifugal pump when it is operating normally. In the event of a fault, the motor
can heat up to a maximum of 110°C and cause burns, so protective equipment should be
Chap. 2.3. "Personal Protective Equipment".
worn, see
2.6.2
Risks Relating to Materials/Substances
On contact with waste water or contaminated pump parts, e.g. when removing obstructions,
Chap 2.3. "Personal
there is a risk of infection. Protective equipment should be worn, see
Protective Equipment".
13
For your Safety
2.7 Owner's Responsibility
It is the responsibility of the owner to ensure the following points are respected:
14
■■
The plant must only be used as intended and in good operating condition,
"Appropriate Usage".
Chap. 2.1
■■
Nothing must prevent the safety devices functioning properly.
■■
Maintenance timetables must be respected and faults dealt with swiftly. The owner should
only tackle faults themselves when these measures are described in this operating
manual. ACO Service is responsible for all other tasks.
■■
Check the type plates on the plant for completeness and legibility,
Plate".
■■
Adequate personal protective equipment must be provided and must also be worn,
Chap. 2.3. "Personal Protective Equipment".
■■
Make the operating instructions available in a legible and complete version at the place of
use and train people in its contents.
■■
Only use qualified and authorised staff,
Chap. 4.5. "Type
Chap. 2.2 "Qualification of Personnel".
Transport and Storage
3
Transport and Storage
This chapter provides information on the correct way to transport and store the plant.
The plant (weights Chap. 5 "Technical Data") and the loose parts (packed in a box) are
Chap. 4.1. "Scope of Supply".
secured on a pallet for delivery and protected by foil. List,
3.1 Safety during Transport and
Storage
The following risks can arise during transport and storage:
WARNING
Read the following safety instructions carefully before transport or storage. If carried out
incorrectly severe injuries may occur.
Ensure the staff carrying out the transport and storage have the necessary qualifications,
Chap. 2.2 "Qualification of Personnel".
Manual transportation of the plant is not permitted
Trying to move too heavy a weight may cause injury
■■
Lifting gear must be used.
Use a forklift truck or truck to move
Severe bruising, blows and serious accidents may result from incorrect
transport
■■
Wear personal protective equipment,
Chap 2.3 "Personal Protective Equipment".
■■
Move the plant while in its delivery packaging (fixed to a pallet).
■■
Fasten the load securely.
■■
Make sure the fastening materials are suitable and undamaged.
Use a crane to move
Severe bruising and blows from falling heavy items
■■
Wear personal protective equipment,
Chap 2.3 "Personal Protective Equipment".
■■
Check the max. permitted load for the crane and the fastenings
■■
Never stand below a hoisted heavy item
■■
Make sure that no other people can access any part of the danger area
■■
Avoid swinging movements while moving
15
Transport and Storage
3.2 Transport
The proper procedure for moving the plant (e.g. -PE V duo) by crane or lifting gear is
described below.
CAUTION The load-bearing capacity of the lifting gear must be at least equivalent to the
indicated weight plus safety margin.
By lifting truck or forklift:
Use a lifting truck or forklift to move the unit
to its assembly location.
By crane:
The hoisting slings or ropes must be attached
to the connecting points .
16
Transport and Storage
3.3 Storage
CAUTION Incorrect storage or storage conditions can cause damage to the plant. The
following steps must be taken:
For short-term storage (less than 3 months)
■■
Store the plant in an enclosed, dry, dust-free and frost-free room.
■■
Avoid temperatures outside the range 0 °C to +60 °C.
For long-term storage (more than 3 months)
■■
Store the plant in an enclosed, dry, dust-free and frost-free room.
■■
Avoid temperatures outside the range 0 °C to +60 °C.
■■
For materials which are subject to corrosion: Apply a coating of preservative to all internal
and external metallic parts.
■■
Check preservative after 6 months and repeat if necessary.
17
Product Description
4
Product Description
This chapter provides information on the scope of supply, features, components and
functions.
4.1 Scope of Supply
Check that the product is supplied undamaged and complete with all parts listed in the
following table.
CAUTION Never install a damaged plant. Report any damage to the plant to the supplier, so
that claims can be processed rapidly.
Tab. 6:
Items delivered with the plant
Unit
Component
Tank, complete
■■
■■
ready to connect
and plug in
■■
■■
■■
■■
■■
Fitting accessories
■■
■■
1x tank (2x tanks for type "parallel")
1x control line (hose, mounted on the
tank and pump control -duo)
1x conduit (hose, mounted on the
tank and mini compressor)
2x connecting cables, 7 m,
(connected to the centrifugal pumps
and pump control -duo)
Mini compressor (connecting cable
connected to the pump control -duo)
1x pump control -duo
Type plate
Illus.
Packaging
Pallet
and
cardboard box
(e.g. -PE V duo)
2x DN 150 double sliding sleeves
(type "parallel")
Box
Fastening kit for buoyancy safety (2x
on type "parallel")
……
5x each screws, washers and
rawlplugs
Documentation
■■
■■
18
Operating instructions
Delivery documents
–
Plastic bag
Product Description
4.2 Product Features
This chapter describes the main characteristics of the plant.
4.2.1
Technical Terms Used
■■
Backflow level:
The highest point in an installation which the polluted water can reach. The backflow level
is found in the area with the greatest diameter and should be installed such that the water
runs back into the sewage system and not into the lifting plant.
■■
Centrifugal pump with channel impeller:
Flow machine; a rotating channel impeller uses centrifugal force to
keep the liquids moving. The channel impeller is suitable for carrying
grey water containing faeces and waste water with short-fibred
normal and high-density solids.
■■
Centrifugal pump with free flow impeller:
Flow machine; centrifugal force is used via a rotating impeller to keep
the liquids moving. A large margin of free space in the volute (free
ball passage) allows the liquid to flow easily via the suction port into
the pump chamber and allows long-fibred and high-density solids,
such as long sanitary towels and textiles, to pass through without
obstructing the volute.
A further advantage: as there is no throttle gap between the impeller
and the volute, this construction offers a high level of operational
safety in applications where there are long standstill periods. This
prevents the impeller from seizing up and thereby obstructing the
centrifugal pump.
19
Product Description
4.2.2
Short Description of the Plant
One (two on type "parallel") tank(s) collect(s) the waste water without pressure and is(are)
fixed to the ground on the installation premises with buoyancy-proof anchorage.
The centrifugal pumps are fastened to a base plate on the tank. Centrifugal pumps with
channel impeller are fitted with a suction pipe leading into the tank. Centrifugal pumps with
free flow impeller are fitted with a volute (with suction and pressure openings) in the tank, in
which the free flow impeller rotates.
The 3-phase-motor that drives the centrifugal pumps is connected by cable to the pump
control -duo.
On the pump delivery side, a backflow valve with drain spigot is bolted downstream of
a flange elbow (type K) or standpipe (type V). A Y-branch pipe brings the two pressure
discharges together, while a special mounting adapter provides the connection to the in-situ
discharge pressure line connection.
A stop valve (accessories) is mounted in each case between the backflow valve and the
Y-branch pipe.
Connection ports for inlet lines (4x lateral, at different heights, and 1x from above) and ventilation are provided on the tank.
A drain plug and connection port (optional manual membrane pump) are available to empty
the tank.
A pilot tube mounted in the tank is connected via a control line to the pump control -duo. A
further conduit connects the pilot tube to a mini compressor.
An inspection cover enables the internal parts and/or tank to be serviced, inspected, and
cleaned.
20
Product Description
4.2.3
Features of the Plant Parts
Tab. 7:
Features of the Plant Parts
Features (• = standard)
Type
-PE K duo
-PE K parallel
-PE V duo
PE V parallel
-1.x VA duo
-2.x VA duo
General
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
-
•
•
•
•
•
•
-
•
•
•
•
•
•
-
•
•
•
•
•
•
-
-
- • • • •
■■
Polyethylene tank
■■
Stainless steel tank
■■
Revision opening for simple maintenance (clear width diameter 320 mm)
■■
Revision opening for simple maintenance (clear width diameter 285 mm)
■■
Fastening kit for tank buoyancy safety
■■
2x DN 80 backflow valves with venting mechanism and drain spigot
■■
2x DN 100 backflow valves (type K-75 only) with venting mechanism and drain spigot
■■
2x DN 80 stop valves, accessories
■■
2x DN 100 stop valves (type K-75 only), accessories
■■
DN 80/80/80 Y-branch pipe
■■
DN 80/80/100 Y-branch pipe
■■
DN 100/100/100 Y-branch pipe (type K-75 only)
■■
■■
DN 80/100 special mounting adapter for elastic connection of discharge pressure line
(Ø108 – 114 mm)
DN 100 special mounting adapter for elastic connection of discharge pressure line
(Ø108 – 114 mm)
2x centrifugal pumps with channel impeller
■■
2x centrifugal pumps with free flow impeller
■■
Pneumatic level switching with 7 m control line
■■
Air bubble injection with mini compressor
■■
Ready to connect, quick to mount
■■
Low cost of maintenance
■■
Flood-proof as per IP 68: Flooding height (from base support surface) max. 2 m, flood
period max. 7 days
Dimensions and Connections
• • • • • •
■■
Maximum tank size: 1500 x 780 x 1400 mm (L x W x H)
■■
Maximum tank size: 1000 x 750 x 690 mm (L x W x H)
■■
Maximum tank size: 1000 x 750 x 990 mm (L x W x H)
■■
Maximum plant size: 1500 x 780 x 1410 (type K-75: 1530) mm (L x W x H)
■■
Maximum plant size: 1500 x 1640 x 1410 (type K-75: 1530) mm (L x W x H)
■■
Maximum plant size: 1000 x 750 x 1475 mm (L x W x H)
■■
Maximum plant size: 1000 x 750 x 1600 mm (L x W x H)
•
•
-
■■
• • -
-
-
-
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
-
•
•
•
•
•
•
•
-
•
•
-
•
•
-
•
•
21
■■
■■
■■
■■
■■
■■
■■
■■
■■
■■
■■
■■
■■
■■
■■
■■
22
2x DN 150 horizontal sockets with pipe external diameter 160 mm for inlet line
connection or overflow connection (type "parallel"), distance from lower edge of tank to
middle of socket 750 mm, at the right/left hand side
2x DN 150 horizontal sockets with pipe external diameter 160 mm for overflow
connection, distance from lower edge of tank to middle of socket 120 mm, at the right
and left hand side
1x DN 150 horizontal socket with pipe external diameter 160 mm for inlet line
connection, distance from lower edge of tank to middle of socket 600 mm, at the front
1x DN 150 horizontal socket with pipe external diameter 160 mm for inlet line
connection, distance from lower edge of tank to middle of socket 800 mm, at the front
1x DN 150 vertical socket with pipe external diameter 160 mm for inlet line
connection, distance from lower edge of tank to socket 1015 mm, at the top
2x vertical connecting flanges for DN 100 replacement socket with pipe external
diameter 110 mm or DN 150 replacement socket with pipe external diameter 160 mm
for inlet line connection, distance from lower edge of tank to connecting flange 640
mm, at the top, optional
2x vertical connecting flanges for DN 100 replacement socket with pipe external
diameter 110 mm or DN 150 replacement socket with pipe external diameter 160 mm
for inlet line connection, distance from lower edge of tank to connecting flange 940
mm, at the top, optional
1x vertical clamp flange for DN 100 pipe with external diameter 110 mm for inlet line
connection, distance from lower edge of tank to socket 640 mm, at the top
1x vertical clamp flange for DN 150 pipe with external diameter 160 mm for inlet line
connection, distance from lower edge of tank to socket 940 mm, at the top
2x horizontal clamp flanges for DN 150 pipe with external diameter 160 mm for inlet
line connection, distance from lower edge of tank to middle of socket 830 mm, at the
right and left hand side
1x DN 100 vertical socket with pipe external diameter 110 mm for vent stack
connection, distance from lower edge of tank to socket 990 mm, at the top
1x DN 100 vertical socket with pipe external diameter 110 mm for vent stack
connection, distance from lower edge of tank to socket 690 mm, at the top
1x DN 70 horizontal socket with pipe external diameter 70 mm for ventilation line
connection, distance from lower edge of tank to middle of socket 35 mm, at the front
1x R 1½" (closed) horizontal connection for drain plug and/or ventilation line
connection, distance from lower edge of tank to middle of pipe connection 65 mm, at
the front
1x Rp 1½" vertical socket for connecting manual membrane pump, distance from
lower edge of tank to socket 300 mm, at the top
1x DN 50 (closed) horizontal connection for drain plug, manual membrane pump and/
or ventilation line connection, distance from lower edge of tank to middle of pipe
connection 48 mm, at the front
-2.x VA duo
-1.x VA duo
PE V parallel
-PE V duo
-PE K duo
Dimensions and Connections
-PE K parallel
Product Description
• • • • -
-
- • - • -
-
• • • • -
-
• • • • -
-
• • • • -
-
-
-
-
- • -
-
-
-
-
-
-
-
- • -
-
-
-
-
- •
-
-
-
-
- •
- •
• • • • - •
-
-
-
- • -
• • • • -
-
• • • • -
-
• • • • -
-
-
-
-
- • •
-PE K parallel
-PE V duo
PE V parallel
-1.x VA duo
-2.x VA duo
Centrifugal pump
-PE K duo
Product Description
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
■■
Channel impeller for 70 mm granulation
■■
Channel impeller for 100 mm granulation (type K-75 only)
■■
Free flow impeller for 80 mm granulation
■■
S3 intermittent duty
■■
Permitted conveyance media temperature up to 40°C (temporarily 60°C)
■■
Three-phase motor 400 V/50 Hz with 7 m connecting cable, protection type IP 68
■■
Shaft seal: Simmerring on the motor side, carbon graphite/ceramic circular rotating
mechanical seal on the medium side
Pump control -duo
• • • • • •
■■
Plastic housing for wall mounting
■■
Dimensions with cable connections: 280 x 310 x 120 mm (W x H x D)
■■
400 V/50 Hz connecting value
■■
IP 54 protection type
•
•
•
•
■■
■■
Ready to plug in: 1.5 m connecting cable and 16 A CEE plug with phase inverter
(Types: up to K-22, V-22, 1.2 + 2.2 VA)
Ready to plug in: 1.5 m connecting cable and 32 A CEE plug with phase inverter
(Types: from K-30, V-30, 1.3 + 2.3 VA)
For level switching liquid levels via back pressure
■■
Control of the centrifugal pump via motor contactor
■■
Soft start (types: K-55, K-75)
■■
5 relay contacts for the output of fault signals
■■
Simple to use
■■
LCD text display
■■
Manual – 0 – Auto functions
■■
Acknowledge button
■■
Compulsory switching on of centrifugal pumps (24 hrs)
■■
Internal acoustic alarm
■■
Isolated overflow alarm
■■
Operating hours counting device
■■
High level of resistance to faults
■■
Level reading using internal pressure transducers
■■
Storage of the last 3 error messages
■■
All settings and fault signals are preserved in event of a mains failure
■■
Rotating field check
■■
■■
When operating manually, the centrifugal pumps automatically switch off after 2
minutes
Pump is switched off via switch-off point and after-running period
■■
Electronic monitoring of power to motor
■■
Group alarm with isolated and non-isolated function
■■
Memory "Number of times pump started"
■■
Ammeter
■■
Service mode
•
•
•
•
•
•
■■
Battery backup, mains-independent alarm (approx. 5 - 6 hours) using built-in 9 V battery,
horn sound level max. approx. 85 dB
• • • • • •
■■
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
• • • • • •
• • • • • •
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
• • • • • •
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
23
Product Description
4.3 Components
Using the PE V duo as an example, the following diagram shows the structure or position
of the individual plant components and is used for unambiguous reference in the following
chapters.
1
2
3
4
5
6
26
25
7
24
23
8
22
9
10
11
12
21
20
13
19
14
18
15
16
17
1 = Air bubble injection line
11 = Centrifugal pump
2 = Mini compressor
12 = Fastening kit
3 = Mini compressor
connecting cable
4 = Level switching control line
5 = Pump control duo
6 = Connecting cable with CEE
plug
7 = †DN 150 connection port
8 = Suspension point
9 = Volute ventilation
10 = Tank
19 = R 1½" connection socket
with plug
13 = DN 70 connection port
20 = Fixing tongues
14 = DN 150 connection port
(can only be used for
parallel construction)
21 = R 2" threaded connection
with screw cap
22 = Standpipe
15 = DN 100 ventilation sockets
23 = Backflow stop
16 = Pilot tube with connecting
flange, incl. hose
grommets and plug cap
24 = Stop valve (accessories)
17 = Inspection cover
25 = Y-branch pipe
26 = Special mounting adapter
18 = Base plate
Illus. 1: Components, type -PE V duo
24
Product Description
4.4 Operating Principle
This chapter describes the functions of the plant.
11
12
13
1
2
3
4
5
6
7
8
9
10
14
15
16
17
18
AL
19
PL
BL
PL OFF
20
21
BL OFF
22
ARP OFF
23
24
1 = In-situ inlet line
10 = Pump control -duo
17 = Stop valve
2 = Stop valve
18 = Centrifugal pump
3 = Tank
11 = Backflow loop bottom of
pipe
4 = In-situ vent stack
12 = Backflow level
20 = Standpipe
5 = Bubbling through air
13 = Waste water drain
21 = Centrifugal pump
6 = Pilot tube
14 = In-situ discharge pressure
line
22 = Free flow impeller
7 = Air bubble injection line
8 = Mini compressor
9 = Level switching control line
15 = Special mounting adapter
16 = Y-branch pipe
19 = Backflow stop
23 = Volute
24 = Suction opening
Illus. 2: Schematic representation of operating principle,
type -PE V duo
The plant is a waste water lifting plant and is used to protect against backflow. All sanitary
drainage objects below the backflow level (12) are at risk of backflow. Waste water (with or
without faeces) from these sanitary drainage objects flows through the inlet line (1) and open
25
Product Description
stop valve (2) into the tank (3).
The water level in the tank (3) is displayed in the display field of the pump control -duo (10). If
the waste water reaches a defined level, the centrifugal pump (18/21) switches on automatically. The free flow impeller (22) rotates, delivers the waste water to the volute (23) via the
suction opening (24) and pushes it further through the standpipe (20) and backflow valve
(19). In the backflow valve, a flap is raised from the valve seat to allow passage of the waste
water. The waste water is raised through the open stop valve (18), the Y-branch pipe (16), the
special mounting adapter (15) into the discharge pressure line (14) over the "bottom of pipe
backflow loop" (11) level and then flows to the waste water drain under gravity (13).
The "overflow alarm" is triggered if waste water accumulates up to the "AL" level, due to a
centrifugal pump malfunction (18+21), for example.
The level switching works as follows:
A pilot tube (6) mounted in the tank (3) is connected via a control line (9) to a diaphragm
pressure switch in the pump control -duo (10). If the waste water level rises, then the air in
the pilot tube (6) is compressed. At a defined pressure, the centrifugal pumps (18+21) are
switched on and off and/or the overflow alarm is triggered.
In order for the automatic level switching to work correctly, the ventilation (4) of the tank (3)
and the steady upward incline of the control line (9) are critical.
If the waste water reaches the "BL " level, a centrifugal pump (18/21) switches on and the
waste water is pumped through the discharge pressure line (14) and the bottom of pipe of
the backflow loop (11). If the waste water level falls to the "BL OFF" level, then the predefined
after-running period for the centrifugal pump (18/21) is activated and the centrifugal pump
(18/21) is switched off at "ARP OFF" once the after-running period elapses.
If the centrifugal pumps (18 + 21) are not in operation, the nonreturn flaps are closed on the
backflow valve seats (17). This means that the contents of the discharge pressure line (14)
cannot flow backwards and cannot empty into the tank (6). To empty the discharge pressure
line in the event of a malfunction, the backflow flap can be raised by turning a venting screw).
Both centrifugal pumps (18 + 21) work alternately, i.e. the switching sequence is automatically reversed each time they are restarted.
The second centrifugal pump (18/21) also switches on if the first centrifugal pump fails, if
there is a larger amount of waste water or when the "PL" water level is reached, and switches
off automatically when the "PL OFF" level is reached.
The volume between the two levels or switch points "ARP OFF" and "BL" represents the usable
volume of the plant. Automatic level switching must be set to the relevant switching points
Chap. 7.5
by the plant user and/or adjusted to suit the individual operating conditions,
"Setting the Pump Control -duo".
Prior to operating the plant, the plant must be filled with water via the inlet line and the level
Chap. 7.7 "Test Run".
switching must be tested,
Operation with a mini-compressor:
A mini-compressor (8) generates continuous compressed air and passes this through the air
bubble injection line (7) into the pilot tube (6). The air (5) bubbles when leaving the pilot tube
26
Product Description
(6) and mixes freely in the waste water in the tank (3). This helps to prevent any blockages
and makes the level switching even more reliable. Thanks to this procedure, fluctuations in
readings can be kept to a minimum.
4.5 Type Plate
A type plate is attached to the tank. The following data needs to be copied from there and
kept easily available for information and queries of all types.
■■
Type
■■
DoP code
■■
Year of construction
■■
Item number
■■
Serial no.
4.6 Accessories
Information on suitable accessories,
Chap. 1.1 "ACO Service".
27
Product Description
4.7 Recommendations for Installation
The following illustration shows a possible way of installing the plant.
13
12
11
10
9
8
1
2
3
4
7
1 = Manual membrane pump
(optional)
2 = Three-way valve (optional)
3 = Drain line*
4 = Pump sump*
5 = Plant
6
5
6 = Stop valve (optional)
11 = Vent stack*
7 = Inlet line*
12 = Discharge pressure line*
8 = Stop valve (accessories)
13 = Backflow loop*
9 = Mini compressor
* In-situ requirements
10 = Pump control -duo
Illus. 3: Installation situation (e.g. -PE V duo)
28
Product Description
4.8 Pump Control -duo
This chapter explains the pump control -duo.
4.8.1
Overview of Operating and Display Elements
The following diagram shows the pump control -duo or position of the individual operating
and display elements and is used for unambiguous reference in the following chapters.
11
P1
1
ACO Pumpen
P2
für Hebeanlag
2
ACO cont
3for lifting pla
4
P1
P2
Artikel-Nr./a
5
manual
10
menu
9
8
Beachten Sie die Betriebsanleitung!
Read operating manual!
7
6
enter
www.aco-haustechn
1 = LED: Fault in pump 1 or 2
2 = LED: Overflow alarm
3 = LED: Pump 1 or 2 running
6 = Switch: clearing malfunctions and accepting
settings
4 = LED: General fault
7 = Switch: switch on
automatic operation
5 = LED: Operational type P1
or P2
8 = Switch: switch off
automatic operation
9 = Control knob: display/
menu selection
10 = Switch: Manual operation
P1 or P2
11 = Display area
Illus. 4: Operating the pump control -duo
29
Product Description
4.8.2
Operating Elements
Operating elements and what they mean:
■■
Query menu settings
menu
Use the control knob to query all information, (error messages,
operating hours, number of pump starts, motor power, etc.), and
adjust all settings. After 20 secs, the display automatically reverts to
the default setting.
■■
Clearing faults (confirming and resetting fault warnings) and adjusting
settings
enter
This button is used to clear all malfunctions and change all settings
once the cause has been remedied. If a fault persists, then the group
alarm relay and the alarm signal are switched off. This also applies
for thermal error 1 and the "overflow alarm".
■■
Switch on manual operation
P1
The buttons are used to manually start pumps P1 and P2. They then
switch off automatically after 2 mins.
■■
Switch off operation
P2
manual
P1
P2
P1
P2
The buttons switch off automatic level switching of pumps P1/P2 or
manual operation.
■■
Switch on automatic operation
These buttons switch on automatic operation of pumps P1 and
P2. The pumps are automatically controlled by the "level switching"
function.
30
Product Description
4.8.3
Display Elements
Display elements and what they mean:
■■
Fault in pump P1 or P2
P1
P2
P1
P2
P1
P2
If there is a fault in pump P1 or P2: LED lights up.
■■
Tank full
If the tank is full = "overflow alarm" LED lights up.
■■
Operational readiness
If pump P1 or P2 is in operation: LED lights up and stays lit.
If pump P1 or P2 is in operation in after-running mode: LED flashes.
■■
Group fault
In the event of a group alarm (e.g. incorrect rotating field): LED lights
up.
■■
Type of pump operation
If the "level control" function switches pump P1 or P2 automatically in
automatic operation: LED lights up and stays lit.
If pump P1 or P2 is operating manually: LED flashes regularly.
If the plant switches off automatically after 2 minutes during manual
operation: LED flashes irregularly.
31
Product Description
4.8.4
Messages in the Display Field
Meaning of messages in display field:
■■
■■
Messages in top row (1)
... (1)
... (2)
……
Water level in tank (when no pump is running)
……
Motor power (if pump is running, or alternating display if both
pumps are running)
……
Setting option (in adjustment mode)
Messages in lower row (2)
……
Pump operating hours (if pumps are not running)
……
Current malfunctions (alternating)
……
Adjustable values (in adjustment mode)
4.8.5
... (1)
... (2)
Settings
The settings in the display field can only be changed in service mode. If service mode has
not been activated, then the settings are displayed but not stored.
■■
After 20 secs, the display automatically reverts to the default setting.
■■
Operating hours and number of pump starts can be queried, but not adjusted.
Changes to settings:
■■
■■
Turn the "menu" control knob (to right or
left), until the value of the setting you are
looking for appears, Chap. 4.8.7.
Setting
(upper row)
Press the "reset/enter" button (the last
value stored starts to flash).
Value/
flashing
menu
enter
(lower row)
■■
■■
32
Turn the "menu" button until the value you
want is reached (turning quickly will step
changes more quickly, turn it slowly to fine
tune).
Press the "reset/enter" switch (value stops
flashing and is saved).
–
Value –
menu
(lower row)
Value/fixed
(lower row)
enter
Product Description
4.8.6
Settings
CAUTION The setting values must be appropriate for the selected inlet connection,
Chap. 7.5 "Setting the Pump Control -duo".
4.8.7
Setting Options
The table below contains an overview of the different setting options in the setting menus.
Tab. 8:
Setting Menus
Upper row
Lower row
Settings menu
Setting
Last fault 1 – 3
Delete value
Next Inspection
days left
■■
■■
■■
90 days
180 days
360 days
Explanation
Upper and lower row
The last 3 errors are stored in non- volatile memory and can be
deleted using the enter/reset- button
Servicing/inspection is due.
Base Load On
0 – 200 cm
Switching point of first pump.
Base Load Off
0 – 200 cm
Release operating point of first pump.
Peak Load On
0 – 200 cm
Switching point of second pump.
Peak Load Off
0 – 200 cm
Release operating point of second pump.
High water level
Ignore
Overflow alarm is switched off.
0 – 200 cm
When exceeding the set value, the collective fault relay and the
flood relay switch.
Running time max.
0 – 60 min
The zero value deactivates this function. If a value of 1 – 60 min. is
set, switching off is carried out if pump operates longer than value
set. The pump restarts only after fault was acknowledged.
Stop delay
0 – 180 sec
The centrifugal pump continues to run after the switch-off point is
reached until the time set here expires.
Max. current-1
Max. current-2
0 – 16.0 A
Inspection
■■
■■
■■
Force activastion
Accoustic alarm
Intermittent alarm
every 90 days
every 180 days
every 360 days
If pump 1 or 2 exceed the preset current consumption for a certain
time, it it switched off. Message P1 or P2: overcurrent is displayed.
Only after operating the push button (7), the pump is cleared.
Changing the service interval.
1 – 10 sec
If the centrifugal pump is not started for a period of 24 hours, it is
automatically run for a period.
Is deactived
-
Is activated
A warning horn is sounded if there is a malfunction.
Is deactived
-
Is activated
The group alarm relay switches on.
Is deactived
-
33
Product Description
Upper row
Lower row
Settings menu
Setting
Pump alternation
Is activated
After every operation of base load pump, a change to the other
pump takes place.
Is deactived
-
Is activated
If the phase sequence is incorrect or if L2 or L3 is missing,
then the "overflow alarm" is activated and the centrifugal pump
cannot be operated.
Is deactived
-
Is activated
All settings can be changed.
Is deactived
Settings are displayed but cannot be changed.
Rotating field fault
Service mode
Language
German – English –
French – ...
Explanation
Upper and lower row
The local language can be selected for the display fields.
The following listing explains individual setting menus:
■■
Block peak load operation
In order to use the pumps in alternating operation only, the switching point for the peak
load operation must be set to zero. The message "Peak load On is switched off" is
displayed.
34
■■
Most minimal level settings (On/Off)
If a value below 5 cm is chosen as switching point, the software automatically uses 5
cm as switching point. If a value below 3 cm is chosen as release operating point, the
software automatically uses 3 cm as release operating point. This also applies to start
of after-running time, starting from 3 cm. This is required for the safe operation of the
switching device.
■■
Transit time change
A max. transit time can be set for the base load pump. After time has elapsed, a
change to the other pump takes place, on the proviso that both pumps are in automatic
operation. After triple change without interruption, the alarm is triggered off additionally
and the message "transit time alarm" is displayed.
■■
Transit time monitoring
The menu point "max. transit time" can be called up. When supplied, value is set to zero, i.
e. function is deactivated. If a value of 1 – 60 minutes is set, pump is switched off if pump
operates longer than set value without interruption. Furthermore, an alarm is triggered off
and a fault signal is displayed. The pump only operates again if fault was acknowledged.
The transit time monitoring applies to automatic and manual operation.
■■
Transit time change + transit time monitoring
It is sensible to activate one of both functions only. If a time is set with both functions,
only the function with the lower time setting is carried out.
Product Description
■■
Lag
The lag allows for pumping down below the pilot tube.
■■
Current limiting
Current limiting (max. current – 1, max. current – 2). Nominal current of pumps can be
directly set. The software in the control adds a certain percentage to the set value in
order to compensate for tolerances. The triggering is carried out with an I²/t function and
thus considers increased starting current of pumps.
■■
Error memory
Even in case of zero voltage, the last fault occurred remains stored and can be called up
in the menu under "last fault". If the fault was called up in the menu, it can be erased from
the memory by means of the acknowledgement button (7).
■■
Rotating field fault
The rotating field monitoring monitors the phase sequence and signals the lack of a
phase. In case of a phase error, the pumps are blocked, an alarm is triggered off and the
message "rotating field error" is displayed. The rotating field monitoring can be activated
and switched off via the menu. When operating 1 ~ motors, the rotating field monitoring
must be switched off.
■■
Service mode
When supplied, the service mode is activated, i. e. all settings can be changed. If the
service mode is switched off in the menu, the settings can only be queried with the digital
potentiometer. While the service mode is deactivated, no settings can be changed except
for national language.
■■
National language
German / English / French / Italian / Spanish / Dutch / Polish / Czech / Portuguese are
included in scope of supply. The national language can be changed, if service mode is
deactivated.
35
Technical Data
5
Technical Data
This chapter provides information about the technical data and dimensions of the plant.
5.1 Plant Technical Data
The following table shows the technical data for the plants.
Tab. 9:
Plant Technical Data
36
Rev count
Granulation
Total
volume
I
Inlet height
Z1
Inlet height
Z2
Inlet height
Z3
Inlet height
from above
compl.
[kW]
[kW]
[A]
[V]
[Hz]
[rpm]
[mm]
[l]
[mm]
[mm]
[mm]
[-]
[kg]
PE K-15 duo
2.01
1.5
3.6
400
50
1450
70
520
240
305
330
330
295
PE K-22 duo
2.94
2.2
5.2
400
50
1450
70
520
240
305
330
330
310
PE K-30 duo
3.87
3.0
6.6
400
50
1450
70
520
240
305
330
330
350
PE K-55 duo
6.71
5.5
11.6 400
50
1450
70
520
240
305
330
330
425
PE K-75 duo
8.97
7.5
15.5 400
50
1450
100
520
240
305
330
330
495
PE V-15 duo
2.01
1.5
4.1
400
50
1450
80
520
240
305
330
330
210
PE V-22 duo
2.94
2.2
5.2
400
50
3000
80
520
240
305
330
330
215
PE V-30 duo
3.87
3.0
7.2
400
50
3000
80
520
240
305
330
330
225
PE V-40 duo
5.1
4.0
10.3 400
50
3000
80
520
240
305
330
330
230
PE K-15 parallel 2.01
1.5
3.6
400
50
1450
70
1040
480
610
660
660
360
PE K-22 parallel 2.94
2.2
5.2
400
50
1450
70
1040
480
610
660
660
375
PE K-30 parallel 3.87
3.0
6.6
400
50
1450
70
1040
480
610
660
660
415
PE K-55 parallel 6.71
5.5
11.6 400
50
1450
70
1040
480
610
660
660
490
PE K-75 parallel 8.97
7.5
15.5 400
50
1450
70
1040
480
610
660
660
560
PE V-15 parallel 2.01
1.5
4.1
400
50
1450
80
1040
480
610
660
660
275
PE V-22 parallel 2.94
2.2
5.2
400
50
3000
80
1040
480
610
660
660
280
PE V-30 parallel 3.87
3.0
7.2
400
50
3000
80
1040
480
610
660
660
290
PE V-40 parallel
5.1
4.0
10.3 400
50
3000
80
1040
480
610
660
660
295
1.1 VA duo
2.01
1.5
4.1
400
50
1450
80
270
–
–
–
155
210
1.2 VA duo
2.94
2.2
5.2
400
50
3000
80
270
–
–
–
155
215
1.3 VA duo
3.87
3.0
7.2
400
50
3000
80
270
–
–
–
155
225
1.4 VA duo
5.1
4.0
10.3 400
50
3000
80
270
–
–
–
155
230
2.1 VA duo
2.01
1.5
4.1
400
50
1450
80
365
185
–
–
245
290
2.2 VA duo
2.94
2.2
5.2
400
50
3000
80
365
185
–
–
245
295
2.3 VA duo
3.87
3.0
7.2
400
50
3000
80
365
185
–
–
245
305
2.4 VA duo
5.1
4.0
10.3 400
50
3000
80
365
185
–
–
245
310
Weight
Frequency
P2
Nominal
current
P1
Motor
power
Voltage
Type
Usable volume
Technical Data
The following diagrams show the dimensions and connection dimensions for the plants.
CAUTION All illustrated stop valves are optional accessories.
285
130
Ø108 – 114,3
120
258
65
100 95
750 (Z2)
600 (Z1)
800 (Z3)
940
260
*300
ca. 1410
*ca. 1530
180
*190
95
* DN 100
1300
ca. 1500
100
780
430
215
250
Illus. 5: Dimensions: Type -PE K duo
750 (Z2)
120
258
65
100 95
600 (Z1)
800 (Z3)
940
260
ca. 1480
180
95
270
160
Ø108 – 114,3
1300
780
250
215
325
ca. 1440
Illus. 6: Dimensions: Type -PE V duo
37
Technical Data
95
95
258
65
120
100
750 (Z2)
ca. 1410
*ca. 1530
260 180
*300 *190
* DN 100
600 (Z1)
800 (Z3)
940
285
130
Ø108 – 114,3
1300
780
780
1500
860
430
215
250
1640
100
Illus. 7: Dimensions: Type -PE K parallel
258
65
750 (Z2)
95
120
100
600 (Z1)
800 (Z3)
940
260
ca. 1470
180
95
285
130
Ø108 – 114,3
780
1300
780
860
215
250
1640
430
325
Illus. 8: Dimensions: Type -PE V parallel
38
Technical Data
260
125
48
265
10
638
688
ca. 1475
180
270
160
Ø108 – 114,3
1000
750
160
275
10
333
1000
300
125
160
Illus. 9: Dimensions: Type -1.x VA duo
270
160
Ø108 – 114,3
1000
750
160
275
10
333
1000
500
300
125
160
48
10
265
938
830
988
260
ca. 1600
180
125
Illus. 10: Dimensions: Type -2.x VA duo
39
Technical Data
5.2 Plant Performance Data
The following illustrations and tables show the performance data.
Tab. 10: Performance data: Type -PE K duo + parallel
Type
Delivery
head
Delivery flow
Range
Q [l/s]
Conveyance media temperature
Normal
Max.
for total delivery head [m]
[m]
4
6
8
10
12
14
16
18
[°C]
[°C]
PE K-15 duo
3–8
18.3
11.7
5.8
–
–
–
–
–
40
60
PE K-22 duo
3 – 10
24.2
18.5
12.5
5.3
–
–
–
–
40
60
PE K-30 duo
4 – 14
33.5
28.4
23.1
16.8
10.3
4.2
–
–
40
60
PE K-55 duo
4 – 17
37.3
32.7
28.1
23.1
18.8
14.1
9.4
–
40
60
PE K-75 duo
6 – 18
–
51.8
46.2
39.2
31.7
23.2
14.2
6.8
40
60
Performance diagram
[m] 20
n=1450 U/min
18
16
10
8
6
4
2
0
0
0
K-7
5
Minimum delivery flow DN 100
12
Minimum delivery flow DN 80
Total delivery head H
14
K5
K-3 5
0
K-2
2
K-1
5
12 24 36 48 60 72 84 96 108 120 132 144 156 168 180 192 [m³/h]
5
10
15
20
25
30
35
40
45
50
[l/s]
Delivery flow Q
Illus. 11: Characteristic curves: Type -PE K duo + parallel
40
Technical Data
Tab. 11: Performance data: Type -PE V duo + parallel
Type
Delivery
head
Delivery flow
Range
Q [l/s]
Conveyance media temperature
Normal
Max.
for total delivery head [m]
[m]
4
6
8
10
12
[°C]
[°C]
PE V-15 duo
3–6
11.0
3.1
–
–
–
40
60
PE V-22 duo
5–7
–
7.8
–
–
–
40
60
PE V-30 duo
6 – 10
–
13.15
9.4
4.35
–
40
60
PE V-40 duo
8 – 12
–
–
13.1
9.6
4.7
40
60
Performance diagram
[m] 15
14
13
12
11
10
V-4
0
8
6
5
4
3
2
1
0
0
0
1
2
5
3
10
V-3
0
Minimum delivery flow DN 100
7
Minimum delivery flow DN 80
Total delivery head H
9
4
15
5
6
20
V-2
2
V-15
7
25
8
30
9 10 11 12 13 14 15 16 17 18 [l/s]
35
40
45
50
55
60
65
[m³/h]
Delivery flow Q
Illus. 12: Characteristic curves: Type -PE V duo + parallel
41
Technical Data
Tab. 12: Performance data: Type 1.x + 2.x VA duo
Type
Delivery
head
Delivery flow
Range
Q [l/s]
Conveyance media temperature
Normal
Max.
for total delivery head [m]
[m]
4
6
8
10
12
[°C]
[°C]
1.1 + 2.1 VA duo
3–6
11.0
3.1
–
–
–
40
60
1.2 + 2.2 VA duo
5–7
–
7.8
–
–
–
40
60
1.3 + 2.3 VA duo
6 – 10
–
13.15
9.4
4.35
–
40
60
1.4 + 2.4 VA duo
8 – 12
–
–
13.1
9.6
4.7
40
60
Performance diagram
[m] 17
16
15
14
13
12
1.4
/2.4
10
9
1.3
/2.3
7
6
5
4
3
2
1
0
Minimum delivery flow DN 100
8
Minimum delivery flow DN 80
Total delivery head H
11
0
0
1
2
5
3
10
4
15
5
6
20
1.2
/2.
2
1.1/2.1
7
25
8
30
9 10 11 12 13 14 15 16 17 18 [l/s]
35
40
45
50
55
60
65
[m³/h]
Delivery flow Q
Illus. 13: Characteristic curves: Type -1.x + -2.x VA duo
42
Technical Data
5.3 Technical Data
for the Pump Control -duo
The following table shows the technical data for the pump control -duo.
Tab. 13: Technical Data for the Pump Control -duo
Characteristic data
Values
Operating voltage
Three-phase current: 3 ~ 400 V (L1, L2, L3, N, PE)
Frequency
50/60 Hz
Control voltage
230 V/AC/50 Hz
Current consumption (contactors activated)
< 20 VA
Connected load, max.
P2 < 5.5 kW (soft start: 7.5 kW)
Range of electrical motor current limiter
0.3 - 12 A (soft start: 16 A)
Isolated alarm contact
3A
Housing
Polycarbonate
Protection type
IP 54
Temperature range
-20 °C to +60 °C
Fuse
5 x 20 1AT (alarm output)
Mains-independent alarm
9 V/200 mAh battery, approx. 7 hrs, volume 85 dB
The dimensions of the pump control -duo and mini compressor can be seen from the
following illustrations.
280 x 120
290 x 150 (soft start)
Illus. 14: Dimensions of the
Pump Control -duo
140
310
380 (soft start)
70 x 60
Illus. 15: Dimensions of the mini
compressor
43
Technical Data
The following illustrations show downsized circuit diagrams for the pump control -duo. The
original scale circuit diagram for each model is provided with the pump control -duo; copies
Chap. 1.1. "ACO Service".
can be obtained if required,
L1 N
17 18
09 10 11 12 13 14
Collective Alarm
Relay
HW
Highwater Alarm
Relay
SSM
dynamic pressure
Collective Alarm
230V/ AC
L1
3
L2
5
L3
6
T3
14
13
W PE
1
4
T2
V
A1
2
T1
U
K1
A2
M1
M
3~
Pump1
1
Temp1
I1
2
A1
K2
A2
M2
3
L2
5
L3
6
T3
14
13
W PE
L1
4
T2
V
1
2
T1
U
M
3~
Pump 2
3
Temp1
4
I2
PE
L1
N
15 16
L1
L2
L2
T3
L3
L3
N
5
6
External lock /unlock
7
8
External buzzer off
Illus. 16: "CEE 16" circuit diagram
44
ACO control box -mono
(rotating current )
L1
T2
5
T1
CEE 16
Option
T 1A L
Output
230VAC 50 Hz
max 1 A
Max 16A
3 ~ 400 / 230 V 50 Hz
HW
09 10 11 12 13 14
dynamic pressure
Collective Alarm
230V/ AC
L1 N
17 18
Collective Alarm
Relay
M1
U
2
T1
3~
M
V
4
W PE
6
T3
14
13
Pump1
T2
5
3
1
A1
A2
L3
L2
L1
Temp1
1
2
M2
A2
A1
K2
U
2
T1
1
L1
3~
M
14
13
W PE
6
T3
5
L3
Pump 2
V
4
T2
3
L2
Temp1
3
4
I2
PE
N
Max 32A
T1
L1
L1
CEE 32
Option
T 1A L
Output
230VAC 50 Hz
max 1 A
L1
15 16
5
T2
L2
L2
T3
L3
L3
N
3 ~ 400 / 230 V 50 Hz
K1
5
6
External lock /unlock
I1
7
8
External buzzer off
SSM
Highwater Alarm
Relay
ACO control box -mono
(rotating current )
Technical Data
Illus. 17: "CEE 32" circuit diagram
45
Technical Data
1
2
3
2
-W2
-Q3
11-17A
-Q1
7.5kW
1
4
3
6T3
5L3
6
5
6
5
/1.3B
-Q1
16A
PE
7
Pump1
-Q8
A1
A2
15
16
-Q6
11-17A
-Q4
7.5kW
2
1
3
4
3
6T3
5L3
6
5
6
5
/1.5B
-Q4
-Q5
1
4
M
3~
Pumpe2
W
2
3L2
V
1L1
4T2
U
2T1
16A
Pump2
PE
/
8
A2
L1-F1
L2
L3
N
START_P2
START_P1
N-P2
N-P1
COM_P1
TEMP_P1
TEMP_P2
COM_P2
PE
ACO control box -duo
(rotating current with soft start)
Illus. 18: "Soft start" circuit diagram
1
1
15
16
-Q2
2
3
W
1
4
V
2
3L2
U
1L1
4T2
M
3~
/
A1
A2
A1
A2
A1
A2
-F1
2A
6
b1 PE
-Q7
5
N1
gr
T3
4
T2
gr
T1
3
N
gr
L3
2
L2
PE
2T1
Pumpe1
A1
Run
Out
ST
In
A1
A2
Run
Out
ST
In
L1
1
N
PE
- W1
-X1
PE
L3
EINSPEISUNG
L2
Supply
46
L1
Installation
6
Installation
This chapter provides information on how to install the plant.
Tab. 14: Prerequisites for Installation
Tools, parts, installation materials
■■
■■
■■
■■
■■
■■
■■
■■
■■
DN 80, 100 or 150 stop valve
16 A, 32 A CEE mains socket
Stanley knife
DN 100 discharge pressure pipe
Torque wrench WAF 17, 19, 24
File
Hammer
Cable cutter
Cable: 2-core/0.75 mm2
■■
■■
■■
■■
■■
■■
■■
■■
Marker
Measuring tape
Open-ended spanner WAF 13, 19,
17, 24
Spirit level
DN 70, 100, 150, 1½" piping
Pipe clamps
Saw
Socket with earth contact
■■
Hammer drill with Ø12 masonry
bit
■■
Screws and rawlplugs
■■
Screwdrivers (straight and Phillips)
■■
Acid-free grease
■■
Side cutter
■■
Vacuum cleaner
■■
16 A, 25 A or 32 A slow blow
fuses
The planner is responsible for the piping layout.
6.1 Safety during Installation
During installation work the following risks must be assumed:
WARNING
The following safety instructions must be read carefully before starting installation. If
ignored severe injuries may occur.
Ensure the staff have the necessary qualifications,
Chap. 2.2 "Qualification of Personnel".
Mechanical hazards
Severe bruising from falling components (e.g. pipe sections)
■■
Wear personal protective equipment,
Chap 2.3 "Personal Protective Equipment".
Electrical hazards
Severe injuries or death are possible from contact with parts which are
connected to mains
■■
Electrical installations may only be performed by a qualified electrician.
■■
Never carry out modifications.
47
Installation
6.2 Sanitary Installation
The following illustration provides an overview of the installation tasks and the in-situ prerequisites, and the following chapters describe these in more detail.
Observe the general requirements for pipework systems,
Chap 6.2.2.
11
10
9
8
1
7
6
5
4
3
1 = Connecting the manual
membrane pump*,
Chap. 6.2.10
2 = Connecting the ventilation
line*,
Chap. 6.2.9
3 = Securing the tank*,
Chap. 6.2.11
4 = Assembling the tank,
Chap. 6.2.1
5 = Connecting the inlet line,*
Chap. 6.2.5
6 = Installing the stop valve in
the inlet line (optional)*,
Chap. 6.2.6
2
7 = Connecting the vent stack,
Chap. 6.2.7
8 = Installing the stop valve
in the discharge pressure
line,
Chaps. 6.2.3, 6.2.4
9 = Assembling the Y-branch
pipe/special mounting
adapter unit*,
Chaps. 6.2.3, 6.2.4
10 = Connecting the discharge
pressure line*,
Chap. 6.2.8
11 = Connecting the backflow
loop*,
Chap. 6.2.8
* In-situ requirements
Illus. 19: Installation works (e.g. -PE V duo)
48
Installation
6.2.1
Assembling the Tank
CAUTION
■■
The installation base for the plant must be strong enough to bear the load and must be
level.
■■
The space where the plant is to operate must be large enough to allow a free working
space of at least 600 mm beside and above all parts which require access during
operation or service.
■■
The erection space must be adequately lit and well ventilated.
■■
A pump sump must be arranged for drainage of the space for lifting plants containing
faecal matter.
Required:
■■
Spirit level
■■
Measuring tape
➜➜
Assemble and align the tank (1), e.g. type
-PE V duo, in its intended location.
1
Types -PE K parallel and -PE V parallel
Two each DN 150 connecting sockets (5+6) with 160 mm external diameter 160 mm are
available on the two tanks (4 + 7).
Two DN 150 double sliding sleeves are supplied as loose parts in the delivery.
CAUTION All sockets are closed.
4
5
6
7
Illus. 20: Position of "Connecting Sockets"
49
Installation
Required:
■■
Spirit level
■■
Measuring tape
■■
Saw
■■
File
■■
Acid-free grease
➜➜
Cut open closed sockets (8) along the
groove (9) and deburr the cut edge.
8
9
As a result of the manufacturing process
there may be uneven wall thickness (lumps of
material).
➜➜
11
➜➜
Grease the spigots (13 + 16) of the
connection ports.
➜➜
Grease the inner sleeve seals on the
double sliding sleeves (14).
12
➜➜
Push the double sliding sleeves (14) onto
the connection ports on one of the tanks
(12).
13
P0ush the connection ports (16) of the
other tank (17) into the double sliding
sleeves (14).
15
➜➜
Push the tanks (12 + 17) together until
they are 860 mm (15) apart.
14
860
➜➜
50
10
Any lumps of material (11) in the area of
the bottom of the socket (10) should be
removed.
16
17
Installation
6.2.2
General Requirements for
Pipework Systems
This chapter includes recommendations for professional pipe laying.
CAUTION To avoid damage to property and interruptions to operations the following requirements must be met:
■■
Pipelines must be installed in such a way that they can empty themselves.
■■
Pipelines must be connected to the plant free from tension. No pipe forces or torque must
be transferred to the plant. Temperature-induced pipework elongation must be compensated for.
■■
Support the weight of the pipes (e.g. using pipe mountings).
■■
For elastic connections which are not fixed longitudinally, ensure the pipes cannot come
apart (e.g. by using pipe mountings).
■■
Ensure all connections to the plant are soundproof and flexible.
■■
Ensure piping installations are frost-resistant.
51
Installation
6.2.3
Install the stop valve in the discharge pressure line
Types -PE K duo, -PE V duo, -1.x VA duo and -2.x VA duo
CAUTION A DN 80 (type k-75: DN 100) stop valve must be installed in the discharge
Chap. 4.6 "Accessories".
pressure line downstream of each of the two backflow valves,
The stop valve is supplied complete with flat seal and fastening kit, comprising screws,
washers and nuts.
The "Y-branch pipe with special mounting adapter" unit (1) is supplied mounted on the two
backflow valves (2).
1
2
Illus. 21: "Y-branch pipe + backflow valves" assembly
Required:
■■
DN 80 or 100 stop valve
■■
Open-ended spanner WAF 24
■■
Torque wrench WAF 24
➜➜
Loosen the mounting adapters (5) on the
connecting flanges of the Y-branch pipe
(3) and the backflow valves (6).
➜➜
Remove the "Y-branch pipe with special
mounting adapter" unit and set aside.
➜➜
Leave/attach the flat seals (4) on/to the
connecting flanges on the backflow valves
(6).
3
4
5
6
52
Installation
➜➜
Position the stop valves (10) on the
connecting flanges of the backflow valves
(13) and ensure the bore holes are flush.
➜➜
Use the fastening kit (11), consisting
of screws, washers and nuts, to create
threaded connections.
7
Position the flat seals (9) on the
connecting flanges of the stop valves (10)
and precisely align the holes/bore holes.
9
➜➜
➜➜
➜➜
➜➜
Position the "Y-branch pipe with special
mounting adapter" unit (7) on the
connecting flanges of the stop valves (10)
and ensure the bore holes are flush.
Use the fastening kit (8), consisting of
screws, washers and nuts, to create
threaded connections.
8
10
11
12
13
Diagonally tighten screw connections (8 +
11) evenly (max. torque 12 N·m).
6.2.4
Assemble the stop valves and Y-branch pipe
(type -parallel)
CAUTION
■■
A DN 80 (type k-75: DN 100) stop valve must be mounted in the discharge pressure
Chap. 4.6 "Accessories". The stop valve is
line on each of the two backflow valves,
supplied complete with flat seal and fastening kit, comprising screws, washers and nuts.
■■
Assemble the "Y-branch pipe with special mounting adapter" unit after connecting the two
Chap. 6.2.1 "Assembling the tank".
tanks,
The "Y-branch pipe with special mounting adapter" unit, 2x flat seals and 2x fastening kits
(screws, washers and nuts) are supplied as loose parts in the delivery.
53
Installation
Required:
■■
DN 80 or 100 stop valve
■■
Open-ended spanner WAF 24
■■
Torque wrench WAF 24
➜➜
Attach the flat seals (6) to the connecting
flanges on the backflow valves (7).
➜➜
Position the stop valves (4) on the
connecting flanges of the backflow valves
(7) and ensure the bore holes are flush.
➜➜
1
Use the fastening kit (5), consisting of
screws, washers and nuts, to create
threaded connections.
➜➜
Position the flat seals (3) on the
connecting flanges of the stop valves (4)
and precisely align the holes/bore holes.
➜➜
Position the "Y-branch pipe with special
mounting adapter" unit (1) on the
connecting flanges of the stop valves (4)
and ensure the bore holes are flush.
➜➜
Use the fastening kit (2), consisting of
screws, washers and nuts, to create
threaded connections.
➜➜
Diagonally tighten screw connections (5 +
2) evenly (max. torque 12 N·m).
6.2.5
2
3
4
5
6
7
Connecting the Inlet Line
CAUTION
54
■■
The nominal width of the inlet line must not be reduced in the flow direction.
■■
Install the inlet line at a gradient to the plant.
■■
A stop valve for shutting-off the inlet must be fitted in the inlet line,
a Stop Valve in the Inlet Line".
Chap 6.2.6. "Fitting
Installation
Types -PE K duo, -PE V duo, -PE K parallel and -PE V parallel
2x DN 150 vertical sockets with external Ø160 mm are available on the tank (1) for
connecting the inlet line(s).
All sockets are closed. The socket(s) must be opened for the required inlet line(s).
1
2
Illus. 22: Position of "Inlet Sockets"
Required:
■■
Saw
■■
File
■■
Pipe sections DN 150
■■
Open-ended spanner WAF 13
➜➜
Cut open closed sockets (3) along the
groove (4) and deburr the cut edge.
3
4
As a result of the manufacturing process
there may be uneven wall thickness (lumps of
material).
➜➜
Any lumps of material (6) in the area of
the bottom of the socket (5) should be
removed.
5
6
55
Installation
➜➜
➜➜
Connect the inlet line (7) using, e.g., the
pipe connector (8) to the socket (9) of the
tank.
7
8
Tighten the screw connection of the pipe
connector (8) by hand.
9
Types -1.x VA duo and -2.x VA duo
The following connections are available on the tank for the inlet line(s),
of connections" and Tab. 15 "Connection design":
5
1
4
2
Illus. 23 "Position
3
Illus. 23: Position of "Connections"
Tab. 15: Connection design
Item
Type
Description
... VA duo
Inlet ...
Procurement
Chap.
2x top inlets in replacement of the inspection covers:
56
The inspection cover is replaced by a DN 100 or DN 150 accessory
package (transitional flange, clamp flange, toroidal sealing ring, washers
and nuts).
2 x lateral inlets:
1+4
1.x + 2.x
2+3
2.x
5
1.x
Clamp flange with o-ring for direct connection of a DN 100 inlet line with
110 mm external diameter to the unit as supplied.
Top inlet:
Included
5
2.x
Clamp flange with o-ring for direct connection of a DN 150 inlet line with
160 mm external diameter to the unit as supplied.
Included
Blank flange assembled on unit as supplied.
The blank flange is replaced by a clamp flange with toroidal sealing ring to
connect a DN 150 inlet line with 160 mm external diameter.
Top inlet:
4.6 "Accessories"
Included
Installation
Top inlet in replacement of the inspection cover/Item 1 + 4
One accessory package (transitional flange, clamp flange, toroidal sealing ring, washers and
nuts), optional, Chap. 4.6 "Accessories"
Required:
■■
DN 100 or 150 accessory package
■■
DN 100 or 150 pipeline
■■
Open-ended spanner WAF 19
■■
Torque wrench WAF 19
20
CAUTION The connecting pipe spigot should
protrude at least 20 mm over the toroidal
sealing ring when connected.
Loosen the nuts (6) of the studs (12) on
the tank lid and set aside.
1
➜➜
Remove the washers (7) from the studs
(12) and set aside.
2
➜➜
Remove the blank flange (9) and set
aside or ensure environmentally correct
disposal.
3
Thread the transitional flange (8) with hole
pattern onto the studs (12) and position
on the flat seal (10) of lid of the tank.
5
Re-position the screws with the washers
(7) and nuts (6) that you previously set
aside, and tighten diagonally and evenly
(max. 12 N·m).
7
➜➜
➜➜
➜➜
➜➜
Slide the clamp flange (4) over the spigot
of the connecting pipe (1).
➜➜
Pull the toroidal sealing ring (5) over the
spigot of the connecting pipe (1).
➜➜
Push the unit comprising connecting pipe
(1), clamp flange (4) and toroidal sealing
ring (5) into the opening (11), thread the
hole pattern of the clamp flange (4) over
the transitional flange studs.
➜➜
Screw together with the washers (3) and
nuts (2), and tighten diagonally and evenly
(max. 12 N·m).
4
6
8
12
11
10
9
57
Installation
Lateral inlet/Item 2 + 3
Two DN 150 clamp flanges and two toroidal sealing rings are supplied as loose parts in the
delivery.
Required:
■■
DN 150 piping sections (external Ø160 mm)
■■
Open-ended spanner WAF 19
■■
Torque wrench WAF 19
CAUTION The connecting pipe spigot should
protrude at least 20 mm over the toroidal
sealing ring when connected.
20
➜➜
58
Loosen the nuts (5) of the studs (1) on the
side wall of the tank and set aside.
➜➜
Remove the washers (4) from the studs
(1) and set aside.
➜➜
Remove the blank flange (2) and set
aside or ensure environmentally correct
disposal.
➜➜
Remove the flat seal (8) and set aside or
ensure environmentally correct disposal.
➜➜
Slide the clamp flange (3) over the spigot
of the connecting pipe (6).
➜➜
Pull the toroidal sealing ring (7) over the
spigot of the connecting pipe (6).
➜➜
Push the unit comprising connecting pipe
(6), clamp flange (3) and toroidal sealing
ring (7) into the opening (9), thread the
hole pattern over the studs (1).
➜➜
Screw together with the washers (4) and
nuts (5), and tighten diagonally and evenly
(max. 12 N·m).
1
2
3
9
8
7
4
5
6
Installation
Top inlet/Item 5
The connection port on the tank is already fitted with a DN 100/DN 150 clamp flange and
toroidal sealing ring.
Required:
DN 100 piping section (external Ø110 mm) or DN 150 (external Ø160 mm)
■■
Open-ended spanner WAF 19
■■
Torque wrench WAF 19
CAUTION The connecting pipe spigot should
protrude at least 20 mm over the toroidal
sealing ring when connected.
20
■■
Loosen the nuts (2) of the studs (6) on the
tank lid, twist off, and set aside.
1
➜➜
Remove the washers (3) from the studs
(6) and set aside.
2
➜➜
Slide the clamp flange (4) over the spigot
of the connecting pipe (1).
3
➜➜
Pull the toroidal sealing ring (5) over the
spigot of the connecting pipe (1).
➜➜
➜➜
➜➜
Push the unit comprising connecting pipe
(1), clamp flange (4) and toroidal sealing
ring (5) into the opening (7), thread the
hole pattern over the studs (6).
Screw together with the washers (3) and
nuts (2), and tighten diagonally and evenly
(max. 12 N·m).
4
5
6
7
59
Installation
6.2.6
Installing the Stop Valve in the Inlet Line (Optional)
CAUTION A DN 100/DN 150 stop valve must be installed in the inlet line (
"Accessories") to shut-off the inlet.
Chap. 4.6
Required:
■■
DN 100 or 150 stop valve (accessories)
■■
Acid-free grease
➜➜
Grease the end of the spigot (4) from the
inlet socket of the tank.
➜➜
Grease the lip seals (3) of the stop valve
(2).
➜➜
Grease the spigot (1) of the inlet line.
➜➜
Push the stop valve (2) on the inlet socket
(4) of the tank.
➜➜
Push the inlet line (1) into the stop valve
(2).
6.2.7
1
2
3
Connecting Vent Stack
A DN 100 vertical socket (1) with external Ø110 mm is available on the tank for the
connecting the vent stack.
1
Illus. 24: Position of "Aeration Slots" (e.g. type -PE-K)
60
4
Installation
CAUTION
■■
The vent stacks on the two tanks can be connected to one and the same line (type -PE K
parallel and -PE V parallel).
■■
Vent stacks must have a constant diameter and must be laid continuously rising up to the
roof of the building. The piping can be inserted into the main or the secondary ventilation.
■■
The vent stack must never be connected to the input side vent stack of a grease
separator.
■■
Aeration valves are not permitted.
Required:
■■
DN 100 piping sections
■■
DN 100 pipe connector
■■
Open-ended spanner WAF 13
➜➜
Connect the vent stack (2) using, e.g., the
pipe connector (3) to the socket (4) of the
tank.
➜➜
Tighten the screw connection of the pipe
connector (3) by hand.
2
3
4
61
Installation
6.2.8
Installing and Connecting the Discharge Pressure Line
The special mounting adapter enables flexible connection of the in-situ DN 100 discharge
pressure line (spigot Ø108 – 114 mm).
On delivery, the sealing ring (7) and the flange ring (6) is placed on the special mounting
adapter (9) and the screws (1) are screwed one turn in the threaded hole of the flange (8).
CAUTION To ensure the plant functions correctly, the backflow loop (1) must have the
lowest point of its pipe (2) above the height of the "backflow level" (3). The backflow level is
normally the pavement height.
The following diagram is a schematic representation of a backflow loop (1). The list which
follows describes the correct installation.
1
2
3
Illus. 25: Backflow loop
■■
Pump delivery quantity [l/s]
The volume of the flow which the centrifugal pump pumps over the total delivery head at
the operational site.
■■
Delivery head in [m]
Head of pressure which the centrifugal pump reaches at the operating level. This
overcomes the static height difference plus the total head loss in the discharge pressure
line.
■■
Total delivery head in [m]
The total delivery head is the total of all static delivery heads and the pressure head
losses in valves and fittings and pipe friction losses.
62
Installation
CAUTION To avoid damage to property and interruptions to operations the following requirements must be met:
■■
Discharge pressure lines must be frost-resistant.
■■
Discharge pressure lines must always be connected to either ventilated pipe systems or
collecting lines. The connections must be installed in the same way as for non-pressurised
lines.
■■
The discharge pressure line must resist at least 1.5 times the max. pump pressure.
■■
The discharge pressure line must be installed continuously rising.
■■
The flow speed in the discharge pressure line must not be less than 0.7 m/s or more than
2.3 m/s.
■■
Never connect other pipes to the discharge pressure line.
■■
Never connect discharge pressure lines for a lifting plant to waste water downpipes.
■■
Never connect ventilation valves to the discharge pressure line.
Required:
■■
Open-ended spanner WAF 19
■■
Torque wrench WAF 19
➜➜
Push the pipe (5) through the flange ring
(6) and the sealing ring (7) and push it
approx. 50 mm into the special mounting
adapter (9).
➜➜
4
Diagonally tighten M12 screws (4) evenly
(max. 15 N·m).
5
6
7
8
9
The use of another sealing ring (7) enables a DN 80 discharge pressure line to be
connected (spigot Ø88 – 90 mm).
Sealing ring can be optionally purchased from ACO,
Chap. 4.6 "Accessories".
63
Installation
6.2.9
Connecting the Drain Line (Optional)
A horizontal DN 70 socket (1) is provided on the tank with external Ø70 mm and one R 1½"
threaded socket (2).
The sockets are closed and must be opened prior to the connection of a drain line.
1
2
3
Illus. 26: Position of "Draining Connections"
Type -PE/Option 1
Required:
■■
Saw
■■
File
■■
DN 70 or R 1½" piping sections
➜➜
Cut open closed sockets (5) along the
groove (4) and deburr the cut edge.
4
Connect the drain line (e.g. hose, hose
clamps).
5
➜➜
Types -PE and -VA/Option 2
Required:
64
■■
Drainage line sections
■■
Pipe tongs or open-ended spanner WAF 19
➜➜
Twist off the thread cap on type -PE or
plug on type (3) and connect the drain line
(e.g. hose grommet, hose, hose clamp,
etc.).
Installation
6.2.10 Connecting the Manual Membrane Pump
(Optional on Type -PE)
A vertical R 1½" threaded socket (2) is provided on the tank.
It is sealed with a plug (1) and must be opened prior to the connection of a manual
membrane pump.
1
2
Illus. 27: Position of "Manual Membrane Pump Connections"
Required:
■■
1½" piping sections
■■
Open-ended spanner WAF 13
➜➜
Twist the plug (1) out of the threaded
socket (2) and connect the suction line
(e.g. screw joint, hose grommet, hose,
hose clamp, etc.).
6.2.11 Securing the Tank
A fastening kit is supplied as loose parts in the delivery. Anchor the aligned tank (1) or (1+ 2,
and the fastening kit.
type parallel) to the ground using the moulded/welded-on tongues
1
2
Illus. 28: Position of "Fixing Tongues"
65
Installation
CAUTION
■■
Plants must be installed and fixed so they cannot swivel.
■■
Plants at risk of floating must be fixed securely so they cannot float.
Required:
■■
Marker (e.g. pencil)
■■
Drill with a 12 mm diameter masonry bit
■■
Hammer, vacuum cleaner
■■
Open-ended spanner WAF 17
■■
Torque wrench WAF 17
➜➜
Mark a drill hole on the ground.
➜➜
Drill 12 mm diameter hole 60 mm deep.
➜➜
Vacuum drilled hole clean.
4
➜➜
Insert a 12 W rawlplug (6) into the drilled
hole.
5
➜➜
Slide R11 washers (4) over wood screws
(3)
➜➜
Push wood screws (3) through the hole in
the slot and screw into the rawlplugs (6).
➜➜
Tighten the wood screws (3)
(max. 10 N·m).
3
6
Types -PE K duo and PE K parallel
In addition to the tongues, the load equalisation support on these two types must also be
anchored to the ground. A fastening kit is supplied as loose parts in the delivery.
Required:
66
■■
Marker (e.g. pencil)
■■
Drill with a 12 mm diameter masonry bit
■■
Hammer, vacuum cleaner
■■
Open-ended spanner WAF 17
■■
Torque wrench WAF 17
Installation
➜➜
Set up the tank (8) in the correct position.
➜➜
Fasten the load equalisation support (7).
8
7
➜➜
Mark a drill hole on the ground.
➜➜
Drill 12 mm diameter hole 60 mm deep.
➜➜
Vacuum drilled hole clean.
10
➜➜
Insert a 12 W rawlplug (12) into the drilled
hole.
11
➜➜
Slide R11 washers (11) over wood screws
(10)
➜➜
Push wood screws (10) through the hole
in the support (9) and screw into the
rawlplug (12).
➜➜
Tighten the wood screws (10)
(max. 10 N·m).
9
12
6.3 Checking the Seal
The following basically applies: All drainage objects for buildings and land must be sealed
(only applies for Germany. Requirements in other countries may vary).
The specifications and requirements for the tightness test procedure must be checked based
on the country in question.
67
Installation
6.4 Electrical Installation
The following illustration provides an overview of the in-situ prerequisites and necessary
electrical works; the following chapters describe these in more detail.
9
P1
P2
ACO Pumpensteuerung
für Hebeanlage Typ: -duo
ACO control box
for lifting plant typ: -duo
Artikel-Nr./article-no.: 0150.38.10
P1
1
P2
manual
menu
Beachten Sie die Betriebsanleitung!
Read operating manual!
enter
www.aco-haustechnik.de
2
8
3
7
6
4
5
1 = Attaching the pump control
-duo,
Chap. 6.4.1
5 = Connecting the potential
compensation*,
Chap. 6.4.9
2 = Attaching the CEE
socket*,
Chap. 6.4.3
6 = Installing the control line
and connecting it to the
pump control -duo,
Chap. 6.4.6
3 = Relaying group alarm
(optional)*,
Chap. 6.4.4
4 = Installing and connecting
the connecting cables of
the centrifugal pumps*,
Chap. 6.4.5
7 = Connecting the air bubble
injection line,
Chap. 6.4.8
Illus. 29: Electrical work
68
8 = Installing and connecting
the cable of the mini
compressor*,
Chap. 6.4.7
9 = Attaching the mini
compressor,
Chap. 6.4.2
* In-situ requirements
Installation
6.4.1
Attaching the Pump Control -duo
A flood-proof free wall surface measuring approx. W x H = 400 x 500 mm is required to
install the pump control -duo.
The connecting cables for the centrifugal pumps and the hoses (control line and "air bubble
injection" line) are each 7 m long. Select the mounting location accordingly.
Required:
■■
Marker
■■
Hammer drill with a masonry bit
■■
Hammer
■■
Vacuum cleaner
■■
Screwdrivers (straight and Phillips)
■■
Screws and rawlplugs
➜➜
Transfer the hole pattern (1) for all
corners in the back panel of the original
pump control -duo (2) to the wall.
➜➜
Drill the holes.
➜➜
Vacuum drilled holes clean.
➜➜
Knock in rawlplugs.
➜➜
Hold pump control -duo (2) against the
wall and fix with the screws.
6.4.2
1
2
Attaching the mini compressor
A flood-proof free wall surface measuring approx. W x H = 100 x 200 mm is required to
install the mini compressor.
Required:
■■
Marker
■■
Hammer drill with a masonry bit
■■
Hammer
■■
Vacuum cleaner
■■
Screwdrivers (straight and Phillips)
■■
Screw and rawlplug
69
Installation
Drill hole for tongue (1) at the requisite
place.
1
➜➜
Vacuum drilled hole clean.
2
➜➜
Insert rawlplug.
➜➜
Hold mini-compressor (2) against the wall
and fix with the screws.
➜➜
6.4.3
Attaching the CEE Socket
The pump control -duo has a 1.5 m long connecting cable with a 16 A or 32 A CEE plug.
CAUTION There will be functional problems if an unsuitable socket is used.
Install a CEE mains socket on-site with the following specification:
16 A CEE mains socket
■■
400 V/50 Hz connection
■■
Right-hand rotating field
■■
Mains fuse max. 3 x 16 A, slow blow
32 A CEE mains socket
■■
400 V/50 Hz connection
■■
Right-hand rotating field
■■
Mains fuse max. 3 x 25 A, slow blow
■■
Mains fuse max. 3 x 25 A, slow blow (types K-55 and K-75)
➜➜
Install a socket (1) on the wall in accordance with the manufacturer's instructions.
6.4.4
Installing and Connecting Cable for Transmitting the
Group Alarm (Optional)
In order to forward the isolated contact as a group alarm, a cable needs to be laid.
Required:
70
■■
2-core/0.75 mm2 cable
■■
Screwdrivers (straight or Phillips)
■■
Cable/side cutters
■■
Pipe clamps
➜➜
Guide the cable through the cable fittings into the pump control -duo and connect
Chap. 5.3 "Technical Data for the Pump Control
according to the circuit diagram,
-duo".
Installation
6.4.5
Installing and Connecting the Connecting Cables of
the Centrifugal Pumps
The connecting cable for the centrifugal pump is 7 m long and is delivered already attached
to the connection terminals in the connection space for the centrifugal pump and in the pump
control -duo. The connecting cable is coiled on the plant and is secured with cable ties.
CAUTION
■■
The ends of the individual wires are marked. If wires are connected incorrectly there is a
risk of a short-circuit.
■■
If the connecting cables are shortened, transfer the markings on each wire.
■■
Make sure the pump motor is rotating in the right direction.
Required:
■■
Screwdrivers (straight or Phillips)
■■
Pipe clamps
■■
Side cutter, Stanley knife
➜➜
Short the cable and guide it through the cable fittings into the pump control -duo
Chap. 5.3 "Technical
connection box, and connect according to the circuit diagram,
Data for the Pump Control -duo".
71
Installation
6.4.6
Installing the Control Line and Connecting it to the
Pump Control -duo
The 7 m control line (1) is supplied already connected to the hose grommet on the tank and
to the pump control -duo. The control line (1) is coiled on the tank and secured with cable
ties.
CAUTION
■■
The control line must not be bent or crushed.
■■
The control line must be installed continuously rising and protected from frost.
■■
Functional faults are possible if the length of the control line is not adjusted correctly.
■■
If necessary, the control line can be shortened.
Required:
■■
Screwdrivers (straight or Phillips)
■■
Pipe clamps
■■
Stanley knife
➜➜
Cut the control line (1) at right angles with
a Stanley knife.
1
➜➜
➜➜
Push a hose clamp (4) over one end (5) of
the 7 m long control line.
Push the hose end (5) onto the hose
grommet (3) of the pump control -duo (2)
and fix with the hose clamp (4).
2
3
4
5
72
Installation
6.4.7
Connecting the Connecting Cable for the Mini Compressor
The mini compressor (1) has a 1.5 m long connecting cable with safety plug. The plug must
be cut off and the connecting cable must be connected to the pump control -duo.
An on-site socket with earth contact can also supply power to the mini compressor.
Connecting value 230 V/50 Hz with mains-side fuse max. 16 A, slow blow.
➜➜
➜➜
Strip insulation from cable ends (2) and
attach cable end ferrules.
Connect to the connection box of the
pump control -duo according to the circuit
Chap. 5.3 "Technical Data
diagram,
for the Pump Control -duo".
6.4.8
1
2
Connecting the Air Bubble Injection Line
The lines (hoses) and connecting parts are supplied already connected to the hose grommet
on the tank and to the mini compressor. The hoses are coiled on the tank and secured with
cable ties.
CAUTION
■■
The hoses must not be bent or crushed.
■■
Hoses must be installed continuously rising and protected from frost.
■■
Functional faults are possible if the length of the hose is not adjusted correctly.
■■
If necessary, the control line can be shortened.
Required:
■■
Screwdrivers (straight or Phillips)
■■
Pipe clamps
■■
Stanley knife
73
Installation
➜➜
Cut the control line (1) at right angles with
a Stanley knife.
1
The description below covers the assembly
of the entire line:
➜➜
Push a hose clamp (7) over the end (12)
of the hose.
➜➜
Push the hose end (12) onto the hose
grommet of the sprung retaining valve
(11) and fix with the hose clamp (7). Note
the direction of installation (10).
➜➜
➜➜
74
Push a hose clamp (7) over one end (9) of
the 500 mm long hose.
Push the hose end (9) onto the hose
grommet of the sprung retaining valve
(11) and fix with the hose clamp (7).
➜➜
Push a hose clamp (7) over the other end
(8) of the hose.
➜➜
Push the hose end (8) onto the hose
grommet of the screw-on connector (6)
and fix with the hose clamp (7).
➜➜
Insert the end of the 100 mm long hose
(5) into the screw-on connector (6) and
clamp.
➜➜
Insert the other end of the 100 mm long
hose (4) into the intake (3) of the minicompressor (2).
2
3
4
5
6
7
8
9
10
11
12
Installation
6.4.9
Connecting the Potential Compensation
Clamping screws (1) are fitted on the pressure-side connecting flange (2) of each centrifugal
pump for connection of the potential compensation.
1
2
Illus. 30: Position of "Potential Compensation Connection"
CAUTION Single-wire cables approved for use in ex zones can be used to connect the
potential compensation. The cross section must comply with the regulations of the local
utility supply company or operator.
75
Commissioning and Operation
7
Commissioning and Operation
This chapter provides you with information about the correct way to commission and operate
the plant.
7.1 Safety during Commissioning and Operation
During commissioning work and operation the following risks must be assumed:
BEWARE
The following safety instructions must be read carefully before starting commissioning and
operation. If ignored, injuries may occur.
Ensure staff have the necessary qualifications,
Chap. 2.2. "Qualification of Personnel".
Contact with waste water
Skin and eye injuries, risk of infection
■■
Wear personal protective equipment,
Chap 2.3 "Personal Protective Equipment".
■■
On contact with skin: relevant skin areas must be washed thoroughly with soap and
disinfected.
■■
If in contact with eyes: Rinse eyes. If eyes continue to water, consult a doctor.
7.2 Commissioning
This chapter describes the requirements for commissioning, the process of commissioning
the plant, and handover to the user.
Prerequisites for commissioning:
■■
All installation work has been completed,
■■
Tank is empty.
■■
No waste water is yet being fed into the plant.
People required for commissioning:
76
■■
Installer
■■
Electrician
■■
Owner or users
Chap. 6 "Installation".
Commissioning and Operation
CAUTION To ensure safe operation of the plant, the following sequence must be followed
when commissioning:
1. Insert the battery in the pump control -duo,
Chap. 7.5. + 7.6
2. Set the pump control -duo,
3. Perform a test run,
Chap 7.7.
4. Set air bubble injection,
5. Carry out checks,
Chap. 7.3.
Chap. 7.8
Chap. 7.9
6. Set to automatic operation,
Chap. 7.10
7. Hand over plant to owner or user,
Chap. 7.11.
7.3 Inserting the Battery in the Pump Control -duo
The battery guarantees the mains-independent alarm will function if the power is interrupted.
Once the battery is inserted in the pump control -duo the alarm is automatically activated.
➜➜
The battery (1) should be inserted in its
position (2) on the circuit board by an
electrician.
1
2
7.4 Automatic Venting of the Volute
During operation the volutes (3) vent independently and protect the centrifugal pumps
from damage.
The water-air mix (1) sprays out of the ventilation lines (4) into the tank (2).
1
2
3
4
77
Commissioning and Operation
7.5 Setting the Pump Control -duo
Settings must be made in the settings menu of the pump control -duo prior to commisChap 4.8.5 "Settings".
sioning. Settings should be made according to the description in
The following table shows the data and values for the menu settings.
Tab. 16: Menu Data
Settings menu
Values
Unit
Explanation
Type
-VA duo
-VA duo
1.x
2.x
Next Inspection days left
600 inlet
750 inlet
830 and
top inlet
90
[...]
Chap.
days
-
Base load ON (BL)
31
61
37
52
57
cm
4.4
Base load OFF (BL OFF)
8
8
8
8
8
cm
4.4
Peak load ON (PL)
36
66
42
57
62
cm
4.4
Peak load OFF (PL OFF)
34
64
39
54
59
cm
4.4
High water level (AL)
41
71
47
62
67
cm
4.4
Running time max.
2
2
2
2
2
Min.
4.8.7
Stop delay
15
15
15
15
15
secs
4.8.7
Tab. 9
A
5.1
Force activastion
Is deactived
-
4.8.7
Accoustic alarm
Is activated
-
4.8.7
Intermittent alarm
Is deactived
-
4.8.7
Pump alternation
Is activated
-
4.8.7
Rotating field fault
Is activated
Service mode
Is deactived
-
4.8.7
Language
English
-
4.8.7
Max. current –1 and –2
78
-PE K and V
4.8.7
Commissioning and Operation
7.6 Setting the Pump Control -duo to Soft
Start the Pumps (Types K-55 and K-75)
If the pumps run loudly, or knocking noises occur in the discharge pressure line during the
test run, the soft start factory settings can be adjusted in consultation with ACO Service,
Chap. 1.1.
P1
P1
1
P2
P2
manual
12
2
menu
enter
11
3
4
5
10
9
8
7
6
1 = LED: ON/Ready
6 = SAA relay: Pump 2
11 = LED: Operation
2 = LED: Run/TOR
7 = SAA relay: Pump 1
3 = Control knob: Start time
8 = Controls beneath front
plate
9 = Holding relay: Pump 2
12 = Control knob: Running
period
4 = Control knob: Stop time
5 = Control knob: Initial voltage
(UINI)
10 = Holding relay: Pump 1
Illus. 31: Soft start relays
Adjust the control knobs as shows in the table below.
Tab. 17: Soft start setting values
Running period
Start time
Stop time
UINI
Holding relay
SAA relay
SAA relay
SAA relay
Pump P1
Pump P2
Pump P1
Pump P2
Pump P1
Pump P2
Pump P1
Pump P2
[secs]
[secs]
[secs]
[secs]
[secs]
[secs]
[%]
[%]
8
8
6
6
6
6
50
50
79
Commissioning and Operation
Controlling the soft start of the pumps:
The operation of the centrifugal pumps must be checked during the test run, based on the
control unit displays and table below.
Tab. 18: Soft start control procedure
< BL
Off
BL
Soft start
BL – BL OFF
Full load
BL OFF –
ARP OFF/
After-running
period
BL OFF –
ARP OFF/
Running down
period
ARP OFF
or
or
or
80
P2*
Full load
Soft stop
End
= LED OFF
= LED lights up and stays lit
= LED flashes
* Pumps P1 and P2 operate alternately
(the display then switches from P1 to P2)
Run/TOR
P1*
ON/Ready
P2*
Run/TOR
P1*
SAA relay
display
ON/Ready
LED
P2*
LED
LED
P1*
Holding relay
display
LED
Control unit
displays
LED
Pump operation
LED
Water level/
Drainage
phase
Commissioning and Operation
7.7 Test Run
This chapter describes the test run.
7.7.1
Specifications
CAUTION To avoid damage to property and operational failures, the water level must be
observed for the switching point "ARP OFF". The value can be found in the following table and
must be checked during the test run via the open inspection cover.
Higher water level
If the water level in the tank is higher, switch the pump on manually and time how long it
takes for the water to reach the level specified in the table below (approx. 20 – 30 mm below
the lower edge of the pilot tube). Add the stopped time to the preset after-running period
and set the pump control -duo accordingly!
Lower water level
Set the after-running period on the pump control -duo to "0". Fill water up to the "BL" level and
pump off automatically until the level reaches "BL OFF". Switch the pump on manually and
time how long it takes for the water to reach the level specified in the table below (approx.
20 – 30 mm below the lower edge of the pilot tube). The stopped time must be set in the
pump control -duo as the after-running period.
Tab. 19: Water Level for Switching Point "ARP OFF"
30
Distance from water line to lower edge of pilot tube
CAUTION If the pumps run loudly, or knocking noises/vibrations occur in the discharge
pressure line during the test run, the after-running period of the pumps can be adjusted in
consultation with ACO Service, Chap. 1.1.
81
Commissioning and Operation
7.7.2
Carry out test run
The work and processes on and in the plant are described below. The illustrations are
schematic.
82
➜➜
Open stop valves in the inlet line and
discharge pressure line (if present).
➜➜
Connect the pump control -duo to the
power supply.
➜➜
Check operational messages being
received by controls.
➜➜
Press "auto" (P1 and P2) for automatic
operation of pumps 1 and 2.
➜➜
Allow water to flow into the tank via the
inlet line or the revision opening.
■■
The water level reaches "BL".
■■
"Pump P1" switches on and pumps the
waste water from the tank above the
backflow level.
➜➜
Interrupt inflow of water.
P1
P2
BL
Commissioning and Operation
■■
The water level reaches "BL OFF".
■■
The after-running period elapses.
■■
"Pump P1" switches off
➜➜
Switch the inlet water on again.
■■
The water level reaches "BL".
■■
"Pump P2" switches on and pumps the
waste water from the tank above the
backflow level.
➜➜
Interrupt inflow of water.
■■
The water level reaches "BL OFF".
■■
The after-running period elapses.
■■
"Pump P2" switches off
➜➜
Switch the inlet water on again.
■■
The water level reaches "BL".
■■
"Pump P1" switches on and pumps the
waste water from the tank above the
backflow level.
➜➜
Increase inflow of water.
■■
The water level reaches "PL".
■■
"Pump P2" switches on and both pumps
pump the waste water from the tank
above the backflow level.
ARP OFF
BL
ARP OFF
BL
PL
83
Commissioning and Operation
➜➜
Interrupt inflow of water.
■■
The water level reaches "PL OFF".
■■
"Pump P2" switches off and "Pump P1"
pumps the waste water from the tank
above the backflow level.
■■
The water level reaches "BL OFF".
■■
The after-running period elapses.
■■
"Pump P1" switches off
➜➜
Press switch to "off" (P1 and P2) and
switch off pumps 1 and 2.
➜➜
Switch the inlet water on again.
PL OFF
ARP OFF
P1
P2
Water level reaches "AL" = overflow alarm.
Red LED is lit and the acoustic alarm sounds.
➜➜
84
Interrupt inflow of water.
AL
+
Commissioning and Operation
➜➜
Press "auto" (P1 and P2) for automatic
operation of pumps 1 and 2.
■■
"Pumps P1 + P2" switch on and both
pumps pump the waste water from the
tanks above the backflow level.
P1
P2
The water level is below "AL".
➜➜
Press the "reset/enter" key.
enter
Red LED goes out and the acoustic alarm
switches off.
■■
The water level reaches "BL OFF".
■■
The after-running period elapses.
■■
"Pumps P1 + P2" switch off
+
ARP OFF
The test run is complete.
➜➜
Repeat the test run for a second time.
85
Commissioning and Operation
7.8 Adjusting Air Bubble Injection
The airflow can be reduced in order to reduce the noise level of the mini-compressor.
CAUTION Only reduce the flow of air to the point where air bubbles still
appear from the end of pilot tube and rise up through the waste water
(still bubbling, check through revision opening).
➜➜
Reduce the airflow using the control knob
(2) on the mini-compressor (1).
1
2
7.9 Control Checks
The following checks must be carried out:
■■
The shut-off devices work correctly
■■
The centrifugal pumps work correctly
■■
The pump control -duo works correctly
■■
The accessories work correctly
7.10 Setting Automatic Operation
Set the following in the pump control -duo:
➜➜
86
Press "auto" (P1 and P2) for automatic
operation of pumps 1 and 2.
P1
P2
Commissioning and Operation
Green LED lights up steadily, pump P1 or
P2 is in automatic mode and is activated
automatically by the level switching function.
P1
P2
Plant is ready for operation.
7.11 Handing over Plant to User
On handover to the user:
1. Explain how the plant works.
2. Hand over the plant in good working order.
3. Provide a handover protocol with all significant data from commissioning (e.g. additions or
changes to the factory settings).
4. Hand over the operating instructions.
7.12 ACO Maintenance Contract
To safeguard the value and ensure that proper operation of the plant is maintained, and also
as a condition of the manufacturer's guarantee, we recommend that work should be carried
out directly by the manufacturer, ACO.
This ensures long-term operational safety, and you will also benefit from adjustments and
updates which result from our ongoing product development programme.
To request a quotation for a maintenance contract please photocopy the next section,
complete all details, and fax it to
Fax + 49 (0) 3 69 65 / 81 9 -3 67.
Request: Quotation for a maintenance contract for the plant
Please send me a quotation for regular maintenance. I am aware this is not binding.
Sender
Type:
Installed on:
Usage:
Postcode 
Town/city


...

...
87
Commissioning and Operation
7.13 Operation
CAUTION The plant may only be used for the purpose for which it is designed,
Chap. 2.1.
The plant runs automatically. The only necessary work or inspections during operation are:
88
■■
Monthly performance of at least 2 test runs,
Chap. 7.7 "Test Run".
■■
Other inspection work on the plant is restricted to maintenance work,
Chap. 8.3.
"Servicing Tasks for Users" + Chap. 8.4 "Servicing Tasks for Skilled Professionals".
Servicing
8
Servicing
Regular maintenance is necessary in order to ensure long-term, safe and interruption-free
operation.
The necessary maintenance activities are described in this chapter.
8.1 Safety during Installation
During servicing work on the plant, the following risks must be assumed:
WARNING
The following safety instructions must be read carefully before starting servicing work. If
carried out incorrectly severe injuries may occur.
Ensure that maintenance personnel have the necessary qualifications,
cation of Personnel".
Chap. 2.2 "Qualifi-
The user should only carry out tasks which are described in this operating instruction.
All other work requires adequate professional training and sufficient experience in dealing
with waste water lifting plants. Responsibility, Chap. 1.1 "ACO Service".
Electrical hazards
Severe injuries or death are possible from contact with parts which are
connected to mains
■■
All work on the electrical equipment in the plant must be carried out by a qualified
electrician.
BEWARE
Contact with waste water
Skin and eye injuries, risk of infection
■■
Wear personal protective equipment,
Chap 2.3 "Personal Protective Equipment".
■■
On contact with skin: relevant skin areas must be washed thoroughly with soap and
disinfected.
■■
If in contact with eyes: Rinse eyes. If eyes continue to water, consult a doctor.
Sharp edges due to damaged materials
Cuts from worn parts
■■
Be especially careful and vigilant.
■■
Wear personal protective equipment,
Chap 2.3 "Personal Protective Equipment".
89
Servicing
8.2 Plant Log
CAUTION A plant log must be kept.
Keeping a plant log has many benefits, e.g. traceability of measures and targeted troubleshooting.
Entries in plant log:
■■
Dates of regular inspection and service work
■■
Malfunctions, causes of malfunctions, steps taken
■■
Dates of repair work carried out
■■
Dates of tests
8.3 Servicing Tasks for Users
This chapter describes the work which can be carried out by a user.
8.3.1
Daily Checks
The following checks need to be carried out every 1 − 2 days.
■■
Check the pump control -duo to make sure the plant is ready for operation.
■■
Take notice of anything unusual (e.g. unusual noises from the centrifugal pumps), react
and take the necessary measures.
8.3.2
Servicing Tasks as Needed
The following work can be carried out by the user if necessary:
CAUTION To avoid damage to property only use normal commercial, non-corrosive cleaning
agents.
90
■■
Clean plant parts
■■
Clean the pilot tube
■■
Clean the pump control -duo
Servicing
8.3.3
Annual Servicing Work
An electrician must change the pump control -duo battery every year.
➜➜
The battery (1) should be inserted in its
position (2) on the circuit board by an
electrician.
1
2
91
Servicing
8.4 Servicing Tasks for Skilled
Professionals
The following table provides an overview of the servicing work which needs to be carried out
Chap. 2.2. "Qualification of Personnel".
by a skilled professional,
CAUTION Servicing work,
in Tab. 20, must be carried out at the following intervals:
Plants operating in commercial premises = every 3* months
Plants operating in apartment buildings = every 6* months
* Only applies in Germany Requirements in other countries may vary.
Tab. 20: Servicing plan for qualified personnel
Plant
Activity
Component
Description
Pump control -duo
Check condition/functioning of signal lights
Check condition/functioning of controls
Check condition/functioning of display fields
Check functions and menu settings
Carry out test run
Check functioning of remote warnings
Check fuses are in place
Tighten clamp connections
Level switching
Check functions
Clean the pilot tube
Check the control line
Check the control line connection
Tank
Check condition
Clean tank
Centrifugal pumps
Check condition/functioning of the motor
Check noise when running
Check condition of impeller and clean
Check condition of volute and clean
Clean outside of motor
Backflow stop
Check condition and functioning
Check condition of flap
Stop valve
Check condition and functioning
Lubricate adjustment spindle
Mini compressor
Check condition and functioning
Check the air bubble injection line
Piping
Check condition
Check connection points
Check attachments
Total plant
Carry out test run
Clean externally and adjacent areas
 = Can use to check off  completed tasks
92
Settings
to be done/completed




























































Troubleshooting and Repairs
9
Troubleshooting and Repairs
This chapter basically provides information on how to troubleshoot and repair the plant.
9.1 Safety during Troubleshooting and
Repairs
During troubleshooting and repair work on the plant, the following hazards must be assumed:
WARNING
The following safety instructions must be read carefully before starting troubleshooting and
repairs. If carried out incorrectly severe injuries may occur.
Ensure that staff have the necessary qualifications,
Personnel".
Chap. 2.2 "Qualification of
The user should only carry out tasks which are described in this operating instruction.
All other work requires adequate professional training and sufficient experience in dealing
with waste water lifting plants. Responsibility, Chap. 1.1 "ACO Service".
Electrical hazards
Severe injuries or death are possible from contact with parts which are
connected to mains
■■
All work on the electrical equipment in the plant must be carried out by a qualified
electrician.
BEWARE
Contact with waste water
Skin and eye injuries, risk of infection
■■
Wear personal protective equipment,
Chap 2.3 "Personal Protective Equipment".
■■
On contact with skin: relevant skin areas must be washed thoroughly with soap and
disinfected.
■■
If in contact with eyes: Rinse eyes. If eyes continue to water, consult a doctor.
93
Troubleshooting and Repairs
Sharp edges due to damaged materials
Cuts from worn parts
■■
Be especially careful and vigilant.
■■
Wear personal protective equipment,
Chap 2.3 "Personal Protective Equipment".
In the event of a fault, the motor of the centrifugal pump can heat up to a maximum of
110°C
Burn injuries
■■
Wear personal protective equipment,
■■
Let the motor cool for at least 30 mins.
■■
Be especially careful and vigilant.
Chap 2.3 "Personal Protective Equipment".
9.2 Troubleshooting
Use the following table to help identify the cause of problems and take the necessary
measures.
Tab. 21: Troubleshooting
Fault
Cause(s)
Remedy/ies
Pump transports nothing
or too little
Shut-off valve in discharge
pressure line is not fully
open/closed
Discharge pressure line
blocked
Impeller blocked
Fully open shut-off device
or
Tank full
Pump not running
94
7.7
Worn pump parts
Clean discharge pressure
line
Dismantle pump and clean
impeller
Dismantle pump and clean
ventilation hole in the
volute casing
Replace worn pump parts
Defective motor
Replace motor
Pump blocked by foreign
body
No connection to power
supply
Automatic operation
switched off
Pump overload protection
has been triggered and
cannot be cleared
Dismantle pump and clean
impeller and volute
Check connection and
repair as needed
Switch on automatic
operation
Dismantle pump and clean
impeller and volute
Venting of volute blocked
Type of expert
required
x
9.3
x
9.3
x
7.4
x
9.3
x
9.3
x
9.3
x
6.4/ 3
7.10
x
9.3
Troubleshooting and Repairs
Pump only runs in manual
mode
Pump is running noisily
and for too long or does
not switch off
Control line for level
switching is leaking,
laid wrongly, kinked or
obstructed
Pilot tube blocked
Check control line and
correct problem
Pressure switch in controls
not working
Discharge pressure line or
vent stack line is blocked
Vent stack is not laid at all
or incorrectly
Wrong size discharge
pressure line, losses too
great
Defective backflow valve
Change controls
Clean the pilot tube
Clean line
Lay vent stack properly
Reduce losses by
selecting a larger nominal
diameter
Open backflow valve; clean
chamber, flap seat and
flap, replace if necessary
Thumping noises/vibrations Pressure or water hammer Increase the pump afterin the discharge pressure in the pressure system
running period or adjust
line when the pump(s) is/
the soft start
are switched off
Display area:
Pump is blocked by
Dismantle pump and clean
foreign
body
and
current
impeller and volute
max. current
limiter has generated a
malfunction
Display elements:
Pump overload protection Dismantle pump and clean
has been triggered and
impeller and volute
cannot
be
cleared
+
+
P1
6.4/ 6
8.3/ 2
x
9.3
x
9.3
x
6.2/ 7
x
6.2/ 8
x
9.3
7.7 + 7.6
x
9.3
x
9.3
P2
Display area:
Overflow alarm
Display elements:
+
Shut-off valve in discharge
pressure line is not fully
open/closed
Automatic operation not
switched on
Defective pump motor
Impeller blocked
Venting of volute blocked
or
+
Discharge pressure line
blocked
Worn pump parts
Fully open shut-off device
7.7
Switch on automatic
operation
Check manual operation, if
necessary replace motor
Dismantle pump and clean
impeller
Dismantle pump and clean
ventilation hole in the
volute casing
Clean discharge pressure
line
Replace worn pump parts
7.10
x
9.3
x
9.3
x
9.3
x
9.3
x
9.3
9.3 Repairs and Spares
For repair work and ordering spares please contact ACO Service, quoting the details shown
Chap. 1.1 "ACO Service".
on the type plate,
95
Decommissioning and Disposal
10
Decommissioning and Disposal
This chapter provides you with information about the correct way to decommission and
dispose of the plant.
10.1 Safety during
Decommissioning and Disposal
During decommissioning and disposal work on the plant, the following risks must be
assumed:
WARNING
The following safety instructions must be read carefully before starting decommissioning
and disposal. If ignored severe injuries may occur.
Ensure that staff have the necessary qualifications,
Personnel".
Chap. 2.2 "Qualification of
Follow additional safety instructions for "Transport and Storage",
during Transport and Storage".
Chap. 3.1 "Safety
Electrical hazards
Severe injuries or death are possible from contact with parts which are
connected to mains
■■
All work on the electrical equipment in the plant must be carried out by a qualified
electrician.
■■
All work on decommissioning the electrical equipment in the lifting plant must be carried
out by a qualified electrician.
BEWARE
Contact with waste water
Skin and eye infections
■■
Wear personal protective equipment,
■■
On contact with skin: relevant skin areas must be washed thoroughly with soap and
disinfected.
■■
If in contact with eyes: Rinse eyes. If eyes continue to water, consult a doctor.
Sharp edges due to damaged materials
Cuts from worn parts
■■
96
Be especially careful and vigilant.
Chap 2.3 "Personal Protective Equipment".
Decommissioning and Disposal
10.2 Decommissioning
Sequence for decommissioning:
1. Disconnect the pump control -duo from the power supply.
2. Flush the connecting lines.
3. Empty and clean the tank and dispose of waste water.
4. Cover tank.
5. Cover pump control -duo and accessories, and protect from damp.
6. If not in use for more than one month lubricate the plant,
Chap. 3.3 "Storage".
10.3 Stopping
Sequence for stopping:
1. Disconnect the pump control -duo from the power supply.
2. Disconnect the cable in the connection box from the pump control -duo.
3. Disconnect the control line and remove.
4. Flush the connecting lines.
5. Empty and clean the tank and dispose of waste water.
6. Dismantle connections.
7. Dismantle plant elements.
10.4 Disposal
The plant is made from re-usable materials.
CAUTION Incorrect recycling endangers the environment unnecessarily. Local disposal
regulations must be respected.
■■
All steel or cast iron components should be separated and recycled.
■■
All rubber (NBR) components should be separated and recycled.
■■
All plastic (PE-HD or PUR) components should be separated and recycled.
■■
Separate out the pump control -duo and electrical components and recycle as electrical
waste.
97
Appendix
Appendix
Index of Tables and Illustrations
List of Tables
Tab. Tab. Tab. Tab. Tab. Tab. Tab. Tab. Tab. Tab. Tab. Tab. Tab. Tab. Tab. Tab. Tab. Tab. Tab. Tab. Tab. 1:
2:
3:
4:
5:
6:
7:
8:
9:
10:
11:
12:
13:
14:
15:
16:
17:
18:
19:
20:
21:
Key data for product identification.........................................................................................7
Fields of application..............................................................................................................9
Personnel qualifications......................................................................................................11
Personal Protective Equipment............................................................................................12
Levels of Risks...................................................................................................................12
Items delivered with the plant..............................................................................................18
Features of the Plant Parts..................................................................................................21
Setting Menus....................................................................................................................33
Plant Technical Data...........................................................................................................36
Performance data: Type -PE K duo + parallel........................................................................40
Performance data: Type -PE V duo + parallel........................................................................41
Performance data: Type 1.x + 2.x VA duo............................................................................42
Technical Data for the Pump Control -duo.............................................................................43
Prerequisites for Installation................................................................................................47
Connection design .............................................................................................................56
Menu Data ........................................................................................................................78
Soft start setting values......................................................................................................79
Soft start control procedure................................................................................................80
Water Level for Switching Point "ARP OFF"............................................................................81
Servicing plan for qualified personnel ..................................................................................92
Troubleshooting ................................................................................................................94
List of Illustrations
Illus. Illus. Illus. Illus. Illus. Illus. Illus. Illus. Illus. Illus. Illus. Illus. Illus. Illus. Illus. Illus. Illus. Illus. Illus. Illus. Illus. Illus. Illus. Illus. Illus. Illus. Illus. Illus. Illus. Illus. Illus. 98
1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20: 21: 22: 23: 24: 25: 26: 27: 28: 29: 30: 31: Components, type -PE V duo...............................................................................................24
Schematic representation of operating principle, type -PE V duo............................................25
Installation situation (e.g. -PE V duo).....................................................................................28
Operating the pump control -duo..........................................................................................29
Dimensions: Type -PE K duo................................................................................................37
Dimensions: Type -PE V duo................................................................................................37
Dimensions: Type -PE K parallel...........................................................................................38
Dimensions: Type -PE V parallel...........................................................................................38
Dimensions: Type -1.x VA duo..............................................................................................39
Dimensions: Type -2.x VA duo..............................................................................................39
Characteristic curves: Type -PE K duo + parallel...................................................................40
Characteristic curves: Type -PE V duo + parallel...................................................................41
Characteristic curves: Type -1.x + -2.x VA duo......................................................................42
Dimensions of the Pump Control -duo...................................................................................43
Dimensions of the mini compressor.....................................................................................43
"CEE 16" circuit diagram.....................................................................................................44
"CEE 32" circuit diagram.....................................................................................................45
"Soft start" circuit diagram..................................................................................................46
Installation works (e.g. -PE V duo)........................................................................................48
Position of "Connecting Sockets".........................................................................................49
"Y-branch pipe + backflow valves" assembly.........................................................................52
Position of "Inlet Sockets" ...................................................................................................55
Position of "Connections"....................................................................................................56
Position of "Aeration Slots" (e.g. type -PE-K)..........................................................................60
Backflow loop....................................................................................................................62
Position of "Draining Connections".......................................................................................64
Position of "Manual Membrane Pump Connections"................................................................65
Position of "Fixing Tongues".................................................................................................65
Electrical work...................................................................................................................68
Position of "Potential Compensation Connection"...................................................................75
Soft start relays.................................................................................................................79
Notes
Notes
This page is for hand-written notes.
99
ACO Passavant GmbH
Im Gewerbepark 11c
D 36457 Stadtlengsfeld
Tel: + 49 (0) 36965 819-0
Fax: + 49 36965 819-361
www.aco-haustechnik.de
ACO. The future of drainage.
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement