Graf Klaro Easy SBR, Instructions For Start-Up, Operation And Maintenance

Page 1: ... Z 55 31 435 discharge class D Be sure to read before starting up Contents 1 GENERAL 4 2 SAFETY NOTICES 6 3 SCOPE OF SUPPLY 9 4 FUNCTION OF THE SBR SYSTEM 11 5 CONTROL AND MACHINE CABINET 14 6 THE SMALL WASTEWATER TREATMENT SYSTEM S CONTROL UNIT 19 7 ADDITIONAL FUNCTION OF THE KLPLUS KL24PLUS AND KLBASIC KL24BASE CONTROL UNIT 30 8 OPERATION AND MAINTENANCE 38 9 FAULT MESSAGES AND RECTIFICATION 42 ...

Page 2: ... by a specialist Companies certified by the DWA or trained by Otto Graf GmbH are considered spe cialists 2 Maintenance must be undertaken by a specialist company as described in the oper ating manual and the approval If claims for warranty are submitted all maintenance logs must be provided if requested 3 Wearing parts are not covered by the warranty nor are defects and damage for which we are not...

Page 3: ...n the following pag es To meet official cleaning requirements it is essential that the system is operated in accordance with our operating and maintenance instructions You will find these instructions on the following pages We also ask you to read the following information carefully The internal control cabinet must be installed in a dry well ventilated room cellar or garage External control cabin...

Page 4: ... operating the system please enter the details of your sys tem here as follows Should you encounter a fault these details will enable our staff to find a remedy faster You will find the details on the type plate fitted to the outside of internal cabinets and the inside of external cabinets ...

Page 5: ...2 Decem ber 2006 on the harmonisation of the laws of Member States relating to electrical equipment designed for use within certain voltage limits 2004 108 EC Directive of the European Parliament and of the Council of 15 Decem ber 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility and repealing Directive 89 336 EEC The following harmonised standard...

Page 6: ...sive atmospheres Fire naked flames and smoking prohibited Danger notices 2 2 1 To ensure safety everyone who comes into direct contact with the system must note the content of this documentation 2 The system must not be used for any purpose other than that described by the manufactur er 3 Local operating and safety requirements and legislation must be followed at all times even if not explicitly m...

Page 7: ...immediately replaced with fully functional equipment 8 Work on electrical equipment may only be undertaken by specialists 9 All safety and danger notices on the machine should always be kept fully legible 10 Hot parts must not come into contact with explosive or highly flammable chemicals 11 Do not put vessels containing liquids on electric switch cabinets short circuits may occur if the liquid is...

Page 8: ...s pheres The control unit must not be fitted or activated in environments with po tential explosive atmospheres or in places where there are flammable materials Sparks in such environments may cause an explosion or fire and this may result in physical injuries or even death Interferences The control unit may cause medical equipment to malfunction This de vice should therefore not be used in close ...

Page 9: ...lifter in the form of a mammoth pump with its own air supply marked in red In the bio reactor you will find stainless steel air distributor system with membrane pipes or aerator plates feed lifter in the form of a mammoth pump with its own air supply marked in red stainless steel air supply system with EPDM membrane finely perforated outflow lifter in the form of a mammoth pump with its own air su...

Page 10: ...ank 3 1 Two tank system in the Carat tank 3 2 One reservoir system in a TWIN underground tank 3 3 Schlamm speicher Puffer SBR Reaktor L Hs Hp HWges E H H BB min H BB max A E 140 340 Sludge storage buffer SBR reactor Sludge storage buffer SBR reactor sludge return ...

Page 11: ...ems for breaking down the organic matter present in the water removal of 4 1 carbon discharge class C The process is a series of 5 steps undertaken in turn and repeated several times a day usu ally 4 times Step 1 Feed The raw wastewater held in the sludge reservoir is fed to the SBR reactor via an air lift pump This is arranged such that only water free of solids is pumped The special design of th...

Page 12: ...mped out and a minimum water level is retained in the SBR stage without further components Step 5 Removal of excess sludge In this phase excess activated sludge is pumped by an air lift pump from the SBR reactor chamber to the sludge reservoir chamber where it is stored This excess sludge is pumped out of the base of the SBR chamber Once the 5th step is complete the cleaning process starts again w...

Page 13: ...ted on this platform Alternatively the precipitant canister can be positioned separately near the switch cabinet There is a metering pump in the system s switch cabinet which pumps the precipitant out of the precipitant canister and into the SBR reactor The precipitant is added during the reactor s feed phase The amount of precipitant needed can be set on the metering pump Mixing takes place durin...

Page 14: ...for distributing the air for aeration and lifting using air lift pumps feed discharge sludge return control unit for automatic mode with preset operating cycles cooling fan only in systems with a rotary valve blower phosphate precipitant pump optional GPRS communication module optional The elements of the control unit visible from the outside are keypad for operating the control unit two row LCD f...

Page 15: ...net for indoor installation 500 x 500 x 300 mm The machine cabinet is prepared for mounting on the wall The wall brackets provided must be attached to the rear of the cabinet first There must be a 230 V socket 16A slow blow near the cabinet The mains supply with a main switch and ventilation grille are located on the right hand side The hose connections and another ventilation grille can be found ...

Page 16: ...ly such that the column is stable firm and stands upright in the soil To reduce earth moisture we recommend filling the space inside the base with a thin layer of cement screed or base filling granulate accessory art no 107607 If this is not done the electric parts may be damaged by corrosion if the soil is very damp Main components 1 Maintenance switch 2 Control unit 3 Strip of valves with 4 sole...

Page 17: ... a few seconds then the system automatically enters normal operation automatic During the self test the words SYSTEM TEST OK the program version and the control unit s serial number are displayed briefly The system s current operating mode is then displayed in the liquid crystal display If a battery has not yet been placed in the control unit and the time and date have not yet been set the control...

Page 18: ...y An intermittent warn ing tone sounds This warning tone only sounds after a delay of several seconds see Item 10 3 Power cut detector When the power supply to the system is restored it automatically restarts as described above provided that there is a sufficiently charged battery in the control unit Important information If the system is disconnected from the mains for more than 24 hours the syst...

Page 19: ...it KLplus KL24plus control unit Figure 3 View of the KLbasic KL24base operating unit Figure 4 View of the KLplus KL24plus operat ing unit Operating status display The system s operating status is indicated by the LED Green Operation Red Fault and by text on the LC screen In normal operating mode aeration mode the liquid crystal display looks like this Figure 5 View of liquid crystal display during...

Page 20: ...on Valve 2 is activated the bio reactor is aerated at intervals aeration Sediment No valves are activated the activated sludge settles in the bio reactor sedimentation Discharc Valve 1 is activated the wastewater is pumped into the discharge discharching SludgeRe Valve 4 is activated the excess sludge is pumped from the reactor into the sludge reser voir sludge return Pause Valve 2 is activated th...

Page 21: ...and disconnect the mains plug Figure 7 View of rear of KLbasic control unit Connections 1 Connection for mains cable 230 V AC 50 Hz 2 X1 Bayonet connection for the solenoid valves 3 X2 Schuko coupling for the air compressor connection 4 COM Connection for communication module optional and or port for PC 5 F1 T8A fuse medium slow blow for the mains connection 6 F2 T2A fuse slow blow for the connect...

Page 22: ... switch into position 0 OFF and disconnect the mains plug Figure 9 View of rear of KL24base control unit Connections 1 Connection for mains cable 230 V AC 50 Hz 2 X1 Pre assembled valve cable 3 X2 Schuko coupling for the air compressor connection 4 COM Connection for communication module optional and or port for PC 5 F1 T6 3A main fuse slow blow Figure 10 View of rear of KL24plus control unit Conn...

Page 23: ...Operating mode remaining time Time remaining in current operating phase Operating mode remaining time Operatin hours Operating hours display for individual valves and compressor operating hours meter reading Manual operatio Manual activation of valves manual operation Hh mm dd dd mm yy Current time day and date Can be set by pressing SET Date Time Vacationinput Set holiday mode max 90 days vacatio...

Page 24: ...s also displayed Pressing the key once takes you back to the maintenance level And pressing again restores automatic mode Note If no key is pressed for 10 minutes normal mode engages automatically Manually controlling the valves and cabinet fan using Manual mode 6 3 2 Each valve should run for at least 5 seconds when testing because it takes some time to moni tor the power consumption of valves be...

Page 25: ...iday mode Pressing takes you back to manual mode Press then press the arrow keys until the following appears on screen example By pressing you can set the time and date using the numerical keys To confirm each change you must press Pressing once takes you back on to holiday mode Pressing takes you back to manual mode The system s time and date MUST be set correctly to ensure accurate recording of ...

Page 26: ...iday mode using the numerical keys Pressing the key saves the input of data for holiday mode and exits this func tion Holiday mode can be set for a maximum of 90 days Pressing once takes you back to the maintenance level And pressing again re stores automatic mode Note If no key is pressed for 2 minutes normal mode engages automatically without the date just entered being saved Reading out errors ...

Page 27: ...sing a particular action code This second maintenance level is reserved for qualified specialists only No claims for warranty can be made if the control unit settings are accessed without authorisation Changing fuses 6 4 Before fuses are changed the system should be switched off using the red maintenance switch To change or check the fuses the control and machine cabinet must be opened using the k...

Page 28: ...witched on In the event of a power cut the charge of one emergency power supply for indicating the power cut will last around 12 hours If the emergency power supply is not required in response to power cuts it is prevented from discharging by a switching circuit Important In the event of mains failure the time date setting is powered for around 10 days by an extra buffer All saved data such as ope...

Page 29: ...restored the device is returned to the monitoring status and the con trol unit continues from where it left off without any keys having to be pressed The fault mes sage disappears automatically If the emergency power supply is flat the device restarts with a cycle pause Power cut Please note If the system is disconnected from the mains for more than 24 hours the system will be unable to clean the ...

Page 30: ...y when the flow of wastewater is low Function 7 1 1 The water level is measured using the pressure in the feed lifter during the feed phase If the water level in the sludge reservoir buffer chamber 1 exceeds a preset level Level measurement set ting the system starts a cleaning cycle If the level is not reached the system goes into cycle pause for 6 hours In this mode the SBR reactor is only vente...

Page 31: ...must be taken to cordon off the open pit The first chamber sludge reservoir buffer where the feed lifter is located must be filled with water up to the height at which a cleaning cycle is to be triggered This level depends on the geometry of the tank and the number of connected inhabitants The recommended buffer heights a above the minimum water level are specified for the various configurations i...

Page 32: ...0 25 15 20 25 30 35 Type Klaro Easy Professional Carat Klaro Easy TWIN TANK No of inhab 4 6 8 4 6 8 Type 3750 l 4800 l 6500 l 3200 l 5200 l 5200 l b cm 101 127 150 92 93 95 Type Carat Klaro Easy multiple tanks Carat XL No of inhab 8 10 12 18 25 35 25 30 Type 2x 2700 l 2x 3750 l 2x 4800 l 2x 6500 l 4x 4800 l 4x 6500 l 2x 8500 l 2x 10000 l b cm 106 109 128 148 192 154 153 169 Type Carat Klaro E Prof...

Page 33: ...ow keys to select Save yes and confirm with the key The calibration is complete and you can exit this menu with the ESC key 2nd step Setting the control parameters It is absolutely essential that the control parameters for the level measurement are set for the system to function correctly Please carefully work through the following points in order service code Go to SERVICE CODE INPUT press the ke...

Page 34: ...nd step described above must be repeated Water level b must be set to 0 cm Recirculation can remain at 2 minutes Safety and fault messages 7 2 2 If the sensor measures a value below 40 mbar the following message appears in the display Fault min level If this happens the system reverts to the normal time controlled mode This is either triggered by too low a water level 40 cm in the sludge reservoir...

Page 35: ...ST8 Consult the installation instructions for the UV module for more details Phosphate precipitation with metering pump Precipitant Please note Iron III chloride is harmful if swallowed and is irritating to skin There is a risk of serious damage to eyes There is a danger of explosion if the product comes into contact with alkali met als allyl chloride or ethylene oxide Please read the accompanying...

Page 36: ...he pump time set in the ser vice menu The amount of precipitant added is therefore dependent on the set time The large Compact pump has a potentiometer for setting delivery The table below shows the amounts that can be metered Refer to the building authori ty approval for the amount required in each case Figure 12 Sketch of precipitant equipment In order to start up the precipitant device the prec...

Page 37: ...mp on via the menu item Manual Operation and check that the precipitant is sucked in correctly Swap the hose connections if necessary The suction hose can optionally be equipped with a suction lance Overview precipitant pumps 7 3 5 Compact DP12 DP24 Figure 13 Compact precipitant pump Figure 14 DP12 and DP24 precipitant pumps Delivery volume 5 5 ml min Reference values for adjusting pump performanc...

Page 38: ...es Anyone en tering the system must therefore always be accompanied by a second person Never follow anyone who has lost consciousness instead seek help as quickly as possible When doing anything other than operating the control unit the maintenance switch should be turned to the 0 position and or the cabinet s mains connector disconnected Work such as maintenance and repairs on the cabinet system ...

Page 39: ...clip fastener and remove the grille by hand The filter mat is not secured in the ventilation shaft and can be shaken and or blown out The time at which the air compressor filter is to be cleaned or replaced depends on the extent of contamination caused by the atmospheric conditions of the application Follow the service documents provided by the compressor manufacturer to check or replace the filte...

Page 40: ...ollowing Inspection of the operating log to check for correct operation nominal actual compari son Check the air filter of the air compressor and the supply exhaust air openings on the control cabinet Air compressor maintenance according to details provided by manufacturer see Annexes Function check on mechanical electro technical and other system parts key to opera tion such as aerator lifts cont...

Page 41: ...y other maintenance COD value NH4 N if required nanorg if required P if required The maintenance work undertaken any damage found repairs undertaken and other infor mation should be summarised in a maintenance report by the maintenance company A suitable template is provided in the Annex Anything established during the analyses should also be documented in this report The system operator should be...

Page 42: ...cation KLbasic KL24base KLplus KL 24plus No display no lamp Power supply is inter rupted Check the power supply to the system and control unit Check microfuse F1 on the supply cable Check the position of the maintenance switch position 1 If the buffer is flat mains failure will not be indicated acoustically or optically No display lamp green Switch off system and switch on again after 10 seconds N...

Page 43: ...high Air compressor defec tive Temperature sensor defective Plug temperature sensor onto rear of con trol unit Check the functionality of the cabinet fan Check air filter in cabinet Provide site with shade Ensure good aeration Check air filter in air compressor Check air compressor in manual mode Have set temperatures checked by maintenance company Replace temperature sensor error temp sensor No t...

Page 44: ...ose connections The water level in the pre treatment section and aeration basin is unusually high System running in holiday mode System running continuously in cycle pause Control unit settings are incorrect The discharge lifter is blocked The air hose to the discharge lifter is leaking Flooding in the discharging system is not allowing water to drain from the system Control unit is defective Exit...

Page 45: ...defective Anchor blocked in dirty tube space If the anchor does not reach the stroke end position when the AC coil is excited this will soon result in coil failure due to thermal overload Rated voltage different from coil voltage Valve does not close Anchor blocked Rated voltage still present Valve does not open Rated voltage not present Solenoid defective Rated voltage different from coil voltage...

Page 46: ...due from keeping animals commercial or agricultural wastewater unless it is comparable to domestic wastewater chemicals pharmaceuticals mineral oils solvents cooling water solids in the form of food waste plastics and hygiene articles coffee filters bottle tops and other domestic items milk and milk products water discharged from swimming pools large volumes of blood If discharging larger volumes ...

Page 47: ...es Contaminate the wastewater Local collection point Medicines Contaminate the wastewater Collection points pharmacies Engine oil Contaminate the wastewater Collection points service stations Waste containing oil Contaminate the wastewater Collection points service stations Plant protection agents Contaminate the wastewater Local collection point Paintbrush cleaners Contaminate the wastewater Loca...

Page 48: ...95 211333 Food waste Cause blockages attract rats Dustbin Wallpaper paste Causes blockages Local collection point Textiles e g nylon tights cleaning cloths handkerchiefs etc Block pipes may paralyse a pump station Used textiles collection point Thinner Contaminates the wastewater Local collection point Bird sand cat litter Cause deposits and pipe blockages Dustbin Cotton buds Block the system Dust...

Page 49: ...nance three times a year the parameters should be noted weekly for systems requiring maintenance twice a year the parameters should be noted monthly Date of check Sludge overflow Turbidity dis colouration Congestion inlet outlet Air filter checked Operating hours counter Yes No Yes No Yes No Yes No Valve 1 Valve 2 Valve 3 Valve 4 Total ...

Page 50: ...the parameters should be noted weekly for systems requiring maintenance twice a year the parameters should be noted monthly Date of check Sludge overflow Turbidity dis colouration Congestion inlet outlet Air filter checked Operating hours counter Yes No Yes No Yes No Yes No Valve 1 Valve 2 Valve 3 Valve 4 Total ...

Page 51: ...the parameters should be noted weekly for systems requiring maintenance twice a year the parameters should be noted monthly Date of check Sludge overflow Turbidity dis colouration Congestion inlet outlet Air filter checked Operating hours counter Yes No Yes No Yes No Yes No Valve 1 Valve 2 Valve 3 Valve 4 Total ...

Page 52: ...taurant without kitchen Restaurant with kitchen Other Grease separator present NG Emptying needed Structural condition visual evaluation of pit body when filled Dividing walls are OK Pit is sealed to the outside Dividing wall between sludge reservoir buffer SBR is leaking Corrosion damage Comments Function check of system parts important to operation Feed lifter valve 1 red Aeration valve 2 blue D...

Page 53: ...trol unit Control unit type Σ operating hours Feed valve 1 Aeration valve 2 Discharge valve 3 Excess sludge reservoir valve 4 Comments Blower Blower type Blower OK Change the slats slat length mm Change the membranes Filter change Cooling fan OK Comments Time of sampling Date Time Sampling site Sampling shaft SBR chamber Sample transport cooled 4 C frozen Air temperature C Water temperature C Odou...

Page 54: ...ml l Ntot ml l Additional comments Operating log available Maintenance noted in the log Programming modified Fault rectified Additional comments To be arranged by the operator The operator is asked to note the substances which must not enter the system see operat ing log Pit is overflowing operator must discharge content Empty pit dispose of sludge reservoir Date and signature ...