ACO H a u s t e c h n i k

Transcription

1 Alarm ACO H a u s t e c h n i k I n s t a l l a t i o n a n d o p e r a t i n g i n s t r u c t i o n s -02 Version Wastewater lifting system according to DIN for the collection and automatic lifting of wastewater with or without faecal matter to above the backflow level. Collecting container of polyethylene for free-standing / above-floor installation in the building Muli-Star -MDS 1 / MWS 1 ACO Pumpensteuerung für Hebeanlage ACO control box for lifting plant Typ/Type: MDS Artikelnummer Betrieb Pumpe/ In operation MAN. Reset Drehfeld OK/ Pump direction ok Störung Pumpe/ Malfunction Vor Öffnen des Deckels Netzstecker ziehen! Remove plug before opening control box Beachten Sie die Bedienungsanleitung!/ Please read installation manual Type MDS 1 M D S 1 Mono Three-phase current Float switch Smallest container size MWS 1 M W S 1 Mono Alternating current Float switch Smallest container size 1

2 Data on the type plate ACO Passavant GmbH Im Gewerbepark 11c Stadtlengsfeld, Germany Telephone 49-(0) Fax 49-(0) Data Please copy and enter the data from the original type plate on the system. Muli-Star Wastewater lifting plant DIN LGA test certificate Year of manufacture Article number Serial number Note These operating instructions contain basic instructions which have to be observed during installation, operation and maintenance. It is therefore essential that the mechanic and responsible qualified staff/operator read these instructions prior to installation and operation, and that they always be available where the machine is installed. 2

3 ACO H a u s t e c h n i k Content Chapter Page 1. Product identification 1.1 Specific addresses EU Declaration of Conformity Installation of wastewater lifting plants, where and why Description: Design / type Description: Pump type, hydraulic portion with free-flow impeller Areas of application Technical data, dimensions, performance diagram / data, characteristic data Scope 2.1 Applicability of the installation and operating instructions General information Notes 3.1 Explanation of symbols and notes Safety notices Directives and standards Product description 4.1 Components Switch box design Function Installation recommendations Information on energy supply Information on potential-free contact - collective fault signal Environmental conditions Accessories Preparation of the product for use 5.1 Transport, delivery and storage Work for the electrician Electrical work

4 Content Chapter Page 6. Operating instructions 6.1 Commissioning Explanation of the operating and indicating elements of the switch box Schematic diagram of the level switching (float switch) Test run process description (in this example, a side inlet is used) Operation Faults and their remedies Servicing 7.1 Instructions for maintenance and repair work Regular inspections Regular maintenance and repair work Repair 8.1 Instructions for maintenance and repair work Decommissioning 9.1 Disassembly Disposal Decommissioning for a limited period of time Stocking of spare parts and after-sales services 10.1 Maintenance and wearing parts Order data Appendix 11.1 Connection diagram for design -MDS Connection diagram for design -MWS

5 ACO H a u s t e c h n i k 1. Product identification 1.1 Specific addresses ACO Passavant GmbH Im Gewerbepark 11c Stadtlengsfeld, Germany Telephone 49-(0) Fax 49-(0) Service ACO Haustechnik GmbH Im Gewerbepark 11c Stadtlengsfeld, Germany Service - Telephone 49-(0) Service - Fax 49-(0) service@aco-online.de Telephone Fax Telephone Fax Telephone Fax Telephone Fax Telephone Fax Telephone Fax 5

6 1.2 EU Declaration of Conformity Herewith the manufacturer: ACO Passavant GmbH Ulsterstraße Philippsthal Declares that the machinery: Muli-Star mono Complies with the guideline: 2006/42/EC Machinery Directive The devices comply with the additional guidelines: 2006/95/EC Low Voltage Directive The following harmonized Standards have been applied: Issued May, 2001 The following authority is involved: - - Additional product information: - Comment: The lifting plant collects and lifts grey water and black water above the backflow level. Representative for documents: Mr. Marco Eulenstein ACO Haustechnik GmbH Im Gewerbepark 11c Stadtlengsfeld Philippsthal, Mr. Ralf Sand Managing Director ACO Passavant GmbH 6

7 ACO H a u s t e c h n i k 1.3 Installation of wastewater lifting plants, where and why General aspects Building regulations According to state building regulations, buildings and other structures may only be erected if the elimination of wastewater is properly and permanently ensured. Property grounds on which wastewater arises must be connected to the public sewer system if they are ready for operation. It is this requirement, i.e., the direct connection of the property drainage to the public sewer system that results in the backflow problem in this area as well. The frequency of backflows depends on the type of sewer system, whether separate or combined. In separate sewer systems, dirty water and rainwater are transported in separate pipe systems. This makes it less common for backflows to occur in dirty water sewers due to factors such as illegal introduction of waste, pipeline blockages and operationally necessary sewer measures; however, such backflows can never be entirely prevented. For economic reasons and to ensure the self-cleaning capability of the system, the current practice is to dimension drainage systems for a moderate level of rainfall. However, it must be expected that heavy rainfalls exceeding the amount used as the basis for calculation will occur. This means that a drainage system overload could occur at any time. Sewer backup The physical effects of a sewer backup are based on the law of communicating tubes. If a backup occurs, the wastewater finds its way through these pipes into the area of the property drainage because the pipe systems of the property drainage are directly connected to the public sewer system. The water rises to the same level as the water in the public sewer. This means that wastewater will continue to escape from all unprotected openings, such as floor drains, toilets, etc., until the water levels have reached equilibrium (Fig. 1-1). Backflow level This results in a specific elevation or level below which special measures must be taken as part of the property drainage system to protect against the risk of backflows on the property. This level is referred to as the backflow level. The pertinent backflow level is defined by the local authorities in the town by-laws. If no such definition exists, DIN and DIN defines the backflow level as the level of the top edge of the street above the location where the property drainage line connects to the public sewer system. Nevertheless, the backing up of water even above this level cannot be completely ruled out, for instance due to pipe blockages. If backed-up water penetrates within buildings into unprotected rooms, masonry walls and foundations can become saturated. Furnishings are subject to water damage. Health risks due to infections cannot be ruled out. For these reasons, the risk and potential damage of backflowing wastewater must be kept as low as possible using preventive measures. According to town wastewater by-laws, the responsibility for these measures generally lies with the property owner. Property owners can hire suitable experts, such as qualified planners and fitters, to properly plan and execute such measures. Figure 1-1: Sewer backflow 7

8 General aspects Protection against backflow The greatest possible protection against backflow can be achieved with a wastewater lifting plant with a pressurised line that runs to above the backflow level (Fig. 1-2, 1-3). Figure 1-2: Protection against backflow with an incline to the sewer using a wastewater lifting plant Figure 1-3: Protection against backflow when the sewer is situated at a higher level than the drainage features Regulations DIN , "Drainage systems on private ground" and "Gravity drainage systems inside buildings" require that dirty water arising below the backflow level and precipitation water from surfaces below the backflow level be brought into the public sewer system in a manner that protects against backflows through the use of an automatic lifting plant. Drainage systems are planned according to the principle that "arising surface water must be diverted away from the building and not brought into the building." Accordingly, surfaces exposed to rain must be drained by separate pump stations outside of the building. All drainage features situated above the backflow area must be drained with natural inclines (gravity principle); the wastewater from these drainage features may not be diverted through anti-flooding valves and may only be diverted through wastewater lifting plants in exceptional cases in which this is absolutely necessary (e.g. old building renovation). 8

9 ACO H a u s t e c h n i k 1.4 Description: Design / type -MDS 1 -M... Mono Wastewater lifting plants with one pump = -mono-design. Used in places where the wastewater flow may be interrupted or in rooms subject to less frequent use. -.D.. Three-phase current The pump motor is a three-phase motor and is operated with three-phase alternating current (400 V / 50 Hz). -..S. Float switch The automatic level-based switching of the pump is regulated by a float switch Minimal size of the collecting container. -MWS 1 -M... Mono Wastewater lifting plants with one pump = -mono-design. Used in places where the wastewater flow may be interrupted or in rooms subject to less frequent use. -.W.. Alternating current The pump motor is an AC motor and is operated with single-phase alternating current (230 V / 50 Hz). -..S. Float switch The automatic level-based switching of the pump is regulated by a float switch Minimal size of the collecting container. 1.5 Description: Pump type, hydraulic portion with free-flow impeller A large open space in the pump housing (a sphere passage of diameter 57 mm) allows the liquid to easily flow through the suction opening into the pump chamber and allows solid and long-fibred thick matter, such as long sanitary towels, textile, etc. to pass through the pump housing without difficulty. Another advantage: Since free-flow pumps do not have a choke gap between the impeller and the pump housing, this design permits great operational reliability for applications with very long periods of inactivity. This prevents the impeller from rusting into place, which would result in blocking of the pump. Figure 1-5: 3D pump cross section Figure 1-4: 3D free-flow wheel 1.6 Areas of application Compact small lifting plant for private residences Pumping medium may be 40 C constantly, 60 C for brief periods 9

10 1.7 Technical data, dimensions, performance diagram / data, characteristic data Technical data Wastewater lifting plant as per DIN for pressure-free collection and automatic lifting of wastewater with or without faecal matter above the backflow level, for installation in rooms, free-standing, collecting container of polyethylene (PE-HD material) Compact pump unit / characteristic data: Collecting container (volume 60 l) with 3 horizontal inlet connections DN 100, with 1 vertical inlet connection of DN 50/DN 100, with inspection opening (diameter 133 mm) for easy maintenance, with bottom outlet R 1 and 48 mm diameter connection for hand diaphragm pump, with ventilation connection DN 50 for connection to plastic pipe, with integrated special check valve (ball integrated into casing) and air intake mechanism, with connection for pressure line / connection flange DN 80 PN 10 (for shutoff valve accessory) and special adapter piece DN 100 for elastic connection of the pressure line (pipe outer diameter mm), with fastening set for anchoring against lifting forces, with elastic connection hardware (NBR hose plus clamps) 1 pc. DN 100 and 2 pcs. DN 50 Pump unit / three-phase motor 400 V, 50 Hz (MDS 1) or AC motor 230 V, 50 Hz (MWS 1), protection type IP 68, with non-blocking free-flow impeller, sphere passage of 57 mm, S2 short-time duty, flood-safe as per IP 68, submersion depth (from mounting surface): max. 2 m, submersion period: max. 7 days Switch box / characteristic data: Casing of plastic for wall mounting, protection type IP 54, dimensions 250 x 230 x 100 mm (W x H x D) Connection data: 400 V / 50 Hz - max. 5 A (MDS 1), 230 V / 50 Hz - max. 10 A (MWS 1) plug-ready; 1.5 m cable with CEE plug / 5-pin (MDS 1) or 1.5 m cable with safety plug (MWS1) External surge protection: Type K circuit breakers, mechanical interlock (MDS 1) or circuit breakers according to the local conditions (MWS 1) Operated via film keypad LED indicators for operation, rotary field monitoring and faults (level alarm, motor alarm/power consumption, mains failure, battery defective, cable break/sensor, external fault signal/humidity sensor) with separate signal sequence Audio signal for all fault messages Battery-buffered, mains-independent alarm (approx. 10 hours) powered by integrated 6 V battery Potential-free collective fault signal Extra input for external fault signal Digital fill level measurement with sensor monitoring (float switch with 5 m cable between lifting plant and switch box) DIP switch for extremely simple container specification during setup Dimensions Power connection cable (1.5 m long) with CEE plug (three-phase current) or safety-plug (AC) Adapter piece for elastic connection of the pressure line DN 100 (Option: Adapter piece DN 80) Switch box (plug-ready) Ventilation DN 50 Integrated special check valve with air intake mechanism Inlet DN 50 Inlet DN 100 Collecting container Attachment for anchoring against upward forces Screw-on inspection lid DN 125 Lid / opening Float switch Connection Ø 48 for hand diaphragm pump Outlet R 1 Free-flow rotary pump 10

11 ACO H a u s t e c h n i k Performance diagram Performance data Muli-Star Capacity Total pump height H in m Type Q MDS 1 MWS 1 m 3 / h l / s m 3 / h l / s Characteristic data Muli-Star Voltage Frequency Rated motor power Current consumption Rotation speed Weight Type in V in Hz P mm kw P 2 in kw in A in rpm in kg MDS MWS

12 2. Scope 2.1 Applicability of the installation and operating instructions The instructions have to be kept in a safe place by the operator. If additional instructions for individual parts of the entire plant have been enclosed, they must be observed as well! These instructions are applicable for ACO Passavant wastewater lifting plants Muli-Star -MDS 1 and Muli-Star -MWS 1 These instructions are used for installing, commissioning, operating, maintaining, repairing and decommissioning. Data on any standards, certification marks, quality marks and trademarks correspond to those valid at the time of going to print. Illustrations, as well as size and weight measurements, may vary. We reserve the right to make changes and improvements without notification in the interest of technical progress. 2.2 General information ACO Passavant GmbH owns the copyright in these instructions. These instructions are intended for the installation, operating, maintenance and supervising staff. They contain instructions and technical drawings which may not be duplicated in whole or in part, may not be disseminated or used by unauthorised persons for competitive purposes or may not be disclosed to other parties. Safekeeping of the instructions The installation and operating instructions have to be available permanently at the location of use of the wastewater lifting plant. Supplements The operator of the system has to supplement the installation and operating instructions with the instructions prescribed by the existing national regulations on accident prevention and environmental protection. Apart from the installation and operating instructions as well as the binding regulations on accident prevention applicable in the country of use and at the location of use, the recognised technical rules for safe and expert work have to be observed. This plant may not be operated above the values indicated in the technical documentation (see section 1.13) with regard to pumping medium, capacity, rpm, pressure, temperature and motor output or other values indicated in the instructions or contractual documentation. Product in general This system has been developed according to the latest state of technology and with the highest of care, and is subject to a permanent quality control. These instructions are intended to facilitate the familiarisation with the plant and its intended uses. They contain important notes on the safe, proper and economic operation of the plant. Observe these notes in order to ensure the reliability and long life of the plant and to avoid risks. The type plate (see page 2) indicates the type as well as the article and serial number which must always be specified in case of questions, repeat orders and especially for spare part orders. If additional information is required as well as in case of damage, please get in touch with the ACO Service Department. 12

13 ACO H a u s t e c h n i k 3. Notes General aspects These operating instructions contain basic notes which have to be observed during installation, operation and maintenance. It is therefore essential that the mechanic and qualified staff/operator responsible for the plant read these instructions prior to installation and operation, and that they always be available where the machine is installed. In addition to the general safety notices listed in this section, the special safety notices in other sections have to be observed as well. The special operating instructions of the equipment supplied by other manufacturers and installed in the lifting plant are also important and have to be observed (see appendix and/or complete documents on delivery)! 3.1 Explanation of symbols and notes This symbol is included with all work safety notes in these operating instructions in which there is a threat to life and the physical condition of humans. Especially in these cases, it is essential to follow these instructions and exercise caution. All work safety instructions have to be shared with other plant operators. Apart from the instructions in these installation and operating instructions, general safety and accident prevention regulations have to be taken into consideration. This symbol is found in the installation and operating instructions next to particularly important passages that must be observed to ensure compliance with the directives, standards, regulations, instructions and the correct sequence of the work as well as to prevent damage to the plant, its parts and its surroundings and to ensure its proper functioning. This symbol indicates environmental protection measures. This dot is used for enumerations. Instructions attached directly to the lifting station have to be observed as well. 13

14 3.2 Safety notices Dangers of failure to comply with safety notices Failure to observe the safety notices can put people at risk as well as cause damage to the environment and the machine. Failure to observe individual safety notices could result in the following hazards, for example: Failure of important machine functions Failure of prescribed maintenance and servicing methods Risk to people from detrimental electrical, mechanical and chemical effects Risk to the environment from leakage of hazardous substances Safety-conscious operation Observe the safety notices listed in these instructions and current national accident-prevention regulations as well as any internal work, operation and safety regulations of the operator. Safety notices for maintenance, inspection and installation If hot or cold machine parts are hazardous, the customer has to protect these parts from being touched. Protection devices of moving parts (e.g. impeller) may not be removed from an operating plant. Leaks (e.g. at the shaft seal) of hazardous pumping material (e.g. explosive, poisonous, hot) must be discharged in such a way that it represents no risk to people or the environment.; legal regulations have to be observed. Dangers posed by electrical energy have to be eliminated (for more detailed information, refer to the National Electric Code and local energy supply company regulations for example). Staff Operating, maintenance, inspection and installation staff have to be appropriately qualified to carry out this work. The operator has to exactly specify the accountability, responsibility and supervision of staff. If staff do not have the necessary knowledge, they have to be trained and instructed accordingly. The operator has to ensure as well that the staff have fully understood the contents of these instructions. The operator has to ensure that corresponding measures are taken to protect the staff. Safety instructions for maintenance, inspection and mounting work The operator has to ensure that all maintenance, inspection and installation work be carried out by authorised and qualified professionals who have sufficiently informed themselves by thoroughly studying the operating instructions. The plant and its components must generally be shut down when performing work on it. The procedure for shutting down the plant described in the instructions has to be observed. Pumps and pumping sets carrying hazardous material must be decontaminated. Legal regulations have to be observed. When the work has been completed, all safety and protection devices have to be immediately reattached and put into operation. Before the machine is put into operation again, the points listed in the section on first commissioning have to be observed. 14

15 ACO H a u s t e c h n i k Designated use Wastewater lifting plants are designed for the pumping of wastewater with or without faecal matter. Any other uses shall not be considered designated. The manufacturer shall not be held liable for any resulting damage; the risk shall be borne by the operator alone. The following must not be introduced: See page 42, section 6.5. Designated use includes also: Observation of all national laws and regulations. Observation of the inspection and maintenance instructions. Observation of the installation, commissioning, operating and maintenance instructions prescribed by the manufacturer. For safety reasons, no modifications of the plant are permitted. Unauthorised alteration and spare-parts manufacture Alterations or changes to the machine are only permitted following consultation with the manufacturer. Original spare parts and accessories authorised by the manufacturer should be used for safety purposes. The manufacturer may refuse liability for resulting damages if other parts are used. The use of ACO Passavant's original parts ensures safe and reliable operation of the wastewater lifting plant. Delay of installation If it is known or if it must be expected at the time of installation that a longer period of time will pass until the plant will be commissioned for the first time, the following measures have to be taken to protect the plant: Protect the plant (and parts) against moisture and soiling (applicable for electric parts in particular). In case of a period of more than one year before the initial operation, an inspection has to be carried out by ACO Haustechnik - Services Department (against invoice). Occasionally move functional parts in order to prevent seizure. If the pump cable is not connected, protect the end from moisture. Shutdown and restart As a matter of principle, work on the plant may be carried out only when the moving parts are at a standstill. The procedure for shutting down the parts of the plant described in the instructions has to be observed. When the work has been completed, all safety and protection devices have to be immediately reattached and put into operation. Before the plant is put into operation again, the points listed in the section on first commissioning have to be observed. 15

16 Electrical safety Prior to any work on electrical systems, the following measures have to be carried out in the order listed here: Disconnect all power connections (switch off main switch or pull power plug). Protect against switching on and check for absence of voltage. The electrical installation of a plant component has to be in conformity with the stipulations of European standards 1012, Part 1 and , Part 1; if and when necessary, the local regulations of the power supply companies have to be taken into consideration. The local potential adaptations have to be included. Work on the electric equipment of the wastewater lifting plant may only be carried out by an electrician or by trained persons under the management or supervision of a qualified electrician in keeping with the rules governing the use of electricity. Environmental protection The waste disposal regulations have to be observed when disposing of matter that was removed from the plant. Safety and health protection measures With respect to the fundamental safety and health protection measures to be observed, reference is made to the pertinent regulations of the professional associations and the German Federal Work Group of Accident Insurance Companies, such as the BGR (rules), BGV (regulations) and BGI (information). 3.3 Directives and standards (Note: the summaries provided below do not claim to be complete) Legal regulations The requirements on operation of property drainage systems are defined by the construction, water and waste management laws of Germany and the German states as well as local bylaws. The ordinances and laws may differ between German states. All legal regulations have in common that they refer to the generally accepted rules and conditions of engineering with regard to specific requirements. 16

17 ACO H a u s t e c h n i k Overview of key standards and directives Standard / directive DIN /2 (product standard) Version Title Wastewater lifting plants for buildings and sites Principles of construction and testing Part 1: Lifting plants for wastewater containing faecal matter / Part 2: Lifting plants for faecal-free wastewater DIN Gravity drainage systems inside of buildings Part 1: General and performance requirements DIN Gravity drainage systems inside of buildings Part 4: Wastewater lifting plants - layout and calculation DIN Drainage systems for buildings and properties Part 100: Additional specifications regarding DIN 752 and DIN DWA-M Backflow prevention with wastewater lifting plants or anti-flooding valves Planning standards and directives Key word Symbol Title Standard / directive; -section- (excerpt) Drainage system Natural incline Backflow protection - Plants consisting of drainage fixtures, pipes and other components that collect wastewater and drain it via gravity. A wastewater lifting plant can be part of a gravity drainage system. - All drainage objects above the backflow level are to be drained by means of natural downward slope and may therefore not be connected to the wastewater lifting plant. - Drainage points beneath the backflow level must be secured against backflow. The protection against backflow is provided by wastewater lifting plants with backflow loop. Only designs with a backflow loop offer a high level of protection against backflow. DIN ; DIN ; DIN ; -4- Backflow level - If the backflow level has not been determined by the responsible authority, the height of the road at the point of connection shall apply. Selection - The planning and selection of wastewater lifting plants must take place according to DIN and DIN Planning documents - Before installation of the lifting plant or anti-flood valve, it is necessary to evaluate whether the plant being installed conforms to the approved planning documents and applicable standards. Accessibility - Accessibility to installation, maintenance, inspection and disposal must be ensured even during operation. Installation site Connection heights Surface water Useful volume - The installation site must have sufficient load-bearing capacity and satisfy the regulations for noise prevention in structures. DIN ; -4- DWA-M 167; DWA-M 167; DWA-M 167; DWA-M 167; The existing drainage pipes have to be checked for suitable connection height. DWA-M 167; Surface water arising outside of the building and below the backflow level must be transported separately from the building wastewater and outside of the building via a wastewater lifting plant. - The useful volume of the lifting plant must be greater than the pressure line volume extending through the check valve up to the backflow loop but no less than 20 l. This ensures that the volume in the pressure line will be exchanged during pump operation. DIN ; DIN ;

18 Standards and directives regarding installation Key word Symbol Title Standard / directive; -section- (excerpt) Collecting container Collecting container for wastewater containing faecal matter may not be structurally connected to the building. DIN ; Pump sump A pump sump must be installed to lift plants for draining rooms of wastewater containing faecal matter. DIN ; -5.1-w Rotation prevention Wastewater lifting plants must be installed with measures to prevent rotation of the plant. DIN ; Protection against lifting forces Plants exposed to lifting forces must be anchored securely against such forces. DIN ; Clearance 600 Spaces for the wastewater lifting plant must be large enough that a clearance of at least 600 mm exists next to and above all parts used in operation and maintenance. DIN ; Illumination The installation room must be sufficiently illuminated. DIN ; Room ventilation The installation room must have sufficient ventilation. DIN ; Double plant A double plant must be installed in situations where the flow of wastewater must not be interrupted. DIN ; Line drainage All pipelines must be installed such that they can drain themselves (except for the pressure line). DIN ; Stress-free The connections of the drainage lines to the wastewater lifting plant must be free of stress. DIN ; Nominal width reduction The lines may not narrow in the direction of flow. DIN ; Inlet pipe A shutoff valve must be situated on the inflow side. DIN ;

19 ACO H a u s t e c h n i k Standards and directives regarding installation Key word Symbol Title Standard / directive; -section- (excerpt) Sound insulation All line connections to the wastewater lifting plant must have sound insulation and be implemented flexibly. DIN ; Weight relief The lines must be appropriately relieved of their own weight. DIN ; Ventilation Ventilation lines (primarily for lifting plants carrying faecal matter) must rise constantly to above the roof without decreasing in nominal width. The line may therefore be run to the main or secondary exhaust ventilation line. DIN ; Ventilation The ventilation of the plant may not be connected to the intake ventilation line of a grease separator. DIN ; Pressure line The pressure line of the wastewater lifting plant must be run such that the base of the backflow loop will be above the backflow level. DIN ; Pressure line The pressure line must be appropriately relieved of its own weight. DIN ; Pressure line A check valve must be installed in the pressure line. If no shutoff mechanism is situated after this point in the plant, the check valve must have an air intake mechanism or some other option must exist for draining. DIN ; Pressure line A shutoff mechanism must be installed in the pressure line after the check valve. This is not necessary if the nominal width of the line < DN 80. DIN ; Pressure line The line must be secured against coming unattached at connections that are not designed to elastically accept longitudinal forces. DIN ; Pressure line min The minimum nominal width of the pressure line must comply with Table 5 of DIN DIN ; Pressure line Pressure lines must always be connected to ventilated ground lines or mains. The connections must be designed as connections for pressure-free lines. DIN ; Pressure line The pressure line must accept at least 1.5 times the maximum pump pressure of the plant. Appropriate pressure pipes must be used. DIN ;

20 Standards and directives regarding installation Key word Symbol Title Standard / directive; -section- (excerpt) Pressure line No other connections may be made to the pressure line. DIN ; Pressure line Pressure lines of wastewater lifting plants may not be connected to wastewater downpipes. DIN ; Pressure line The flow rate in the pressure line must not fall below 0.7 m/s or exceed 2.3 m/s. DIN ; Pressure line Ventilation valves are not permitted in the pressure line. DIN ; Pipeline The lines routes must be protected against frost. DIN ; Electrical equipment Electrical systems that are not flood-safe must be installed in dry and well-ventilated rooms such that they are safe from flooding. DIN ; Electrical connections The electrical connection work may only be performed by a qualified electrician. The applicable state-specific regulations must be observed. DIN ; Standards and directives regarding operation Key word Symbol Title Standard / directive; -section- (excerpt) Commissioning Inspection Commissioning must be performed by appropriate experts, and the immediate supplier of the wastewater lifting plant will be responsible for ensuring that such experts be available. During commissioning, a test run with water must be performed for at least two switching operations. Dry running must be avoided during the test run. Checks to be performed before, during and after this test run: See standard. Wastewater lifting plants should be inspected once a month by the operator to ensure correct functioning by monitoring a minimum of two switching operations. DIN ; DIN ; Maintenance Maintenance contract The plant must be maintained by an expert. The maintenance intervals should not exceed: - 3 months in commercial operations. - 6 months in multifamily dwellings. - 1 year in single-family dwellings. Work to be carried out during maintenance: See standard. - It is recommended that plant operators conclude a maintenance contract for regular performance of maintenance and service work. DIN ; DIN ;

21 ACO H a u s t e c h n i k 4. Product description 4.1 Components Figure 1-6: Description A casing 1 of polyethylene functions as collecting container. To prevent lifting forces the container is anchored with mounting bracket 3. The hydraulic parts (pump casing and free-flow impeller) of the rotary pump and the float switch are contained within the collecting container. The connection cable of the float switch is run through the connection lid 8 and the cable opening is sealed water-tight. The three-phase or alternating current motor of the free-flow rotary pump 9 sits outside the collecting container. An inspection lid 6 allows maintenance, control and cleaning of the interior components and the container. The pump discharge side is integrated into the container with a special check valve 10 that has an air intake mechanism that can be operated from the outside. An adapter piece 11 to DN 80 serves as the exterior transition. A special fastening element 12 is connected to the adapter piece. The spigot end of the DN 100 pressure line can be inserted into the special fastening element at the installation site and elastically secured with the supplied fastening materials. During installation, a shutoff valve of DN 80 (accessories) is installed between the adapter piece 11 and the special fastening element 12. The inlet connections (3 on side at various heights and 1 from above) and ventilation 7 are located on the container. The inlet connection that should be used as inlet must first be opened by sawing off the sealed end piece. The drain screw 2 (base drain) and a connection 13 for a hand diaphragm pump are located at a low point on the side of the container. The lifting plant is connected to the switch cabinet 14 by 5 m pump and float switch cables List 1 Collecting container of PE-HD 2 Connection DN 25 (for base drain) 3 Mounting bracket with screws and pin for securing against lifting forces 4 Inlet connection DN 100 (sealed) 5 Inlet connections DN 50 and 100 (sealed) 6 Inspection lid DN Connection DN 50 for exhaust ventilation 8 Lid / opening for float switch (analogue level sensor) 9 Free-flow rotary pump with three-phase motor (MDS 1) or AC motor (MWS 1) 10 Integrated special check valve with air intake mechanism 11 Adapter piece to DN 80 Flange connection DIN 2501 PN Special fastening element for elastic connection of the pressure line (spigot Ø mm) 13 Connection Ø 48 mm for hand diaphragm pump 14 Switch box for MDS 1 with 1.5 m cable and CEE plug or for MWS 1 with 1.5 m cable and safety plug or 21

22 4.2 Switch box design Switch box for Muli-Star -MDS 1 / MWS 1 lifting plant Technical data Dimensions: 250 x 230, 100 mm (WxH, D) ACO Pumpensteuerung für Hebeanlage ACO control box for lifting plant Typ/Type: MDS Betrieb Pumpe/ MAN. Reset In operation Artikelnummer Protection type IP 54 Drehfeld OK/ Pump direction ok Störung Pumpe/ Malfunction Alarm Material: Plastic, white Vor Öffnen des Deckels Netzstecker ziehen! Remove plug before opening control box Figure 1-7: Switch box for -MDS 1 Beachten Sie die Bedienungsanleitung!/ Please read installation manual Connection data MDS: Connection data MWS: Surge protection MDS: (external) Surge protection MWS: (external) 400 V / 50 Hz, max. 5 A 230 V / 50 Hz, max. 10 A Generally with type K circuit breakers, mechanically interlocking on 3 poles Use automatic circuit breakers in keeping with the local conditions Connection design: Plug-ready; 1.5 m cable with CEE plug 16 A (MDS 1) or safety plug (MWS 1) ACO Pumpensteuerung für Hebeanlage ACO control box for lifting plant Typ/Type: MWS Betrieb Pumpe/ MAN. Reset In operation Störung Pumpe/ Malfunction Artikelnummer Alarm LED indicators: 1 x operation / green 1 x rotary field / green (only on MDS 1) 1 x fault / red, in detail: Motor alarm / power consumption, cable break / sensor, alarm level, mains failure, battery defective, external fault signal / humidity sensor (with separate signal sequence) Vor Öffnen des Deckels Netzstecker ziehen! Remove plug before opening control box Beachten Sie die Bedienungsanleitung!/ Please read installation manual Operation: Via film keypad 1 x button automatic 1 x button manual 1 x button reset Figure 1-8: Switch box for -MWS 1 Messages: 1 x audio signal for all fault signals 1 x potential-free collective fault signal Input: 1 x extra input for external fault signal Control: Digital fill level measurement with sensor monitoring, DIP switch for extremely simple container specification Additional features: Battery-buffered, mains-independent alarm (approx. 10 hours) powered by integrated 6 V battery, volume 90 db A 22

23 ACO H a u s t e c h n i k 4.3 Function M Figure 1-9: Cross section for Fig ACO Pumpensteuerung für Hebeanlage ACO control box for lifting plant Typ/T ype: MDS Betrieb Pumpe/ In operation MAN. Alarm S Störung Pumpe/ Malfunction Vor Öffnen des Deckels Netzstecker ziehen! Remove plug before opening control box L Artikelnummer Reset Drehfeld OK/ Pump direction ok Beachten Sie die Bedienungsanleitung!/ Please read installation manual J A Level 1 K D Level 3 I C Level 0 B H E G F Figure 1-10: Cross sections from Figure 1-9 placed against each other, stretched representation Description The wastewater flows through the inlet A into the collecting container B. If the wastewater reaches "level 1," the float switch C and switch box S start the pump motor D. The free-flow impeller E turns, draws the wastewater through the suction opening F into the pump casing G and pushes it further through the pressure opening H and the check valve I (ball K is pushed away from the pressure opening H into the side pocket J of the check valve) into the pressure line M and above the backflow level (shut-off valve L must be open). If the water level falls below "level 0," the pump will be switched off. The volume between the switch points "level 0+1" corresponds to the useful volume of the collecting container. If the pump is not switched on due to an existing fault / defect (see fault causes), an alarm is triggered in the switch box upon reaching of "level 3," and the situation must be evaluated. The automatic level switch is set to the corresponding switch points by the manufacturer (according to the use of the inlet from above or on the side, see page 39). Before commissioning, the lifting plant must be filled with water and the switching operations tested (see test run section 6.4). 23

24 4.4 Installation recommendations Design of Muli-Star -MDS 1 1 Lifting plant Muli-Star -MDS 1 2 Switch box 3 Inlet line Inlet line 2 5 Inlet line 3 6 Pressure line 7 Container ventilation line Inlet shutoff valve (accessories) 9 Pressure line shutoff valve (accessories) 10 Power cable with CEE plug 11 CEE socket 12 Backflow loop 13 Backflow level Figure 1-11: Design of Muli-Star -MWS 1 1 Lifting plant Muli-Star -MWS 1 2 Switch box 3 Safety socket 5 4 Connection cable with safety plug 5 Backflow loop 6 Container air exhaust 7 Pressure line 8 Inlet pipe 9 Inlet shutoff valve (accessories) 10 Collecting container drain line 11 Hand diaphragm pump (accessories) 12 Three-way cock (accessories) 13 Pressure line shutoff valve (accessories) Pump sump (built into installation site) 14 Figure 1-12: 24

25 ACO H a u s t e c h n i k 4.5 Information on energy supply Water supply For general cleaning work and internal cleaning of the collecting container, a fresh water tapping point (R ¾") should be provided in the vicinity, if possible. Hot water should also be available, if possible. Power supply Switch box for type MDS 1 The plug-ready switch box has a 1.5 m connection cable with CEE plug 16 A. A CEE socket in the vicinity of the switch box must be provided at the installation site. Connection data: 400 V / 50 Hz, max. 5 A. The external surge protection is generally implemented with type K circuit breakers with 3-pole mechanical interlocking. This ensures a complete separation from the mains network and prevents 2-phase operation. Switch box for type MWS 1 The plug-ready switch box has a 1.5 m connection cable with a safety plug. The operator has to fit a German earthing contact safety plug socket near the switch box. Connection data: 230 V / 50 Hz, max. 10 A. Use an automatic circuit breaker for external surge protection in keeping with the local conditions. 4.6 Information on potential-free contact - collective fault signal The switch box has a potential-free contact for transmission of a collective fault signal. The contact is realised with a changeover contact. This electrically isolates the electrical power circuits of the devices being connected. The pin assignment information can be found in the corresponding connection diagram (see appendix or enclosure with switch box). 4.7 Environmental conditions The installation site of the lifting plant must be easily accessible; in other words, parts of the wastewater lifting plant that must be operated and maintained must have a clearance on all sides from the wall or other equipment of at least 0.6 m. It must be possible to run the inlet line DN 100, the pressure line DN 80 or DN 100, the ventilation line DN 50 and the electrical connection cable into the installation area from outside. A position safe from flooding must be selected for the switch box and a wall area of approx. W x H = 300 x 300 mm must be kept free. For installation of a hand diaphragm pump, a wall surface of W x H = 300 x 800 mm and a pump sump of at least L x W x H = 400 x 400 x 450 must be provided. 25

26 4.8 Accessories Identification diagram 1 Toroidal sealing ring DN 80 2 Inlet shutoff valve 3 Signal system (not shown) 4 Manual diaphragm pump 5 Three-way cock, shutoff valve 6 Pressure line shutoff valve Figure 1-13: Example Muli-Star -MWS 1 Toroidal sealing ring DN 80 (Ø mm) 1 Article number Inlet line shutoff valve DN NBR lip seal Article number

27 ACO H a u s t e c h n i k Alarm device NA Description The item NA 1.2 is used to provide an alarm signal even in the event of a blackout. A potential-free contact can be connected to a Building Monitoring System. An output (12 V, max. 1 A) for the operation of a signal transmitter is also available. The internal battery (12 V, 1.2 AH) is automatically recharged Technical data Operating voltage: 230V/AC 50/60Hz, Case: 125 x 175 x 75 mm, polycarbonate, protection class: IP 65, battery: 12 Volt 1.2 AH, temperature range: - 20 until + 50 C, contact point:: 4 A (1AG/Cd0), alarm output:: 12 V 1A max., cable fitting: 3pcs M16 x 1.5. Connection: plug-in with cable (2 metres). Operating temperature of the transformer can reach ca. 70 C! When battery is fully discharged, recharging can last up to 100 hours Article number Manual diaphragm pump 4 -Technical data Pump of grey cast iron, diaphragm and balls oil-resistant, capacity 45 l/min at 50 strokes/min., pump height max. 10 m suction height max. 6 m, R.11/2. Direction of flow Article number Direction of suction Three-way cock, shutoff valve R 1 1/2 5 Direction of flow Article number Direction of suction 1 Sense of rotation Article number Direction of suction 2 Pressure line shutoff valve DN Characteristic data DN Dimensions in mm Article number H L d Connection dimensions according to DIN PN 10, with 1x seal and fastening set 27

28 5. Preparation of the product for use 5.1 Transport, delivery and storage Delivery Check that the delivery is complete and intact. The wastewater lifting plant and its components are generally delivered in a cardboard box (600 x 600 x 550 mm).. Figure 1-14: Transport Never lower and lift the parts directly. Transport instructions Appropriate care must be taken to prevent damage to the wastewater lifting plant and its components. The low total weight of 29 kg allows the plant to be carried. Sufficient gripping points (e.g. pipe connections, casing recesses, etc.) exist. When transporting the wastewater lifting plant and its components by means of a crane, the safety regulations for load-carrying equipment and lifting devices have to be observed. Do not stand under suspended loads. Do not exceed the permissible carrying weight of the lifting device. Transport with fork-lift truck For transport by fork-lift truck, the wastewater lifting plant and its components must be placed on a suitable transport unit (such as a wooden pallet). Transport by crane hooks I For the transport of the wastewater lifting plant by crane hooks, please attach the corresponding guy ropes to the units delivered. Do not transport the plant suspended from the pump or float switch cable. Storage The packaged wastewater lifting plant should be stored in a closed frost-proof room. 28

29 600 Spaces 600 ACO H a u s t e c h n i k 5.2 Work for the electrician List of mounting work 1 Set up the collecting container 2 Anchor the collecting container against lifting forces 3 Remove the transport protection from the float switch 4 Connect the pipes 5 Connect the inlet pipe 6 Connect the ventilation pipe 7 Install shutoff valve (accessories) and special fastening element 8 Connecting the pressure line 9 Connect the drain line 2 9 Figure 1-15: Set up the collecting container The collecting container must rest level on a flat concrete floor. Related technical notes (not necessarily complete) for the wastewater lifting plant must be large enough that a clearance of at least 600 mm exists next to and above all parts used in operation and maintenance. The installation room must be sufficiently illuminated. 1 The installation room must have sufficient ventilation. Anchoring the collecting container against lifting forces To ensure that the collecting container does not float up if the area around it floods, it must be anchored to the floor at the two fastening points with the supplied fastening set. Sufficient sound insulation to prevent transmission of structure-borne sound into the structure is provided by rubber mats provided by the installer. Related technical notes (not necessarily complete) Wastewater lifting plants must be installed with measures to prevent rotation of the plant. Plants exposed to lifting forces must be anchored securely against such forces. 2 29

30 Removing the transport protection of the float switch 3 Check the ease of motion by slowly lifting and lowering the float switch. Figure 1-16: Removing the transport protection Connect the pipes Pipe forces and moments must not act on the plant. The escape of toxic and hot pumping media can cause fatal injuries. By no means may the system be used as a fixed point for the pipe system. Expansions of the pipe system caused by high temperature have to be compensated by suitable measures in order to relieve the wastewater lifting plant. Failure to do this may result in leaks that allow the pumping medium to escape. 4 Connect the inlet pipe Related technical notes (not necessarily complete) All pipelines must be installed such that they can drain themselves (except for the pressure line). The connections of the drainage lines to the wastewater lifting plant must be free of stress. The lines may not narrow in the direction of flow. Connection Three horizontal pipe connections DN 100 (1 on front, 2 on side) and 1 vertical pipe connection DN 100 with transition to DN 50 (from above) are available for connection of the inlet line(s). The connections are all sealed. After determining which connections will be used, the respective connection caps must be cut off with a saw at the corresponding notch. The inlet line provided by the installer with shutoff valve is then connected appropriately to the spigot end. The connection dimensions of the connections correspond to DIN 877. The inlet line must be dimensioned and installed according to DIN 1986 Part 2. 5 A shutoff valve must be situated on the inflow side. All line connections to the wastewater lifting plant must have sound insulation and be implemented flexibly. The lines must be appropriately relieved of their own weight. Figure 1-17: Example: Top pipe connection, DN 100 / DN 50 Notch for saw cut Connection variants In detail: Parts list 1 Pipe DN 100, provided by installer / outside Ø 110 mm A2 Slip-on collar DN 100 (provided by installer) B2 Shutoff valve DN 100 with sleeve gasket for pipe Ø 110 mm (ACO accessory, ) 3 Connection spigot DN 100 AHA / outside Ø 110 mm Variant Title Part image A * Sliding collar B Shutoff valve * Variants only for direct toilet connection or as intermediate installation container - shutoff valve 30

31 ACO H a u s t e c h n i k Connect the ventilation pipe A pipe connection DN 50 with outer diameter 52 mm is situated on the collecting container (top). A connector for elastic connection of the ventilation line must be provided by the customer. Related technical notes (not necessarily complete) All line connections to the wastewater lifting plant must have sound insulation and be implemented flexibly. The lines must be appropriately relieved of their own weight. 6 Ventilation lines (primarily for lifting plants carrying faecal matter) must rise constantly to above the roof without decreasing in nominal width. The line may therefore be run to the main or secondary exhaust ventilation line. The ventilation of the plant may not be connected to the intake ventilation line of a grease separator. Installation of a shutoff valve (accessories) and the special fastening element Standards require that a shutoff element be installed for pressure lines of DN 80 or larger. ACO Haustechnik offers a matching DN 80 shutoff valve as an accessory. The special fastening element that is supplied loose with the plant must be connected to the shutoff valve. Related technical notes (not necessarily complete) A shutoff mechanism must be installed in the pressure line after the check valve. This is not necessary if the nominal width of the line < DN Mounting sequence A B Place the seal (5) and shutoff valve (4) on the adapter piece (7) and mount with the fastening set (6) Place the seal (2) and special fastening element (1) on the shutoff valve (4) and mount with the fastening set (3) List of main components Special fastening element 2 Seal 7 Figure 1-18: 3 Fastening set 4 Shutoff valve 5 Seal 6 Fastening set 7 Adapter piece ACO accessory,

32 min Connecting the pressure line Related technical notes (not necessarily complete) The pressure line of the wastewater lifting plant must be run such that the base of the backflow loop will be above the backflow level. The pressure line must be appropriately relieved of its own weight. Connection The special fastening element allows the elastic connection of the customerprovided pressure line DN 100 (pipe end Ø mm) or DN 80 (pipe end Ø mm, with a different toroidal sealing ring / accessory ). To accomplish this, slide the flange ring and toroidal sealing ring over the customer-provided pipe end, insert the pipe at least 50 mm into the special fastening element and install with the fastening set. 8 A check valve must be installed in the pressure line. If no shutoff mechanism is situated after this point in the plant, the check valve must have an air intake mechanism or some other option must exist for draining. (Included as standard in this lifting plant). Customer-provided pressure line Flange ring The line must be secured against coming unattached at connections that are not designed to elastically accept longitudinal forces. The minimum nominal width of the pressure line must comply with Table 5 of DIN Pressure lines must always be connected to ventilated ground lines or mains. The connections must be designed as connections for pressure-free lines. The pressure line must accept at least 1.5 times the maximum pump pressure of the plant. Appropriate pressure pipes must be used. Toroidal sealing ring Special fastening element Figure 1-19: Tighten screw connections with a max. tightening torque of 15 Nm. Connection variants In detail: Parts list 1 Pipe DN 80, provided by installer / outside Ø 90 mm 2 Pipe DN 100, provided by installer / outside Ø 108 or 110 mm 3 Pipe DN 100, provided by installer / outside Ø 114 mm 4 Toroidal sealing ring for DN 100 (included) Part Title Connection DN / outside Ø... mm Pipe outside Ø 90 mm Pipe outside Ø mm Pipe outside Ø 114 mm Toroidal sealing ring DN / Ø / Ø / Ø Toroidal sealing ring for DN 80 (ACO accessory, ) 5 Toroidal sealing ring DN

33 ACO H a u s t e c h n i k Backflow loop The backflow loop be installed with the discharging pipe base above the backflow level. Pipe base Backflow level Figure 1-20: Backflow loop Notes on pump capacity, pump height and total pump height Pump rate in l/s Rate of flow at which the pumping media is pumped up to the total pump height by the wastewater lifting pump at its operating point. Pump height in m Pressure head applied by the wastewater lifting pump at its operating point for overcoming the static height difference as well as the total loss height in the pressure line. Total pump height in m The total pump height is the sum of the static pump height and the pump head losses in valves and fittings plus pipe friction losses (all in m). The following must absolutely be considered in determining the spacing between the wastewater lifting plant and the pipe base of the backflow loop: The pump capacity and pump height of the wastewater lifting plant pump must be greater than or equal to the total pump height. Connecting the drain line 9 A connection of diameter 48 mm (sealed, front surface must be cut off for use) is found on the front of the collecting container and a threaded connection Rp 1 on the side. A fixed drain line (e.g. with hand diaphragm pump, accessory) can be connected at one of these two points so that the container can be emptied for maintenance work. 33

34 5.3 Electrical work List of work The electric connection of the control has to be carried out by an expert in keeping with the applicable regulations of the German Association of Electricians. 1.1 Switch box 1.2 Rechargeable battery was to connect 2 connect 3 Float switch connection cable 4 Potential-free signals All electrical systems used must satisfy the standard IEC 364 / VDE 0100; in other words, for example, the power sockets must have earthing terminals. The power network to which the plant is connected must have a highly sensitive residual current circuitbreaker IA <30 ma. For installation in bath and shower rooms, the corresponding DIN VDE 0100 Part 701 regulations must be observed. All electrical devices such as switch box, alarm emitter and power socket must be installed in dry rooms and safe from flooding. 5 External fault signal Figure 1-21: Depicted here: Muli-Star -MWS Switch box ACO Pumpensteuerung für Hebeanlage ACO control box for lifting plant Typ/Type: MDS Betrieb Pumpe/ MAN. Reset In operation Drehfeld OK/ Pump direction ok Störung Pumpe/ Malfunction Artikelnummer Alarm The switch box must be installed at an easily accessible location that is safe from flooding (consideration should also be given to ensuring that the audio alarm signal can be heard easily). An open wall surface of approx. W x H = 300 x 300 mm. The distance from the switch box installation site to the wastewater lifting plant also depends on the length of the connection cables for the pump and float switch (included cables each 5 m long, pump cable already connected to the connection box of the pump motor). 1.1 Vor Öffnen des Deckels Netzstecker ziehen! Remove plug before opening control box Figure 1-22: Switch box -MDS 1 shown here Beachten Sie die Bedienungsanleitung!/ Please read installation manual Switch box for type MDS 1 The plug-ready switch box has a 1.5 m connection cable with CEE plug 16 A. A CEE socket in the vicinity of the switch box must be provided at the installation site. Connection data: 400 V / 50 Hz, max. 5 A. The external surge protection is generally implemented with type K circuit breakers with 3-pole mechanical interlocking. This ensures a complete separation from the mains network and prevents 2-phase operation. Switch box for type MWS 1 The plug-ready switch box has a 1.5 m connection cable with a safety plug. The operator has to fit a German earthing contact safety plug socket near the switch box. Connection data: 230 V / 50 Hz, max. 10 A. Use an automatic circuit breaker for external surge protection in keeping with the local conditions. Rechargeable battery was to connect 1.2 Before operation rechargeable battery (available inside switch gear) has to be connected!. 34

35 ACO H a u s t e c h n i k Pump connection cable The connection cable is 5 m long and already connected to the connection box of the pump motor. The cable length can be adapted to the local conditions (take note of the wire labelling). The electrical connection to the terminal strip of the switch box must take place according to the connection diagram (see appendix to these installation and operating instructions or enclosure with switch box). When using an extension cable (max. 25 m total length), this must correspond in quality to the supplied connection cable H07RN-F 4G 1.5 mm². 2 Float switch connection cable The connection cable is 5 m long and already run to the corresponding lid with a tight seal. The cable length can be adapted to the local conditions (take note of the wire labelling). The electrical connection to the terminal strip of the switch box must take place according to the connection diagram (see appendix to these installation and operating instructions or enclosure with switch box). When using an extension cable (max. 25 m total length), this must correspond in quality to the supplied connection cable: Ölflex line PVC-JZ 4G 0.5 mm². 3 Potential-free signals A corresponding cable (provided by installer) must be installed for forwarding of the potentialfree collective fault signal. The electrical connection to the terminal strip of the switch box must take place according to the connection diagram (see appendix to these installation and operating instructions or enclosure with switch box). 4 External fault signal A corresponding cable (provided by installer) must be installed for forwarding of an external fault signal. The electrical connection to the terminal strip of the switch box must take place according to the connection diagram (see appendix to these installation and operating instructions or enclosure with switch box). 5 35

36 6. Operating instructions 6.1 Commissioning Prerequisites Before operation rechargeable battery (available inside switch gear) has to be connected!. All connecting and mounting work has to be completed. All electrical work must be completed. Rechargeable battery has been connected (inside switch gear). Motor / switch box connection terminal screws have been retightened. Pipelines must be flushed clean. The collecting container must be thoroughly cleaned (to remove any construction waste or dust). The level switch has been adjusted according to the connected inlet (section 6.2 DIP Switch and section 6.3) Test run has been completed successfully. Test run (See section 6.4 for a detailed description) The commissioning must be performed by a qualified expert as described in DIN1986 Part 31. During commissioning, a test run with water must be performed for at least two switching operations after flushing the pipeline and cleaning the collecting container. The test run must take place according to the specifications in these operating instructions as well as DIN The commissioning must be documented in writing with notation of key data, such as the setting the protective motor switch. The following points must be performed or checked before, during or after the test run: electrical protection of the wastewater lifting plant according to lec and local regulations, valve sliders (actuation, open position, seal), switching and configuration of the switch levels in the collecting container, absence of leaks in the plant, valves, fittings and lines, checking the operating voltage and frequency, function test of the check valve, fault signalling device, fastening of the pressure line, protective motor switch, testing by briefly unscrewing individual fuses (two-phase operation), indicator lights, measuring instruments and meters, and function test of any installed hand pump. Presence during initial operation If the lifting plant is not used for an extended period of time, the pump must be removed and stored together with the switch box in a dry location. The following persons should be present during commissioning: fitter electrician operating staff / operator Handover The plant must be transferred to the operator in a functional condition. The functioning of the plant must be explained, and a transfer report must be provided. A copy of the installation and operating instructions must be provided. 36

37 ACO H a u s t e c h n i k 6.2 Explanation of the operating and indicating elements of the switch box Front view of the switch box ACO Pumpensteuerung für Hebeanlage ACO control box for lifting plant Typ/Type: MDS Betrieb Pumpe/ MAN. Reset In operation Drehfeld OK/ Pump direction ok Artikelnummer Alarm Figure 1-24: Switch box for -MWS 1 ACO Pumpensteuerung für Hebeanlage ACO control box for lifting plant Typ/Type: MWS Betrieb Pumpe/ MAN. Reset In operation Artikelnummer Alarm Störung Pumpe/ Malfunction Störung Pumpe/ Malfunction Vor Öffnen des Deckels Netzstecker ziehen! Remove plug before opening control box Beachten Sie die Bedienungsanleitung!/ Please read installation manual Figure 1-23: Switch box for -MDS 1 Vor Öffnen des Deckels Netzstecker ziehen! Remove plug before opening control box Beachten Sie die Bedienungsanleitung!/ Please read installation manual Indicators Indicator Designation Consumer Explanation Pump operation Pump Lit when the pump is in operation. Rotary field OK Pump Lit when the rotary field is correctly connected. Only then is the plant ready for operation. (Indicator not present on MWS design) Fault Various Type of fault Reset (2 x button) Number of blinks ** Motor (power consumption) Yes * 1 Float switch cable break No * 3 High alarm / level 2 reached No 4 Power failure No 5 Battery defective or not conneced No 6 External fault signal No 7 Rotary field is incorrectly - permanent Pump Lit in automatic mode * Pump not in operation ** Each blink signal (sequence of blinks) is followed by a 4 seconds pause Buttons Buttons Designation Consumer Explanation All Switches automatic mode ON and OFF. ON: Plant is in operation OFF: Only manual operation of the pump is possible MAN Pump Pump has been switched to manual and only runs as long as the button is pressed. Reset All Press once: audio signalling of all fault signals is disabled. The visual indication of all fault signals is automatically reset after correction of the respective error except for motor current and motor temperature. In these cases, the fault signal must be reset by pressing twice. Signal Signal Designation Consumer Explanation Alarm All Audio indication of the fault signal 37

38 Partial view of the switch box interior Base setting of float PRG. Serial interface Pull the power plug and confirm the absence of power before opening the casing. After successfully entering the container configuration, the lid of the control must be closed again properly. Only then may the power plug be plugged back in. Jumper ON Jumper OFF DIP switch Float switch calibration Motor follow-up time * Motor rated current 0 Control dial (potentiometer) s 1 5 A * Follow-up time preset to 1 s DIP switch Switch Position Consumer Explanation 1 2 ON (up) or Float switch and pump Regulates the base setting of the float switch or level switching. At the factory, DIP switch 1 is set to ON and to OFF (for use of the side inlet 180). If the side inlet 250 is used, DIP switches must be switched to OFF and DIP switch 2 to ON. If the top inlet is used, DIP switches must be switched to OFF and DIP switch 3 to ON (see also the schematic diagram of the level switching in section 6.3 on p. 39). 3 4 OFF (bottom) : Only one DIP switch may ever be in the ON position. Switch 4 is not used. Control dials Control Title Consumer Explanation 0 The normal setting is -30. With this controller, the switching level of the pump can Float switch calibration Float switch be adjusted by + 60 mm. + means: switch point moved upward - means: switch point moved downward s Motor follow-up time Pump motor Regulates the follow-up time of the pump / setting range 1-15 seconds. The time is set at the factory to 1 sec (changes should only be made after consultation with ACO service). 1 5 A Motor rated current Pump motor Regulates the cutoff current (amps) / motor protection (set at factory), to be checked on-site. Type -MDS 1 = 5 A Type -MWS 1 = 10 A 38

39 ACO H a u s t e c h n i k 6.3 Schematic diagram of the level switching (float switch) With side inlet 180 With side inlet 250 With top inlet used Image Image Image DIP switch settings DIP switch settings DIP switch settings Schematic diagram Schematic diagram Schematic diagram Level 0 Level 1 Level 2 Level 3 Level 0 Level 3 Level 2 Level 1 Level 0 Level 3 Level 2 Level 1 Follow-up end Reference Follow-up end Reference Follow-up end Reference Level Level information in mm Follow-up end Level Level information in mm Follow-up end Level Level information in mm Follow-up end Level 1 (switch on point of the pump) must be checked during the test run. In event of deviations, the value must be readjusted with the float switch calibration control dial (for a description, see section 6.3 Test Run). NOTE Reference = Container bottom Follow-up end = Shutoff point of the pump Level 0 = Start of pump follow-up time Level 1 = Switch on point of the pump Level 2 = High alarm off Level 3 = High alarm on 39

40 6.4 Test run process description (in this example, a side inlet is used) States / reactions Water is still standing in the collecting container from the leak test (if performed). Open the valves in the inlet line and pressure line (if present). Connect power (e.g. CEE socket/plug). Check operating indicators. On switch box: Press automatic button, LED lights. Let water run through connected drainage fixtures. Water and float switch reach "level 0," follow-up time of the pump starts. Interrupt water flow N/A Switching cycle 3 Switching cycle 4: Check the switch on level Follow-up time has passed, pump switches off, water has reached "followup end level." Water and float switch reach "level 1," pump switches on and pumps the contents above the backflow level. States / reactions States / reactions Switching cycle 2 Work Switching cycle 1 Water and float switch reach "level 1," pump switches on and pumps the contents above the backflow level. Work Work Start Level 1 Level 0 Follow-up end : Interrupt the pump process immediately upon switching on at the switch box (press automatic button - automatic off, LED off, pump off) and simultaneously interrupt the flow. Through the open inspection lid, check that switch on level 1 (distance from bottom to water line) matches the level information for the inlet used (value in mm, on page 39). If a deviation exists, readjust the float switch calibration control dial (in the range ± 30 mm). Then start water running again. Start water flow. Level 1 40

41 ACO H a u s t e c h n i k Switching cycle 5: Check high alarm fault signal Switching cycle 6: Check alarm reset States / reactions The water and float switch reach "level 3," high alarm fault signal is indicated visually and audibly on the switch box. Pump switches on and pumps the contents above the backflow level, water and float switch reach "level 2," high alarm fault signal is visually and audibly reset on the switch box. Work Interrupt water flow On switch box: Press MAN button and hold pressed. Level 3 Level 2 On switch box: Release MAN button. On switch box: Press automatic button, LED lights. States / reactions The pump switches back on after interruption (button MAN to automatic) and pumps the contents above the backflow level until "level follow-up end" is reached. Work Switching cycle 7 Test run complete. Follow-up end The plant is ready for operation. To ensure functional safety, the switching operations must be observed over multiple cycles. 41

42 6.5 Operation Automatic mode Manual mode After completion of the test run: On switch box: Press automatic button, LED lights. Water entering the plant will be automatically pumped over the backflow level. By pressing and holding the MAN button (button automatic to OFF), the pump can be switched on independently of the automatic control. However, this may only be done while the container is filled above the shut-off level and only for a brief time (e.g. for checking the direction of rotation). Use / designated use / obvious misuse Designated use includes also: Observation of all national laws and regulations. Observation of the inspection and maintenance instructions. Observation of the installation, commissioning, operating and maintenance instructions prescribed by the manufacturer. For safety reasons, no modifications of the plant are permitted. Warranty Information on warranty and liability can be found in our General Terms of Business. The plant is not designed for sustained operation! The specified pumping data apply only for intermittent operation (S2). The maximum permissible inflow volume must be less than the pumping capacity of the pump. Operating range limits Operation Use / designated use Wastewater lifting plants are designed for the pumping of wastewater with or without faecal matter. They dispose of household wastewater from toilets, baths, wash rooms and showers. Any other uses shall not be considered designated. The manufacturer shall not be held liable for any resulting damage; the risk shall be borne by the operator alone. Obvious misuse In accordance with DIN1986 Part 3 item , no hazardous materials may be introduced into the wastewater lifting plant. These include: (List not necessarily complete) waste materials such as rubbish, glass, etc. hardening substances such as cement, lime, gypsum, mortar, etc. mixtures that pose fire hazards such as petrol, heating oil, paint, etc. aggressive and/or toxic substances such as acids, bases, etc. pipe cleaning agents that damage the drainage fixtures, pipes, etc. cleaning agents, disinfectants and washing detergents in excessive quantities animal faecal matter such as liquid manure, dung, leavings, etc. substances with high bacterial load or infectious substances such as slaughterhouse wastes, animal bodies, blood, etc. vapours and gases such as steam, chlorine, etc. radioactive substances. In departure from this, harmful substances may be introduced in very small quantities and very diluted form or very low concentration. Limits Dry running must absolutely be avoided! Pumping medium temperature 40 C, max. 5 minutes up to 65 C. Ambient temperature to 40 C (air). No sustained operation! S 2 operation! Not for aggressive pumping media! Switching frequency To avoid a high temperature rise in the motor and excess loads on the motor, seals and bearings, the number of switch-on operations must not exceed 60 per hour. Lifting capacity The data such as total pump height, total capacity and plant performance diagram can be found in section The plant works fully automatically. The only regular work that needs to be carried out on the plant is the maintenance work described in section

43 ACO H a u s t e c h n i k 6.6 Faults and their remedies Fault Potential cause Remedy Motor (power) 1 blink Electrical overload Hydraulic overload Pump or impeller blocked Motor defective Check hydraulic conditions Clean pump or impeller Check motor Float switch cable break 3 blinks Cable break or short-circuit in cable Float switch defective Check cabling to sensor Check float switch High alarm 4 blinks Float switch has reached level 2 Inspect entire plant Check float switch Power failure Phase failure Check power supply 5 blinks Battery defective or not connected 6 blinks Battery not connected Battery empty or incorrectly connected Battery old/defective Connect battery Connect battery correctly Charge battery Replace battery, if necessary External fault signal Normal external alarm signal Check external alarm signal 7 blinks Pump runs loud and relatively long pumps little or nothing does not run only runs in manual mode constantly switches on and off at intervals, possibly with backup in the inlet line Pump rotation direction incorrect Delivery pipe is blocked Pump or impeller blocked Motor defective Automatic button not enabled Check valve defective Ventilation hole on spiral casing blocked Check direction of rotation Check pressure line Clean pump or impeller Check motor Press button Inspect check valve Remove motor plate and clean hole NO indicator Retighten loosened screw connections with the following torques: M 6 at 6-7 Nm M 10 at 9-10 Nm Work on the electrical equipment of the wastewater lifting plant may only be carried out by an electrician. Disconnect the power supply to the pump before checking the impeller. Do not repeatedly operate the motor manually if the motor protection has tripped. In case of uncertainties in remedying failures, get in touch with ACO Service by all means. Telephone

44 7. Servicing 7.1 Instructions for maintenance and repair work General aspects Work on the electrical equipment of the wastewater lifting plant may only be carried out by an electrician or by trained persons under the management or supervision of an electrician in keeping with the rules governing the use of electricity. Prior to all maintenance work on the wastewater lifting plant, the power supply to the electric equipment has to be interrupted and protected against being switched back on. Only use tools insulated against the conduction of electricity! Always re-tighten connections undone during maintenance and repair work. The contents arising during the operation of the wastewater lifting plant as well as the replaced parts have to be disposed of according to the environmental protection regulations. Preservation of value and function, maintenance contract We recommend 1 to 4 maintenance sessions per year to preserve the value and proper functioning of the plant (see section 3.3). We recommend to have the regular maintenance and repair work carried out by the manufacturer, ACO Passavant GmbH. This not only ensures constant operational safety, you also profit from revisions and modernisations which we carry out within the framework of our product development. To request an offer for a maintenance contract, please copy the section below, fill it in completely and fax to the fax number: / In case of queries, please all our Service Department at: / Request of an offer for a wastewater lifting plant maintenance contract Please send a non-binding offer for regular maintenance of the plant. Fax no.: / Last name, first name Street address Postal code, town Date of installation Type as per type plate Telephone / fax number Single-family dwelling Multi-family dwelling 7.2 Regular inspections NOTE After a flooding, we recommend an inspection before recommissioning the plant. Wastewater lifting plants should be inspected once per month by the operator to ensure correct functioning by monitoring at least two switching operations (see section 6.4 Test Run). 44