INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

KESSEL Closure Valve for KESSEL Aqualift®-F lifting stations for wastewater with or without sewage

Quick installation

Rotatable outlet connection

Easy operation

High pressure resistance

Order Nr. 28 683, 28 694

Product Advantages

Name/Sign Date Town Company stamp

Installationof this unit should be carried out by a licensed professionalservicer:

Service

Edition: 08/2011ID-Number: 240-060Subject to technical amendments

Safety Instructions

Dear customer,

We are happy, you decided to choose a product made by KESSEL.Before leaving the factory the whole station has been subject to a strict quality control. However, we kindly ask you to check whetherthe station has been delivered completely and without any damage. In case of transport damage, please look for the regulations inchapter „guarantee“ of this instruction.

Prior to installation and putting into operation of the Aqualift – it is in your interest - and essential that you carefully read and follow theinstallation-, operation-, maintenance- and repair instructions.

KESSEL AG

This instruction handbook contains important security advices which must be followed at all times during installation, operation, maintenance and repair of the power unit. The security advices are labelled as follows.

General warning sign according to ISO 3864-B-3-1 tagging endangering of persons.

Warning sign according ISO 3864-B-3-6 to caution against voltage.

This word indicates security advices, disregarding these will cause severe danger for the station and it’s function.Caution

This instruction handbook must be available at all times in the station.

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Table of contents

1. Safety Instructions .......................................................................................................... Page 2

2. General .......................................................................................................... Page 4

3. Technical Data .......................................................................................................... Page 5

4. Installation and Assembly .......................................................................................................... Page 7

5. Operation .......................................................................................................... Page 10

6. Inspection and Maintenance .......................................................................................................... Page 11

7. Replacement parts .......................................................................................................... Page 12

8. Warranty .......................................................................................................... Page 14

2. General

4

The KESSEL closure valve is available se-parately as an accessory or may be alreadyintegrated in a KESSEL Aqualift F lifting sta-tion for wastewater with or without sewage.The lifting station should be installed in frostand weather protected rooms.

The closure valve consists of the followingoperational elements (see Illustration 1)

InIn order for the KESSEL closure valve tooperate properly it should only be connec-ted to the appropriate KESSEL lifting stati-on – the appropriate lifting stations are listin the Installation and Assembly portion ofthis manual. If the closure valve is to beused on different pumps then additionalparts are required. If this is the case the in-stallation company is responsible for properinstallation of the closure valve.

Excessive force should not be applied to theclosure valve such as using it as a step.Damage occuring to the closure valve fromimpropery installation, operation or use arenot covered under this product’s warranty.

ill. 1

Operating handle

Safety lock

DN 100 outlet

ill. 2

Closure valve dimensions

5

3. Technical Data

KESSEL Closure Valve dimension installedon an KESSEL Aqualift® F lifting station

Il. 3 shows a single pumpAqualift®-F

Il. 4 shows a twin pump Aqualift®-F

ill. 3 ill. 4

3. Technical Data

6

A licensed installation company should in-stall the closure valve on the Aqualift F liftingstation. Insallation requires the following➤ Disconnecting the Aqualift F lifting station

from its power source➤Assuring that no wastewater enters the lif-

ting station during installation (all drainagefixtures connected to the lifting stationmust not be used or operated

➤ During installation, workers should wearprotective clothing to prevent bodily con-tamination with the septic wastewater.Smoking, eating or drinking during instal-lation is not allowed.

ill. 5 ill. 6 ill. 8

ill. 7

Safety bolts

Safety bolts

For models up to and incl. May 2009

For models beginningJune 2009

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4. Installation and Assembly

Gaskets should be properly lubricated befo-re the closure valve is installed. Once the clo-sure valve has been installed, it should beconnected or reconnected to the pressure pi-ping – be sure that all gaskets are seatedproperly.

In order to better meet on-site requirements,the closure valve is rotatable in 45 degree in-crements (Illustration 9)

ATTENTION:➤ The T-section on twin pump lifting stati-

ons should only be installed in the ver-tical position (see Illustrations 6 and 8).Installing the closure valve in a non-ver-tical position makes it impossible tofirmly secure the fastening bolts whichcould result in a non-water tight connec-tion.

➤ The connection from the closure valve’soutlet to the on-site pressure drainagepipe should only be done with the inclu-ded flexible hose connector (see liftingstation installation and operation ma-nual)

ill. 9

4. Installation and Assembly

8

After the closure valve has been installed on a single or twin pump KESSEL Aqualift® F Lifting Station – it should look like one one of theunits shown below:

ill. 11ill. 10

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5. Operation

The closure valve makes it possible to ea-sily close off the outlet pressure pipe beforedoing any type of service work on the liftingstation – for example servicing / cleanignthe integrated non-return flap inside the lif-ting station’s outlet.During normal lifting station operation, theclosure valve should be in the open positi-on (red handle (B) in the up position and thesafety lock (A) locked into place (Ill. 12).

To close the closure valve first lower the sa-fety lock (A) 90 degrees to the horizontal po-sition (Illustration 13 Number 1).Now push down the red closure handle(Number 2) (a twisting motion while pus-hing down the red handle makes this ea-sier). Once in the down position, the red clo-sure handle should be turned in the clock-wise direction (Ill. 14 Number 4) so that thebase of the handle is securely locked in the

recessed plastic holders. The closure valvenow is in the closed / shut off position (Ill. 15).To open the closure valve perform theabove steps in the reverse order. Onceopen, it should be checked that the red clo-sure handle is in the fully up position andthat the safety lock is re-clipped into placeto assure that the closure handle is not un-intentionally closed.

ill. 12 ill. 13 ill. 14 ill. 15

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A

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6. Inspektion und WartungDuring inspection and maintenance of theAqualift F Lifting Station, the closure valveshould also be inspected and serviced if re-quired. In the closed position, no more than1 liter of water should pass through the clo-

sure lock within a period of 15 minutes.

Note: Disassembling the closure valve isnot allowed. Defective parts should be re-

placed with only original KESSEL replace-ment parts.

7. Warranty1. In the case that a KESSEL product is de-

fective, KESSEL has the option of repairingor replacing the product. If the product re-mains defective after the second attempt torepair or replace the product or it is econo-mically unfeasible to repair or replace theproduct, the customer has the right to can-cel the order / contract or reduce paymentaccordingly. KESSEL must be notified im-mediately in writing of defects in a product.In the case that the defect is not visible ordifficult to detect, KESSEL must be notifiedimmediately in writing of the defect as soonas it is discovered. If the product is repairedor replaced, the newly repaired or replacedproduct shall receive a new warranty iden-tical to that which the original (defective)product was granted. The term defective

product refers only to the product or partneeding repair or replacement and not ne-cessarily to the entire product or unit. KES-SEL products are warranted for a period of24 month. This warranty period begins onthe day the product is shipped form KES-SEL to its customer. The warranty only ap-plies to newly manufactured products. Ad-ditional information can be found in section377 of the HGB. In addition to the standardwarranty, KESSEL offers an additional 20year warranty on the polymer bodies ofclass I / II fuel separators, grease separa-tors, inspection chambers, wastewatertreatment systems and rainwater storagetanks. This additional warranty applies tothe watertightness, usability and structuralsoundness of the product.

A requirement of this additional warranty isthat the product is properly installed andoperated in accordance with the valid in-stallation and user's manual as well as thecorresponding norms / regulations.

2. Wear and tear on a product will not be con-sidered a defect. Problems with productsresulting from improper installation, hand-ling or maintenance will also not be consi-dered a defect.

Note: Only the manufacturer may open sea-led components or screw connections.Otherwise, the warranty may become nulland void

01.06.2010

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9. Replacement Parts

Pos.Nr. Amount Article Number Description

1 1 240-053 90 degree outlet housing DN 100

2 1 240-035 Closure assembly

3 1 240-027 O-ring

4 4 240-058 Securing bolts M6

5 4 240-059 Securing nuts M6

Connection with lifting station*

Pos.Nr. Amount Article Number Description

6 1 240-037 O-ring

7 8 240-038 Securing bolts M8

8 8 240-039 Securing nuts M8

➇ill. 16

➅

� Backwater protection

� Lifting Stations and pumps

� Drains and shower channels

� Separators-Grease Separators-Oil- / Fuel-/Coalescence Separators-Starch Separators-Sediment Separators

� Septic Systems

� Inspection Chambers

� Rainwater Management Systems