Operating Manual for SBR small wastewater treatment systems KLARO and KLARO Easy with controller KLbasic und KLplus We provide clear water No mechanics in the wastewater No pumps in the wastewater No electrical parts in the wastewater
No mechanics in the wastewater No pumps in the wastewater No electrical parts in the wastewater
IMPORTANT: This operation log contains information about the installation of the plant to its maintenance and must therefore be read prior to the commissioning the plant! All safety instructions must be observed! The operation log must be kept handy during the operating time of the plant! Information about the plant For any queries during the operation of the plant, you should enter the data of your plant here as follows. By means of this data, our employees will be able to help you faster if a fault occurs. You can find this data on the type plate which is on the outside of the cabinet door with indoor switch cabinets and in the interior of the cabinet with outdoors switch cabinets. 3
TABLE OF CONTENTS Page 1. About these operating instructions 6 1.1. Original language of the documentation 6 1.2. Completeness 6 1.3. Responsibility 7 2. Safety 7 2.1. Explanation of warnings and prohibitions 7 2.2. Hazard warnings 8 2.3. Warnings 9 2.4. Operating exclusions 10 3. Warranty 10 4. Function of the SBR system 10 4.1. Plants for carbon elimination (effluent classes C) 11 4.2. Plants with additional nitrogen elimination 12 4.3. Plants with additional phosphate elimination 13 4.4. Plants with additional hygienisation 13 5. The control of the small wastewater treatment plant 13 5.1. Connections on the control 15 5.2. Operating the control 16 5.2.1. Querying the operating hours 17 5.2.2. Driving the valves and the cabinet fan manually by means of the Manual mode 17 5.2.3. Setting the date / time 18 5.2.4. Setting the vacation mode 19 5.2.5. Reading out errors reading out old faults 20 5.2.6. Displaying the settings 20 5.2.7. Service menu and action code 20 5.3. Replacing fuses 20 5.4. Functional principle of the power outage detection device 21 6. Additional functions of the KLplus and KLbasic controls 22 6.1. Underload detection (KLplus) 22 6.1.1. Functional principle 23 6.1.2. Commissioning 23 6.1.3. Switching off the fill-level detection 25 6.1.4. Safety and fault messages 26 6.2. Optional additional functions with extension cable (KLplus and KLbasic) 26 6.2.1. Connection of an external fault indicator 26 6.2.2. Connection of a connector for switching the compressor 26 6.2.3. Connection of a UV reactor 26 6.2.4. Phosphate precipitation using the dosing pump 26 7. Maintenance, servicing and operation 28 7.1. Tasks of the operator 29 7.1.1. Daily check 29 7.1.2. Weekly checks 29 7.1.3. Monthly checks 29 7.1.4. Sludge drainage 29 7.2. Maintenance and servicing by skilled maintenance personnel 31 4
7.3. Operating instructions 32 8. Fault messages and troubleshooting 34 8.1. Fault message on the display 34 8.2. Unusual water levels rectifying a fault 36 8.3. Possible incidents on solenoid valves 37 ANNEX 38 9. Maintenance documentation 39 9.1. Form for monthly check marks 39 9.2. Maintenance protocol for KLARO small wastewater treatment plants 40 10. Technical data 42 10.1. Technical data of the controls 42 10.1.1. Circuit diagram, EPP cabinet with KLbasic control 43 10.1.2. Circuit diagram, EPP cabinet with KLplus control 43 10.1.3. Circuit diagram, I cabinet with KLbasic control 44 10.1.4. Circuit diagram, I cabinet with KLplus control 44 10.1.5. Circuit diagram, A column with KLbasic control 45 10.1.6. Circuit diagram, A column with KLplus control 45 10.1.7. Circuit diagram, A column, A cabinet 1+2 with indicator lamp with KLplus control 46 10.1.8. Equipment list 47 10.1.9. Circuit diagram, extension cable 48 11. EC declaration of conformity 49 12. Additional tests of the plants 53 12.1. Tested purification performance with underload 53 13. Datasheets of the plant 54 13.1. Piston compressor Nitto 54 13.2. Becker and Rietschle rotary slide compressors 60 TABLE OF FIGURES Page Figure 1 Diaphragm tube aerator... 11 Figure 2 Diaphragm plate aerator... 11 Figure 3 View of the KLbasic control unit... 14 Figure 4 View of the KLplus control unit... 14 Figure 5 View of the liquid crystal display during the ventilation phase... 14 Figure 6 View of the control panel... 15 Figure 7 View of the rear of the KLbasic control... 15 Figure 8 View of the rear of the KLplus control... 15 Figure 9 drawing air lifter charging... 23 Figure 10 System drawing precipitation unit... 27 Figure 11 Precipitant pump Compact... 27 Figure 12 Precipitant pump DSP 9911... 27 5
1. About these operating instructions These operating instructions constitute a part of the product and must be read prior to the commissioning of the plant. Keep these operating instructions during the entire life of the plant and have them ready for reference. 1.1. Original language of the documentation In its original version, this documentation was written in the German language. Copyright Spitzwegstrasse 63 D-95447 Bayreuth (Germany) Technical support: +49 (0) 9 21 16 27 9 330 Email: info@klaro.eu Internet: www.klaro.eu All rights expressly reserved. Reproduction or communication to third parties, in whatever form, is not permitted without the written consent by. 1.2. Completeness These instructions were compiled with due diligence. Any liability of the manufacturer due to incorrect or missing information and linguistic deficiencies or printing errors in the documentation will be excluded. If you detect any incomplete information and/or errors, please inform us about these at the abovementioned address. When compiling these instructions, maximum possible coherence between the facts contained herein and the associated system was paid attention to. Nevertheless, all technical data, stated measurements and figures in these instructions are non-binding. Any claims to the concrete design of a system cannot be derived from these. We reserve the right to make changes to a system as part of improvements and developments without changing these instructions. An obligation to install changed technical systems in plants that have already been completed and delivered cannot be derived from this. This documentation is updated on a regular basis. The following installation instructions must be observed and can be requested from if required: - Indoor cabinets - Outdoor cabinets - KLARO retrofitting kits, complete plant KLARO and KLARO Easy - External alarm unit - Replacement of the control - Submersible pump as clearwater lift - Factory calibration of the control - Submersible pump for additional buffer] Print version: 02.2013 6
1.3. Responsibility Any responsibility of the manufacturer expires in the event of: Non-compliance with or insufficient use of the information provided in these operating instructions, Use of spare parts or parts in the system that have not been approved by the company, Improper operation of the wastewater treatment plant, Removal, manipulation or bridging of guards, Unauthorised modifications to the system, Improper performance of maintenance tasks and replacement of spare parts. Unauthorised modifications to the plant or operation of the plant exceeding the specifications stipulated by the manufacturer result in the expiration of any warranty claims. 2. Safety This chapter contains information about safety measures and residual risks. Please read this chapter carefully before using the plant in order to ensure safe handling of the plant to the greatest possible extent. 2.1. Explanation of warnings and prohibitions Hazard warning Hazardous electrical voltage warning Fall hazard warning Hot surface warning Hand injury warning Explosive atmosphere warning Ban on fire, naked light and smoking 7
2.2. Hazard warnings 1. In order to ensure safety, all persons who come in direct contact with the plant must familiarise themselves with the content of this documentation. 2. It is not permitted to use the system for any purposes other than described by the manufacturer. 3. Locally applicable work and safety regulations and laws must always be complied with even if these are not explicitly referred to in these operating instructions. The same applies to environmental regulations. 4. When the operator detects errors or hazards, the manufacturer or the competent maintenance company must immediately be informed about these. 5. During normal operation of the machine, safety precautions must never be removed or bridged. Safety precautions may only be temporarily bridged or stopped functioning by the maintenance technician for cleaning and maintenance purposes. 6. When handling chemical substances, direct contact with chemicals must be avoided as far as possible. Before working with these substances is permitted, the package instructions must be read and observed. 7. If the use of personal protective equipment (protective gloves, protective glasses, gloves, ear protection etc.) is mandatory, care must be taken to ensure that this protective equipment is actually used. Defective or damaged protective equipment must immediately be replaced with properly functioning protective equipment. 8. Work on the electrical system may only be carried out by skilled personnel. 9. All safety and hazard warnings at the machine must be kept in well readable condition at any time. 10. Hot parts must not come in contact with explosive or easily inflammable chemicals. 11. Do not place any containers with liquids onto electrical switch cabinets; spilling the liquid may cause short-circuits. 12. The plant must not be operated when under the influence of alcohol (consider possible residual alcohol from the day before!) or medication impairing the ability to perceive and react. 13. Before any maintenance and cleaning work, the plant must be disconnected from the mains. 14. The plant must, except for maintenance purposes, always be switched on, since otherwise correct wastewater treatment cannot be ensured. 8
2.3. Warnings These warnings must be always observed; otherwise, personal injuries or damage to property may occur! Installation site Mains connection Explosive atmospheres Make sure that the machine cabinet is not installed above or right next to water containers. Risk of electric shock if not installed properly. Connect the machine cabinet only to a 230 V socket or earth connection that has been properly installed according to instructions and is protected with a preliminary 16 A fuse in accordance with the technical data. During a thunderstorm, the electrical devices connected to the mains can be damaged. An overvoltage protection in the domestic electrical installation is recommended as protective measure. The connection line must be installed in such a manner that it does not become a tripping hazard. The control must not be installed or switched on in environments with potentially explosive atmospheres or in places where flammable materials exist. In such environments, sparks can cause an explosion or fire and this can, in turn, result in personal injuries or even death. Interferences The control can cause malfunctions of medical equipment. Therefore, the control should not be operated right next to medical devices. Damage The control must not be operated when the housing or the insulation of a line are damaged or pinched. Service work Service work on the machine cabinet may only be performed by authorised specialist personnel and/or electrically skilled persons. After having been replaced, the battery supplied must be properly disposed of. Battery replacement Voltage supply The power supply must be permanently ensured. Please make sure that the control cabinet is sufficiently protected (16 A). Additional power consumers on the same fuse can disrupt the operation. 9
2.4. Operating exclusions The control was specially developed for use in SBR small wastewater treatment plants. The control must not be operated in areas posing a danger to life and limb: Control of machines, vehicles and safety-relevant processes, Research technology handling hazardous substances, Medical technology, Nuclear power technology, etc. 3. Warranty The plant / the retrofitting kit has been assessed and produced according to the state of the art. The product has left our factory in faultless condition. Within the scope of warranty, defects resulting from the manufacture or the material used are rectified by us free of charge. These defects must have demonstrably occurred despite proper installation according to instructions and with due regard to the operating conditions in accordance with these installation instructions. Upon delivery, please check the control for any possible damage. For defects, please contact your contracting party/dealer immediately describing the error and identifying your plant. Our Terms and Conditions are binding. We expressly point out to you that the warranty expires in the event of: Improper installation, Uncommon use, Flooding, Lightning strikes and other overvoltage. 4. Function of the SBR system KLARO and KLARO Easy are fully biological small wastewater treatment plants that work according to the principle of the SBR method (activated sludge plant in the impoundment method). The SBR plant is designed for the discharge of the entire domestic waste water. The discharge of other wastewater, e.g. the wastewater from restaurants and/or industrial enterprises etc., is only permitted when this was already known and considered when designing the plant. Biocides, toxic or biologically incompatible substances must not enter the plant, since they impede the bacteria important for the wastewater treatment and cause biological process problems (more detailed information is provided on the following pages). In order to comply with the official requirements for treated wastewater, it is absolutely necessary to operate the plant according to our operating and maintenance instructions that can be found on the following pages. In principle, the plant consists of two steps: sludge storage with an integrated pre-buffer and an activated sludge level in the closed impoundment method (SBR reactor). The upstream sludge storage with an integrated buffer performs the following functions: - Storage of primary and secondary sludge, - Retention of settleable solids and floating solids, 10
- Storage of the supply water, - Compensation of volume- and concentration-related fluctuations in inflowing wastewater. The wastewater treatment plant is operated by means of a microprocessor control that drives the aerator and the air distribution for the different lifts via solenoid valves. Your competent water authority has determined limit values for the water quality of the treated wastewater. Accordingly, you have purchased a plant of the effluent class which definitely complies with these limit values. Depending on the certification, both the interval between the prescribed maintenances (at intervals of 4 or 6 months) and the scope of the effluent values to be verified vary. The following table provide an overview of the effluent values of KLARO. KLARO values: KLARO values Degree of efficiency COD BOD 5 NH 4 -N N inorg SS FC germs P tot 39 mg/l 9 mg/l 6,1 mg/l 18,7 mg/l 15 mg/l 1,9/100ml 0,4 mg/l 94,6 % 97,3 % 84,4 % 67,4 % 96,2 % 99,9 % 95,0 % 4.1. Plants for carbon elimination (effluent classes C) This method is a sequence of five work steps that are carried out one after the other and are repeated several times a day (normally four times). - Work step 1 (valve 1) : feed - The raw wastewater stored temporarily in the sludge storage is led to the SBR reactor via an air lift. This reactor is positioned in such a manner that only water free of solids is pumped. By means of a special design of the lift, a minimum water level in the sludge storage is guaranteed. Thus, the limitation of the water level using further components (e.g. by means of a float switch) is not necessary. - Work step 2 (valve 2): ventilation During this work step, the wastewater is aerated and mixed. The ventilation is provided by diaphragm tubes or plates installed on the chamber bottom. The ventilation device of the plant is supplied with ambient air by an externally installed control cabinet. The required air is generated by an aerator. The ventilation is normally operated intermittently. Figure 1: Diaphragm tube aerator Figure 2: Diaphragm plate aerator 11
This ventilation causes two effects at the same time: The micro-organisms of the activated sludge are supplied with oxygen that is required for their metabolic activity and, thus for the degradation of the contaminants. There is intensive contact between wastewater and bacteria. - Work step 3: settling phase This work step constitutes a resting phase, during which no ventilation takes place. The activated sludge can settle according to the principle of gravity (sedimentation phase). In the upper area, a clearwater zone develops and a sludge layer at the bottom. Any occurring floating sludge is above the clearwater zone. - Work step 4 (valve 3): clearwater extraction During this phase, the biologically treated wastewater (clearwater) is pumped out of the SBR step. This pumping process is carried out by means of air according to the airlift pump principle (air lift). The air lift is designed in such a manner that any occurring floating sludge on the clearwater layer is not pumped. A minimum water level in the SBR step is kept without any further components. - Work step 5 (valve 4): excess sludge extraction During this working step, excess activated sludge by means of the air lift is led back from the SBR reactor chamber into the sludge storage chamber and stored there. This excess sludge is pumped close to the bottom of the SBR chamber. After this fifth work step has been completed, the treatment process can start again with work step 1. Four of the cycles described above are normally processed per day. An individual adjustment of the switching times and the cycle number is possible after consultation with. This adjustment may only be carried out by an authorised specialised maintenance company. In addition to this, it is possible to manually switch the plant into the vacation mode. The vacation mode is a significantly reduced operation of the plant during longer periods of time without inflowing wastewater. By means of the KLplus control, the plant can be operated depending on the actual amount of wastewater. For this, the fill-level detection must be activated by a specialist. Important: All chambers / containers must be aerated. This is normally performed by the wastewater line vented via the roof. If required, additional ventilation lines or ventilation openings must be installed. In doing so, the ventilation lines must be positioned in such a manner that natural ventilation is possible (chimney effect). 4.2. Plants with additional nitrogen elimination The nitrogen degradation is also carried out biologically by means of certain strains of micro-organisms. Plants with additional nitrification create, by means of particularly intensive ventilation, optimum living conditions for nitrifying bacteria which convert ammonia to nitrate. In plants designed for additional denitrification, the circulation of the water and activation of the denitrifying bacteria are achieved by short 12
aeration periods at the beginning of the ventilation phase. These bacteria transform nitrate into elementary nitrogen. 4.3. Plants with additional phosphate elimination The phosphate precipitation is carried out by adding polyaluminium chloride in the SBR reactor. A removable supporting platform in the dome or on the dividing wall of the container is part of the phosphate precipitation unit. The precipitant canister is on this platform. The switch cabinet of the plant is equipped with a dosing pump. This dosing pump draws the precipitant out of the precipitant canister and releases the precipitant in the SBR reactor. The precipitant is added during the feed phase of the reactor. The precipitant quantity required can be set by means of the dosing pump. The mixing takes place during the ventilation phase. Together with the phosphate, the precipitant forms an indissoluble compound that settles well in the container. The commissioning and handling of the pump is described in section 6.2.4. 4.4. Plants with additional hygienisation The additional KLARO UV module is used for sterilising the biologically treated wastewater. The germs in the wastewater are removed by means of ultraviolet light (UV). This is an effective, economic and particularly environmentally friendly method. UV light eliminates pathogenic micro-organisms within seconds without residues, harmful by-products or reduction of quality through odours. The effect of the UV light is made use of by means of particularly effective UVC radiation (254 nm). Within a few seconds, it causes a photochemical reaction in the DNA (deoxyribonucleic acid) that is vital for all microorganisms. As a result of this, the micro-organism is either eliminated or its ability to multiply is destroyed. With the UV dose values used for sterilisation, the UV irradiation does not cause any undesirable side reactions. Since no disinfection-effective substance is added to the water due to the UV irradiation, there are no depot effects after the water has passed the UV reactor. 5. The control of the small wastewater treatment plant The plant is operated by means of the control in the cabinet door (and/or in the interior of the cabinet with outdoors cabinets). The control allows setting the operational parameters, displaying the operating states and querying the plant parameters. Furthermore, the operating times can be programmed by a specialised company. In the automatic mode, the contrast of the display can be changed by pressing the ESC and the arrow keys at the same time. The following figures show the structure of the control units. 13
KLbasic control KLplus control Figure 3 : View of the KLbasic control unit Figure 4: View of the KLplus control unit Display of the operating states The operating state of the plant is displayed by the light-emitting diode (green = operation / red = fault) and as text on the LC screen. In the normal operating mode (ventilation mode), the liquid crystal display is as follows: Aeration 120.10m aeration rest: 120.10 Min Figure 5: View of the liquid crystal display during the ventilation phase In the automatic mode, the liquid crystal display indicates the current working phase and the remaining time of this work step. If a fault occurs, the message at which component the fault occurred (e.g. fault compressor) appears on the liquid crystal display. Note: The correct behaviour in the event of a fault is described in more detail in section 8. The following work phases are displayed: KLbasic display Performed process KLplus display Charchng Valve 1 is driven; the feed lift conveys wastewater to charging be treated from the sludge storage into the bioreactor. Denitrif Valve 2 is intermittently driven; the activated sludge denitrification is briefly mixed with the wastewater. This process is followed by long pauses (reaction times). Aeration Valve 2 is driven; the bioreactor is aerated at aeration intervals. Sediment No valve is driven, the activated sludge settles in the sedimentation bioreactor. Discharc Valve 3 is driven; the clearwater is pumped into the discharging outlet. SludgeRe Valve 4 is driven; the reactor pumps the excess sludge return sludge into the sludge storage. Pause Valve 2 is driven; the bioreactor is aerated at cycle pause 14
KLbasic control KLplus control intervals (significantly less than during the ventilation" phase). Vacation Valve 2 is driven; the bioreactor is aerated at Vacation oper. input intervals, no purification cycle is processed. XX.XXm Display of the remaining time. rest: XXXX.XXm As a matter of principle, the control is operated using the keypad. Figure 6: View of the control panel Symbol Key assignment Function Symbol Enter key Selection of the operating mode, input confirmation Scrolling Display of the operating modes and queries ----------- Acknowledgement Number keys Input acknowledgement without saving Acknowledgement of fault messages Programming of the plant by entering numbers.. 5.1. Connections on the control The connectors and fuses are on the rear of the KLbasic und KLplus control units. Attention: For all work on the electrical system, the main switch must be set to 0 (OUT) and the mains plug must be disconnected! Figure 7: View of the rear of the KLbasic control Figure 8: View of the rear of the KLplus control 15
KLbasic control Connections: 1 Connection for the mains 230 V AC ~ 50 Hz, 2 X1: Bayonet connection for the solenoid valves, 3 X2: Schuko coupling for the connection of the aerator, 4 COM: connection for communication module, (optional) and/or interface for the PC, 5 F1: T8A fuse 8 ampere, medium time lag, for the mains connection, 6 F2: T2A fuse 2 ampere, time lag, for the connected consumers. 7 X4: connection for extension cable: external alarm unit. KLplus control Connections: 1 Connection for the mains 230 V AC ~ 50 Hz, 2 X1: Bayonet connection for the solenoid valves, 3 X2: Schuko coupling for the connection of the aerator, 4 COM: connection for communication module, (optional) and/or interface for PC, 5 F1: T8A fuse, for the mains connection, 6 F2: T2A fuse 2 ampere, time lag, for the connected consumers, 7 Connection for the temperature probe; must be plugged in! 8 X3: connection for extension cable: UV lamp and dosing pump, 9 X4: connection for extension cable: external alarm unit and contactor monitoring, 10 P: connection for the pressure measuring hose. 5.2. Operating the control From the automatic mode, you can start different queries. By pressing, you can access the first operation level. Using the two arrow keys and pressing afterwards, you can now call the individual queries: By pressing, you can access the first maintenance level. Using the two arrow keys and pressing afterwards, you can now call the individual queries: KLbasic display Meaning KLplus display Operating state Remaining time Current working phase, remaining time Operating state Remaining time Operatin hours Display of the operating hours of the individual valves and the compressor operating hours 16
KLbasic control KLplus control Manual operation Hh:mm dd dd-mm-jj Vacation input Read out errors Adjustments: Operatio code Service menu Manual driving of the valves Current time, day and date. Can be set using SET. Setting the vacation mode (max. 90 days) Here, operational breakdowns are saved and can be read out. Using, you can switch between the error message and the corresponding date. By means of the arrow keys, the current setting can be displayed. For specialist personnel For specialist personnel manual operation Date Time Vacation oper. Read out old errors Setup report operation code service code enter 5.2.1. Querying the operating hours Press the key. The following display appears on the screen: Press the appears on the screen: key. The following display Operation hours Operating hours meter reading By pressing again, the operating hours for By pressing again, the number of the valves 1-4 can be called one after the other operating hours of valve 1 (feed) are shown. by means of the arrow keys. Then, the By pressing the arrow keys, you total operating hours of the compressor are can call the operating hours of the other shown. valves, of the compressor, of the UV lamp By pressing once, you can return to the and the pump for the phosphate precipitation one after the other. Moreover, the capacity display Show operating hours. By pressing, of the plant is shown. you can access the menu Manual mode. By pressing once, you can return to the maintenance level. By pressing this key again, you can return to the automatic mode. Note: If no key has been pressed for 10 minutes, the normal mode is automatically set. 5.2.2. Driving the valves and the cabinet fan manually by means of the Manual mode When checking the valves, each valve should run at least five seconds, since the monitoring of the power consumption of the valves takes some time until a possible fault is detected. Following the valves, the cabinet fan, if any, can also be driven and checked. 17
KLbasic control In the automatic mode: press, then press the arrow key until the following display appears on the screen: KLplus control Press, then press the arrow key until the following display appears on the screen: Manual operation Manual operation By pressing the key, the following display appears: valve1: off By pressing, you can switch on and off the selected valve. By means of the arrow keys, the individual valves can be selected. By pressing once, you can return to the display Manual mode. By pressing again and performing a selection using the arrow keys, the manual mode can be now set for all functions. Using valve 1 as example, the following display will now appear on the screen: manual valve1: off By pressing the numbers 1 for ON and 0 for OUT, you can switch on and off the valve 1 in the manual mode. The same procedure can be applied to the other valves. As described above, the selection can be performed using the arrow keys. By pressing the key once, you can return to the maintenance level. By pressing this key again, you can return to the automatic mode. 5.2.3. Setting the date / time Press, press the arrow keys afterwards, until the following display (example) appears on the screen: Press, press the arrow keys afterwards, until the following display (example) appears on the screen: 20:15 Mo 19-12-07 19-12-2007 Mo 20:15:56 By pressing, the time and date can be set using the arrow keys. In order to confirm By pressing, the time and date can be set using the number keys. In order to confirm the adjustment, must also be 18
KLbasic control KLplus control the adjustment, each case. must also be pressed in pressed in each case. By pressing once, you can access the By pressing once, you can access the vacation mode. By pressing, you can vacation mode. By pressing, you can return return to the manual mode. to the manual mode. A correctly set time and date display of the plant is absolutely necessary in order to ensure that the recording of the operating hours and possible faults can be understood. The integrated clock works with an accuracy of maximum deviation of five minutes a year. There is no automatic adjustment from summer to winter time. Note: If no key has been pressed for 10 minutes, the normal mode is automatically set. 5.2.4. Setting the vacation mode Note: The vacation mode implies a reduced operation of the wastewater treatment plant. This mode may only be used if no wastewater enters the wastewater treatment plant during the selected period of time. Wastewater that enters the plant during the vacation mode will not be purified. The vacation mode is automatically switched on and off according to the data you have entered. Press, press the arrow keys afterwards, until the following display appears on the screen: Press, press the arrow keys afterwards, until the following display appears on the screen: Vacation input Vacation date setup By pressing the key again, the input for the vacation data is enabled: Start of the vacation period: By pressing, the data for the day, month and year is entered in the TT-MM-JJ format. After each day, month or year input, must be pressed. End of the vacation period: By pressing, the data for the day, month and year is entered in the TT-MM-JJ format. After each day, month or year input, must be pressed. By means of the key, you complete the data entered for the vacation mode and save this data. By pressing, you can return to the display of the automatic mode. By pressing the key again, the input for the vacation data is enabled: vacation start: 21-05-2007 By pressing the key again and entering of the end date of the vacation mode using the number keys: vacation end: 21-05-2007 By means of the key, you save the data entered for the vacation mode and exit this function. 19
KLbasic control KLplus control The vacation mode can be set for a maximum of 90 days. By pressing once, you can return to the maintenance level. Pressing this key again, you can return to the automatic mode. Note: If no key has been pressed for two minutes, the normal mode is automatically set without saving the date that has been just entered. 5.2.5. Reading out errors reading out old faults The control saves fault messages and the operation of the valves using the function Manual mode in the so-called logbook. By means of this function, the past fault messages can be called with their respective dates and times. The individual messages can be called using the arrow keys. You can exit this menu item by pressing the Esc key. Note: Up to 128 fault messages can be saved. If this number has been reached, the oldest message is always deleted for each new message. The memory can be deleted by skilled maintenance personnel in the service menu using the command Emptying the logbook. 5.2.6. Displaying the settings With this menu item, the current settings of the control can be displayed. Changing these settings is not possible. This menu item is used for analysing the setting without making changes. 5.2.7. Service menu and action code In the service menu, the operational parameters can be changed. The access to these parameters is protected by a code. The operational parameters can also be changed by means of a specific action code. This second maintenance level may only be accessed by qualified specialist personnel! In the event of unauthorised interference with the control settings, the warranty claim expires! 5.3. Replacing fuses Before replacing the fuses, the plant must be switched off by means of the red main switch! In order to replace or check fuses, the control and machine cabinet must be opened with the key supplied. The micro-fuses described above are on the rear of the control. Used fuses: Micro-fuse Supply line F1 Consumer F2 230 V / 50 Hz 8 A, medium time lag 2 A, time lag In order to replace the micro-fuses, please proceed as follows: Turn the head of the holder by applying slight pressure and using a slot screwdriver SL 1.0 x 5.5 for a quarter turn to the left (anti-clockwise). 20
Remove the head of the holder with the fuse. Replace the fuse. Insert the head with the fuse into the opening of the holder. Gently press on the head of the holder using a screwdriver and fix the fuse by turning the head for a quarter turn to the right (clockwise). Note: If you are not able to solve the problem, please contact your maintenance company or KLARO as soon as possible. 5.4. Functional principle of the power outage detection device The control is equipped with a power outage detection device that is powered by an integrated emergency power supply (buffering). In the delivery state, the emergency power supply is empty. It is charged after the control has been switched on. In the event of a blackout, the charge of an emergency power supply is sufficient for signalising the power outage for approx. 12 hours. If the emergency power supply is not used to compensate power outages, the discharge of the emergency power supply is prevented from being discharged by means of a circuit. Important: In the event of a power outage, the setting of the time / date is supplied with power by means of an additional buffering for a period of approx. 10 days. All saved data such as operating hours, programme settings etc. are preserved. If, however, date and time have not been set, weekly operating hours of the aggregates are no longer saved. Future error messages are then saved with an incorrect date. If the plant is disconnected from the mains (e.g. due to a blackout, when the internal fuse is blown or when separated from the wall socket), the detection device sends alternately an acoustic and visual signal regardless of the actual cause. The device reacts to a power outage with a delay of five seconds. This prevents that short outages that often occur, for instance, during a thunderstorm, but do not impair the overall function of the wastewater treatment plant, are unnecessarily signalled. - The five-second delay is followed by an intermittent with a read flashing signal. At intervals of five seconds, five flashing signals are continually sent with a beep for a period of approx. 12 hours (with a completely charged emergency power supply). - Switching off the device is not possible in this state. When the mains voltage returns, the device is reset to the monitoring state without any further keys being pressed and the control continues to run from the point at which it was interrupted. The fault message disappears automatically. When the emergency power supply is discharged, the operation of the plant is restarted with a cycle pause. Blackout Attention: If the plant has been disconnected from the mains for more than 24 hours, the purification of the existing wastewater is not possible or only possible to a very restricted extent. Never switch off the plant (except for maintenance of plant components and function-restricting faults of the plant) 21
6. Additional functions of the KLplus and KLbasic controls 6.1. Underload detection (KLplus) Malfunction Attention: The activation of the fill-level-dependent mode must be carried out by a maintenance technician or an export. Any incorrect calibration of the plant can cause that the plant is permanently run in the saving mode (cycle pause)! In this case, proper purification is not possible! As standard, the KLplus control is equipped with a pressure sensor by means of which the fill level in the first chamber can be determined. This function is used for saving energy with low amounts of inflowing wastewater. This function is switched off in the delivery state. During commissioning, the plant is run in the automatic mode regardless of the amount of inflowing wastewater. 22
6.1.1. Functional principle The water level is measured by means of the pressure in the feed lift during the feed phase. If the water level in the sludge storage / buffer (chamber 1) exceeds a previously set fill-level height ( Fill-level detection setting ), the plant starts a purification cycle. If the fill level is not reached, the plant enters the cycle pause for a period of six hours. During this cycle pause, the SBR reactor is only aerated sporadically in order to keep the bacteria alive. If the previously set water level was not reached in the first chamber after four subsequent measurements, the plant pumps, via the excess sludge lift, water out of the reactor and back into the first chamber. After the water has been pumped back, the plant measures the water level again. With no or little inflowing wastewater, the reactor is thus also fed after a certain period of Figure 9: Drawing air lifter charging time. Hence, the normal purification performance can also be maintained for a longer period of time in times of absence or underload. The number of the purification cycles performed can be queried via the menu item operating hours. In doing so, the actually performed purification cycles are placed in relation to the cycles carried out in the automatic mode (four cycles a day) and displayed as a percentage (capacity of 25 % to 100 %). 6.1.2. Commissioning Fall hazard During any work on the opened cover of the cesspit, there is a tripping and fall hazard! The open pit must be secured by means of suitable measures. The first chamber (sludge storage / buffer) equipped with the feed lift must be filled with water up to the height at which a purification cycle is to be activated. This water level depends on the geometry of the container and the connected PE. In the following table, the recommended buffer heights a above the minimum water level are stated for the different constellations. 23
Recommended maximum buffer heights a in the sludge storage / buffer: Retrofitting for round containers: SBR chamber Semi-circle Ø 2.0 m Ø 2.2 m Ø 2.5 m PE number 4 6 8 4 6 8 12 4 6 8 12 16 20 a [cm] 10 15 20 8 12 16 24 6 9 12 18 24 31 SBR chamber Full circle Ø 2.0 m Ø 2.2 m Ø 2.5 m PE number 8 12 16 20 16 20 25 30 35 40 50 12 16 20 25 30 35 40 50 a [cm] 10 14 20 24 16 20 25 30 35 40 50 9 12 15 20 23 27 31 38 Klaro container, concrete: PE number Container type 4 6 8 8 12 16 20 25 40 50 2x 2x 2x 4x ZK224 ZK224 ZK225 ZK226 ZK228 EK225 EK226 EK228 EK226 4x EK228 Height a [cm] 8 12 16 16 24 16 20 25 20 25 Height b [cm] 101 105 124 150 193 124 154 194 154 194 PE number Container type 12 16 20 30 35 40 40 50 2x 2x 2x EK/ZK/E EK/ZK/E ZK259 ZK2510 ZK2512 EK2510 EK2512 EK2512 K 259 K 2512 Height a [cm] 18 24 31 23 27 31 20 25 Height b [cm] 178 190 238 189 234 238 180 232 Klaro Easy: Cristall Carat PE 4 6 8 4 6 8 10 12 16 20 25 35 number Type 2x 2.65 3.75 4.80 6.50 2x 3.75 2x 4.80 2x 6.50 4x 3.75 4x 4.80 4x 6.50 a [cm] 6 11 15 10 13 15 13 13 15 11 15 18 b [cm] 106 111 115 106 128 145 109 128 148 106 132 154 1 st step: calibration of the pressure sensor The calibration of the sensor is absolutely necessary for the initial commissioning. Please carefully follow the instructions provided below: Service code enter calibrate? no measuring Go to the menu item ENTER SERVICE CODE, press the key and enter the following code after having been requested to do so: 9 9 9 9. Select CALIBRATION YES by using the arrow keys ( ), confirm this input by pressing the key and start calibration Three measurement processes are carried out automatically. 24
enter current water level: 000 cm Enter the current fill level b of chamber 1 measured by you using the folding metre stock (measured from the bottom of the container to the water surface) save? cm No and confirm this input by pressing. The value entered here indicates the distance c from the bottom of the container to the feeding point of the lift. Select Save Yes by using the arrow keys ( ) and confirm this input by pressing the key. The calibration has now been completed and you can exit this menu by pressing the ESC key. 2 nd step: setting the control parameters Setting the control parameters for the fill-level detection is absolutely necessary in order to ensure that the plant works correctly. Please carefully follow the instructions provided below: service code enter level measuring setup Fill level Start from: 000 cm Recirculation: 2 min alert flooding from: 000 cm Go to the menu item ENTER SERVICE CODE, press the key and enter the service code after having been requested to do so. Select Set fill-level detection by using the arrow key to the left ( ) and confirm this input by pressing the key. Enter the water level b at which a treatment cycle is to be started. Confirm this input by pressing the key. Enter the value 2 min using the number keys and confirm this input by pressing the key. The required settings have now been completed and you can exit the menu by pressing the ESC key. (As from software version 8.29) NOTE: The activation of the flood warning message is not absolutely necessary in order to ensure that the plant works correctly. When saving the value 000 cm, this warning message remains deactivated. In order to activate this warning message, measure the height between the bottom of the container and the lower edge of the emergency overflow in the dividing wall or, with full circle plants, at the outlet. With containers, you can enter the value applicable to your plant from the table above. The designation of your container can be found on the corresponding delivery note. Confirm this input by pressing the key. When saving the value 000 cm, the flood warning message is deactivated. 3 rd step: function control Now, the fill-level detection can also be carried out in the manual mode. For this, the fill-level detection must be switched on using the number 1. The control independently performs a measurement. After this measurement process has been completed, the measured value is displayed. 6.1.3. Switching off the fill-level detection In order to switch off the fill-level detection and have the cycles run again in the time-controlled mode, the 2 nd step described above must be repeated. The water level b must be set to 0 cm. The recirculation can remain set to two minutes. 25
6.1.4. Safety and fault messages If the sensor measures a value of less than 40 mbar, the message Fault: min. fill level appears on the display. In this case, the plant returns to the normal time-controlled mode. This can be attributed to either too low a water level ( 40 cm) in the sludge storage / buffer or a leakage in the pressure or measuring hose. In this case, we recommend you to contact the manufacturer. 6.2. Optional additional functions with extension cable (KLplus and KLbasic) By connecting an additional cable to the connection X3 or X4, the range of functions of the control can be extended. The following extensions are possible: ST5 Connection of a phosphate dosing pump ( X3), ST6 Connection of an external alarm unit ( X4), also for KLbasic, ST7 Monitoring of a contactor for a three-phase current compressor ( X4), ST8 Connection of a UV reactor ( X3). 6.2.1. Connection of an external fault indicator Via the potential-free output ST6, an external alarm unit such as an indicator lamp mounted to the outside of the cabinet can be connected. More detailed information can be found in the MoAnl 10 Externe Warnmelder [InstInstr 10 external alarm unit]. 6.2.2. Connection of a connector for switching the compressor If the power supply of the installed compressor is higher than 6 amperes, a contactor is additionally installed in the cabinet by means of which the compressor is driven. Via the input Contactor monitoring ST7, the switching state of the contactor is monitored. 6.2.3. Connection of a UV reactor Via the connection ST8, a downstream UV reactor can be connected to the control. More detailed information can be found in the MoAnl 11 UV-Anlagen [InstInstr 11 UV plants]. 6.2.4. Phosphate precipitation using the dosing pump Precipitant Attention: When swallowed, iron(iii)-chloride is harmful to health and also irritates the skin. There is a risk of serious injury to the eyes. There is an explosion hazard in connection with alkali metals, allyl chloride and ethylene oxide. Read the corresponding safety datasheet before using phosphate precipitants! When handling iron(iii)-chloride, protective clothing must be worn. Keep precipitant containers away from unauthorised access by others and children. 26
Plants delivered with the phosphate precipitation function are equipped with a hose pump in the cabinet. A suction hose and a pressure hose are connected to the pump. The runtime of the hose pump is determined by the time set for the pump in the service menu. The amount of the added precipitant thus depends on the set time. The large pump Compact is equipped with a potentiometer for setting the performance. The table below provides an overview of the dosing possibilities. The respectively required dosage can be found in the respective certification (see CD). In order to commission the precipitation unit, the container with the precipitant must be installed in a frost-proof place (e.g. machine cabinet, either on the dividing wall or in the Figure 10: System drawing precipitation unit dome-shaped manhole of the plant). The pressure hose and the suction hose must also be installed in a frost-proof place. The pressure hose must be inserted into the SBR reactor and positioned in such a manner in the reactor that the outlet opening is above the reactor tank and it is ensured that the precipitant falls directly into the wastewater to be treated and does not wet any components (aggressive chemical, risk of damage to the components!). The outlet opening must, under no circumstances, be immersed into the water! Insert the suction hose into the precipitant container to the extent that the suction from the bottom is ensured. Connect the suction hose and pressure hose to the hose coupling nipples of the pump and fix them using the union nuts. Under the menu item Manual mode, switch on the phosphate pump and check whether the precipitant is sucked correctly. If required, interchange the hoses at the connections. Reference values for setting the pump performance P [ml/min] 1 1.5 2 5.5 3 11.0 4 15.0 5 19.0 6 22.5 7 26.0 8 30.5 9 35.0 10 37.5 Output: 5.5 ml/min Figure 11: Precipitant pump Compact Figure 12: Precipitant pump DSP 9911 27
7. Maintenance, servicing and operation The plant must be switched on at any time. As operator of a small wastewater treatment plant, you are obliged to ensure the error-free operation of the plant. Almost all operational breakdowns cause a deterioration of the purification performance of the plant. Therefore, these operational breakdowns must be detected at an early stage and rectified by you or by a qualified maintenance technician. During any work on the opened cover of cesspit, there is a tripping and fall hazard! The open pit must be secured by suitable measures. Persons involved and/or third parties may fall into the container! Children are particularly at risk! Fall hazard Due to the biological degradation processes in small wastewater treatment plants, the generation of (possibly toxic) gases must be expected. Therefore, entering the plant must always be secured by a second person. In any case, a fainted person must not be followed, but help must be sought as soon as possible. High voltage For activities other than operating the control, the maintenance switch must be set to 0 and/or the mains plug of the cabinet must be pulled out! Any maintenance and repair work on the cabinet system must be carried out by a maintenance technician or an electrician! 28
7.1. Tasks of the operator In order to ensure an error-free operation, the following checks must be performed: 7.1.1. Daily check - It must be checked whether the plant is run properly. This is the case if the operating indicator lamp lights up green and no warning signal can be heard. A fault is displayed as described in chapter control of the plant. In the event of an incident, we ask you to read the liquid crystal display and to inform the service personnel about the displayed fault or, if possible, to rectify the fault yourself. 7.1.2. Weekly checks - Checking the water levels; sludge must not enter the SBR chamber in an uncontrolled manner, - Checking the inlets and outlets for clogging (visual check), - Reading the operating hours counters of the aerator (total operating hours), the ventilation (valve 2) and the sludge return (valve 4), if required, also the operating hours counter of further aggregates and recording them in the operation log, - Function control of the lifts and the ventilation via the setting Manual mode. 7.1.3. Monthly checks - Visual check for any sludge overflow, blurring or discolouration in the outlet, - Checking the inlets and outlets for clogging (visual check), - Reading the operating hours counters of the aerator (total operating hours), the ventilation (valve 2) and the sludge return (valve 4), if required, also the operating hours counters of further aggregates and recording them in the operation log, - Checking the air filter: The filter of the switch cabinet ventilation (ventilation grilles on the left and right side in the housing wall with an inside cabinet and/or on the rear with an outdoors cabinet) must be checked and, if required, cleaned or replaced. For this, the grilles on the outside of the cabinet must be removed. The snap lock can be unlocked by applying slight pressure and using a screwdriver and the grille can be removed by hand. The filter mat lies, without any further fastening means, in the ventilation pit and can be shaken out and/or blown out. The interval at which the filter of the aerator must be cleaned or replaced depends on the extent of contamination caused by the atmospheric conditions around the application. In order to check or replace the filter on the compressor, the service documentation of the compressor manufacturer provided in the annex must be complied with. - Checking the phosphate precipitation unit (if any): function control of the precipitant pump and checking the fill level of the precipitant container, - Checking the function of the power outage alarm unit. 7.1.4. Sludge drainage In a small wastewater treatment plant, there are different types of sludge. Only the faecal sludge that accumulates in the first chamber is removed. It consists of sedimented residues resulting from the wastewater treatment. In small wastewater treatment plants, the faecal sludge and/or sewage sludge consists of dead micro-organisms of the biological treatment stage and the settled solids resulting from the pre-cleaning. The height of the accumulated sludge in the sludge storage is measured by skilled maintenance personnel using a sludge pipette. The plant is designed in such a manner that, with permanent full-load operation and compliance with the operator and maintenance obligations, the 29