ACO Powerlift Pro Manuel utilisateur
Instructions for Use
For safe and proper use, read carefully through the instructions for use and all other
documents enclosed with the product, pass them on to the end user and keep them until the
end of the product's life.
ACO Civil Engineering
Issued: 2019-09-26
V1.0_DE Original Instructions
For non-faecal and faecal wastewater, for installation in the
ground
Powerlift prefabricated pumping station
Powerlift Pro
Type PSD-P: Pumpstation Duo
(2 Pumps)-Polymerbeton
Powerlift Concrete
Type PSD-B: Pumpstation Duo
(2 Pumps)-Concrete
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Powerlift prefabricated pumping station
Introduction
ACO Tiefbau Vertrieb GmbH (referred to as ACO in the following) thanks you for your trust and
hands over to you a product which is state-of-the-art and has been tested for proper condition as
part of quality controls carried out before delivery.
Figures in these instructions for use are provided for basic understanding and may differ,
depending on the product version and the installation situation.
ACO Service
Accessories, refer to "Product catalogue": http://katalog.aco-tiefbau.de
For additional information regarding the prefabricated pumping station, ordering spare parts and
services e.g. maintenance contracts, general inspections, please contact ACO Service.
ACO Service
Im Gewerbepark 11c
36457 Stadtlengsfeld, Germany
Tel.: + 49 (0) 36965 819-444
Fax: + 49 (0) 36965 819-367
Target group
The target group for these operating instructions is technically trained skilled personnel.
The personnel must have the appropriate qualications, Chapter 1.3 "Personnel
qualications". Areas of responsibility, competence and monitoring of the personnel must be
closely regulated by the operator. Any lack of knowledge in the personnel must be rectied
through training and instruction by adequately trained skilled personnel. Training on the system
shall be carried out only under the supervision of technical skilled personnel.
Guarantee
For information regarding the guarantee, refer to General Terms and Conditions of Business
("Allgemeine Geschäftsbedingungen"),
http://www.aco-tiefbau.de/agb
Symbols used
Certain information in these instructions for use is marked as follows:
Tips and additional information, which make the work easier
■Bullet points
ÎActions to be carried out in the specied order
References to other information in these instructions for use and other documents
Introduction
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Powerlift prefabricated pumping station
Table of Contents
Table of Contents
1 For your safety .................................................................................................6
1.1 Intended use ...................................................................................................... 6
1.2 Normative specications..................................................................................... 7
1.3 Personnel qualications....................................................................................... 7
1.4 Personal protective equipment ............................................................................ 8
1.5 Warnings ........................................................................................................... 8
1.6 Responsibility of the Owner ................................................................................. 9
1.7 Transport and storage ...................................................................................... 10
1.8 Decommissioning and disposal.......................................................................... 10
2 Product Description.......................................................................................11
2.1 Product features............................................................................................... 11
2.1.1 Basic equipment................................................................................... 11
2.1.2 Accessories ......................................................................................... 14
2.2 Components .................................................................................................... 18
2.3 Operating principle ........................................................................................... 19
3 Installation ....................................................................................................21
3.1 Installation example (schematic diagram)............................................................ 21
3.2 Overview of earthwork and installation works...................................................... 22
3.3 Earthworks ...................................................................................................... 24
3.3.1 Specications....................................................................................... 24
3.3.2 Digging the excavation.......................................................................... 25
3.3.3 Installing the container in the basic shaft................................................. 25
3.3.4 Installing shaft components with PSD-P................................................... 26
3.3.5 Installing shaft components with PSD-B................................................... 29
3.3.6 Laying and connecting the on-site inlet pipe ............................................ 32
3.3.7 Laying and connecting the on-site ventilation pipe.................................... 32
3.3.8 Laying and connecting the on-site blank cable pipe.................................. 33
3.3.9 Laying and connecting the on-site pressure pipe ..................................... 33
3.3.10 Installation in the outdoor cabinet (optional) ............................................ 36
3.3.11 Backlling the excavation ...................................................................... 37
3.3.12 Leak test ............................................................................................. 38
3.4 Installation work ............................................................................................... 38
3.4.1 Assembling the access ladder ............................................................... 38
3.4.2 Assembling the chain holder and guide pipe............................................ 39
3.4.3 Installing the submersible pumps ........................................................... 39
3.4.4 Assembling the level sensor (optional) .................................................... 41
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3.5 Electrical installation ......................................................................................... 54
3.5.1 Overview of the electrical installation work.............................................. 54
3.5.2 Supplying heating (optional) and work plug socket (optional) with current .. 55
3.5.3 Installing the control.............................................................................. 55
3.5.4 Connecting the control to the power supply ............................................ 55
3.5.5 Connections for the control ................................................................... 56
3.5.6 Connecting and clamping the connecting cables of
the pumps and level sensors ................................................................. 56
3.5.7 Check the rotational direction of the pumps ............................................ 58
3.5.8 Connecting the control cable (optional)................................................... 58
3.5.9 Connecting the air bubble injection......................................................... 59
3.5.10 Connecting the malfunction or fault signalling equipment (optional) ........... 60
3.5.11 Installing ex-barrier................................................................................ 60
4 Commissioning..............................................................................................61
4.1 MultiControl Duo control.................................................................................... 61
4.1.1 Controls and display elements ............................................................... 61
4.1.2 Menu items and settings ....................................................................... 63
4.1.3 Changing the settings ........................................................................... 65
4.2 Level Control PS 2 Control System .................................................................... 65
4.2.1 Controls and display elements ............................................................... 65
4.2.2 Menu items and settings ....................................................................... 67
4.2.3 Changing the settings ........................................................................... 69
4.3 Commissioning settings.................................................................................... 69
4.3.1 Powerlift PSD-P-1000 with TBasin = 685.................................................. 70
4.3.2 Powerlift PSD-B-1000 with TBasin = 480 ................................................. 71
4.3.3 Powerlift PSD-B-1000 with TBasin = 1070 ............................................... 72
4.3.4 Powerlift PSD-B-1500 with TBasin = 395 ................................................. 73
4.3.5 Powerlift PSD-B-1500 with TBasin = 795 ................................................. 74
4.3.6 Powerlift PSD-B-2200 with TBasin = 515 ................................................. 75
4.3.7 Powerlift PSD-B-2200 with TBasin = 505 ................................................. 76
4.3.8 Powerlift PSD-B-2200 with TBasin = 585 ................................................. 78
4.3.9 Settings for the installed prefabricated pump station ............................... 79
4.4 Starting up the submersible pumps.................................................................... 80
4.5 Execute test run............................................................................................... 81
4.6 Setting the air bubble injection (optional) ............................................................ 85
5 Troubleshooting.............................................................................................86
Table of Contents
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Table of Contents
6 Technical Data ...............................................................................................88
6.1 Prefabricated pumping station........................................................................... 88
6.1.1 Dimensions .......................................................................................... 88
6.1.2 Key data .............................................................................................. 89
6.2 Submersible pumps – non-faecal wastewater...................................................... 90
6.2.1 SAT-100/D, SAT-150/D and SAT-200/D.................................................. 90
6.2.2 SAT-50/2/32/D and SAT-75/2/32/D...................................................... 94
6.2.3 SAT-V 75/2/50/D and SAT-V 150/2/50/D.............................................. 97
6.2.4 SAT-Q 300/65/D, SAT-Q 300/80/D, SAT-Q 400/65/D, SAT-Q 400/80/D
and SAT-Q 750/80/D.......................................................................... 100
6.2.5 SAT-Q 300/80/4/D and SAT-Q 550/80/4/D ......................................... 103
6.2.6 SAT-Q 1000/100/D, SAT-Q 1000/100/4/D and SAT-Q 1500/100/D...... 105
6.2.7 LW-KP 1325...421, LW-KP 1325...422, LW-KP 1325...423 and LW-KP
1325...424........................................................................................ 107
6.3 Submersible pumps – faeces-containing wastewater ......................................... 110
6.3.1 KL-AT-M 200/4/80 D-Ex, KL-AT-M 300/4/80 D-Ex and
KL-AT-M 400/4/80 D-Ex ...................................................................... 110
6.3.2 KL-AT-V 400/2/80 D-Ex, KL-AT-V 400/4/100 D-Ex and
KL-AT-V 550/2/80 D-Ex....................................................................... 113
6.3.3 SITA 150 N-Ex, SITA 200 N-Ex, SITA 300 N-Ex and SITA 550 N-Ex .......... 115
6.4 MultiControl Duo control.................................................................................. 117
6.4.1 Key data ............................................................................................ 117
6.4.2 Circuit diagram................................................................................... 118
6.5 Level Control PS 2 Control System .................................................................. 119
6.5.1 Key data ............................................................................................ 119
6.5.2 Circuit diagram................................................................................... 119
Appendix: Commissioning report........................................................................ 120
For your safety
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Powerlift prefabricated pumping station
1 For your safety
Read the safety instructions before installing and operating the prefabricated pumping
station, in order to prevent personal injuries and damage to property.
1.1 Intended use
The prefabricated pumping station is used for collecting and automatic lifting of non-faecal and
faecal wastewater above the backow level. The wastewater is drained into the drainage sewer
safely for people and without damaging structures or contaminating the ground.
IMPORTANT
■The maximum wastewater temperature must not exceed 40 °C.
■The installation fittings and components (e.g. inlet immersion pipe, pressure pipe parts)
are designed for operation as a prefabricated pumping station. They are not designed
to be a step or foot board for people and storage e.g. heavy cleaning devices. The
bearing force is not designed for such purposes.
■The use of an access aid for accessing or entering the prefabricated pumping station is
anchored in the requirements of the employers' liability insurance association.
The prefabricated pumping station is intended for installation in the ground below the backow
level in the following types of projects:
■Drainage for sanitary rooms
■Drainage for rainwater surface areas
■Protection for separator plants, which are built into the ground, against backflow from
public sewers
Harmful substances must not be discharged into the prefabricated pumping station:
■Heavy metals, e.g. zinc, lead, cadmium, nickel, chromium
■Aggressive substances, e.g. acids (pipe cleaning agent with pH value below 4)
■Alkaline solutions, salts and condensates
■Cleaning products and disinfectants, washing-up agents and detergents in overdosed
quantities or quantities that result in disproportionate foaming
■Flammable or explosive substances, e.g. petrol, benzene, oil, phenols, solvent-based
paints, white spirits
■Solids, e.g. kitchen waste, glass, sand, ashes, fibrous material, synthetic resins, tar,
cardboard, textiles, greases (oils), leftover paint
■Liquid substances, which can harden, e.g. gypsum, cement, lime
■Ecocides, e.g. plant treatment and pest control products
■Wastewater from manure pits and keeping of livestock, e.g. liquid manure, slurry, dung
For your safety
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Powerlift prefabricated pumping station
Other possible uses and changes are not allowed. Installation of unapproved parts impairs
safety and excludes any guarantee from ACO. In the event of replacement, only use original ACO
parts or spare parts approved by ACO.
1.2 Normative specifications
Requirements based on the listed or currently relevant standards:
■EN 12056-1
Gravity drainage systems inside buildings”
■EN 752 “Drain and sewer systems outside buildings”
■DIN 1986-100: Drainage systems for buildings and property
– Part 100: Provisions in connection with DIN EN 752 and DIN EN 12056“
1.3 Personnel qualifications
Activities Person Knowledge
Layout, operational changes Planners
Knowledge of building systems and services and applicable
standards and directives
Evaluation of wastewater technology application cases
Proper layout of drainage systems
Below ground installation Skilled people Specic knowledge of carrying out civil engineering works
Sanitary installation Skilled people Installation, xing and connection of pipes
Electrical installation Electrician Work on electrical connections to power supply must be
carried out by qualied electricians only
Operation monitoring Owner, operating
company No specic requirements
Launch, maintenance Qualied persons “Qualied persons” in according to DIN 1986-100*
Disposal Skilled people Appropriate and environmentally friendly disposal of materials
and substances, knowledge of recycling
*Denition of “competent people” in accordance with DIN 1986-100:
“Competent people are employees of companies independent of the operating company/owner, experts or other
institutions, who veriable have the required technical knowledge to operate, maintain and check wastewater lifting
plants to the scope named here and have the equipment required to test wastewater lifting plants. In individual
cases, in larger operational units, these tests and inspections can also be carried out by internal personnel of the
operating company who are qualied people, independent with regard to their area of responsibility and who are not
bound by instructions, and who have the same qualication and technical equipment.”
For your safety
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Powerlift prefabricated pumping station
1.4 Personal protective equipment
Personal protective equipment must be made available to the personnel and supervisors must
check that it is used or worn.
Manda-
tory
sign
Meaning
Safety footwear provides good slip resistance, especially in wet conditions, as well as a high degree
of penetration resistance (e.g. in case of nails) and protects the feet from falling objects (e.g. during
transport).
Protective gloves protect hands from infections (moisture-tight protective gloves) and minor bruises
and cuts, especially during transport, installation, maintenance and dismantling.
Protective clothing protects the skin from minor mechanical effects and infections.
A safety helmet protects against head injuries, e.g. in case of falling objects or knocks in the event of
low room heights.
Safety glasses and goggles protect eyes from infections, especially during launch, maintenance and
repair.
1.5 Warnings
In the instructions for use, warnings are identied by the following warning symbols and signal
words.
Warning symbols
and signal words Meaning
DANGER
Personal injuries
Hazard with a high degree of risk which, if not prevented, results in death
or severe injuries.
WARNING Hazard with a moderate degree of risk which, if not prevented, can result
in death or severe injuries.
CAUTION Hazard with a low degree of risk which, if not prevented, can result in
minor or moderate injuries.
IMPORTANT
Damage to property
Hazard which, if not prevented, can result in the damage of products and
their functions or an item/property in the surrounding area.
For your safety
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Powerlift prefabricated pumping station
1.6 Responsibility of the Owner
Due diligence in the owner’s, or the operator’s, area of responsibility:
ACO recommends that an operating log be kept and that inspections, servicing, maintenance
work, repairs etc. be documented, so that verication exists in case of an insurance claim.
Planning and installation
Requirements in accordance with the relevant standards and regional regulations must be
complied with, these include, among other things:
■Layout and dimensioning
■Protection against backflow
■Installation of pipes
Operation monitoring
■Monitoring normal operation, Chapter 1.1 “Intended use”.
■Monthly performance of at least 2 trial runs.
■Controlling the prefabricated pumping station, e.g. unusual running noises of pumps.
■Controlling the readiness of the prefabricated pumping station for operation on the
control system.
Maintenance
Wastewater lifting plants must be operated and maintained in such as way as to ensure proper
functioning and operating safety. We recommend that plant owners/operating companies
conclude a maintenance contract for the regular servicing and maintenance work to be
undertaken.
ACO Service would be pleased to undertake the servicing and maintenance work professionally.
Maintenance intervals for the prefabricated pumping station:
■Commercial operation = every 3 months
■Operation in detached houses and multiple dwelling buildings = every 6 months
Additional (unscheduled) servicing:
■After flooding
■Before putting back into service
For your safety
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Powerlift prefabricated pumping station
1.7 Transport and storage
IMPORTANT Note during storage and transport:
■Store the plant parts in frost-protected premises.
■If intermediate storage is required, then the manhole base section must be protected
against water ingress.
■Never drive the forks of a fork-lift truck or lift truck directly under the plant parts.
■Where possible, do not remove the packaging and transport restraints until the
components are at their installation site.
■If transporting the unit parts using a crane or crane hook:
Comply with the accident prevention regulations
Check the working load limit of the crane and the slings
Never stand under the suspended load
Prevent other persons from entering the entire danger zone
Avoid oscillating motion (swinging) during transport
1.8 Decommissioning and disposal
IMPORTANT Improper disposal is a hazard for the environment. Comply with the regional
disposal regulations.
■Completely drain and clean the plant when decommissioning.
■Separate the unit parts according to their material and hand them over for recovery or
recycling.
■Electrical equipment must never be disposed of in household waste.
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