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Operating Manual

We provide clear water

for SBR small wastewater treatment systems KLARO and KLARO Easy

with controller KLbasic und KLplus

No mechanicsin the wastewater

No pumpsin the wastewater

No electrical partsin the wastewater

No mechanics in the wastewater

No electrical parts in the wastewater

No pumps in the wastewater

Operating Manual for SBR small wastewater treatment systems

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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.


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TABLE OF CONTENTS Page

1. About these operating instructions 61.1. Original language of the documentation 61.2. Completeness 61.3. Responsibility 7

2. Safety 72.1. Explanation of warnings and prohibitions 72.2. Hazard warnings 82.3. Warnings 92.4. Operating exclusions 10

3. Warranty 10

4. Function of the SBR system 104.1. Plants for carbon elimination (effluent classes C) 114.2. Plants with additional nitrogen elimination 124.3. Plants with additional phosphate elimination 134.4. Plants with additional hygienisation 13

5. The control of the small wastewater treatment plant 135.1. Connections on the control 155.2. Operating the control 16

5.2.1. Querying the operating hours 175.2.2. Driving the valves and the cabinet fan manually by means of the “Manual mode“ 175.2.3. Setting the date / time 185.2.4. Setting the vacation mode 195.2.5. Reading out errors – reading out old faults 205.2.6. Displaying the settings 205.2.7. Service menu and action code 20

5.3. Replacing fuses 205.4. Functional principle of the power outage detection device 21

6. Additional functions of the KLplus and KLbasic controls 226.1. Underload detection (KLplus) 22

6.1.1. Functional principle 236.1.2. Commissioning 236.1.3. Switching off the fill-level detection 256.1.4. Safety and fault messages 26

6.2. Optional additional functions with extension cable (KLplus and KLbasic) 266.2.1. Connection of an external fault indicator 266.2.2. Connection of a connector for switching the compressor 266.2.3. Connection of a UV reactor 266.2.4. Phosphate precipitation using the dosing pump 26

7. Maintenance, servicing and operation 287.1. Tasks of the operator 29

7.1.1. Daily check 297.1.2. Weekly checks 297.1.3. Monthly checks 297.1.4. Sludge drainage 29

7.2. Maintenance and servicing by skilled maintenance personnel 31


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7.3. Operating instructions 32

8. Fault messages and troubleshooting 348.1. Fault message on the display 348.2. Unusual water levels – rectifying a fault 368.3. Possible incidents on solenoid valves 37

ANNEX 38

9. Maintenance documentation 399.1. Form for monthly check marks 399.2. Maintenance protocol for KLARO small wastewater treatment plants 40

10. Technical data 4210.1. Technical data of the controls 42

10.1.1. Circuit diagram, EPP cabinet with KLbasic control 4310.1.2. Circuit diagram, EPP cabinet with KLplus control 4310.1.3. Circuit diagram, I cabinet with KLbasic control 4410.1.4. Circuit diagram, I cabinet with KLplus control 4410.1.5. Circuit diagram, A column with KLbasic control 4510.1.6. Circuit diagram, A column with KLplus control 4510.1.7. Circuit diagram, A column, A cabinet 1+2 with indicator lamp with KLplus control 4610.1.8. Equipment list 4710.1.9. Circuit diagram, extension cable 48

11. EC declaration of conformity 49

12. Additional tests of the plants 5312.1. Tested purification performance with underload 53

13. Datasheets of the plant 5413.1. Piston compressor Nitto 5413.2. Becker and Rietschle rotary slide compressors 60

TABLE OF FIGURES PageFigure 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


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1. About these operating instructionsThese 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© KLARO GmbHSpitzwegstrasse 63D-95447 Bayreuth (Germany)Technical support: +49 (0) 9 21 – 16 27 9 – 330Email: [email protected]: www.klaro.euAll rights expressly reserved. Reproduction or communication to third parties, in whatever form, is not permitted without the written consent by KLARO GmbH.

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. Ifyou detect any incomplete information and/or errors, please inform us about these at the above-mentioned address.When compiling these instructions, maximum possible coherence between the facts contained hereinand the associated system was paid attention to. Nevertheless, all technical data, stated measurementsand 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 KLARO GmbH 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


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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

KLARO GmbH,• 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


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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.


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2.3. Warnings

These warnings must be always observed; otherwise, personal injuries or damage to property may occur!

Installation site

Make sure that the machine cabinet is not installed above or right next to water containers. Risk of electric shock if not installed properly.

Mains connection

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 apreliminary 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.

Explosive atmospheres

The control must not be installed or switched on in environments with potentially explosive atmospheres or in places where flammable materialsexist. 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, thecontrol 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.

Battery replacement

After having been replaced, the battery supplied must be properly disposed of.

Voltage supply

The power supply must be permanently ensured. Please make sure that thecontrol cabinet is sufficiently protected (16 A). Additional power consumers onthe same fuse can disrupt the operation.


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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 theoperating 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 isdesigned 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,


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- 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 aeratorand the air distribution for the different lifts via solenoid valves.

Your competent water authority has determined limit values for the water quality of the treatedwastewater. 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:COD BOD5 NH4-N Ninorg SS FC germs Ptot

KLARO values

39 mg/l 9 mg/l 6,1 mg/l 18,7 mg/l 15 mg/l 1,9/100ml 0,4 mg/l

Degree of efficiency

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): ventilationDuring 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


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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 phaseThis 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 extractionDuring this phase, the biologically treated wastewater (clearwater) is pumped out of the SBRstep. 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 extractionDuring 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 ispumped 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 KLARO GmbH. 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 modeis 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 linevented 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


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aeration periods at the beginning of the ventilation phase. These bacteria transform nitrate intoelementary nitrogen.

4.3. Plants with additional phosphate elimination

The phosphate precipitation is carried out by adding polyaluminium chloride in the SBR reactor. Aremovable 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 theUV 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 micro-organisms. 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.


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KLbasic control KLplus control

Figure 3 : View of the KLbasic control unit Figure 4: View of the KLplus control unit

Display of the operating statesThe 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:

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 be treated from the sludge storage into thebioreactor.

charging

Denitrif Valve 2 is intermittently driven; the activated sludgeis briefly mixed with the wastewater. This process is followed by long pauses (reaction times).

denitrification

Aeration Valve 2 is driven; the bioreactor is aerated at intervals.

aeration

Sediment No valve is driven, the activated sludge settles in the bioreactor.

sedimentation

Discharc Valve 3 is driven; the clearwater is pumped into the outlet.

discharging

SludgeRe Valve 4 is driven; the reactor pumps the excess sludge into the sludge storage.

sludge return

Pause Valve 2 is driven; the bioreactor is aerated at cycle pause

Aeration120.10m

aerationrest: 120.10 Min


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intervals (significantly less than during the “ventilation" phase).

Vacationinput

Valve 2 is driven; the bioreactor is aerated at intervals, no purification cycle is processed.

Vacation oper.

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 SymbolEnter key Selection of the operating mode, input

confirmationScrolling Display of the operating modes and

queries

Acknowledge-ment

Input acknowledgement without savingAcknowledgement of fault messages

----------- Number keys 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


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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.

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 firstoperation 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 stateRemaining time

Current working phase, remaining time Operating stateRemaining time

Operatinhours

Display of the operating hours of the individual valves and the compressor

operating hours


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Manualoperation

Manual driving of the valves manual operation

Hh:mm dddd-mm-jj

Current time, day and date. Can be set using SET. DateTime

Vacationinput

Setting the vacation mode (max. 90 days) Vacation oper.

Read outerrors

Here, operational breakdowns are saved and can be

read out. Using , you can switch between the error message and the corresponding date.

Read outold errors

Adjustments: By means of the arrow keys, the current setting can be displayed.

Setup report

Operatiocode

For specialist personnel operation code

Servicemenu

For specialist personnel service codeenter

5.2.1. Querying the operating hours

Press the key. The following display appears on the screen:

By pressing again, the operating hours for the valves 1-4 can be called one after the other

by means of the arrow keys . Then, the total operating hours of the compressor are shown.

By pressing once, you can return to the

display “Show operating hours“. By pressing ,you can access the menu “Manual mode“.

Press the key. The following display appears on the screen:

By pressing again, the number of operating hours of valve 1 (feed) are shown.

By pressing the arrow keys , you can call the operating hours of the other valves, of the compressor, of the UV lamp and the pump for the phosphate precipitation one after the other. Moreover, the capacity of the plant is shown.

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.

Operating hoursmeter reading

Operation hours


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In the automatic mode: press , then press the

arrow key until the following display appears on the screen:

By pressing the key, the following display appears:

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“.

Press , then press the arrow keyuntil the following display appears on the screen:

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:

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 keysafterwards, until the following display (example) appears on the screen:

By pressing , the time and date can be set

using the arrow keys . In order to confirm

Press , press the arrow keysafterwards, until the following display (example) appears on the screen:

By pressing , the time and date can be set using the number keys. In order to

confirm the adjustment, must also be

manual valve1: off

Manual operation

valve1:off

Manualoperation

19-12-2007 Mo20:15:56

20:15 Mo19-12-07


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the adjustment, must also be pressed in each case.

By pressing once, you can access the

vacation mode. By pressing , you can return to the manual mode.

pressed in each case.

By pressing once, you can access the

vacation mode. By pressing , you can return 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 adjustmentfrom 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. Thevacation mode is automatically switched on and off according to the data you have entered.

Press , press the arrow keysafterwards, until the following display appears on the screen:

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.

Press , press the arrow keysafterwards, until the following display appears on the screen:

By pressing the key again, the input for the vacation data is enabled:

By pressing the key again and entering of the end date of the vacation mode using the number keys:

By means of the key, you save the data entered for the vacation mode and exit this function.

Vacationinput

vacation end: 21-05-2007

vacationstart: 21-05-2007

Vacation date setup


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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 skilledmaintenance 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 230 V / 50 Hz

Supply line F1 8 A, medium time lag

Consumer F2 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).


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– 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 integratedemergency 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 orwhen separated from the wall socket), the detection device sends alternately an acoustic and visualsignal 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)


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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 amaintenance technician or an export. Any incorrect calibration of the plant can causethat 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.


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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 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 theheight 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.

Figure 9: Drawing air lifter charging


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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

4 6 8 8 12 16 20 25 40 50Container type

ZK224 ZK224 ZK225 ZK226 ZK2282x

EK2252x

EK2262x

EK2284x

EK2264x

EK228Heighta [cm] 8 12 16 16 24 16 20 25 20 25Heightb [cm] 101 105 124 150 193 124 154 194 154 194

PE number12 16 20 30 35 40 40 50

Container typeZK259 ZK2510 ZK2512

2x EK2510

2x EK2512

2x EK2512

EK/ZK/EK 259

EK/ZK/EK 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

number

4 6 8 4 6 8 10 12 16 20 25 35

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

1st step: calibration of the pressure sensorThe calibration of the sensor is absolutely necessary for the initial commissioning. Please carefully follow the instructions provided below:

Service codeenter

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.

calibrate?no

Select “CALIBRATION YES“ by using the arrow keys (←→), confirm this

input by pressing the key and start calibration …measuring… Three measurement processes are carried out automatically.


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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)

and confirm this input by pressing .save?

____ cm NoThe 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.

2nd step: setting the control parametersSetting 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 codeenter

Go to the menu item “ENTER SERVICE CODE“, press the key and enter the service code after having been requested to do so.

level measuring setup

Select “Set fill-level detection“ by using the arrow key to the left (←) and

confirm this input by pressing the key.Fill level

Start from: 000 cmEnter the water level b at which a treatment cycle is to be started. Confirm

this input by pressing the key.Recirculation: 2 min

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.

alert floodingfrom: 000 cm

(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 thekey.When saving the value “000 cm”, the flood warning message is deactivated.

3rd step: function controlNow, the fill-level detection can also be carried out in the manual mode. For this, the fill-level detectionmust 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 2nd step described above must be repeated. The water level b must be set to 0 cm. The recirculation canremain set to two minutes.


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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 monitoringST7”, 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 ethyleneoxide.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.


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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 respectivecertification (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 dome-shaped manhole of the plant). The pressure hose andthe 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 openingmust, 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 precipitantis sucked correctly. If required, interchange the hoses at the connections.

Figure 10: System drawing precipitation unit

Reference values for setting the pump performance

P [ml/min]1 1.52 5.53 11.04 15.05 19.06 22.57 26.08 30.59 35.0

10 37.5

Output: 5.5 ml/min

Figure 11: Precipitant pump Compact Figure 12: Precipitant pump DSP 9911


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7. Maintenance, servicing and operationThe 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.

Fall hazard

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!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!


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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 lamplights 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 aggregatesand 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 pitand 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 conditionsaround 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 thataccumulates 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 sludgeconsists 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 skilledmaintenance 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


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sludge storage room is large enough for at least twelve months. Low-load operation extends this period of time accordingly. Timely sludge disposal is necessary in order to prevent the solids from entering the biological stage in the event of increasing sludge production. Sludge regulation and disposal areimportant requirements for a good purification performance and long life of the small wastewater treatment plant.The sludge disposal regulations are laid down by the local authorities. Either regular or demand-orientedsludge removal is required:- Regular sludge removal takes places on specific dates and is set by the local authorities to once

and/or twice a year depending on the type of the plant, size of the chambers and connectedinhabitants.

- Demand-oriented sludge removal is flexible and takes place at shorter or longer time intervals. In this case, skilled maintenance personnel check the sludge level (sludge level measurement) and inform the competent disposal company about the date of the required sludge disposal. With a filling of the sludge storage of 70 % at the latest, the sludge must be disposed of. In individual cases, the skilled maintenance personnel inform the operator who then arranges himself/herself a date for the sludge disposal.

If the maintenance and the sludge removal coincide, the sludge may only be removed after the maintenance has been completed. The sludge removal must be recorded in the operating log. In this respect, please also read the instructions provided by your specialist company.

For the sludge removal, the following aspects must be observed:In most cases, only the primary settlement chamber of the small wastewater treatment plant must be emptied. With an incorrect sludge regulation of the plant, the suction of the lower section of the tertiary treatment chamber or the suction of the floating sludge from the surface may also be necessary. First, the floating sludge is sucked from the surface; then, the suction tube is placed on the

bottom of the pit, A residual amount of water of approx. 10 cm should be left on the bottom of the primary

settlement chamber, After the drainage has been completed, the primary settlement chamber must be refilled

with fresh water!Complete drainage of the small wastewater treatment plant only makes sense if an operational breakdown occurs for which the cause cannot be determined or if repair work must be performed below the water level inside the container. Whether such complete drainage is necessary is best decided by the skilled maintenance personnel.

It is essential that you, as operator of a small wastewater treatment plant, ensure that the correct chamber of the plant is pumped. Excessive pumping of sludge can interfere with the operation of a small wastewater treatment plant and causes unnecessary costs!


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7.2. Maintenance and servicing by skilled maintenance personnel

The maintenance must be carried out by a specialised company (skilled personnel)1. For this, the owner of the plant must conclude a maintenance contract with a qualified specialist.Note! During retrofitting work or maintenance work on the electrical components of the plant, the control cabinet must be disconnected from the power supply by means of a main switch or maintenance switch of the plant. It must be ensured that the switch is protected against being switched on by means of a lock.The following work must be performed as part of the maintenance:

- Inspection of the operating instructions including assessing that the plant works properly (target/actual performance comparison),

- Checking the air filter of the aerator and the supply and exhaust air openings of thecontrol cabinet,

- Maintenance of the aerator according to manufacturer’s instructions (see annexes!).- Function control of the operation-critical mechanical, electro-technical and other components

of the plant such as the aerator, lift, control unit, valves, alarm unit and the battery of the power outage detection device,

- Checking the sludge height in the sludge storage; if required, the sludge removal must be provided for by the operator (for instructions, see section 0),

- Performing general cleaning work, e.g. removal of deposits,- Checking the state of repair of the plant,- Checking sufficient ventilation and exhaustion,- Examinations in the aeration tank:

• Even ventilation picture (bubble picture),• Oxygen concentration (O2/l > 2 mg); if required, adjustment of the operating times of the

compressor,• Sludge volume fraction (< 400 ml/l). If the sludge volume is below 100 ml/l or above 400 ml/l, the duration of the sludge extraction must be changed in consultation with KLARO GmbH.

- Samples from the outlet and analysis of the following values:For each maintenance:

- Temperature of the wastewater,- Settleable solids,- pH value,- Odour,- Colour,- Visibility depth,- COD value,- NH4-N (when required),- Ninorg (when required),

P (when required).

1 Specialised companies are operator-independent companies whose employees (skilled personnel)have, due to their professional training and participation in relevant qualification measures, the qualification required for the operation and maintenance of small wastewater treatment plants.


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Any performed maintenance work as well as any detected damage or repair work carried out and further action must be summarised in a maintenance report by the maintenance company. The corresponding formcan be found in the annex. The findings of the examinations must also be recorded in the maintenance report. The maintenance report must be handed over to the operator of the plant so that this report can be submitted to the competent authority after having been requested to do so. The maintenance report must be attached to the operating instructions. Please keep the operation log easily accessible. Note: Breakdowns of the plant due to inadequate maintenance (e.g. of the compressor) exclude free

replacement within the scope of warranty.

7.3. Operating instructions

As a matter of principle, only substances that, due to their nature, correspond to domestic untreated wastewater may be supplied to the plant for treatment.Biocides, toxic or biologically incompatible or non-degradable substances must not enter the plant, since they cause biological process problems. In particular, the following substances must not be discharged:

- Rainwater from roof surfaces and courtyard areas,- Infiltration water (e.g. drainage water),- Residues arising from animal farming in solid and liquid form,- Commercial or agricultural untreated wastewater provided that it cannot be compared with

domestic untreated wastewater,- Chemicals, pharmaceuticals, mineral oils, solvents,- Cooling water,- Coarse substances in the form of leftovers, plastics and sanitary products, coffee filter bags,

bottle lids and other household items,- Milk and dairy products,- Discharge water from swimming pools,- Larger quantities of blood.

If larger quantities of fats or vegetable oils accumulate, it is recommended to pre-clean the fat-containingwastewater in a fat separator that is installed upstream to the wastewater treatment plant (Caution:Faeces must not be discharged into the fat separator!).

In the table below, individual substances that must not be disposed of using the wastewater treatment plant are listed once more in more detail:

Solid or liquid substances thatmust not be disposed of using the drain and/or toilet:

What damage they do: Where they are adequately disposed of:

Adhesive plaster Clogs the pipes Dustbin

Ash Does not decompose Dustbin

Bird sand, cat litter Causes deposits and clogging of the pipes

Dustbin

Brush cleaners Poison the wastewater Collection point of the administrative district

Cat litter Clogs the pipes Dustbin

Cement water Settles, concretes Hire specialist company


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Chemicals Poison the wastewater Collection points

Cigarettes Settle in the plant Dustbin

Cleaning agents except for those which are chlorine-free (environmentally friendly)

Poison the wastewater, corrode pipes and sealings

Collection point of the administrative district

Condoms Clogging Dustbin

Cooking oil Causes deposits and clogging of the pipes

Collection points of the administrative district

Corks Settle in the plant Dustbin

Cotton buds Clog the plant Dustbin

Deep-frying fat Settles in the pipes and causes clogging

Dustbin

Disinfecting agents Kill bacteria Do not use

Leftovers Cause clogging, attract rats Dustbin

Medication Poisons the wastewater Collection points, pharmacies

Motor oil Poisons the wastewater Collection points, petrol stations

Nappies Clog the pipes Dustbin

Paint Poisons the wastewater Collection point of the administrative district

Panty liners Cause clogging, non-degradable plastic foils spoil the waters

Dustbin

Pesticides Poison the wastewater Collection point of the administrative district

Photographic chemicals Poison the wastewater Collection point of the administrative district

Plant protection products Poison the wastewater Collection point of the administrative district

Razor blades Risk of injury for the workers in the sewer system and wastewater treatment plant

Dustbin

Textiles (e.g. nylon stockings, cleaning rags, handkerchiefs etc.)

Clog the pipes, can bring a pump station to a halt

Used clothing collection

Thinners Poison the wastewater Collection point of theadministrative district

Toilet blocks Poison the wastewater Do not use

Tube cleaners Corrode pipes and sealings, poison the wastewater

Collection point of the administrative district

Varnish Poisons the wastewater Collection point of the administrative district


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Wallpaper paste Causes clogging Collection point of the administrative district

Waste containing oil Poisons the wastewater Collection points, petrol stations

For general questions relating to these problems, please feel free to contact KLARO GmbH in Bayreuthat any time.

8. Fault messages and troubleshooting

Technical faults during the plant operation (breakdown of an aggregate) are displayed both visually and

acoustically. The acoustic fault signal of the control can be switched off by pressing . The visual error

display is only acknowledged after pressing the key once again.In the event of a power supply outage, an integrated battery-supplied power outage warning device sends alternately an acoustic warning signal and a visual message. In this case, no acknowledgement is possible.

Voltage!

For any work on the machine cabinet exceeding the operation of the control,the cabinet must be disconnected from the mains voltage.

8.1. Fault message on the display

- Error message as text on the liquid crystal display,- Operating indicator lamp lights red.

Display

Liquid crystal display

Possible cause Rectification

KLbasic KLplusNo display, no light • Power supply is

interrupted• Check the power supply to the plant and

to the control.• Check the micro-fuse F1 on the supply

line.• Check the position of the main switch

(position 1).With an empty buffering, a power outage is neither displayed acoustically nor visually.

No display, light lights green • Switch off the plant and switch it on again after ten seconds.

No / weak display • Contrast is setincorrectly

• Hold down the Esc key set the contrast by using the arrow keys.

Set clock

set clock • Internal clock / date not set

• Set clock via the menu item “Date and time”.

Compresofailure

**error**compressor error

• Compressor does not work / does not consume power

• Check the main fuse F1.• Check the compressor via the manual

mode.Valve 1 **error** • Valve does not work • Check the value via the manual mode.


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Display



KLbasic KLplusfailure valve 1 • Fuse blown

• Solenoid defective• Valve blocked due to

contamination

• Check the micro-fuse of the consumers F2.

• Check the valve for possible burn marks.• Unscrew the valve from the metal bar,

check the valve for contamination andremove all contamination particles (seemaintenance instructions in the annex).

Valve 2failure

**error**valve 2 error

Valve 3failure


Valve 4failure


- **error**UV unit error!

• UV lamp does not work • Check the UV lamp and the remaining life of the lamp.

- **error**min water level

• Compressed-air lineleaking from the control to the feed lift, e.g. due to a loose hose

• Check the hose line for leakages.

- **error**alert flooding

• Water level is too high in one chamber

• Compressed-air lineclogged, e.g. due to bent hose

• See section 8.2.• Check the hose line for bends.

- **error**temperaturemax

• Temperature probe not plugged in

• Cabinet fan does not work

• Filters in the cabinet andin the compressor are contaminated

• Direct sunlight onto the cabinet

• In the service menu, too high temperatures have been entered for switching on the cooling fan and the maximum temperature

• Aerator defective• Temperature probe

defective

• Plug in the temperature probe on the rear of the control.

• Check the functions of the cabinet fan.• Check the air filter in the cabinet.• Shade the site of the cabinet.• Provide for cool ventilation.• Check the air filter in the aerator.• Check the aerator in the manual mode.• Have the set temperatures checked by

the maintenance company.• Replace the temperature probe.

- **error**temp.-sensor

• Temperature sensor is missing

• Temperature sensor has not been completely connected to the socket

• Temperature sensor defective

• Replace sensor.• Provide for a secure connection between

the control and temperature sensor; then, disconnect the control for ten seconds from the mains and switch it on again;check whether a fault message “temp. sensor” is displayed.

Power failure **error**power failure

• Blackout• Plant switched off by

means of the main switch

• There is no voltage on the switch cabinet

• Fuse of the residual current device has been initiated

• Await the blackout.• Switch on again the plant by means of the

main switch.• Check the supply line to the switch

cabinet.• Search for and rectify the cause for the

initiation of the residual current device (possible cause: solenoid valve defective).

Error modem

**error**modem

• Rechargeable batteriesin the module have not been charged

• Wait five seconds until the rechargeable batteries have been charged.

• Connect the modem to the mains.


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Display



KLbasic KLpluscompletely

• No mains voltage is applied to the modem

• No SIM card inserted into the modem

• SIM card is not logged in into the network

• Insert the SIM card into the modem.• Wait until the card has logged in;

otherwise, position the antenna in such a manner that reception is possible.

8.2. Unusual water levels – rectifying a fault

Observation Possible cause Rectification

The water level in the primary settlement chamber is unusuallyhigh; the water level in the aeration tank is normal.

• The lift on valve 1 is not driven,• Too short a pump time has been set

for lift 1,• The feed lift is clogged,• The air supply to the feed lift is

leaking.

• Drive valve 1 in the manual mode and check the function of the lift.

• Have the time period for valve 1extended by the servicecompany.

• Have the primary settlement chamber pumped out and clean the lift.

• Have the primary settlement chamber pumped out and seal the hose connections.

Both the water level in the primarysettlement chamberand the water level in the aeration tank areunusually high.

• Plant is being run in vacation mode,• Plant is being permanently run in

cycle pause,• Control settings are incorrect,• The outlet lift is clogged,• The air hose to the outlet lift is

leaking,• The flood in the outlet channel

prevents the water from draining off the plant,

• Control is defective.

• Exit the vacation mode (see section Fehler! Verweisquelle konnte nicht gefunden werden.).

• Have the control settingschecked by skilled maintenance personnel.

• Have the SBR reactor pumpedout and clean the lift.

• Have the SBR reactor pumpedout and seal the hose connections.

• Await the flood,• Contact the maintenance

company.The plant smells, the treated wastewater is blurred and/ordiscoloured.

• Insufficient air volumes are drawn into the plant,

• Unbalanced ventilation due todefective diaphragm unit.

• Have the ventilation time extended by the servicecompany.

• Check the ventilation picture,contact the maintenance


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Observation Possible cause Rectification

company.Ventilation picture is unbalanced and/orlarge air bubbles rise sporadically.

• Diaphragm unit defective,• Sealing on the aerator bar is leaking.

• Contact the maintenance company.

• Contact the maintenance company.

Solenoid valves switch unusually loudly.

• Valve seat of the solenoid valve iscontaminated.

• Unscrew and clean the solenoid valve.

8.3. Possible incidents on solenoid valves

Observation Possible cause

Armature does not operate. • Supply voltage has been interrupted or is insufficient,• Solenoid is defective,• Armature is blocked in the contaminated tube area. If the armature

does not reach its final position, this can, with an activated alternating current coil, lead to a failure of the coil within a short period of time (thermal overload),

• Nominal voltage and coil voltage are different.Valve does not close. • Armature is blocked!

• Nominal voltage is still applied.Valve does not open. • No nominal voltage is applied,

• Solenoid is defective,• Nominal voltage and coil voltage are different.

Version: 02 / 2013Subject to technical changes!


KLARO GmbH38

ANNEX


KLARO GmbH 39

9. Maintenance documentation

9.1. Form for monthly check marks

Dat

e of

the

chec

k

Slud

geov

erflo

w?

Burr

ing/

dis-

colo

urat

ion

Clo

ggin

gin

let/o

utle

t?

Air f

ilter

ch

ecke

d? Operating hours counterOperating instruction: Press “Esc” twice, press “Set” twice =

operating hours valve 1 2 3 4 compressor

yes

no yes

no yes

no yes

no

ValveΣ UV Phos

1 2 3 4


KLARO GmbH40

9.2. Maintenance protocol for KLARO small wastewater treatment plants

Location (address):

Maintenance company: Maintenance date:

Serial number: Order no.:

Plant size: PE Actual connection: PE

Name of the operator: Customer no.:

Street: Telephone no.:

Postal code/place: Fax no.:

Installed by: Commissioning:

Is commercial wastewater also discharged? No

Restaurant without kitchen Restaurant with kitchen Other

Fat separator available, NG Drainage required

State of repair (visual assessment of the pit body when filled):

Dividing walls are OK Pit is tight to the outside

Dividing wall between SS+P & SBR is leaking Corrosion damage

Remarks:

Function control of the operation-critical plant components:

Feed lift / valve 1 (red) Ventilation / valve 2 (blue)

Outlet lift / valve 3 (black) Excess sludge lift / valve 4 (white)

Power outage warning device (battery) Phosphate precipitation pump (optionally)

UV reactor (optionally) External indicator lamp (optionally)

Air supply / ventilation moderate, intensive, circulation clearly visible

Aerator picture / ventilation fine bubbles even

Remarks:

Sludge storage + buffer:

Sludge height: cm Floating sludge height: cm

The operator should have the cesspit drained.

SBR reactor:

Oxygen concentration: mg/l (normally approx. 4-6 mg/l, minimum 2 mg/l)

Sludge volume fraction: ml/l (maximum 400 ml/l)

Remarks:


KLARO GmbH 41

Control

Control type: Σ-Operating hours:

Feed (valve 1): Ventilation (valve 2):

Outlet (valve 3): Excess sludge extraction (valve 4):

UV reactor: Renew lamp in operating hours

Remarks:

Fan

Fan type: Fan is OK

Replacement of the lamellae (length of the lamellae: mm) Replacement of the diaphragms

Filter replacement Cooling fan is OK

Remarks:

Time of sampling Date: Time:

Sampling point: Sampling manhole SBR chamber

Sample transport: Cooled 4°C Frozen

Air temperature: °C Water temperature: °C

Odour None Some Strong Rotten Earthy

Colouring None Some Strong Beige Brown

Blurring None Some Strong Opaque

Floating solids None Some Many

Dry substance

Activated sludge kg TS / m³ Ptot

Settleable solids ml / l pH value

BOD5 ml / l COD ml / l

NH4-N ml / l Ntot ml / l

Additional remarks

Operation log is available. Maintenance was recorded in the operation log.

Programming was changed.

Fault was rectified.

Additional remarks:

To be initiated by the operator himself/herself

The operator is asked to pay attention to the substances that must not be discharged (see operation log).

Pit is flooded, operator must have the pit drained.

Remove sludge from the pit (dispose of sludge storage).

Date and signature


KLARO GmbH42

10. Technical data

10.1. Technical data of the controls

- Preliminary fuse 12 A (provided by the customer)- Voltage supply 230 V / 50 Hz- Micro controller with internal FLASH, RAM, ADC

Outputs for• Aerator• Four solenoid valves for the air blast.

Additional features of KLplus:• Dosing pump (phosphate pump),• UV lamp,• Fan,• External fault indicator.

- All outputs 230 V AC, aerator ≤ 6 A, dosing pump, UV lamp and cabinet fan- ≤ 0.5 A, solenoid valves ≤ 0.09 A- Several outputs can be switched on at the same time.- Cable break monitoring for all outputs by measuring the output currents,- Contactor monitoring by means of detecting the switched voltage, 230 V AC- Fault message display via LED (red/green), buzzer for power outage and change-over contact up

to 230 V AC,- Serial interface RS232 with 9,600 baud via jack socket,- Real-time clock with a deviation of five minutes/year, battery-buffered,- Logbook, failure-safe,- Temperature monitoring,- Internal 9 V block battery for restricted operation in the event of a operating power outage,- Monitoring of the discharge state,- Operating temperature range 0 ºC ... +55 ºC,- Acceptable temperature range without operation -20 ºC ... +85 ºC

Within the device:- Relative humidity of 10...95 %, non-condensing,- Degree of protection: IP54, at the front (with properly affixed front foil),- Operating voltage 230 V AC, ± 20 %, 50 Hz,- Protection by means of micro-fuse 8 A (medium time lag), can be replaced from the outside;

additional micro-fuse 2 A (time lag) for the total current of the outputs without aerator and fan.


KLARO GmbH 43

10.1.1. Circuit diagram, EPP cabinet with KLbasic control

10.1.2. Circuit diagram, EPP cabinet with KLplus control


KLARO GmbH44

10.1.3. Circuit diagram, I cabinet with KLbasic control

10.1.4. Circuit diagram, I cabinet with KLplus control


KLARO GmbH 45

10.1.5. Circuit diagram, A column with KLbasic control

10.1.6. Circuit diagram, A column with KLplus control


KLARO GmbH46

10.1.7. Circuit diagram, A column, A cabinet 1+2 with indicator lamp with KLplus control


KLARO GmbH 47

10.1.8. Equipment list

Art.No. Quan. Description / Marking Mar. Technical datas901382 1 Control KL plus A1 230V / 50Hz / 5W901381 1 Control Klbasic A1 230V / 50Hz / 5W980284 1 Microfuse M8A, medium delay F1 230V / 8A980283 1 Microfuse T2A, delay F2 230V / 2A980283 1 Fuse clip 8WA1011-1SF12 F3 250V / 6,3A980283 1 Microfuse T2A, delay F3 230V / 2A901113 1 Turn signal lamp LED H1 230V / 19mA456232 1 Permanent lamp 851 H1 230V / 7W901169 1 Warning light buzzer 480 H1 230V / 7W983102 1 Warning light with buzzer LED H1 230V / 40mA981265 1 UV-Disinfection plant ABOX S 50 (basic version) H2 230V / 50Hz / 75W981263 1 UV-Disinfection plant ABOX S 50 (complete version) H2 230V / 50Hz / 155W901183 1 Compressor/Air compressor LA60B M1 230V / 50Hz / 0,43A / 64W+/- 20%901170 1 Compressor/Air compressor LA80B M1 230V / 50Hz / 0,57A / 86W+/- 20%901013 1 Compressor/Air compressor LA120B M1 230V / 50Hz / 1,00A / 130W+/- 15%901060 1 Compressor/Air compressor LAM200 M1 230V / 50Hz / 1,80A / 215W+/- 20%901170 1 Compressor/Air compressor DT4.4 M1 230V / 50Hz / 1,65A / 180W901171 1 Compressor/Air compressor DT4.6 M1 230V / 50Hz / 1,65A / 180W901172 1 Compressor/Air compressor DT4.8 M1 230V / 50Hz / 3,90A / 350W901173 1 Compressor/Air compressor DT4.10 M1 230V / 50Hz / 370W901174 1 Compressor/Air compressor DT4.16 M1 230V / 50Hz / 550W901192 1 Filter ventilator KA1238XA2BMT M2 230V / 50Hz / 0,15A / 23W / 178m³/h981821 1 Filter ventilator 87603 M2 230V / 50Hz / 0,17A / 36W / 300m3/h980954 1 Filter ventilator SK 3326.107 M2 230V / 50Hz / 0,35A / 64W / 500m3/h981543 1 Filter ventilator SK 3327.107 M2 230V / 50Hz / 0,95A / 115W / 700m3/h981932 1 Filter ventilator 87605 M2 230V / 50Hz / 0,65A / 150W / 838m3/h901210 1 Metered peristaltic pump SR15 M3 230V / 50Hz / 4,5W / 1,8ml/min980733 1 Metered peristaltic SR18 M3 230V / 50Hz / 5,5W / 5-50ml/min981314 1 Metered peristaltic Concept 2105mcs M3 230V / 50Hz / 5,5W / 5-50ml/min981315 1 Metered peristaltic Compact R M3 230V / 50Hz / 5,5W / 75ml/min980978 1 Main switch KG10B T202/D-A045 FT2 S1 230V / 50Hz / 20A981398 1 Connection cable 3m H05VV-F W1 3G1,5mm²

- 1 Connection cable of the control 0,9m H05VV-F W2 3G1,5mm²901383 1 Extension cable ZK K3-2 1,23m Y-JB W3 8G0,75mm²901384 1 Valve cable ZK K1-4, l=1,2m, Y-JB W4 7G0,75m²901385 1 Valve cable ZK K1-1, l=1,2m, Y-JB (with cooling ventilator connection) W4 7G0,75m²901258 1 Valve cable ZK K1-3, l=0,23m, Y-JB (EPP indoor switch cabinet) W4 7G0,75m²908700 1 Ventilator cable long, l=1,2m, Y-JZ (indoor switch cabinet) W5 3G0,5mm²908701 1 Ventilator cable long, l=0,32m, Y-JZ (outdoor switch cabinet) W5 3G0,5mm²

- 1 Air compressor cable, l=1,6m, H05VV-F W6 3G0,75mm²- 1 Connection cable air compressor 0,15m H05VV-F W7 3G0,75mm²- 1 Peristaltic pump pipe I=0,13m AWG22 / H07V-K W8 2G0,33mm² / 1G1,5mm²

908702 1 Peristaltic pump pipe l=0,13m, H07V-K W8 1G1,5mm²980552 1 Warning light cable 1m W9 2G0,5mm²980123 1 Wiring conductor l=0,1m, H07V-K, black W10 1G1,5mm²

- 1 UV-module cable, l=2,5m, YSLY-JB W11 3G1mm²- 1 Connecting cable, l=0,3m, Y-JZ W12 3G1mm²

980122 1 Wiring conductor l=0,5m, H07V-K, blue W13 1G1,5mm² 980123 1 Wiring conductor l=0,5m, H07V-K, black W14 1G1,5mm² 908704 1 Grounding cable "ring+conductor", l=0,3m, H07V-K, green-yellow W15 1G1,5mm² 908703 1 Grounding cable "ring+ring", l=0,3m, H07V-K, green-yellow W16 1G1,5mm² 908704 1 Grounding cable "ring+conductor", l=0,3m, H07V-K, green-yellow W17 1G1,5mm²

- 1 Shockproof plug (EPP indoor switch cabinet) X0.1 250V / 50Hz / 16A- 1 Shockproof plug (indoor switch cabinet) X0.1 250V / 50Hz / 16A

981980 1 Cap rail socket-outlet (outdoor switch cabinet) X0.2 250V / 50Hz / 16A- 1 Circula plug X1 250V / 50Hz / 10A- 1 Plug with screwed connection, green X1.0 320V / 50Hz / 12A / 3pol. / bis 2,5mm²- 1 Socket with screwed connection, green X1.0 320V / 50Hz / 12A / 3pol. / bis 2,5mm²- 4 Magnetic valve plug X1.1-1.4 250V / 50Hz / 10A / 2pol.+PE- 1 Schuko coupler X2 250V / 50Hz / 16A- 1 Industry plug connector X3 50-250V / 50Hz / 10A / 7pol.+PE

982122 4 Plug with screwed connection, green X3.5-X3.8 320V / 50Hz / 12A / 3pol. / bis 2,5mm²982123 4 Socket with screwed connection, green X3.5-X3.8 320V / 50Hz / 12A / 3pol. / bis 2,5mm²981322 1 Angle coupler black. RST20i4 X5 230-400V / 50Hz / 4pol.901228 1 Air diffuser for-fould Y1-Y4 230V / 50Hz / 16VA


KLARO GmbH48

10.1.9. Circuit diagram, extension cable


KLARO GmbH 49

11. EC declaration of conformity

The manufacturer: KLARO GmbHSpitzwegstrasse 63D-95447 Bayreuth (Germany)Telephone: +49-921-16279-0Fax: +49-921-16279-100Internet: www.klaro.eu

hereby declares that the product KLARO, small wastewater treatment plant in concrete containers for4 to 50 PE, complies with the requirements laid down in the following directives and regulations:

2011/305/EU “Regulation No. 305/2011 of the European Parliament and of the Council of 9 March 2011 laying down harmonised conditions for the marketing of construction products.”

2006/42/EC “Directive of the European Parliament and of the Council of 17 May 2006 on machinery, and amending Directive 95/16/EC.”

2006/95/EC “Directive of the European Parliament and of the Council of 12 December 2006 on the harmonisation of the laws of Member States relating to electrical equipment designed for use within certain voltage limits.”

The following harmonised standards were applied:

EN 12566-3 “Small wastewater treatment systems for up to 50 PT – Part 3: Packaged and/or site assembled domestic wastewater treatment plants”

EN 60204-1 “Safety of machinery – Electrical equipment of machines – Part 1: General requirements”

EN ISO 13849-1 “Safety of machinery – Safety-related parts of control systems – Part 1: General principles for design”

This EC declaration of conformity becomes null and void when the product is modified without approval.

Bayreuth, 9th March 2011

On behalf ofWaldemar Schütz Alexander Kaufmann(Chief executive officer) (Chief technical officer)


KLARO GmbH50

KLARO GmbHSpitzwegstrasse 63

95447 Bayreuth

13

EN 12566-3

Prefabricated wastewater treatment plantfor the treatment of domestic wastewater

KLAROMaterial: concrete

Effectiveness of the treatment:Efficiency of the purification performance(with a tested organic contamination load a day of

dkgBOD 2.05 = )

COD: 86 %

BOD5: 95 %

SS: 88 %

NH4-N*: 99 %(*for wastewater temperatures > 12°C)

Purification capacity (calculation):

- Nominal organic contamination load a day(BOD5)

- Nominal inflow a day (QN)

0.06dPE

kg⋅

0.15dPE

m⋅³

Resistance to penetration of water: (test with water)

Passed

Stability: (static calculation) Passed

Durability: Passed


KLARO GmbH 51

EC declaration of conformity

The manufacturer: KLARO GmbHSpitzwegstrasse 63D-95447 Bayreuth (Germany)Telephone: +49-921-16279-0Fax: +49-921-16279-100Internet: www.klaro.eu

hereby declares that the product KLARO Easy, small wastewater treatment plant in plastic containers for4 to 50 PE, complies with the requirements laid down in the following directives and regulations:

2011/305/EU “Regulation No. 305/2011 of the European Parliament and of the Council of 9 March 2011 laying down harmonised conditions for the marketing of construction products.”

2006/42/EC “Directive of the European Parliament and of the Council of 17 May 2006 onmachinery, and amending Directive 95/16/EC.”

2006/95/EC “Directive of the European Parliament and of the Council of 12 December 2006 on the harmonisation of the laws of Member States relating to electrical equipment designed for use within certain voltage limits.”

The following harmonised standards were applied:

EN 12566-3 “Small wastewater treatment systems for up to 50 PT – Part 3: Packaged and/or site assembled domestic wastewater treatment plants”

EN 60204-1 “Safety of machinery – Electrical equipment of machines – Part 1: General requirements”

EN ISO 13849-1 “Safety of machinery – Safety-related parts of control systems – Part 1: General principles for design”

This EC declaration of conformity becomes null and void when the product is modified without approval.

Bayreuth, 9th March 2011

On behalf ofWaldemar Schütz Alexander Kaufmann(Chief executive officer) (Chief technical officer)


KLARO GmbH52

KLARO GmbHSpitzwegstrasse 63

95447 Bayreuth

13

EN 12566-3

Prefabricated wastewater treatment plantfor the treatment of domestic wastewater

KLARO EasyMaterial: plastic

Effectiveness of the treatment:Efficiency of the purification performance(with a tested organic contamination load aday of

dEWkgBOD⋅

= 3.05 )

COD: 95 %

BOD5: 97 %

SS: 96 %

NH4-N*: 90 %(*for wastewater temperatures > 12°C)Ptot: 95 %

Purification capacity (calculation):

- Nominal organic contamination load a day(BOD5)

- Nominal inflow a day (QN)

0.06dEW

kg⋅

0.15dEW

m⋅³

Resistance to penetration of water: (test with water)

Passed

Stability: (practical test) Passed

Durability: Passed


KLARO GmbH 53

12. Additional tests of the plants

12.1. Tested purification performance with underload

Small wastewater treatment plants and underload operation – this combination has long been considered as extremely difficult to do. Nevertheless, we have set ourselves the goal to put our own SBR small wastewater treatment plant to the test and have it tested for underload. With success, as has been demonstrated in the test report.


KLARO GmbH54

13. Datasheets of the plant

13.1. Piston compressor Nitto

Thi

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2 2 3 4 5 8 9 10

1


KLARO GmbH 55

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ATT

EN

TIO

N

Term

Saf

ety

and

Ope

ratin

g In

stru

ctio

ns


KLARO GmbH56

1.In

stal

latio

n si

te s

elec

tion

Inst

all o

ur b

low

er n

ear

the

sept

ic ta

nk.

If th

e pi

pelin

e is

long

, the

sew

age

trea

tmen

t may

not

per

form

wel

l due

to a

n in

suffi

cien

t airf

low

.In

stal

l in

a pl

ace

whi

ch is

con

veni

ent f

or m

aint

enan

ce.

Don

, t ins

tall

over

a m

anho

le o

r on

sof

t gro

und.

Avo

id a

reas

whe

re w

ind-

blow

n le

aves

and

dus

t gat

hers

.In

stal

l in

a w

ell v

entil

ated

pla

ce.

Inst

all a

t lea

st 3

0cm

aw

ay fr

om th

e w

all o

f a h

ouse

.In

stal

latio

n in

the

shad

e is

rec

omm

ende

d to

sup

pres

s he

at g

ener

atio

n of

the

blow

er.

Don

inst

alle

d ov

er th

e w

ater

leve

l ot t

he s

ewag

e ta

nk/a

quar

ium

to a

void

any

bac

kflo

w o

f the

wat

er.

If th

e bl

ower

is in

stal

led

unde

r th

e w

ater

leve

l a b

ackf

low

val

ve m

ust b

e us

ed.

, t ins

tall

the

blow

er w

here

it w

ill b

e flo

oded

with

wat

er. M

ake

sure

that

the

blo

wer

is

Don

, t ins

tall

whe

re th

ere

is e

xces

s m

oist

ure

or h

umid

ity.

2.M

etho

d of

Inst

alla

tion

The

bas

e sh

ould

be

mad

e of

con

cret

e st

rong

eno

ugh

to b

ear

the

wei

ght a

nd b

lock

vib

ratio

n fr

omth

e bl

ower

.T

he b

ase

shou

ld b

e at

leas

t 10c

m a

bove

the

grou

nd le

vel a

nd 5

cm la

rger

than

the

exte

rnal

dim

ensi

ons

of th

e bl

ower

.P

rovi

de a

sep

arat

e po

wer

out

let t

o be

onl

y us

ed f

or th

e bl

ower

.E

lect

rical

wor

k m

ust b

e do

ne b

y a

qual

ified

ele

ctric

ian.

The

pow

er s

uppl

y sh

ould

be

the

rate

d vo

ltage

sho

wn

on th

e la

bel o

n th

e bl

ower

and

be

fitte

d w

ithan

ear

th le

akag

e br

eake

r an

d ov

er-c

urre

nt b

reak

er.

The

pow

er o

utle

t use

d sh

ould

be

wat

erpr

oof a

nd in

clud

e an

ear

th c

onne

cted

to g

roun

d.P

lace

the

blow

er h

oriz

onta

lly o

n th

e ba

se.

A s

oft r

ubbe

r ho

se m

ust b

e us

ed fo

r co

nnec

tion

betw

een

the

air

outle

t of t

he b

low

er a

nd th

e pi

pe.

The

rub

ber

hose

mus

t be

fast

ened

with

hos

e cl

amps

.W

hen

mak

ing

the

conn

ectio

n, le

vel t

heai

r ou

tleta

nd th

e pi

pe to

ens

ure

the

hose

is n

ot k

ink

ed o

rbl

ocke

d.B

efor

e st

artin

g th

e op

erat

ion

of th

e bl

ower

, ens

ure

that

the

wat

er le

vel i

n th

e se

ptic

tank

isap

prop

riate

and

the

valv

es o

n th

e pi

pelin

e ar

e p

rope

rly o

pene

d.

3.S

tart

ope

ratio

n

Inse

rt th

e po

wer

plu

g in

to th

e po

wer

out

let w

ith fu

ll co

ntac

t so

that

the

plug

itse

lf do

es n

ot w

obbl

e.In

com

plet

e co

nnec

tion

may

cau

se a

n el

ectr

ic s

hock

or

a fir

e.A

fter

star

ting

oper

atio

n en

sure

that

ther

e is

;N

o ai

r le

akag

e fr

om th

e ho

se a

nd th

e pi

pe c

onne

ctio

n.N

o ab

norm

al n

oise

from

the

blow

er.

No

vibr

atio

n tr

ansm

itted

to th

e gr

ound

due

to s

trai

ned

pipi

ng.

4

Blo

wer

Blo

wer

Bas

e

Bas

e

Wat

er ta

nk o

r P

ond

Hos

e

Hos

e

Wat

er le

vel

Air

outle

t of B

low

erH

ose

clam

p

Hos

e cl

amp

Aer

obic

Sew

age

Trea

tmen

tTan

k

Ear

th L

eaka

ge B

reak

erO

ver

Cur

rent

Bre

aker

Wat

erpr

oof P

ower

Out

let w

ith g

roun

ding

Pow

er D

istr

ibut

ion

Line

4.In

stal

latio

n (S

eptic

Tank

App

licat

ion)

1 1 2 3 4 5 6 7 8 9 10 112 3 4 5 6 7 8 9

3.S

afet

y In

stru

ctio

n

1.C

autio

ns1

ME

DO

blo

wer

s ar

e O

ILLE

SS

.N

ever

lubr

icat

e th

em.

2 A

ll bl

ower

s ha

ve a

lread

y be

en p

reci

sely

adj

uste

d.N

ever

dis

asse

mbl

e th

em.

(Do

not t

ry to

loos

en th

e H

ex.b

olts

on

the

End

cap)

2.R

epla

cem

ent o

f Filt

er E

lem

ent

1 B

e su

re to

unp

lug

the

blow

er b

efor

e st

artin

g th

e re

plac

emen

t wor

k.2

Loo

sen

the

Bin

d S

crew

1 a

nd r

emov

e th

e F

ilter

Cov

er 4

.3

Rem

ove

the

Filt

er E

lem

ent(

s) 5

from

the

Upp

er C

ase

6 an

d re

plac

e w

ith n

ewO

ne(s

).A

t the

sam

e tim

e, c

lean

the

air

inle

t of t

he F

ilter

Cov

er 4

and

the

Upp

erC

ase

6 .

4 A

ssem

ble

the

Filt

er C

over

4 w

ith th

e F

ilter

Cov

er G

aske

t 3 s

ecur

ely

posi

tione

d.5

Mou

nt th

e F

ilter

Cov

er 4

to th

e U

pper

Cas

e 6

, the

n tig

hten

with

the

Bin

d S

crew

(s)

1 .

6T

ime

to r

epla

ce th

e F

ilter

Ele

men

tIt

is r

ecom

men

ded

that

the

Filt

er E

lem

ent(

s) is

cle

aned

or

repl

aced

with

new

one

(s)

depe

ndin

g on

the

exte

nt o

f its

det

erio

ratio

n as

det

erm

ined

by

the

atom

osph

eric

con

ditio

nsar

ound

the

appl

icat

ion.

Th

e fi

lter

ele

men

t(s)

sh

ou

ld b

e ch

ecke

d e

very

th

ree

mo

nth

san

d s

ho

uld

be

rep

lace

d je

arly

.

3.R

epla

cem

ent o

f Pis

ton

Set

Ass

y1

Be

sure

to u

nplu

g th

e bl

ower

bef

ore

star

ting

the

mai

nten

ance

wor

k.2

Rem

ove

the

Upp

er C

ase

6 , l

oose

n al

l the

Hex

.Bol

ts 9

on

the

Hea

dcov

er 1

0 an

d re

mov

e it.

Inca

se it

is h

ard

to r

emov

e th

e H

eadc

over

10

inse

rt a

flat

hea

d sc

rew

driv

er to

the

slot

(s)

on th

eed

ge o

f the

Hea

dcov

er 1

0 an

d tw

ist t

he s

crew

driv

er g

ently

to o

pen.

3Ta

ke o

ut th

e P

isto

n S

et A

ssy(

s).

4 R

epla

ce a

ll P

isto

n S

et A

ssys

, G

aske

t A 1

1 an

d G

aske

t B 1

2 w

ith n

ew o

nes.

Be

sure

to k

eep

the

Teflo

n S

eal o

f the

Pis

ton

13 a

way

from

any

dus

t, sw

arf,

wat

er, o

il or

gre

ase.

Try

not t

o to

uch

the

Teflo

n S

eal o

f the

Pis

ton

13 w

ith y

our

finge

rs.

5 I

nser

t the

Pis

ton

Set

Ass

y(s)

into

the

Pum

p B

ody.

Inst

all G

aske

t A 1

1 on

the

Hea

dcov

er 1

0 an

d G

aske

t B 1

2 on

the

Pum

p B

ody,

then

fast

en th

e H

eadc

over

10

with

the

Hex

.Bol

ts 9

.Tig

hten

the

Hex

.Bol

ts 9

eve

nly

and

alte

rnat

ely

then

gra

dual

ly fu

lly ti

ghte

n.6

Bef

ore

putti

ng th

e U

pper

Cas

e 6

bac

k, s

tart

the

blow

er a

nd c

heck

if th

ere

is a

nyai

ral

ong

the

Hea

dcov

er 1

0 or

the

Noz

zle

Sea

l(s)

leak

age

33by

brie

fly b

lock

ing

the

air o

utle

t.In

cas

e th

ere

is a

n ai

ral

ong

the

Hea

dcov

er 1

0 ,

re-p

ositi

on G

aske

t A 1

1 an

dle

akag

eG

aske

t B 1

2 th

en r

e-fa

sten

the

Hex

Bol

ts 9

.In

cas

e th

ere

is a

n ai

ral

ong

the

Noz

zle

leak

age

Sea

l(s)

33ch

eck

if th

e no

zzle

sea

l is

inst

alle

d on

the

airta

nk p

rope

rly a

nd p

ress

the

pum

p bo

dydo

wn

to a

llow

the

out

let p

ort o

f the

Hea

dcov

er to

cat

ch th

e N

ozzl

e S

eal(s

) co

rrec

tly.

7 P

ut th

e U

pper

Cas

e 6

back

afte

r in

stal

ling

Gas

ketC

8 o

n th

e B

otto

m C

ase

prop

erly

.Fa

sten

the

Bin

d S

crew

s/To

rx S

crew

s 7

even

lyan

d al

tern

atel

y.8

5

5.M

aint

enan

ce (

Ref

er th

e sk

etch

es o

n th

e ne

xt p

age)

Slo

t

Teflo

n S

eal

Pis

ton

Pis

ton

Set

Ass

embl

y re

plac

emen

t per

iod

It is

sug

gest

ed th

at th

e P

isto

n S

et A

ssem

bly

is r

epla

ced

ever

y 24

mon

ths

resp

.afte

r 20

.000

h d

epen

ding

on

the

exte

nt o

f the

blo

wer

´s p

ress

ure

and

airf

low

det

erio

ratio

n.T

here

is a

gro

ove

on e

ach

Teflo

n S

eal o

f the

Pis

ton

indi

catin

g th

e de

gree

of w

ear.

If on

e or

bot

h gr

oove

s ar

ew

orn

away

, rep

lace

men

t of t

he P

isto

n S

et A

ssem

bly

isre

com

men

ded.


KLARO GmbH 57

6

Bin

d S

crew

Torx

Scr

ew

Torx

Scr

ew

19S

prin

g

19S

prin

g

19S

prin

g

18S

prin

g S

eat

18S

prin

g S

eat

13P

isto

n

13P

isto

n

13P

isto

n

12G

aske

t B

12G

aske

t B

12G

aske

t B

12G

aske

t B

11G

aske

t A

11G

aske

t A

11G

aske

t A

10H

eadc

over

10H

eadc

over

10H

eadc

over

9H

ex B

olt

9H

ex B

olt

8G

aske

t C

8G

aske

t C

8G

aske

t C

7B

ind

Scr

ew

7To

rx S

crew

6U

pper

Cas

e

6U

pper

Cas

e

6U

pper

Cas

e

5F

ilter

Ele

men

t

5F

ilter

Ele

men

t

5F

ilter

Ele

men

t

4F

ilter

Cov

er

4F

ilter

Cov

er

4F

ilter

Cov

er

3F

ilter

Cov

er G

aske

t

3F

ilter

Cov

er G

aske

t

3F

ilter

Cov

er G

aske

t

1B

ind

Scr

ew

1B

ind

Scr

ew

7B

ind

Scr

ew

1B

ind

Scr

ew

29H

ex B

olt

32N

ozzl

e S

eal

32N

ozzl

e S

eal

33N

ozzl

e S

eal

Air

Out

let

Blo

wer

Bod

y

Blo

wer

Bod

y

Bot

tom

Cas

e

Bot

tom

Cas

e

Bot

tom

Cas

e

Nev

er lo

osen

thes

e fo

ur (

4) H

ex.

Bol

ts o

n th

e E

ndca

p.

Out

let P

ort

Out

let P

ortOut

let P

ort

Slo

t for

scr

ewdr

iver

Slo

t for

scr

ewdr

iver

Slo

t for

scre

wdr

iver

Nev

er lo

osen

thes

e ei

ght (

8) H

ex.

Bol

ts o

n th

e E

ndca

p.

Blo

wer

Bod

y

Air

Out

let

Air

Out

let

Pis

ton

Set

A's

sy

Nev

er lo

osen

thes

e tw

elve

(12

) H

ex.

Bol

ts o

n th

e E

ndca

p.

Pis

ton

Set

A's

sy

Pis

ton

Set

A's

sy

LA28

B/ L

A45

B-

-

LA60

-A

/ LA

80A

-

LA10

0/ L

A12

0-

-

LA

-60B

/LA

-80B

4.P

urch

asin

g su

gges

tion

for

the

mai

nten

ance

par

ts

1 F

ilter

Ele

men

t

Mod

elP

art N

o.Q

uant

ity

LA28

B/L

A45

B/L

A10

0/LA

120

--

--

LB02

369

10pc

s.se

t

LA60

B/L

A80

B-

-LB

0393

710

pcs.

set

2 R

epai

r P

arts

Kit

Mod

elP

art N

o.Q

uant

ity

LA28

B-

LB01

288

1 se

t

LA45

B-

LB03

514

1 se

t

LA60

B-

LB03

519

1 se

t

LA80

B-

LB03

517

1 se

t

LA10

0/LA

120

--

LB04

151

1 se

t

3

Con

tent

s of

Rep

air

Par

ts K

it

Par

ts In

clud

edLA

28B

/LA

45B

--

LA60

B/L

A80

B-

-LA

100/

LA12

0-

-

5

Filt

er E

lem

ent

11

2

11

Gas

ket A

12

3

12

Gas

ket B

12

3

13

Pis

ton

12

3

18

Spr

ing

Sea

t1

23

19

Spr

ing

12

3

7

Pis

ton

Bos

sS

prin

gS

prin

g S

eat

Gre

ase

Teflo

n S

eal

Pis

ton

sect

iona

l vie

w

Cau

tions

Loca

t the

spr

ing

into

the

pist

on b

y ro

tatin

g it

cloc

kwis

e.C

heck

that

gre

ase

is p

rese

nt o

n th

e co

nvex

face

of t

he s

prin

g se

at.

( If

no g

reas

e is

pre

sent

, ple

ase

cont

act y

our

supp

lier)

Nev

er u

se s

tand

ard

grea

se a

s it

may

cau

se a

mal

func

tion.

Kee

p th

eTe

flon

Sea

l aw

ay fr

om a

ny d

ust,

swar

f, w

ater

, oil

or g

reas

e.


KLARO GmbH58

No.

Par

t Nam

eLA

28B

Q'ty

LA45

BQ

'tyN

o.P

art N

ame

LA28

BQ

'tyLA

45B

Q'ty

1B

ind

Scr

ewLP

3058

11

LP30

581

1

2S

ealW

ashe

rLP

3063

52

LP30

635

2

3F

ilter

Cov

er G

aske

tLQ

0260

72

LQ02

607

2

4F

ilter

Cov

erLQ

0257

51

LQ02

575

1

5F

ilter

Ele

men

tLQ

0260

51

LQ02

605

1

6U

pper

Cas

eLB

0293

71

LB02

937

1

7B

ind

Scr

ew U

LLP

3058

14

LP30

581

4

Torx

Scr

ew C

ELQ

0308

24

LQ03

082

4

8G

aske

t CLQ

0260

11

LQ02

601

1

9H

ex B

olt

LP31

316

4LP

3131

64

10H

eadc

over

LQ02

567

1LQ

0206

31

11G

aske

t ALQ

0104

31

LQ01

043

1

12G

aske

t BLQ

0104

21

LQ01

042

1

13P

isto

nLA

7062

51

LB03

132

1

Pis

ton

Sub

Ass

yLA

7062

61

LB03

133

1

Inle

tVal

veLP

3091

61

LP30

916

1

Val

ve R

etai

ner

ALP

1154

81

LP11

548

1

CS

Rin

gLP

1294

81

LP12

948

1

18S

prin

g S

eat

LP12

155

1LP

1215

51

19S

prin

gLP

3062

01

LQ02

743

1

20H

ousi

ngLB

0318

41

LB03

184

1

SE

Rin

gLP

1247

52

LP12

475

2

Val

ve R

etai

ner

BLP

1373

52

LP13

735

2

23O

utle

tVal

veLP

1035

92

LP10

359

2

24S

crew

5 x

20

LP12

599

2LP

1259

92

25In

sula

tion

Bus

hLP

1035

52

LP10

355

2

26R

ear

Cyl

inde

rLA

7184

31

LA71

843

1

27F

ield

Cor

e A

ssy

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(071

57)2

2437


KLARO GmbH60

13.2. Becker and Rietschle rotary slide compressors

Note:The Becker rotary slide compressors used by us are equipped with a pressure control valve that is factory pre-set to a maximum pressure of 0.5 bar.With our plants, an operating pressure of < 0.3 bar is common. If a pressure of > 0.5 bar (e.g. due to a bent air hose) occurs at the plant, a part of the air is blown off via the pressure control valve. Thus, the compressor is protected against damage or excessive wear and tear.

www.becker-international.com

Warning Notice1.

Interdiction2.

Oil

Rules3.

Advice4.

Wear protective gloves Wear protective ear-muffs Sound level informatione.g. 85 dB (A)

Wear protective goggles

AIR

max.

800m

-p

VACUUM

+p

PRESSURE

L1

L2

L3

L1 L3L2

50/60 Hz=OFF

=ON

3000 h

i +

L2 L1 L3

I > I > I >

M3

U1 V1 W1

High Voltageaccording to ANSIAmerican, NationalStandardsInstitute

Qualified StaffMarked operations may only be executed by qualified electricians

High VoltageOnly qualified staff maywork on electroniccomponents

Automatic Start-UpWhen servicing the device must be turned off

Hot Surfacewill cause burns. Let device cool down before maintenance

NoteIgnoring notices will cause severe damage to the pump

Pump works without oil Avoid absorption of oil fumes

Marked areasmay not be subject to weight

Explosive substancesmay not be conveyed

Toxic Substancesmay not be conveyed

Flammable Substances may not be conveyed

Liquidsmay not be conveyed

AssemblyIncorrect fitting position

Active principleRotary vane pump Only air may be conveyed

Active principleside channel fan only air may be conveyed

MaintenanceRegularly execute themarked procedures

Safety valveSpecificationVacuum pump

SpecificationCompressor

Factory-made Revol-ving field clockwise as pre-requisite for pump attachment

Switch intervalNot more than 10x per hour

Filter MaintenanceService according to dust accumulation exchange old cartridge dispose old

Blow out marked areaswith air pressure

Maintenance intervalObserve minimum gatevalve measurementevery 3.000 hours

Arrange Motor-circuitswitch

Storing / AssemblyProtect pump from humidity

AssemblyCharacteristic data is valid up to 800m abovesea level

Further Information(optional Data)- name plate- Internet


KLARO GmbH 61

DT

4.4

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KLARO GmbH62

2-3

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29-3

1

D-4

2279 W

uppert

al

info

@becker-

inte

rnational.com

SERVICE

ww

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Sale

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serv

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etw

ork


KLARO GmbH 63

DT

4.6

/0-6

1

MA

X.

PR

ES

SU

RE

MA

X.

Vm

/h

3

mb

ar

Made in Germany

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ar

No

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m /h

3

mbar

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m

MA

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Made in Germany

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3 d

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37

44

AIR

28100027211 05/11

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XX

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NX

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X

3 M

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XX

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XX

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50

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KLARO GmbH64

2-3

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OF

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KLARO GmbH 65

11

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g

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DT

4.8

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PR

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X.

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37

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Mat.N

r. X

XX

XX

XE

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XX

X

3 M

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XX

XX

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NoU

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XX

XX

XX

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78


KLARO GmbH66

2-3

Min

OF

F

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56

35

Made in G

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hr/

year

No

min

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mbar

Typ

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hzahl / speed

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ting

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ssure

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year

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mbar

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15

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SERVICE

ww

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KLARO GmbH 67

DT

4.1

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MA

X.

PR

ES

SU

RE

MA

X.

Vm

/h

3

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Made in Germany

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EN

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37

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100m

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EN

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KLARO GmbH68

2-3

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OF

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56

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V

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7 k

g

15

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AA

A>

100m

m

A>

4"

> 5

°C

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max.

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ww

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Sale

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KLARO GmbH 69

36

,5 k

g

80

,5 lb

s

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DT

4.2

5K

MA

X.

PR

ES

SU

RE

MA

X.

Vm

/h

3

mb

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Made in Germany

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No

min

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SERVICE

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Sale

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The KLARO principleMaximum operating reliability!

No mechanics, pumps orelectrical parts in the wastewater!

• Almost all possible approvals

• Extremely short delivery times thanks to optimised production

• Legal threshold values undercut by up to 90%

• 98% treatment performance in 6 hours

• Certified underload detection

• Fully-biological mode of operation

• Quality products, with extremely high customer satisfaction levels

• Minimal power consumption

• All transportation processes per-formed by air-lift pump

• Treat water and introduce it back into the natural cycle

• Only one tank required for sys-tems of up to 20 PE (Personnel Equivalent)

Our benefits

• Suitable for retrofitting to practi-cally any tank shape

• Retrofitting possible in single, twin, triple and multi-chamber pits

• Installation possible in any type of tank, from plastic to fibreglass to concrete

All components are permanently connected to the filtering tank. All transportation

processes are performed by the air-lift pump. All electrical parts are located securely

outside the tank in the switch cabinet.

KLARO GmbH

Spitzwegstraße 63

95447 Bayreuth

Telephone: +49 (0) 921 16279-0

Fax: +49 (0) 921 16279-100

E-Mail: [email protected]

More information at

www.klaro.eu

Technical hotline

+49 (0) 921 16279-330

© KLARO GmbH Bayreuth 2013 / Art.-Nr. KKA 0016-02-2013engPhoto copyright: KLARO GmbH

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