Graf One2clean+ XXL Montageanleitung

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Instructions for

start-up, operation and maintenance

one2clean+

one2clean+ XXL

Small wastewater treatment

systems

Control unit version KL24plus

The points described in these in-

structions must be observed in all

cases. Failure to do so shall invali-

date the warranty. For any addi-

tional items purchased through

GRAF, you will receive separate

installation instructions in the

transport packaging.

The components must be checked

for any damage before the system

is transferred to the pit.

You will receive separate instruc-

tions for installation of the system.

Be sure to read before starting

up!

Contents

1. General information 2

2. Safety 3

3. Description of function 6

4. Control unit 8

5. Start-up 18

6. Level measurement 19

7. Operation and maintenance 22

8. Fault messages and rectification 28

9. EC conformity declaration 31

10. Technical data 32

11. Template for weekly / monthly check notes 34

12. Maintenance log for GRAF small wastewater

treatment systems 37

13. Notes 39

1.General information

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1. General information

Below you will find some important information for safely operating your system for a long time to come.

•The SBR system is designed to receive all domestic wastewater. Other wastewater, e.g. from restau-

rants and / or commercial premises etc., may only be received if this was specified and taken into

account in the system's design.

•Biocides, toxic substances or substances which are not biocompatible must not enter this system

because they hinder bacteria important to wastewater cleaning and cause problems in the biological

process (detailed information is provided on the following pages).

To meet official cleaning requirements, it is essential that the system is operated in accordance

with our operating and maintenance instructions. You will find these instructions on the following

pages.

We also ask you to read the following information carefully:

The External control cabinets should be located as much in the shade as possible to prevent

them from overheating in the summer.

At all times ensure that the cabinet, especially its ventilation apertures, are not covered and are

freely accessible for maintenance work.

External control cabinet: Ventilation apertures on the rear

The power supply must be ensured at all times. Please ensure that the fuse on the control cabi-

net is sufficient (16 A). Additional electrical fixtures on the same fuse may disrupt operation.

2.Safety

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2. Safety

This chapter contains details relating to safety measures and residual risks. Read this chapter through

carefully before using the system to ensure that it is used as safely as possible.

Intended use2.1

The control unit was specifically developed for use in SBR small wastewater treatment systems. The con-

trol unit must not be used in areas representing a danger to life and limb:

control of machinery, vehicles and safety processes,

research technology involving hazardous substances,

medical technology,

nuclear power technology,

etc.

Explanation of warning notices and prohibitions2.2

Warning of danger

Warning of dangerous voltage

Warning of tripping risk

Warning of hot surface

Warning of hand injuries

Warning of explosive atmospheres

Fire, naked flames and smoking prohibited

2.Safety

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Danger notices2.3

1. To ensure safety, everyone who comes into direct contact with the system must note the content of

this documentation.

2. The system must not be used for any purpose other than that described by the manufacturer.

3. Local operating and safety requirements and legislation must be followed at all times, even if they

are not explicitly mentioned in these instructions. The same applies to environmental requirements.

4. If the operator becomes aware of mistakes or dangers, the manufacturer or responsible mainte-

nance company must be informed immediately.

5. Safety precautions must never be removed or bypassed during normal operation of the wastewater

treatment system. Safety precautions may only be temporarily bypassed or deactivated by the

maintenance fitter during repairs and maintenance.

6. When working with chemical substances, contact with the chemicals should be avoided Before the-

se substances may be used, the instructions for use on the packaging must be read and followed.

7. If the use of personal protective equipment (safety shoes, protective glasses, gloves, ear defenders,

etc.) is prescribed, ensure that they are used. Defective or damaged protective equipment must be

immediately replaced with fully functional equipment.

8. Work on electrical equipment may only be undertaken by specialists.

9. All safety and danger notices on the machine should always be kept fully legible.

10. Hot parts must not come into contact with explosive or highly flammable chemicals.

11. Do not put vessels containing liquids on electric switch cabinets; short circuits may occur if the liquid

is spilled.

12. The system must not be operated by anyone under the influence of alcohol or medication which lim-

its cognitive ability or ability to react.

13. The system must be de-energised before any maintenance or cleaning work takes place.

14. Other than for maintenance purposes, the system should always be left switched on, otherwise cor-

rect wastewater cleaning cannot be guaranteed.

2.Safety

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Warning notices2.4

Be sure to observe this information. Failure to do so may result in personal injury or damage to property!

Installation loca-

tion

Ensure that the machine cabinet is not installed above or in the direct vicinity of water

vessels. There is a risk of electric shock if improperly installed.

Mains connection

Only connect the machine cabinet to a correctly installed 230 V socket or earth cable

which is fused with an upstream 16 A fuse.

Electrical equipment connected to the mains may be damaged during a storm. We

would recommend fitting surge protection in the building to protect against this.

The connection cable must be laid in a way it won’t represent a tripping hazard.

Explosive atmos-

pheres

The control unit must not be fitted or activated in environments with potential explo-

sive atmospheres or in places where there are flammable materials. Sparks in such

environments may cause an explosion or fire and this may result in physical injuries

or even death.

Interferences

The control unit may cause medical equipment to malfunction. This device should

therefore not be used in close proximity to medical equipment.

Damage

The control unit must not be operated if the housing or cable insulation is damaged or

crushed.

Service work

Service work on the machine cabinet may only be undertaken by authorised special-

ists / electricians.

Voltage supply

The power supply must be ensured at all times. Please ensure that the fuse on the

control cabinet is sufficient (16 A). Additional electrical fixtures on the same fuse may

disrupt operation.

3.Description of function

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3. Description of function

Description of the wastewater treatment process3.1

The one2clean+ wastewater treatment system is a fully biological system and functions on the principle of

the retention process with extended aeration (Sequencing Batch Reactor). The system basically consists

of an aerobic stage, which is split into a rest and an aeration zone, linked together in the lower section.

This process therefore subjects all the domestic wastewater directly to aerobic wastewater treatment.

Blowing in compressed air aerates the entire system and the resultant aerated sludge biologically cleans

the wastewater.

The coarse materials and floating solids in the wastewater are initially retained using a scum guard in the

rest zone. Then the wastewater passes into the aeration zone via an aperture under the scum guard.

The rest zone is aerated too, so the retained solids are also aerobically broken down over the course of

time. In the one2clean+, the wastewater is treated without pre-treatment so no anaerobic putrefaction

processes can occur.

The SBR procedure is a series of different steps, undertaken one after another and at least once a day.

Step 1: Aeration

In the first phase, the wastewater is put straight through aerobic treatment for a fixed

time. As a result, the microorganisms (aerated sludge) are supplied with the oxygen

needed for the breakdown and then pressure aeration causes mixing. The system's

aeration equipment is supplied with ambient air by a compressor. Aeration is intermit-

tent so that targeted wastewater cleaning is possible. Different ambient conditions can

thereby be achieved.

Step 2: Settle

There is no aeration in the second phase. The aerated sludge and the remaining settle-

able solids can now settle with the aid of gravity. A clear water zone forms at the top

and a sludge layer at the bottom. Any floating sludge is on top of the clear water zone.

Step 3: Clear water extraction

In this phase, the biologically cleaned wastewater (clear water) is drawn out of the SBR

stage. It is pumped out by an air lift (or mammoth) pump, which uses compressed air.

The air lift pump is designed not to pump out any floating sludge on top of the clear

water layer. A minimum water level is maintained in the system without any further

components.

In multi-tank systems, there is also a phase in which the sludge is returned to the system.

Once step is complete, the cleaning process starts again with step 1.

Two cycles are undertaken a day. The maintenance company can individually adapt the switching times.

3.Description of function

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Structure of one-tank systems3.2

Figure 1: One-tank system

Structure of multi-tank systems3.3

Figure 2: Two-tank system

Sampling point

Clear water lifter

Scum baffle

Pipediffusors

Sampling point

Clear water lifter

Pipe Diffusors

Pipediffusors

Sludge return

Connection pipe

4.Control unit

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4. Control unit

Connections to the KL24plus control unit4.1

The figures below show the basic structure of the switch cabinet of a two-tank system.

Figure 3: EPP cabinet with 3-way air distributor

The following connections can be found on the switch cabinet:

1. 230V AV ~ 50 Hz mains connection, for con-

necting the control unit to a socket

2. Compressor connection, for connecting the

compressor to the control unit via an integrat-

ed two pin plug

3. Compressor's air connection. This is used to

connect the strip of valves integrated in the

switch box to the compressor

4. Hose connection (19 mm) for connecting the

aeration unit

5. Hose connection (13 mm) for connecting the

discharge lifter

6. Hose connection (13 mm) for connecting the

sludge lifter

7. One unused hose connection

Figure 4: Air distributor with stepped motors

Y4 Y3 Y2

Compressor

Compressor connection

Connection for power supply

Connection 6 mm

for level sensor

aeration

sludge lifter

discharge lifter

(two tank systems)

Control unit

4.Control unit

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Connections on the rear of the control unit4.2

Figure 5: Rear of KL24plus control unit

Connections:

1 Connection for mains cable

230 V AC ~ 50 Hz

2 X1: Pre-assembled valve cable

3 X2: two pin plugs for the air compressor connection

4 COM: Connection for communication module (optional) and/or port for PC

5 F1: T6.3A main fuse, slow blow

6 F2: T2A fuse for UV module, slow blow

7 Connection for temperature sensor, "must be plugged in!"

9 X3: Connection for UV module

10 P: Connection for pressure measuring hose

Connections on the air distributor/valve block4.3

When delivered, the control unit is already correctly connected to the corresponding connection on the air

distributor/valve block.

A distinction is made between three different air distributor variants:

1. 4-way air distributor (4 separate valves Y1 …Y4)

2. 3-way air distributor (3 separate valves Y2 …Y4) and

3. 2-way air distributor (2 separate valves Y3 and Y4)

To allow you to correctly connect up at a later date, the connectors of the control unit (X1.1 …X1.4), their

function (aeration, clear water extraction or sludge extraction) and the connections on the air distributor in

a matrix are shown in detail in the table below.

Control unit

Air distributor connections

Functions

Valves

Connectors

3-way

Aeration

Valve 1

X1.1

Clear water extraction

Valve 2

X1.2

Sludge Return

Valve 3

X1.3

-----

Valve 4

X1.4

4.Control unit

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Starting up the control unit4.4

Once the system has been connected to the power supply, perform a brief system test. The system test

takes a few seconds and checks the real-time buffering. During this time, the LED lights up red. Then the

LED switches to green and the start phase is complete. During the system test the words "SYSTEM TEST

... OK" appear. The program version and the control unit's serial number are displayed briefly. The sys-

tem's current operating mode is then displayed in the liquid crystal display. Once the system test is com-

plete, the date and current time should be checked and adjusted if necessary.

After checking the date/time, the function of the installed parts should be checked. The check can only

take place as soon as the installed parts are connected to the control cabinet via the air hoses needed.

The check should be carried out via the "Manual operation" menu item in the control unit. The individual

installed parts should be activated and checked in turn.

The system should be reset to automatic mode once the check is completed successfully.

PLEASE NOTE: The clear water lifter will only work if the tanks are filled.

If the time and date are not set correctly, operating faults are saved with the wrong times.

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