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Service Handbook Waterclean 600 CD, LP/MP, PI

1. 21 3 2 Mixing Chlorine Flocculation Agent and Antiscalant 22 3 2 1 Initial Starting of Oporto 22 E ee Cl EE 22 SC WE e E EE 24 3 2 4 Metering Amounts and Mixing of the Post Chlorination 25 RN ee E le e BEE 25 3 2 5 1 Mixing of the flocking test solution 25 Service Handbook 08 2004 3 CONTENTS WTC 600 LP MP Contents 3 2 5 2 Perform Hocking TOS ani data 26 3 2 5 3 Evaluate flocking test tdi 26 3 3 Connecting the Equipment u u 27 3 3 1 Connections Valves and Indicators ooononnnnnncnnnnnononnnnanacacnnnnonnnnnononannrncnnnnnnnnnos 27 3 3 1 1 Pressure increase Module seen enne 28 3 3 1 2 RO Module with Preliminary Filters I 28 9 92 Electrical GO et 29 3 3 2 1 Pressure increase PUMP eege ES Ibo ei e ees diete dte crus 29 3 9 2 2 Preliminary FILS en A Sse Jade ae a ee ae 29 3 3 2 3 Metering AMO uuu emere p n RR Ee este ot nta ie denda 29 KE E WEE 31 3 3 2 5 Reverse OSMOSIS System nsn 31 3 4 Starting Operation cocina cis 31 3 4 1 Metering Stato vecinas lada tilda 31 3 4 2 Media filter and activated carbon filter sneessnnnesenenssernreeennrereneresrnrsssrrrnsrrrn nerne 32 3 4 2 1 AI LH 32 KE Ee du
2. 20 Operational Scope 74 Other Maintenance 61 Overview of COMponents sssseesseeeseer eee 10 P Password entry 81 Perform flocking test 25 Post chlorination metering 11 Post chlorination metering point 11 Power outlets 3x for metering stations 11 Pre chlorination 21 Pre chlorination metering 11 Pre chlorination metering point 11 Pre chlorination Module 13 Preliminary Filter 28 Pressure control valve 11 46 Pressure switch 46 Pressure tube module 46 Pressure increase Module seese 27 Pressure increase Pump 15 28 Programming 32 PUPS sc esu rad o a Lt 14 Putting Out of Operation 41 Q Quality of the Untreated Water 8 Service Handbook 08 2004 WTC 600 LP MP R RC Protective Switch 15 RE le BEE 31 Removing the Preservation After Longer Operational 52 Repl
3. 11 Control Panel and Display 14 Control System 66 Service Handbook 08 2004 LIST OF KEY WORDS D De conserving 35 Declaration of Conformity 71 Description of the System 13 Design of the Flushing and Disinfection Equipment 46 Desinfectio rias 42 Diagnosis menu 88 Differential pressure switch 11 Disinfection EE 48 Disposal of Chemicals 8 Drain the metering station and flush 50 Drain the pre filter 52 Drinking water flowmeter 11 Drinking water sampling tap 11 Drinking water to the flushing tank 46 E Electrical Connections 28 Electrical control system 46 Emergency Stop eerte te Reis 15 Evaluate flocking test 25 F i T Tc 19 Fine Filter E E ETE T 14 43 A S aa maa ap asada 46 Fine filter candle 11 Fine filter housing esse 11 First fill of the metering tanks 21 Float SWItGh eret ete
4. 61 Malfunction Cause and Corrective Action 56 Malfunction Indication at the Operating Panel 57 Malfunctions Media and Activated Carbon Filter 59 Malfunctions of the RO Control and Metering Pump 58 Manometer karrierre a 46 Manometer activated carbon filter Inl t DreSSUF isi a a iia 11 Manometer concentrate pressure 11 Manometer fine filter input pressure 11 Manometer fine filter output pressure 11 Manometer media filter inlet pressure 11 Manometer pump pressure 11 Manostat viciado lacio 11 Manual automatic rotary switch 11 Manual Operation 16 Master switch seeeeeeseessesseeessess 11 Measuring cell sse 46 Media and Activated Carbon Filter 31 Media and activated charcoal Plug ee acere Ee eR Ebrei 11 Oe TER EE 11 Media filter control 11 Mediafilter and Activated Carbon Filter 14 Membranes 11 Membrane pressure pipe 11 Menu Selection 34 Menu Structure 85 Metering Amounts and Mixing of the Post Ch
5. Suction height too Ensure supply pressure high pump is not to the pump mains self priming supply submerged pump Supply pressure of Flow rate through see 4 5 4 the reverse preliminary filter osmosis too low too low Differential Filter soiled Replace filter cartridge 4 1 pressure of the preliminary filter gt gt 1 bar Pressure switch Replace pressure 2 2 defective switch pay attention to Pos 4 9 setting Flow rate in sand Filter clogged Initiate backwashing 3 4 2 filter too low Conductance Permeate Yield too high Increase flow of 3 4 3 7 value conductance value concentrate exceeded too high Very high salt Check cause 1 content in notify sales dept untreated water Defective seal or IReplace parts switch off ETL membrane system if required Conductance Calibrate again ETL SLP value probe replace if required defective Table 29 1 See untreated water analysis operational start up record Service Handbook 08 2004 57 MAINTENANCE WTC 600 LP MP 4 5 3 Malfunctions of the RO Control and Metering Pump Indication Malfunction Cause Corrective Action Chap Fig Indication of RO Fuse defective Have replaced by ETL control dark electrician diagram in switch cabinet Short circuit Replace defective parts general Solenoid valve Replace defective parts ETL defective Motor winding Replace defective parts ET
6. Keep the untreated water supply open until water comes out of the connection hose N Oo B WO ww Interrupt the untreated water supply and undo the screw fitting at the media filter inlet of the AM version or the activated carbon filter inlet A version 8 Quickly place the end of the connection hose in a discharge which is lower than the WTC 600 system the filters are levered out if necessary repeat steps 5 8 4 4 5 Removing the Preservation After Longer Operational Interruptions Carry out the following work steps to remove the preservation 1 Remove the blind discs see Section 3 3 1 2 2 Provisionally connect the drinking water line to the waste water canal 3 Completely fill the media and activated carbon filters with water remove the control head first and backwash each twice 4 Flush the reverse osmosis see Section 3 4 3 7 5 Replace the fine filter if required d Sulfite 5 kg Item No 6 769 040 0 2 RM 1 2 Propandiol 51 Item No 6 290 910 0 52 Service Handbook 08 2004 WTC 600 LP MP MAINTENANCE 4 4 6 Flushing the pre filter The WTC 600 LP MP pre filter must be flushed if the differential pressure of the pre filter immediately after back washing is more than 0 5 bar CAUTION Before flushing the filter check the manometer for correct display values and exchange if necessary CAUTION Pre filter blockages are caused above all by changed water constituents A renewed water analysis must be ca
7. Volume of the RM Item No disinfection solution I P3 Oxonia Active ml 30 75 1 2 bottle 6 294 010 0 Table 22 Composition of the disinfection solution Item No 6 768 354 0 48 Service Handbook 08 2004 WTC 600 LP MP MAINTENANCE 4 4 3 Acidic and Alkaline Cleaning If the original drinking water capacity and quality can not be reached an acidic cleaning or an alkaline cleaning of the equipment is to be carried out Aids Universal indicator paper1 pH 0 14 Chemicals for cleaning and for neutralization Work Steps 1 The equipment is prepared for cleaning compare with Chapter 4 4 1 2 Switch the RO system to the disinfection operating mode and allow the cleaning solution to circulate for approx 30 minutes CAUTION Maximum temperature of the cleaning solution during cleaning 35 C Minimum temperature of the cleaning solution during cleaning 15 C CAUTION End the cleaning when a change of the pH value can no longer be detected CAUTION If the cleaning solution is strongly soiled it should be neutralized and rejected Continue the cleaning with new solution 3 After finishing the cleaning switch the RO equipment to the switched off operating mode B Connect the untreated water supply to the RO equipment again guide drinking water and concentrate outlet to the canal Plug in the earthing contact plugs of the metering pumps Switch the RO equipment to the operating mode 5 6
8. Starting Position RO equipment set to switched off operating mode and switched off with main switch 46 Service Handbook 08 2004 WTC 600 LP MP MAINTENANCE Work Steps 1 Fill 30 liters of chorine free drinking water into the flushing container 20 16 2 Switch on master switch and set RO system to Switched off operating mode 3 Close the untreated water inlet depressurise system Use connection hoses and flushing pump 20 19 to connect the flushing tank with the untreated water sampling tap Feed the drinking water adapter and connection hose from the drinking water outlet 20 8 to the flushing tank Feed the concentrate adaptor and connection hose from the concentrate outlet 20 12 to the flushing tank Unplug the earthing contact plugs of the metering pumps Switch the flushing pump on 4 Switch the system to disinfection operating mode and adjust the water pressure to 2 bar using the untreated water sampling tap 5 Disconnect the metering pump earthing pin plug 5 If none of the connections are leaking switch off the flushing pump set the RO system to switched off operating mode and make up the cleaning solution by addition to chemicals in accordance with Tables 22 23 and 24 to the flushing tank Carefully add chemicals while stirring continuously Definitely wear protective clothing for this Service Handbook 08 2004 47 MAINTENANCE WTC 600 LP MP 4 4 2 Disinfection A disinfecti
9. The modification will be stored of the entered data are acknowledged before leaving the setting menu This menu point assures branching to the diagnosis menu see item 4 4 5 At the beginning of the diagnosis all actuators of the unit are switched off The sytem returns to the previous status if diagnosis is completed Service Handbook 08 2004 WTC 600 LP MP APPENDIX 4 4 2 Calibration menu The calibration menu is used to adjust the sensors The following functions are available Menu point 1 Cy permeate 2temp permeate 3 calibr reset Function Calibration of permeate sensor If the menu point 1 Cy permeate is chosen a submenu appears with two items 1 min Cy and 2 max Cy 1 min Cy please remove the Cy sensor and press the key 2 max Cy Important The temperature must be calibrated before calibration of the conductivity Connect the Cy sensor Now the current permeate conductivity has to be determined by means of a standard meter and this value has to be entered by numerical editing The entered value is equated with the current conductivity after actuation of the l key Calibration of permeate temperature sensor For that purpose the current permeate temperature has to be defined with a standard meter and this value has to be entered by means of numerical editing The entered value is equated with the current temperature when the key is then actuated This menu point allows to r
10. 5 6 290 910 0 Sulfite 5 kg 6 769 040 0 Soda 6 287 014 0 RM 511 Vaporapid bio descaling acid 6 290 239 0 Table6 Cleaning Chemicals Attention Note national variants 2 5 3 Filter Product Item No Filter element Du 6 414 466 0 Replacement set metering pump 6 762 172 0 Table 7 Filter Elements Service Handbook 08 2004 19 OPERATION OF THE SYSTEM WTC 600 LP MP 3 Operation of the System 3 1 Assembly and Starting Operation Assembly Chapter Checking the scope of delivery delivery note Placing the equipment in the set up location and positioning Connecting the untreated water to the WTC 600 LP MP connecting the WTC 600 PI in between if required depending on delivery scope 2 2 3 3 2 1 3 3 1 Installing the piping for backwashing and drinking water 2 2 Installing the float switch 3 3 2 4 Filling and connecting the sand filter and the activated carbon filter 3 4 2 Connecting the electrical system SLP 3 3 2 Table 8 Assembly work to be carried out upon starting operation Starting Operation Chapter Establishing the untreated water supply 2 2 Manually actuating the sand filter backwashing 3 4 2 Manually actuating the activated carbon filter backwashing 3 4 2 Flushing the reverse osmosis 3 4 3 7 Filling the chemicals container 3 2 Adjusting the flow rates 3 4 3 8 Filling out the metering table in the operating instructions
11. 7 Leave the RO system to run for 30 minutes 8 Reinstate the original piping layout 9 Regulate the RO equipment according to the type plate and draw up record 10 Dispose of the cleaning solution in accordance with the regulations Item No 6 768 355 0 Service Handbook 08 2004 49 MAINTENANCE WTC 600 LP MP 4 4 3 1 Cleaning Solution for Acidic Cleaning Volume of the RM Kleen MCT 103 I Item No cleaning solution I 30 1 0 6 294 009 0 Table 23 Composition of the cleaning solution for acidic cleaning Neutralise by adding soda 6 287 014 until the pH value is approx 7 4 4 3 2 Cleaning Solution for Alkaline Cleaning Volume of the RM Kleen MCT 511 I Item No cleaning solution I 30 1 0 6 294 008 0 Table 24 Composition of the cleaning solutions for alkaline cleaning Neutralise by adding RM Vaporapid bio descaling acid 6 290 239 until the pH value is approx 7 4 4 4 Conserving 4 4 4 1 Drain the metering station and flush Initial situation RO system switched off Work steps 1 Dispose of the contents of the metering stations according to the local regulations 2 Flush the tank with drinking water 3 Flush the metering pumps with drinking water 4 Unscrew the metering hoses and drain 4 4 4 2 Conserve the RO system When the RO equipment should not be used for more than 14 days then it must be conserved NOTE After a maximum of 6 months the conserv
12. E Figure6 WTC 600 PI 2 3 2 Safety Installations Emergency Stop The emergency stop switch 7 4 main switch is located on the side of the switch box RC Protective Switch RC protective switch external i 30 mA Circuit Breaker Automatic circuit breaker 7 3 10 A for power limitation of the power outlets etc Motor Protection Switch The motor protection switch 7 2 is factory set depending on the power consumption of the RO pump compare circuit diagram 7 1 and must be checked WTC 600 Nominal output Actual power Motor protection RO pump consumption switch setting LP 400 V 2 2 kW 1 5 kW 4A MP 400 V 2 2 kW 2 2 kW 5 1A LP 230V 2 2 kW 1 5 kW 10A MP 230 V 2 2 kW 2 2 kW 14A Table 2 Setting of motor protection switch Service Handbook 08 2004 15 DESCRIPTION WTC 600 LP MP Microfuses Two microfuses 7 6 for protection of the control electronics 7 5 are located on the control board for the electronics 5x20 6 3 A time delay 5x20 0 1 A time delay Figure 7 Switch cabinet and control electronic 2 3 3 Operating Modes 2 3 3 1 Automatic Operation Standard Operating Mode After switching on the main switch the system is fully automatic controlled through the electronic control system and the float switch in the drinking water tank The mode selector switch is in the Auto position The control system usually operates in the normal plane in the operating mode oper
13. Service Handbook 08 2004 gt 1 ackn failure lt 2 operat mode 1 ackn failure gt 2 operat mode lt operation mode OPERATION operation mode Stop are you sure gt no lt yes are you sure no gt yes lt 1 ackn failure gt 2 operat mode lt RO 1000 V 01 34 Stop 41 OPERATION OF THE SYSTEM 3 4 6 Desinfection Enter user password compare with Chapter 3 4 3 1 Indication Press the Y pushbutton one time Indication Press the RETURN pushbutton Indication Press the pushbutton Indication Press the RETURN pushbutton Indication Press the pushbutton Indication Press the RETURN pushbutton Indication Press the RETURN pushbutton Indication Press the Y pushbutton Indication System in disinfection operation mode gt 1 ackn failure lt 2 operat mode 1 ackn failure gt 2 operat mode lt operation mode OPERATION operation mode STOP are you sure gt no lt yes are you sure no gt yes lt 1 ackn failure gt 2 operat mode lt operation mode STOP operation mode Desinfection WTC 600 LP MP CAUTION During the disinfection operation mode all safety quest are switched off CAUTION Observe the pressure after the fine filter If less than 2 bar switch off the equipment immediately High pressure pum
14. 2 4 with the exception that the 4 Y keys do not only allow to select numbers but also letters capital small and special characters 4 2 7 Confirmations Various menu activities require confirmations in order to avoid data entry errors The user is asked to confirm that modifications of operating settings parameters and adjustments are actually correct Confirmation is done with the key select yes followed by the da key Otherwise the system will return to the level from which the function was called in e g menu without any consequences no modification wil be stored 82 Service Handbook 08 2004 WTC 600 LP MP APPENDIX 4 3 Operating levels Similar to the operating modes the user surface has different operating levels Normal level In this level the text display shows the operating mode the operating condition the current measured values and operating values as well as special messages maintenance message by means of different scrolling masks see 4 3 1 User level The user level see 4 3 2 allows operation and setting of the most important functions and operating settings parameters respectively as well as the calibration of the conductivity sensors Technician s level The technician s level is a extended user level It allows to carry out the functions of the user level to manipulate all operating settings parameters and to fulfil a hardware test by means of a specific diagnostic function T
15. 89 WTC 600 LP MP APPENDIX sen eA dn 11e s jeuoneJedo y 6uuejue Jaye doo sp d oan Jed x A snorosuoo INO Do aq o s Ja9YS jolluo2 siu sy euay SUONOUNHEJN U l moy yBnoJy Joven Bunjuuq Jon UOQUBO payennoy ysemyoegq 1eiunoo ojnsseJd Jeu sul ajen elmssald jo peeue sunoufui u92u05 dung elnssalg 1 dO geq Bunejedo uoneJedo Durpels jo ayeq ON 1Ue d S3J0M uuo Sri Kyoedeo Bul 5 anye jnpuoo Jaye papayun Jorge omg iddns Jajem Domgamun jo d uone e1su Jo uone2o P L ed ejeq 1ueudinb3 diN d 009 OLM y 40 p1028H Bunerado Service Handbook 08 2004 90 WTC 600 LP MP A Acidic and Alkaline Cleaning 49 Acknowledging Data Inputs 35 Activated Carbon Filter 31 Activated carbon filter 11 Adjusting Operating Parameters and Balancing Value 35 Alphanumerical editing 82 Anti Scalant and Post Chlorination 14 Antiscalant 23 Antiscalant metering 11 Antiscalant metering point 11 Appendix uester iro na tete x Se RUD E 62 Assembly and Starting Operation 20 Automatic Operation Standard Operating Mo
16. U u u u u uu u nnne 10 1 6 Units and Designations U AEN eenegen 11 2 Beer eege 11 20 2 1 OVervVieW ee ee ee R dci aaa a su haha 11 2 2 FloW Diada Maa A Eegen 13 2 3 Description of the System u uu u u uu 14 2 3 Modular Desi et li ds 14 2 3 1 1 Pre chlorination Module ed ere ais 14 2 3 1 2 eer lee Kee EE 14 2 3 1 3 Mediafilter and Activated Carbon Filter nro 15 2 3 1 4 RO System Pump and Fine Filter ANEN 15 2 3 1 5 Control Panel and Display id 15 2 3 1 6 Anti Scalant and Post Chlorination i n 15 2 3 1 7 Pressure increase Pump WEE 16 2 3 2 Safety Installations adi ada ica 16 2 9 3 Operating Modes obe bee Ren n eden dase ud enn ghee 17 2 3 3 1 Automatic Operation Standard Operating Mode 17 23 32 Manual Operation es u tte is 17 2 4 Technical Data WTC 600 LP MP u u 18 2 5 Consumption Materials U U u u u uu u 20 2 5 1 Chemicals for Metering Container 20 2 5 2 Cleaning Chemicals A 20 CR EE 20 3 Operation of the System 21 43 3 1 Assembly and Starting Operation
17. if PRODUCTION has to be followed by CONCENTRATE FLUSH with pump or CONCENTRATE DISPLACEMENT without pump technician flush displacement Prelesect if tank is equipped with an overflow or not Should the tank have an overflow the produced water continues to flow into the tank during CONCENTRATE DISPLACEMENT FLUSH and DISCONTINUOUS RINSE technician with without overflow Service Handbook 08 2004 WTC 600 LP MP 3 2 Operating parameters APPENDIX The control system allows the following operating parameter settings realization see item 4 The resulting behaviours are described in the chapter operating conditions The values in brackets are the standard values after system reset see item 4 4 4 LIM aaLIM t delay LIM t delay aaLIM t delay lack of pressure t delay at start t pressure available t rinse Service Handbook 08 2004 function right of access possible setting function right of access possible setting function right of access possible setting function right of access possible setting function right of access possible setting function right of access possible setting function right of access possible setting function right of access possible setting Permeate limit value used to switch the unit off in case limit is exceeded or if a DISPOSAL process is to be finished If this value is
18. retta Pt edi 65 RO T9000 User manual u u uu does escort ita or td 67 Operating Record for the WTC 600 LP MP r 84 List of key WOIdS ia 86 88 Service Handbook 08 2004 5 WTC 600 LP MP Service Handbook 08 2004 WTC 600 LP MP GENERAL 1 General 1 1 Introduction This service manual contains basic instructions and information which are to be observed upon set up operation and maintenance Therefore it is imperative that the service manual is read by the installer as well as by the responsible specialist staff prior to installation and starting of operation Please observe not only the general safety instructions listed in the section Safety Instructions but also the special safety instructions included in the other sections 1 2 Marking of Instructions The safety instructions contained in these operating instructions which in case of non observance can cause dangerous situations for persons are specially marked with the general symbol for dange The safety instructions contained in these operating instructions which in case of non observance can cause poisoning cauterizing etc for persons are specially marked with the death s head symbol CAUTION Following this symbol are recommendations or tips which make working easier and provide for secure operation NOTE Following this symbol are recommendations or tips which make working easier and provide for secur
19. 0 t maintenance 11 psalarm mess 12 psconcertrate 13 pstank type inputs 5 pslanguage 16 system reset Service Handbook 08 2004 85 APPENDIX 4 4 1 Main menu WTC 600 LP MP The details of the different menu points of the main menu are described below Menu point 1 Ackn failure 2 Operat mode 2 Cy permeate 4 Temp permeate 5 Hour meter 6 Cy limits 7 Optional alarm 8 Calibration 9 Setting 10 Diagnosis 86 Function This menu point allows to acknowledge an operating failure the only possibility if ps acknowledgement with password This menu point allows to change the operating mode by means of a selection For safety purposes selection only can be made between STOP and OPERATION as well as STOP and DISINFECTION respectively direct change over from OPERATION to DISINFECTION is not possible Permanent display of current permeate conductivity To leave this menu point press one of the keys Permanent display of current permeat temperature To leave this menu point press one of the keys Calling in display of the operating hours meter Numerical entry of LIM and aaLIM Setting selection of ps LIM high This menu point assures branching to the calibration menu see item 4 4 3 The new calibration will be stored if the entered data are acknowledged before leaving the calibration menu This menu point assures branching to the setting menu see item 4 4 4
20. Canal connection supplied by customer gt DN 50 Hydraulic Data Maximum allowable flow rate in filteroperation 1 3 m h Amount of waste water produced during backwashing 2 m h ca 670 liter per backwashing Allowable Operating Conditions Maximum pressure 6 bar Metering Pump Feed capacity at max counter pressure 10 bar 1 Uh Metering Container Weight with pump 10 kg Connections Hose connections PE di do 4 6 Hose connection ventilation PVC di do 4 6 Float Switch Minimum hysteresis 300 Table 4 Technical Data Service Handbook 08 2004 WTC 600 LP MP 2 5 Consumption Materials 2 5 1 Chemicals for Metering Container Swear protective equipment and observe safety instructions DESCRIPTION For mixing of the metering solution use the measuring cup with the handle 250 ml or 1000 ml NOTE Explanations of the units see Chapter 1 6 NOTE A metering container from the WTC 600 CD metering station has a volume of 75 liter Product ItemNo Chlorinated lime 6 291 505 0 Sterilization agen RM 852 6 291 772 0 RM 5000 hardness stabilization 6 290 991 0 RM 5001 Flockulents 10 6 294 703 0 RM 5001 Flockulents 60 6 294 716 0 Table 5 K rcher Original Products 2 5 2 Cleaning Chemicals Product Item No RM Kleen MCT 511 6 294 008 0 RM Kleen MCT 103 6 294 009 0 RM P3 Oxonia Active 6 294 010 0 RM 1 2 Propandiol
21. If the menu consists of more than two lines the displayed section is automatically displaced within the whole menu scrolled the selected menu point being marked with arrows at the left and right sides of the display e g gt 9 settings This selected menu point is called in with the key A menu is finished with the ESC key return to normal level At certain program points settings calibrations uncommitted input nested menus appear That means that the selection of a menu point starts a further menu sub menu In that case the ESC key causes return to the preceding menu 4 2 3 Selection The selection serves to chose one out of different options usually operating settings When a selection is called in e g via a menu the name of the selection appears in the upper display line operating settings the lower line displays the current status value With the Y keys all further options can then be displayed As soon as the key is pressed the currently displayed option is then accepted stored as new operating setting A selection can be interrupted with the ESC key without having carried out any modification Service Handbook 08 2004 81 APPENDIX WTC 600 LP MP 4 2 4 Multiselection The multiselection allows to select various arguments simultaneously for the purpose of this paper argument means any type of setting In the lowest line of the text display appears for that purpose a chain of 0 and 1 Each on
22. Instructing the operator operating instructions Table 9 Overview of start up work A water analysis with the following values must exist for commissioning of the WTC 600 Total hardness GH in dH ron Fe in mg l Manganese Mn in mg l Ammonium NH or NH in mg l System yield determined by the sales department Normal case 75 in special cases 50 20 Service Handbook 08 2004 WTC 600 LP MP OPERATION OF THE SYSTEM 3 2 Mixing Chlorine Flocculation Agent and Antiscalant 3 2 1 First fill of the metering tanks The first time they are filled the metering tanks are filled with 30 litres of chlorine free water This is taking from the reverse osmosis at the drinking water sampling tap 1 12 For the first fill of the metering tank the system is switched to disinfection mode and set to the following flow rates Drinking water 100 l h Concentrate 600 l h CAUTION During the disinfection operating mode all confirmation queries are switched off Observe the pressure downstream of the fine filer as soon as it is less than 2 bar pressure immediately switch off the system The high pressure pump is running dry Use the prescribed system yield 50 or 75 and the water analysis to determine each of the chemical quantities for a 30 litre metering solution according to Chap 3 2 to 3 5 add to the tanks and mix well Switch the system to operation mode 3 2 2 Pre chlorination CAUTION Only use drin
23. KARCHER Service Handbook Waterclean 600 CD LP MP PI 1 024 5 905 521 08 2004 FOREWORD WTC 600 LP MP Foreword Good servicing and maintenance requires comprehensive practical training and clearly organised documents This is why we offer all servicing engineers regular basic training and further qualification courses for the whole product range In addition we compile service manuals for the main units which can be used as instructions to start with and as a reference work later on In addition we issue regular Service Information about on going developments of our products Thetexts and pictures can only be copied and duplicated or passed on to thirdparties after obtaining explicit permission from ALFRED K RCHER GmbH amp Co CUSTOMER SERVICE TRAINING P O Box 160 D 71349 Winnenden www kaercher com 2 Service Handbook 08 2004 WTC 600 LP MP CONTENTS Contents AAA A 7 10 1 1 Introducir sida ta ld libi dq dataset tend 7 1 2 Marking of Instructions RAE uu T J 7 1 3 Intended USe uuu iac mae III IIIa tl s asus 7 1 4 GE Ae 8 1 4 1 Quality of the Untreated Water tcs 8 1 4 2 Chlorination of Drinking Water mete dte Ee par cetus 8 1 4 3 Disposal of Chemicals dui eo dte entr EE 8 1 44 Handling Electricity Protection Class ANNE 9 1 5 General installation notes
24. L defective Water level in Pump does not Suction line untight Retighten screwed ETL container is draw in fittings Replace constant for suction line days Suction line Flush or replace clogged suction line Crystals debris in Clean valves 4 2 the valves metering head Membrane torn or Replace membrane 4 2 membrane push rod torn out Pump does not Air in the suction Bleed pump meter line and in the metering head Lift adjustmenta While the pump is zero running turn in direction adjustment values see 3 3 1 Crystals debris in Clean valves 4 2 the valves metering head Valves not Check correct line up of mounted correctly valves and correct if required direction of arrow Injection fitting Check direction of flow blocked and correct if required or eliminate plug direction of arrow Table 30 58 Service Handbook 08 2004 WTC 600 LP MP MAINTENANCE 4 5 4 Malfunctions Media and Activated Carbon Filter Fine Filter and Flocculation Indication Malfunction Cause Corrective Action Chap Fig More than one Backwashing is Load of debris Install suitable preliminary 3 4 2 4 backwashing initiated too often too high treatment consultation Tab 24 per day through sales diagnosis controller Backwashing no Pump defective Replace pump or sufficient repair Intake side of Clean pump clogged Intake side of Shorter line set up pump too long notify sales
25. LURE HARD MOTOR FAILURE Unit switches off WATER LIMITENT CONTACT active LACK OF PRESSURE PRESSURE SWITCH active Unit switches off MAINTENANCE When the preset maintenance interval is over the LED display OPERATION starts to flash but only if control system is in the operating conditions DISPOSAL PRODUCTION ON CONCENTRATE DISPLACEMENT FLUSH or DISCONTINUOUS RINSE This alarm message can only be switched off by a technician who has then to enter a new maintenance interval see item 4 4 4 Besides the above mentioned failures also other types of failure exist These are erroneous calibration ranges failure message on text display internal system failures flashing FAILURE light and initialization failures EEPROM fail message in text display immediately after having switched the system on or during operation As these failures correspond to malfunctions which the user cannot repair the supplier has to be informed immediately if such failures occur ATTENTION As an internal system failure will interrupt program run failures will not be monitored Such a control system must not be used any more Service Handbook 08 2004 79 APPENDIX WTC 600 LP MP 4 Operation 4 1 User interface The user interface of the RO 1000 consists of a text display 16x2 characters a keyboard covered with a protective film 6 keys and 7 indicator lights 4 1 1 Indicator lights The indicator lights correspond to the most im
26. MP 3 4 3 8 Initial startup OPERATION OF THE SYSTEM Setthe equipment to the operation operating mode see 3 4 4 Set the drinking water capacity to 600 Uh For very cold water the drinking water capacity of 600 l h is not achieved Then adjust the maximum pump pressure of 21 bar MP or 14 bar LP Adjust the concentrate capacity to 200 I h for very cold water possibly somewhat more Closing the pressure control valve 11 1 Closing the concentrate control valve 11 8 Pump pressure and concentrate pressure increase Pump pressure and concentrate pressure increase Drinking water amount increases Drinking water amount increases Concentrate amount increases Concentrate amount decreases Conducting capacity increase Conducting capacity increase Table 20 Operating performance of the reverse osmosis when changing the pressure control and concentrate control valve CAUTION For all changes of the settings to the system the following values may not be exceeded under any circumstances Maximum pump pressure 21 bar MP or 14 bar LP Drinking water amount 650 liters per hour maximum Untreated Drinking water Concentrade Yield water capacity capacity 1200 I h 600 I h 600 l h 50 800 l h 600 I h 200 I h 75 Table 21 Typical yields at maximum drinking water capacity and untreated water temperature of 15 C NOTE The drinking water capacity must never be set
27. MP DESCRIPTION Flow Diagram 2 2 Ajeresedas peljddns OzNaszp eo ld uoluesul SZ xueus esou ym oznasz enO ay u d Nexesedas p llddns OZNaszpP eo ld uoluesul GZ xueus sou UNA oznasz jenno 9rv ejequesuoy E r uoneuuo uo 1sod 104 uoneoo Buu l W os LH au azem 9jSEM lulor Up 8lv o Kjeyeedes pelddns Dep mu deo SLNGOZP eed uotuesul Sz xueus esou uw oznase jenno 4eq 60 440 Jed SL NO dN d1009 DLM uiejs As sisouisQ asionoy Y 9InpoiN Vv Ajeyeredes peljddns OZNGSzP eoeld uoruesul SZQ xueus esou yim Ajayeredas paljddns OZNGSzP soe uoluesul SZQ xueus esou ym ozNasz eu Mun Ionuoo inss iqd eseoJoui SANSSIAG S lnpoW Fr Ajayesedas p llddns 0ZNGSZP o ld uolu sul SZ xueus esou uy ozNasz eu 42012 0 OEZ 0 Bulysemyoeg au Bumes 1944 uoqieo peyeAnov z SINPON Ajeyeredes peljddns OZNaszpP eoeld uoluesul SZ xueus esou YIM ozNasz eu xA9019 0 00 Z 0 Bulysemyoeq y Buas uone n220 pue Jeu pues uoneunojuo2 e4d Service Handbook 08 2004 Flow diagram of the complete reverse osmosis system RO system Figure 2 12 WTC 600 LP MP DESCRIPTION 2 3 Description of the System 2 3 1 Modular Design The installation is a drinking water conditioning system Its core application is the emineralization of brackish wate
28. PERATION OF THE SYSTEM WTC 600 LP MP 3 3 2 Electrical Connections 3 3 2 1 Pressure increase Pump 230 V external via connection cable 3 3 2 2 Preliminary Filter In delivery condition the preliminary filters are connected to the power outlets 1 f on the rear side of the RO equipment 3 3 2 3 Metering Station The pumps of the projected metering stations are connected to the power outlets 1 g NOTE The cable from the float switch must be inserted in the metering pump unit Digital input release Alarm output empty alarm For connection of the control cables in the electrical switching cabinet the blind py See connections in the flange plate 13 4 are T EE vi EN UD replaced by the enclosed cable screw fittings eie le dri n 13 3 rna punc Connect the control cables in accordance with Table 13 NOTE The complete connecting diagrams plans 13 1 are located in the switch cabinet NOTE The connections for signal inputs Figure 13 Connections metering stations that are not required are bridged at the connecting terminal 13 2 28 Service Handbook 08 2004 WTC 600 LP MP Metering Container Type Function OPERATION OF THE SYSTEM Signal Line Connecting Terminal El Cabinet Pre chlorination Alarm output 12 1 not required Empty signal black Digital input 12 2 Release brown blue not required
29. Sand Heavily soiled Notify sales conglutinated water Differential Filtrate of the sand Small particles Install preliminary 4 1 pressure of filter turbid come through treatment fine filter quickly exceeds 1 bar Filtrate of the Small particles Check sand filter 4 1 activated carbon come through install preliminary filter turbid treatment as required Filter material No backwashing Carry out backwashing 3 4 2 1 conglutinated carried out for too if without success long replace sand Too much Reduce metering amount flocculation agent of flocculation agent added carry out backwashing Indication of the Power supply Notify electrician controller disconnected remains dark Control wheel Control switch or Replace controller does not stand switching still mechanism defective No changes of Backwashing is Controller Change 3 4 2 4 the back notinitiated incorrectly programming washing programmed counter Tabelle 31 Service Handbook 08 2004 59 MAINTENANCE WTC 600 LP MP 4 6 Maintenance Plan 4 6 1 Maintenance During Operation Module Cycle Time Activity Chap Fig RO module Flow meter Daily Check drinking water capacity 3 3 1 2 11 6 RO module Differential Daily Check pump and concentrate 1 13 pressure pressure 1 14 RO control Display Daily Check drinking water 1 11 conductance value Metering container Weekly Check filling and refill 3 2 Media filter activated carbon Wee
30. TE Briefly pressing the ADVANCE pushbutton after selecting runs you through the diagnosis indication Service Handbook 08 2004 33 OPERATION OF THE SYSTEM WTC 600 LP MP 3 4 3 Starting Operation of the RO System 3 4 3 1 Operating Levels and Passwords Normal Level In this level the operating mode the operating condition as well as the current measuring and operating values are indicated on the display 5 2 with the help of changing rotating masks see figure 16 NOTE The user operates the equipment in normal level Entering a password is not required User Level The user level enables operation as well as adjustment of the most important functions and operating settings parameters as well as the calibration of the LF sensors User password gt V Technician Level The technician level is an extended user level Apart from the functions of the user level it enables the manipulation of all operating settings parameters as well as a hardware test with the help of a diagnosis function Technician password gt ESC dk a S ESC v d a NOTE To enter a password the respective key sequence must be entered in the normal level within one minute NOTE For settings and menus of the RO 1000 control system see figure 22 NOTE Enter the settings of the projected system in the diagram on page 64 3 4 3 2 Menu Selection The menu consists of several lines which are arranged below each other in a li
31. ace the activated carbon or filter sand 54 Reverse OSMOSIS control 11 Reverse Osmosis Module RO Module 44 Reverse Osmosis System 30 RO 1000 Manual 66 RO control factory settings 62 RO control program structure 64 RO Filter Replacement 44 RO Module with Preliminary Filters 27 EO PUIYND trol tes eie ies 46 RO System Pump and Fine Filter 14 S Safety Installations 15 Safety Instructions 70 Sampling valve for drinking water 46 Sampling valve for untreated water 46 Scope of Application 69 Selecting Several Arguments at tie an ense et 35 elle EE 81 Selection of an Option 34 Selection of menu 81 Setting menu 88 Solenoid valve 46 AUD ti da 72 Starting Operation 30 31 Starting Operation of the RO System 34 T Technical Data 89 Technical Data WTC 600 LP MP 17 Technician s l
32. after operation failure with STOP discontinuous rinse interlocked rinse t interval 0 NY PRODUCTION OFF RINSE INTERVAL rinse t interval reached DISC RINSE until t rinse is reached IF TANK FULL no longer active If TANK FULL no longer active DISPOSAL until t disposal is reached AND a value below LIM permeate is reached PRODUCTION ON until TANK FULL is active concentrate disposal or displacement ps concentrate displacement CONCENTRATE DISPLACEMENT until t concentrate is reached CONCENTRATE RINSE until t concentrate is reached 78 Service Handbook 08 2004 WTC 600 LP MP APPENDIX 3 5 Operating failures failure messages The control system is able to detect operating failures during OPERATION and DISINFECTION and to display them Usually the unit will be stopped if a failure occurs However operating settings exist for the failures CY EXCEEDED and HARDWATER which make it possible that such a failure is only displayed without interruption of the production During the operating mode DISINFECTION only a MOTOR FAILURE can be detected The different operating failures failure messages as well as their reasons and consequences are as follows Denomination Reason Consequence CY EXCEEDED Cy perm gt LIM Unit switches off if ps LIM high switch off FORCED STOP FORCED STOP active Unit switches off MOTOR FAI
33. al letters bold LEFT UP DOWN LED s capital letters bold RINSE DISPOSAL inlets outlets capital letters bold PUMP FAILURE INLET VALVE operating settings italics ps hard water ps pumps operating parameters italics LIM t rinse operating modes capitals underligned STOP ON operating conditions capitals underligned PRODUCTION DISPOSAL operating failure capitals underligned MOTOR FAILURE FORCED STOP The following abbreviations will be used Cy perm permeate conductivity t perm permeate temperature Remark The terms on off as well as STOP and OPERATION could cause mix ups they are therefore defined as follows On off describes the existence non existence of the mains supply voltage STOP and OPERATION describe an operating condition which obviously only can exist when the system is switched on 1 6 Declaration of Conformity The Control Unit complies with the following standards and test regulations to be fixed in the framework of the CE conformity standards Service Handbook 08 2004 71 APPENDIX WTC 600 LP MP 2 Installation Start up 2 1 Basic Requirements for System Installation The following remarks have to be observed during installation and connection of the RO 1000 unit The connected consumers must not exceed the max admissible loads of the circuit outputs as well as the total output of the unit see item 5 in case of inductive loads the phase angles have to be taken
34. ank min Break contact Tank max Break contact Language English Tabelle 34 62 Service Handbook 08 2004 WTC 600 LP MP APPENDIX WTC 600 MP MP A MP AM in voltages 230 V and 400 V Operating mode Switched off LF limits GW 1500 GWV 400 Alarm option Switch off Calibration Permeate temperature Executed Permeate conductivity Executed Settings t GW delay 01 min t GWV delay 05 min t pressure deficit 1s t Press start up delay 9 9 s t pressure available 60 s t discont flushing 10 min or longer depending on specifications t flushing interval 24 h or less depending on specifications t Concentrate displacement 01 min t min disposal min 005 s t max disposal max 60 min t maintenance 3500 h Vw fault acknowledgement No password Vw concentrate Displacement Vw tank type With overflow Inputs Forced stop Break contact Motor protection Break contact Pressure switch Break contact Tank min Break contact Tank max Break contact Language English Tabelle 35 Service Handbook 08 2004 63 APPENDIX WTC 600 LP MP RO control program structure 1 Ackn failure 2 Operat mode STOP OPERATION DISINFECTION Lim pS cm War __uS cm 7 ps LIM exc do not stop do stop 8 calibration 1 temp permeate 2 cy permeate gt X x C XXX uS cm 1 Cond OBEN max XXX uS cm 2 Cond UNTEN min 3 calibr reset 9 setti
35. at more than 650 l h meaning that at higher lower feed water temperature the pump pressure and concentrate pressure must be decreased increased respectively by means of the ball valves compare figure 11 Check the conductance value according to the reading on the display Demineralization rate 94 99 Switch off the system at the main switch Connect drinking water line in tank Switch on the system at the main switch Drinking water is produced and fills the tank Tank filled The level float switches off the solenoid valve and the pump until the switch of the level float signals empty and the RO system switches on again Service Handbook 08 2004 37 OPERATION OF THE SYSTEM WTC 600 LP MP Checking the pressure control device shut the untreated water supply for this The RO system must switch off after a short time THE Fault LED must light at the operating panel Lack of pressure is indicated on the display 5 2 Afterwards open the untreated water supply again Delete the malfunction indication with the ESC pushbutton 5 3 Enter operator password Use AN keys to call up menu item 6 LF limits L Press pushbutton Use the tb keys to set the limiting value upper limiting value of the drinking water conductivity 20 of the untreated water conductivity value Use the key to change to warn value Use AN keys to set the warn value warning value of the drinking
36. ation With the exception of an error acknowledgement only in case of pre selection Vw acknowledgement by actuating the ESC key button no further operating by the operator is possible this is to protect the control system against unintended unauthorized manipulations NOTE By entering the respective password the user level or the technician level for input of operating parameters etc is cleared see section 3 4 3 1 The program structure is given in the appendix Figure 21 NOTE Operating parameters and setting values are listed on the data sheet by the manufacturer cf Tables 34 and 35 2 3 3 2 Manual Operation The float switch in the drinking water tank is deactivated by the manual automatic rotary switch Manual position so that the plant can run continuously CAUTION Manual operation is not standard operating mode as the system does not switch off automatically 16 Service Handbook 08 2004 WTC 600 LP MP DESCRIPTION 2 4 Technical Data WTC 600 LP MP Parameter WTC 600 LP WTC 600 MP Ambienttemperature 1 C 50 C Storage temperature delivery to 10 C Humidity lt 100 r F Supply voltage 3 400V 50 Hz 1 230V 50 Hz Pre filter controls prim sec 230 V 12 V 50 Hz Metering pumps 230 V 50 60Hz Wiring 3 Ph N PE Electrical protection 16A Connected electrical load 2 2 kW 2 2 kW Effective electrical power consumption 1 5 kW 2 2 kW Mechanical protection prot
37. ation means must be flushed and renewed if required 50 Service Handbook 08 2004 WTC 600 LP MP MAINTENANCE Aids Conserving tank Four connection hoses Chemicals for conservation compare with Table 25 and for neutralization Conductive capacity measuring unit for measurement comparison after flushing Protective clothing goggles gloves apron External pump Starting Position RO equipment set to switched off operating mode and switched off with main switch Work steps 1 2 oN Qu o P 10 Fill 25 litres of chlorine free drinking water into the flushing tank 20 16 Connect the untreated water inlet depressurise the system Use the connection hoses and flushing pump 20 19 to connect the flushing tank with the untreated water sampling tap Feed the drinking water adapter and connection hose from the drinking water outlet 20 8 to the flushing tank Feed the concentrate adapter and connection hose from the concentrate outlet 20 12 to the flushing tank Switch on the flushing pump Switch system to disinfection operating mode and adjust water pressure to 2 bar manometer 4 7 using the untreated water sampling tap Disconnect the earthing pin plug of the metering pumps Add sodium bisulphite to the flushing tank If the system is to be protected against frost then slowly add the RM 1 2 propandiol Allow the conservation solution to circulate for 10 minutes The more RM 1 2 propandi
38. culation test solution to 500ml up to ideal flocculation the yield is 75 11 drops x 80 880 ml RM 5001 per 10 litres of metering solution Service Handbook 08 2004 25 OPERATION OF THE SYSTEM WTC 600 LP MP 3 3 Connecting the Equipment 3 3 1 Connections Valves and Indicators Depending on the local untreated water supply the WTC 600 LP MP is connected directly to the off site supply or supplemented through a WTC 600 PI pressure increase module The following constructional measures must be observed The off site untreated water supply must be equipped with a shut off device supplied by user customer All pipes lines untreated water backwashing concentrate and drinking water to be installed without mechanical tension Drinking water line to be installed with free run out and no further shut off devices Backwashing line to be installed with steady drop under no circumstances inclined upward For easy and secure operation and main tenance of the system minimum clearances A from the walls are to be observed O Q e Page Minimum clearances cm B B 10 C Table 12 Minimum clearances Figure8 Minimum clearances WTC 600 LP MP Figure9 Water connections WTC 600 PI Installation space incl working space for maintenance and operation not including piping WTC 600 LP and MP width x depth 1300 x 1900mm WTC 600 LP A LP AM MP A MP AM width x depth 1700 x 1900 m
39. de 16 B Backwashing Regeneration 31 Balancing Values 35 Basic elements 81 Basic Requirements for System Installation 72 C Calibration menu 87 Check VAMO quise ensi ode 46 Chemicals for Metering Containe 19 Chlorination of Drinking Water 8 GIrcult Breaker un u kr eod i exe 15 Cleaning Chemicals 19 Cleaning in Case of Malfunction 45 Cleaning Solution for Acidic Cleaning 50 Cleaning Solution for Alkaline Cleaning 50 Concentrate control valve 11 46 Concentrate flowmeter 11 Concentrate to the flushing tank 46 Concussion restrictor 11 Conductivity and temperature measuring cell dri 11 Confirmations spa 82 Connecting the Equipment 26 Connections Valves and Indicators 26 Conserve the RO system 50 Conserving otio esi teo Pr drm buie 50 Consumption Materials 19 Control activated carbon filter 11 Control cabinet
40. dication are you sure Press the pushbutton gt no lt yes Indication are you sure Press the RETURN pushbutton no gt yes lt Indication i 1 ackn failure Press the ESC pushbutton gt 2 operat mode lt Service Handbook 08 2004 39 OPERATION OF THE SYSTEM WTC 600 LP MP Indication RO 1000 V 01 34 The equipment produces and starts with Disposal rejection Operating conditions Production LED lights Reject LED lights After the reject period has run off normal production with rotating indication W Temp RO 1000 V 01 34 12 30 hours meter Production on perm 12 uS cm 1111h 11 min When the RO equipment starts the intake valve for untreated water is opened and the RO pump starts after the preset time and given pressure 3 4 4 1 Operating Messages for Normal Operation 1 System does not produce because tank is full The tank full LED lights at the operating panel ndication K Displacement and afterwards Production off on the display Cause The float switch in the drinking water tank has switched 2 System does not produce during regeneration flushing The regeneration LED lights at the operating panel Indication Forced stop on the display Cause One of the preliminary filters is being cleaned 3 The system does not produce at malfunction indication Metering station empty The fault LED lights Indication Hard water Cause Empty sen
41. e of these characters represents an argument A 0 argument is inactive a 1 argument is active A curser flashing block can be moved with the keys between the different characters arguments and the corresponding description of the argument then appears in the upper display line e g name of operating mode An argument can be activated inactivated with the Y key The current setting of all arguments is accepted stored with the a key 4 2 5 Numerical editing The numerical editing is required to set the internal operating parameter and to enter the adjusted values The procedure is the same as used for decade switches When numerical editing is called in e g via a menu the name of the operating parameter adjusted value appears in the upper display line The current value is displayed in the lower line A flashing block cursor always marks the figure which can be modified this modification new setting can be achieved with the 4 Y keys Cursor displacement is achieved with the gt keys so that other figures can be modified too The displayed value is stored as new operating parameter when the a key is actuated The ESC key allows to interrupt the procedure without any storage even if a new figure was entered 4 2 6 Alphanumerical editing The alphanumerical editing is required to set the message text for the uncommitted input failure message The procedure is the same as for numerical editing see item 4
42. e operation Instructions that are attached directly to the equipment must be observed under all means and kept in completely readable condition 1 3 Intended Use The equipment is intended for the conditioning of untreated water into drinking water The retention degree of harmful chemical substances and biological pathogens or contaminants is very high The quality of the produced drinking water ultimately depends on the contamination degree and salt content of the untreated water Prior to the initial starting of operation we recommend carrying out an analysis of the untreated water Continuous drinking water quality can be ensured only when the equipment is controlled regularly The respective national or international drinking water regulations are to be observed Under consideration of these rules of conduct water produced from this system can quite safely be classified as drinking water Service Handbook 08 2004 7 GENERAL WTC 600 LP MP 1 4 Safety Instructionse 1 4 1 Quality of the Untreated Water Sufficient quality of the untreated water must be ensured Faultless drinking water is achieved only when all filters of the equipment are maintained regularly 1 4 2 Chlorination of Drinking Water When applying post chlorination the limit values set by national laws must be main tained The chemicals used have a caustic and fire promoting effect Dangers Danger of fire in case of contact with comb
43. ebele EE ER 3 4 2 3 Backwashing Regeneration ir per aves teer odisse Dom eus 32 342 4 reel O 33 3 43 Starting Operation of the RO System a 35 3 4 3 1 Operating Levels and Passwords I r 35 SAS Mente ci asa 35 3 4 3 3 Selection of an Option oa dE 35 3 4 3 4 Selecting Several Arguments at the Game 36 3 4 3 5 Adjusting Operating Parameters and Balancing Values 36 3 4 3 6 Acknowledging Data E e 36 3 4 3 7 Operational Interruptions EE 36 9 4 9 8 Initial SIBPIUD o id 38 3444 Normal Operation usa 40 3 4 4 1 Operating Messages for Normal Operation oooocccccnonccccnnocccccnonccncncnanancnnnanaccnnnnnnos 41 3 4 5 Putting Out of Operation eater tae tle cule tab dec gerne 42 A A EE 43 d Maintenance eene in 44 62 4 1 hnic Tr 44 4 2 Metering Station WTC 600 CD u J 44 4 8 Reverse Osmosis Module RO Module J 45 43 1 RO Filt r Replacement isis u me eie e ete nelle tia da 45 4 4 Cleaning in Case of Malfunction u u u 46 4 4 1 Design of the Flushing and Disinfection Equipment 47 4 42 DisinfectiOn oper da 49 4 4 3 Acid
44. ection against water Switch cabinet IP44 Pump and valves IP44 Metering pump IP44 Power outlets plug inserted lt IP44 Minimum temperature of untreated water 5 C Maximum temperature of untreated wate 35 C Reference temperature 15 C pH value untreated water 6 9 5 pH value during cleaning 3 11 System input pressure and flow 2 6 bar at min 2 m h Capacity range 15000 l day 10 Maximum drinking water capacity 650 l h Dimensions Hx Wx D WTC 600 LP MP WTC 600 LP MP A 1800 x 660 x 720 mm 1800 x 1120 x 720 mm WTC 600 LP MP AM 1800 x 1120 x 720 mm Weight in delivery condition without filter container WTC 600 LP MP 135 kg WTC 600 LP MP A 155 kg WTC 600 LP MP AM 175 kg Table3 Technical Data depending on the system version Service Handbook 08 2004 17 DESCRIPTION Filter Container WTC 600 LP MP Volume per container 1031 Filling capacities Mediafilter Support pebbles 2 0 3 15 mm 15 kg Filter sand 0 4 0 8 mm 100 kg Filter amounts activated carbon filter Support pebbles 1 2 mm 15 kg Activated carbon filter F100 32 kg Water connections Inlet threaded connection hose nozzle Outer diameter d25 Drinking water threaded connection hose nozzle Outer diameter d25 Concentrate threaded connection hose nozzle Outer diameter d25 Outlet for flushing water HT pipe d50
45. eer eres 30 Flocculation Agent 24 Flocculation metering 11 Flocculation metering point 11 Flocculation Module 13 Flow Diagram sii ca e hee ctore 12 Flow meter concentrate 46 Flow meter drinking water 46 Flushing pump 46 Flushing tank inne tette oes 46 Flushing the pre filter 53 Function of Terminals seeeeeeeeeee eeen e eene 73 G General pe EE 69 General installation notes 9 General Remarks 69 H Handling Electricity Protection Class 9 High pressure pump 11 91 LIST OF KEY WORDS l Indicator lights 80 Aital FNO aaa ise 31 Initial Startup m tede 37 Input solenoid valve 11 Installation Start up 72 Instructions for Use 70 K Keyboard rita ici 80 M Main men 86 Maintenance 43 Maintenance During Operation eeeseeeen 60 Maintenance Plan 60 Maintenance Plan Service
46. en valve by hand only danger of damaging Feinfilter 5p Art Nr 6 414 466 0 Service Handbook 08 2004 43 MAINTENANCE WTC 600 LP MP Replacing the membrane Set the pump lift adjustment knob 8 1 to 100 Unscrew the 4 screws size 6 mm at the metering head and remove the metering head Unscrew the membrane to the left Reattach the sealing membrane1 intermediate ring and support disc again Screw in new membrane Bring the push rod to the end of suction stroke position by switching the mains voltage on off Reassemble metering head and tighten screws over cross tightening torque 4 Nm Bleed the pump 8 3 and put into operation again After 48 hours of operation retighten the metering head screws tightening torque 4 Nm 4 3 Reverse Osmosis Module RO Module 4 3 1 RO Filter Replacement The RO filters are to be replaced when cleaning and disinfection as a measure to increase the capacity have been without success Filter replacement Select the switching off operating mode and release the system pressure Loosen the connections concentrate connection 18 2 drinking water connection 18 1 and supply 18 5 and unscrew pressure tube 18 4 with tube clamps 19 5 from the frame CAUTION Do not loosen the tube clamps because of height adjustment Release securing rings 19 1 Unscrew connections 19 2 Screw extractor tool into thread of drinking wate
47. er media filter inlet pressure 1 3 Media filter 1 4 Differential pressure switch 1 5 Concussion restrictor 1 6 Flocculation metering point 2 1 Manometer activated carbon filter inlet pressure 2 2 Activated carbon filter 4 1 Antiscalant metering point 4 2 Non return valve 4 3 Untreated water sampling tap 4 4 Manometer fine filter input pressure 4 5 Fine filter housing 4 6 Fine filter candle 4 7 Manometer fine filter output pressure 4 8 Input solenoid valve 4 9 Manostat 4 10 High pressure pump DESCRIPTION 4 11 Manometer pump pressure 4 12 Membrane pressure pipe 4 13 Membrane 4 14 Manometer concentrate pressure 4 15 Concentrate control valve 4 16 Concentrate flowmeter 4 17 Pressure control valve 4 18 High pressure pump 4 19 Conductivity and temperature measuring cell drinking water 4 20 Drinking water flowmeter 4 21 Drinking water sampling tap 4 22 Non return valve 4 23 Post chlorination metering point 4 24 Reverse osmosis control 6 1 Pre chlorination metering 6 2 Antiscalant metering 6 3 Post chlorination metering 6 4 Flocculation metering Items 1 1 to 6 4 are attached to the components as reference numbers Media filter control Control activated carbon filter Control cabinet Manual automatic rotary switch Master switch gt o Qa 0 O o Media and activated charcoal plug sockets g Power outlets 3x for metering stations Service Handbook 08 2004 11 WTC 600 LP
48. eset adjustment of the two measuring inputs to the internal standard values ATTENTION Internal calibration is not a correct adjustment Service Handbook 08 2004 87 APPENDIX 4 4 3 WTC 600 LP MP Setting menu The calibration menu is used to adjust the sensors The following functions are available Menu point 1 t Cy LIM 2 t Cy alarm 3 t lack of pressure 4 t delay at start 5 t press availabe 6 t disc rinse 7 trinse interval 8 t concentrate 9 t disposal 10 t maintenance 11ps failure alarm 12 ps concentrate 13 ps type of tank 14 inputs 15 ps language 16 system reset 4 4 4 Function Numerical editing of t delay LIM Numerical editing of t delay aaLIM Numerical editing of t delay lack of pressure Numerical editing of t delay at start Numerical editing of t pressure failure Numerical editing of t rinse Numerical editing of t rinse interval Numerical editing of t concentrate Numerical editing of t disposal Numerical editing of t maintenance Selection of ps acknowledgment Selection of ps concentrate Selection of ps tank type Setting of input types valve with open rest pos opener Selection of ps language As soon as this function is called in and acknowledged the internal hours meter will be deleted set to O Diagnosis menu The diagnosis allows direct display manipulation of the input output conditions for testing purposes ATTENTION Under these conditions failure detection is
49. evel 84 Terms and Definitions 71 TOM diSplaM acted e tr dotem asa 80 U Units and Designations 9 Untreated water sampling tap 11 User interface 80 User s Level 84 W WTC 600 LP LP A LP AM in voltages 230 V and 400 62 WTC 600 MP MP A MP AM in voltages 230 V and 400 63 Service Handbook 08 2004 LIST OF KEY WORDS 93
50. exceeded during PRODUCTION RINSE or CONCENTRATE DISPLACEMENT FLUSH for the time defined for t delay LIM an ALARM MESSAGE will be activated user technician meas range 0 5 50uS cm 40 uS cm Attention the set value must be above aaLIM Permeate limit value activating an ALARM MESSAGE in the display and on off of the malfunction LED if this value is exceeded for the time defined for t delay aaLIM user technician 0 5 50uS cm 10 uS cm Attention the set value must be lower than LIM Time delay for wrong permeate limit value see above technician 0 99 min 1 min Time delay for advance alarm in case of wrong permeate limit value see above technician 0 99 min 5 min Time delay to release PRESSURE FAILURE if PRESSURE SWITCH is inactive technician 0 99s 1s Period of time of permanent pressure at start of operation after opening of the inlet valve before the pumps begin to work technician 0 9 9s 0 5s Period of time until PRESURE FAILURE is released if pumps do not start after opening of inlet valve technician 0 99s 5s Duration of a DISCONTINUOUS RINSE technician 0 99 min 5s 75 APPENDIX t rinse interval t concentrate t min disposal t max disposal t maintenance 76 function right of access possible setting function right of access possible setting funtion right of access possible setting function right of access possible set
51. ft of the TIME OF DAY pushbutton 15 2 is to be pressed a circular indentation can be felt under the front foil The changing of the flashing positions is carried out with the ADVANCE pushbutton 15 3 NOTE If a different adjustment than the factory setting is required enter and acknowledge by pressing MANUAL REGEN 15 4 WTC 600 LP MP K CONTROLLER 1 Figure 15 XP Controller When pressed continuously the number values run through in double digits from the current value to 99 by briefly pressing the pushbutton the indication changes upward by the value 1 Moving on to the next enter position is done by pressing the pushbutton mentioned in the 2nd column in Table 17 TIME OF DAY 1 Sets the time 2 Starts the programming of time steps ADVANCE 1 For changing of parameters during proggramming 2 Calls up the diagnosis see Table 24 press for 10 sec MANUAL REGEN 1 Activates a manual regeneration 2 Runs step by step through the regeneration steps Covered pushbutton Left of the TIME OF DAY pushbutton Starts the programming Table 16 Input preliminary filter control Position Indication Description At the media filter 1 Covered pushbutton 0 200 Media filter back washing at 02 00 minutes 2 Covered pushbutton 0 200 Media filter back washing at 02 00 full hours At the activated carbon filter 1 Covered p
52. he different operating levels and their functions as well as the operating options and the displayed texts as far as possible are described below 4 3 1 Normal level According to the operating mode the sequence of displays in the normal level is as follows Operation STOP Disinfection RO1000 V1 10 Operating Condition RO1000 V1 10 RO 1000 V1 10 STOP Disinfection W temp 12 3 C Perm 12 3 uS cm Operating Hours 12345 h 12 min The only operation which is admitted is the acknowledgement of a failure only for ps acknowledgment without password the purpose is to protect the control system against unintentional unauthorized manipulations When the system is switched on it always is in the normal level so that is also can be called the basic level Service Handbook 08 2004 83 APPENDIX WTC 600 LP MP 4 3 2 User s Level Access to the user level is achieved by entering a user s password see 4 2 1 This level allows operation and setting of the most important functions and operating settings parameters respectively The operating status is not displayed because display is used to represent the menus to do selections and editing The functional scope corresponds to that of the main menu see 4 4 1 but without the menu points Setting and Diagnosis Ifthere is no key actuation for more than 10 min and provided that the current function does not correspond to the display of measured values the control sy
53. ic and Alkaline Cleaning sc des 50 4 4 3 1 Cleaning Solution for Acidic Cleaning a rr 51 4 Service Handbook 08 2004 WTC 600 LP MP CONTENTS Contents 4 4 3 2 Cleaning Solution for Alkaline Cleaning rr 51 4 4 4 o EE 51 4 4 4 1 Draining and rinse the metering stations 51 4 4 4 2 Conserve RO systems r nn cre e nnne nenne 51 4 4 4 3 Draining the pre filter esses eene nnne nnne 53 4 4 5 Removing the Preservation After Longer Operational Interruptions 53 44 6 Rinsing the prelio Duo oorr E 54 4 4 7 Replacing the activated carbon or filter Sand 55 4 5 Malfunction Cause and Corrective Action 57 4 5 1 Metering Station LED and Indicator LEDs at the Switch Cabinet 57 4 5 2 Malfunction Indication at the Operating Panel 58 4 5 3 Malfunctions of the RO Control and Metering Pump 59 4 5 4 Malfunctions Sand and Activated Carbon Filter Fine Filter and Flocculation 60 4 6 Mainte a ce Pla TERME 61 4 6 1 Maintenance During Operation 61 4 6 2 Maintenance Plan Service ANEN 62 PPD GIGI duc 63 84 RO control manufacture settings ENNEN 63 RO control program structure ede eI P
54. ing and reinsert the central control valve again after removing the cover Connect the hydraulic connections again 3 4 2 2 Starting Operation After filling the filters must be backwashed For this the complete system is to be connected hydraulically and electrically and to be switched on at the main switch The reverse osmosis system must be in the Switched Off operating mode compare 3 4 3 3 4 5 The backwashing is initiated manually with the MANUAL REGEN pushbutton 15 4 and takes approx 15 minutes The procedure can be followed on the display of the controller Step 1C Backwashing duration approx 10 min Step 2C and 3C Without function Step 4C Initial filtration duration approx 3 min Afterwards the filter is ready for operation 3 4 2 3 Backwashing Regeneration For cleaning of the filters the flow direction of the water is reversed so that the settled debris particles are moved to the outlet of the flushing water The filters are equipped with different devices for actuation of backwashing Activated carbon filter Time controlled 1 x per night Standard 2 30 a m Manually any time Media filter Pressure difference upon contamination of the filter Standard 1 bar difference Time controlled 1 x per night Standard 2 00 a m Manually any time Service Handbook 08 2004 31 OPERATION OF THE SYSTEM 3 4 2 4 Programming To start the programming the covered pushbutton 15 1 to the le
55. into account All inductive consumers valves motors contactors transformers of the unit have to be provided with suitable interference suppressors RC element varistor diode Should other devices with a high mains borne interference level be installed in the surroundings of the control system suitable external interference suppressors line filters have to be installed at the supply voltage input The clamps must not be actuated with too much force The screw less terminal clamps are suitable for single core and fine core conductors without sleeves of up to 0 5mm2 for sensor and analog output terminals and up to 2 5 mm2 respectively all further terminals According to the manufacturer s instructions it is not necessary to use core sleeves All assembly activities have to be done in accordance with the corresponding VDE regulations 2 2 Start up For the first start up of the unit after its installation the below mentioned steps have to be carried out in the given order Should the control system not operate in the described manner or if other malfunctions are discovered the electric supply has to be interrupted immediately and repaired by the manufacturer 1 Install control and fix all terminal clamps It has to be taken into account that the softener output is not protected by fuses A short circuit at this output may therefore destroy the conductor lines 2 Switch on mains supply voltage afte
56. ion so that you can directly try to realize the explained items and functions As some of the modules are directly related to other ones it is recommended to follow the given order of the different chapters Should there arise any problems or questions during the operation of the control system please ask for our advice and assistance Please try to localize the problem as exactly as possible and to record any actions or conditions which caused the problem this will enable us to help you as quickly as possible The supplier does not accept any liability with regard to any faults contained in this documentation Under no circumstances whatsoever a liability for any damages related directly or indirectly to the delivery and use of this documentation is accepted 1 2 Scope of Application The RO 1000 system is a control system for reverse osmosis units of different sizes lts technical features are Microprocessor control with liquid crystal text display and keyboard covered with a protective film LED displays for operation malfunction disinfection disposal regeneration and tank full Circuit inputs regeneration motor protection available by Limitent contact pressure switch min permeate level as well as max permeate level Relay outputs inlet valve outlet valve concentrate valve system pump as well as alarm Conductivity sensor for permeate optional 2 to 200 uS cm resolution 0 2 accuracy 1 tempera
57. iscalant OPERATION OF THE SYSTEM The drinking water for the metering solution is taken from the sampling tap for drinking water 1 4 21 The antiscalant metering quantity can be set with a very good approximation using the following table The optimum quantity can only be calculated using a calculation program after a precise water analysis has been carried out The typical metering range lies between 2 and 5 mg l Where water hardnesses are higher than 28 dH special design is necessary If this design is not possible the following setting is recommended 5 mg l RM5000 and 50 yield until the precise design is available Range of Water Hardness Antiscalant mg l Metered Run down amount of Tank Service RM 5000 ml Life h per 101 Metering Solution 1 0 7 dH 2 5 58 214 2 7 14 dH 3 69 214 3 14 21 dH 4 92 214 4 2128 dH 5 115 214 Table10 Metering of antiscalant at 75 yield Range of Water Hardness Antiscalant mg l Metered Run down amount of Tank Service RM 5000 ml Life h per 101 Metering Solution 1 07 dH 2 5 87 214 2 7 14 dH 3 104 214 3 14 21 dH 4 138 214 4 21 28 dH 5 173 214 Table Metering of antiscalant at 50 yield 1 dH 1 79 frH 1 dH 17 9 mg CaCO3 l 1 rH 10 0 mg CaCO3 I Service Handbook 08 2004 23 OPERATION OF THE SYSTEM WTC 600 LP MP 3 2 4 Metering Amounts and Mixing of the Post Chlorinati
58. ive tape 5 Clean the pressure tank with clean water and check for internal damage 6 Fill with new filter material cf Chap 3 4 2 1 Initial fill 7 Screw on the control head reinstate the connections fit the controller 8 Reinstate untreated water inlet 9 Switch on the WTC 600 at the master switch and trigger two consecutive backwashes 10 Switch the WTC 600 to Run operating mode 11 Finished Disposing of the replaced filter material The replaced filter material must be disposed of according to the local waste regulations Service Handbook 08 2004 55 MAINTENANCE WTC 600 LP MP 4 5 Malfunction Cause and Corrective Action 4 5 1 Metering Station LED and Indicator LEDs at the Switch Cabinet Indication Malfunction Cause Corrective Action Chap Fig Red fault LED Pumpinmetering Metering Refill check float switch 2 3 1 5 lights station blocked container empty 3 2 3 3 2 4 Sensor signal Check sensors 2 3 1 5 missing check bridges in ETL 3 3 2 switch cabinet check sensor wiring Red Backwashing of Not necessary as 2 3 1 5 regeneration the sand filter or the equipment LED lights activated carbon automatically filter active switches on again Red tank full Float switch in the Drinking water Not necessary as 2 3 1 5 LED lights drinking water tank tank full the equipment 3 3 2 4 has switched automatically switches on again Switch defecti
59. king water to dilute the original chlorine product upstream of the chlorination point This water is taken from the drinking water tap 1 4 21 1 Take the system yield 50 or 75 from the evaluation of the untreated water analysis 2 Take the analysis values for iron Fe manganese Mn and ammonium NH3 or NH4 in mg l from the untreated water analysis 3 Iron content x04 Manganese content X0 6 Ammonium content x8 00 Basic requirement 1 2 Total 4 For 50 yield Total x 192 ml RM 852 per 10 litre metering solution OR Totalx51 ml calcium hypochlorite 1ml corresponds to 1 05g per 10 litres metering solution Service Handbook 08 2004 21 OPERATION OF THE SYSTEM WTC 600 LP MP 5 For 75 yield Total x 128 ml RM 852 per 10 litre metering solution OR Totalx34 ml calcium hypochlorite 1ml corresponds to 1 05g per 10 litres metering solution These values are entered in the customer s operating instructions Calculation example Yield 75 Iron Fe 1 0 mg l Manganese Mn 1 0 mg l Ammonium NH 0 2 mg Iron content 10x 04 2 04 Manganese content 1 0 x 0 6 0 6 Ammonium content 02x 80 1 6 Basic requirement 1 2 Total 3 8 For 75 yield Total x 128 486 ml RM 852 per 10 litre metering solution OR Total x 34 129 ml calcium hypochlorite 1ml corresponds to 1 05g per 10 litres metering solution 22 Service Handbook 08 2004 WTC 600 LP MP 3 2 3 Ant
60. kly Automatic backwashing check 3 4 2 4 filter operation meter Control sheet Weekly Fill out Appendix Metering stations Every 4 weeks Clean and flush metering 4 2 container Float switch drinking Every 4 weeks Visual check of switch water tank Metering stations Yearly or every Clean intake and pressure 4 2 4000 hours valves Metering stations Yearly or every Replace membrane 4 2 4000 hours Fine filter Every 3 Replace filter 4 1 months RO module when conserved Every 6 Renew conservation 4 4 4 months Tabelle 32 60 Service Handbook 08 2004 WTC 600 LP MP MAINTENANCE 4 6 2 Maintenance Plan Service NOTE Measured and read values are to be entered into the maintenance record Module Work to be Carried Out Media filter Assess general condition Differential pressure after backwashing Read adjustment of the differential controller Read amount of backwashings Activated carbon filter Assess general condition Differential pressure after backwashing Chlorine measurement in filtrate 1 18 Read amount of backwashings Fein filter Read differential pressure Amount of used up filters since last service Reverse osmosis Assess general condition Data input according to daily operating log and operational start up record Leakage tightness of the complete equipment in particular Changeovers PVC metal Sliding sealing high pressure pump Question the
61. lorinati 24 Metering Station 28 30 Metering Station LED and Indicator LEDs at the Swi 56 Metering Station WTC 600 CD 43 92 WTC 600 LP MP Microfuses 16 Mixing Chlorine Flocculation Agent and Antiscalan 21 Mixing of the flocking test solution 24 Modular Design 13 Motor Protection Switch 15 Multiselection 82 N Non return valve 11 Normal level 83 Normal Operation 39 Numerical editing 82 O Operating conditions 78 Operating failures failure messages 79 Operating levels 83 Operating Levels and Passwords 34 Operating Messages for Normal Operation 40 Operating Modes 16 Operating parameters 75 77 Operating settings 74 Operation ui ita 80 Operation of the System
62. lter 2 3 1 4 RO System Pump and Fine Filter The fine filter is located on the front side of the equipment It is connected directly in front of the RO system The RO pump 4 2 pumps the pre filtered water through two RO filters 4 1 which are connected in series Figure4 RO pump 2 3 1 5 Control Panel and Display The control panel is used for data input in the control and as LED indicator for the operating modes and malfunction indications 5 1 EE 2 Parameters are entered with the arrow pushbuttons Data input is acknowledged with the ENTER pushbutton 5 4 and cancelled Z with the ESC pushbutton 5 3 E Programming conditions etc are indicated in the display 5 2 Figure5 Control panel and display 2 3 1 6 Anti Scalant and Post Chlorination For hardness stabilization of the untreated water and post chlorination of the drinking water a WTC 600 CD metering station is connected to the RO module in the same manner as for pre chlorination 40 Service Handbook 08 2004 WTC 600 LP MP DESCRIPTION 2 3 1 7 Pressure increase Pump If required the WTC 600 PI pressure increase pump 6 1 is connected between untreated water supply and RO system It is used for pressure increase of the untreated water NOTE A pressure increase pump should be used for a water pressure flow pressure lt 2 bar CAUTION Observe mechanical protection as well as protection of the connection cable against water
63. m WTC 600 CD width x depth 500 x 1100 mm WTC 600 PI width x depth 600 x 200 mm 26 Service Handbook 08 2004 WTC 600 LP MP OPERATION OF THE SYSTEM 3 3 1 1 Pressure increase Module Connection to the RO system 9 2 Hose shank d25 Connection to the untreated water 9 3 Hose shank d25 CAUTION Observe mechanical protection of the electrical connection cable 9 1 as well as protection against water The fan wheel of the pump must be at least 20 cm away from the next wall CAUTION Otherwise damage to the motor caused by heat build up must be considered 3 3 1 2 RO Module with Preliminary Filters In the delivery condition blind discs are installed for means of preservation to the screwed connection above the Antiscalant 10 1 metering line as well as to the drinking water connection 11 4 and to the concentrate connection 11 3 These are to be removed before starting operation Metering line connection for pre chlorination 10 2 Untreated water connection 10 3 hose shank d25 Concentrate drain 10 4 HT pipe d50 Drinking water connection 11 4 hose shank d25 Metering line connection for post chlorination 11 5 Sampling valve for drinking water 11 6 Sampling valve for untreated water 11 9 Pressure control valve 11 1 Flow meter concentrate 11 2 Flow meter drinking water 11 7 m Figure 11 Connections front Concentrate control valve 11 8 Service Handbook 08 2004 27 O
64. n dropping bottle close bottle 5 Cast away the remainder 24 Service Handbook 08 2004 WTC 600 LP MP OPERATION OF THE SYSTEM 3 2 5 2 Perform flocking test Auxiliaries Transparent cup 1 litre with marking at 0 5 litre 6 277 001 0 Dropping bottle with test solution 6 394 426 0 Plastic eating spoon Work Steps 1 Measure pH value of water has to be between 6 and 9 2 Pour 0 5 Liter raw water into cup 3 Give 10 drops of flocking test solution into spoon 4 Fill flocking test solution into cup at this stir strongly for 5 seconds 5 Leave cup flocking has to start within 1 minute and settle significantly NOTE If no flockung has start repeat test and change quantity of flocking test solution first more test solution if not successful repeat with less test solution If analysis is not possible on the spot take out 2 litres of test solution and store in refrigerator at ca 4 C until analysis Cooling maintains cloudiness by suspended matter NOTE Shake well before measurement in laboratory 3 2 5 3 Evaluate flocking test Adjustment of dosing pump flocking means Stroke 40 Frequency 70 The required amount of flocculation agent RM 5001 is then calculated as follows For 50 yield number of drops x 120 ml RM 5001 per 10 litres metering solution For 75 yield number of drops x 80 ml RM 5001 per 10 litres metering solution Calculation example The flocculation test gave 11 drops of floc
65. nents assemblies which are marked with this symbol protective measures are to be taken Switch off the power Secure against restarting Check and assess that no voltage is given The electrical connection of the equipment may be carried out only by a qualified electrician The power supply cable must be fitted with a protective conductor protection class 1 5 General installation notes Only use food safe components and resources on the drinking water side Pay special attention to hygienic cleanliness when installing drinking water pipes 1 6 Units and Designations Unit Designation bar bar pressure di da Diameter inside diameter outside g h Gram per hour Hz Hz frequency Liter yh Liter per hou mg h Milligram per hour mg l Milligram per lite ml Milliliter V AC Volt AC W Watt power dH Degree of hardness water hardness uS cm Microsiemens per cm spec conductance value ETL Spare parts list LW Conductance value SLP Circuit Diagram Table Units and their meaning NOTE 1000 milliliter 1 liter 1000 mg 1 Service Handbook 08 2004 DESCRIPTION WTC 600 LP MP 2 Description 2 1 Overview Figure1 Overview of components 10 Service Handbook 08 2004 WTC 600 LP MP Legend for figure 1 and figure 2 1 1 Pre chlorination metering point 1 2 Manomet
66. ngs 1t delay LIM 2 t del aa LIM min 5 3 t low pressure 4 t press hys JA RTI El 5 t press TO 6 t washing n 7 t wash int 8t concentrate min 9 t disposal Min Max _ Ss min 10 t maintenance 11 ps acknowl without passord only with passw displacement washing 2 ps concentrate with overflow no overflow 13 ps tank type 1 extern stop open closed 14 inputs 2 drive protection closed 3 pressure closed 4 tank min no active closed 5 tank max open closed Deutsch English 6 syst reset Italiano 1 digit input 2 digit output 3 lights 4 cy permeat 5 temp perm France a D e c Di Q o Figure 21 64 Service Handbook 08 2004 WTC 600 LP MP Service Handbook 08 2004 APPENDIX 65 APPENDIX RO 1000 Manual Control System RO 1000 MANUAL 66 WTC 600 LP MP Service Handbook 08 2004 WTC 600 LP MP APPENDIX Contents T General u a Y 69 74 1 1 General remarks n 69 1 2 Scope UU EE 69 13 Instructions Tor USE uuu uU oed u ii E ebrr er asdf e ecu sd derer ues 70 1 4 Safety Instructions DE DE 70 1 5 Terms and Definitions aiii dd ad 71 1 6 Declaration of Conformity geet ii 71 2 Installation Start up I uu u J J 72 73 21 Basic Requirements o 72 22 Sauna ia 72 2 3 Function O MMS A a 73 3 Operational EE 74 79 3 11 Operating Senting
67. not active Menu point 1 digital input 2 digital output 3 lights 4 Cy permeate 5 temp permeate 88 Function Display of the current conditions of the digital inputs see item 2 3 Display is like a multiselection but with the difference that the conditions of the arguments cannot be set they depend on the input conditions Manipulation of the digital circuit outputs see item 2 3 by means of a multiselection Manipulation of the lights item 4 1 1 by means of a multiselection Permanent display of the current permeate conductivity This display can be cancelled by actuating one of the keys Permanent display of the current permeate temperature This display can be cancelled by actuating one of the keys Service Handbook 08 2004 WTC 600 LP MP APPENDIX 5 Technical Data The following table contains all significant technical data of the RO 1000 control nominal service voltage main frequenCy Hz nominal voltamps V A ambient temperature range operation C ambient temperature range storage C relative air humidity C A conductivity range uS cm accuraCy of measurement ref to range end 9 value without sensor temperature range Y switching current of circuit inputs 30 m adm relay load for 230 V AC 4 A adm relay load for 24 V DC 1 A total installed load 1000 total installed load solenoid valves 250 protection class es VA VA Service Handbook 08 2004
68. ol is added the lower the drinking water flow Do not change the pressure regulating valve and concentrate regulating valve settings Set the system to switched off operating mode and switch off the master switch Disconnect the flushing tank and seal the untreated water inlet as well as the drinking water and concentrate outlet with sealing discs 5 005 260 0 same places as for initial startup cf Chap 3 3 1 2 NOTE Dispose of the conservation solution according to the regulations Service Handbook 08 2004 51 MAINTENANCE WTC 600 LP MP Preservation solution I Sulfite 5kg g RM 1 2 Propandiol 51 I 30 300 5 0 Table 25 Chemicals for conserving solutions 4 4 4 3 Drain the pre filter If the WTC 600 is shutdown for a lengthy period the pre filters have to be drained this prevents bacterial growth and the filter material from caking as well as frost damage Work steps 1 Back wash both pre filters to remove any air from the containers The first back washing step can be aborted after one minute by pressing the manual regeneration key the 4th step can be skipped by pressing the manual regeneration key Interrupt the untreated water supply depressurise the filter Undo hose 6 390 962 0 from the hose nozzle at the outlet of the activated carbon filter Attach a connection hose to this hose nozzle and screw tight with a hose clamp Fix the other end of the connection hose to the filter control heads
69. on The chlorine quantity given matches a chlorine content of 0 3mg l in the drinking water The following quantities of RM 852 or calcium hypochlorite are each required for 10 litres of metering solution RM 852 Sterilization Agent 32 ml Chlorinated Lime 17 ml 18 g Example 75 litres ready mixed metering solution one metering tank consists of 7 5 x 32 240 ml RM 852 or 7 5 x 17 128ml 136 g calcium hypochlorite and chlorine free drinking water cf Chapter 3 2 3 for extraction The quantities must be adjusted accordingly for higher or lower chlorine contents Example Chlorine content 1 2 mg l RM 852 4 x 32 ml 128 ml Chlorinated Lime 4x17 68ml 3 2 5 Flocculation Agent The exact demand in flocculents can only be determined by test Therefore a test solution is mixed first then the raw water is flocked and finally the dosing quantity is evaluated 3 2 5 1 Mixing of the flocking test solution Auxiliaries Measuring cup with 500 ml scale 6 277 001 0 within service kit Desalinated water refill water for car batteries Flocculent RM 5001 6 294 716 0 resp 6 294 703 Measuring cup 25 ml 6 394 425 0 within service kit Dropping bottle 50 ml PE 6 394 426 0 within service kit Plastic eating spoon Work Steps 1 Give 25 ml flocculent RM 5001 into measuring cup 2 Fill up with desalinated water to 500 ml 3 Stir up thoroughly with plastic eating spoon 4 Give 50 ml of this into a clea
70. on I 600 30 0 75 6 294 010 0 Table 26 Composition of the disinfectant solution 10 Flush the service kit with drinking water 11 Switch the RO system to run operating mode 4 4 7 Replace the activated carbon or filter sand If the differential pressure at the pre filters does not reduce despite flushing the filter medium cf Chap 4 the filter material must be replaced Auxiliaries Wet dry vacuum NT 602 ECO 4 metal suction pipes 0 5m 1 408 151 0 6 902 050 0 Remove the plastic rings from the metal pipes Filling funnel Shovel Spare parts required Activated carbon filter bed Sand filter bed Spare parts possibly required Filter pressure tank Set of O rings Initial situation 4 901 090 0 6 812 049 0 6 414 721 0 6 414 714 0 6 414 710 0 6 414 713 0 WTC 600 set to switched off operating mode and switched off at the master switch Untreated water pipe shut off 54 Service Handbook 08 2004 WTC 600 LP MP MAINTENANCE Work steps 1 Unscrew the controller from the control head and place to the side 2 Unscrew the untreated water filtrate and back washing pipes from the control head 3 Unscrew the control head from the pressure tank and pull of off the submersed pipe 4 Suck out the water and filter material Tip If the suction pipe blocks loosen by sucking in air and shaking the pipe CAUTION Firmly push the metal pipes together or secure with thin adhes
71. on of the RO equipment becomes necessary when acidic and alkaline cleaning was not successful NOTE The metering containers supply lines etc should also be disinfected Aids Per acetic acid test stripes Chemicals for disinfection and neutralization Work Steps 1 The equipment is prepared for disinfection compare with Chapter 4 4 1 2 Switch the flushing pump on 3 RO equipment in the disinfection operating mode allow disinfection solution to circulate for approx 5 10 minutes 4 RO equipment in the switched off operating mode allow disinfection solution to react for approx 15 minutes 5 After disinfecting dispose of the solution according to the regulations 6 Connect the soft water supply to the RO equipment again guide drinking water and concentrate outlet to the canal CAUTION The drinking water and concentrate line must not have contact with the canal due to danger of germs free fall as in pouring 7 Plugin the earthing contact plugs of the metering pumps 8 Open the untreated water valve and switch the RO equipment to the operation operating mode 9 Flush the RO system for approx 30 minutes and use peracetic acid test strips peracetic acid content 0 mg l to check the drinking water is free of disinfectant adjust system and enter disinfection in the operating log book 10 Reinstate the original piping layout 11 Thoroughly flush the hoses and pump with drinking water Danger of corrosion
72. operator about malfunction indications Metering pump Clean replace valves Replace membrane Functional test of float switch Function of empty signal to reverse osmosi Leakage tightness corrosion Table 33 Maintenance work to be carried out during service 4 7 Other Maintenance When the RO equipment should not be used for more than 14 days then it must be conserved After a maximum of 6 months the conservation means must be flushed and renewed if required Service Handbook 08 2004 61 APPENDIX Appendix RO control factory settings WTC 600 LP MP WTC 600 LP LP A LP AM in voltages 230 V and 400 V Operating mode Switched off LF limits GW 600 GWV 160 Alarm option Switch off Calibration Permeate temperature Executed Permeate conductivity Executed Settings t GW delay 01 min t GWV delay 05 min t pressure deficit 1s t Press start up delay 9 9 s t pressure available 60s t discont flushing 10 min or longer depending on specifications t flushing interval 24 h or less depending on specifications t Concentrate displacement 01 min t min disposal min 005 s t max disposal max 60 min t maintenance 3500 h Vw fault acknowledgement No password Vw concentrate Displacement Vw tank type With overflow Inputs Forced stop Break contact Motor protection Break contact Pressure switch Break contact T
73. ore removing the system The system can only be repaired if it is completely removed and the failure correctly described The max admissible load of the circuit outputs as well as the total admissible load of the unit see item 5 must not be exceeded 1 4 Safety Instructions The following safety instructions are imperative Diagnosis see item 3 3 allows direct manipulation of all actuatores valves pumps etc without interlocks or monitoring Access to this function therefore requires a password and only should be used by the experts Should the control system not react in the normal way it has to be switched off immediately and the maintenance service has to be informed Do not try to repair the control system yourself loss of guarantee always call the authorized maintenance staff Only this will guarantee a reliable and safe function of the system When a protection device was activated fuse motor circuit breaker you should first try to clear the problem e g clean the pump before reactivating the protection device Frequent actuation always is due to a sensor actuator failure which also could damage the control system itself Non observance of these instructions may cause damage to the control system and the unit which may result in a loss of warranty 70 Service Handbook 08 2004 WTC 600 LP MP APPENDIX 1 5 Terms and Definitions The following scripts will be used for this manual keys capit
74. otor protection limitent 26 MOTL E input motor protection limitent 27 DRS M mass pressure switch 28 DRS E input pressure switch 29 NIVU M mass min top level 30 NIVU E input min top level 31 NIVO M mass max top level 32 NIVO E input max top level 33 sensor permeate screening 34 sensor permeate A white 35 sensor permeate B brown 36 sensor permeate C yellow 37 sensor permeate D green Service Handbook 08 2004 73 APPENDIX 3 Operational Scope 3 1 Operating settings WTC 600 LP MP The control system allows to preselect the following operating settings realization see item 4 The resulting control behaviours are described in the chapter Operating Conditions The standard values setting after parameter reset are marked by in the appropriate field ps LIM high ps acknowledgment ps concentrate mode ps tank type 74 function right of access possible setting function right of access possible setting function right of access possible setting function right of access possible setting Preselect if unit is to be switched off if LIM is exceeded or if a failure message is sufficient user technician switch off do not switch off Prelesect if acknowledgment of failures is possible in the normal level without password or only in the user technician level 2with password technician without password with password Preselect
75. owing differences occur compared to the initial startup The drinking water flow drops by 200l h at the same pressure The conductivity doubles at the same pressure and temperature The differential pressure between the pump pressure and concentrate pressure increases by more than 2 bar NOTE Alkali cleaning with RM MCT 511 first then acid cleaning with RM MCT 103 NOTE Only disinfect if cleaning is unsuccessful Propandiol Item No 6 290 910 0 Service Handbook 08 2004 45 MAINTENANCE 4 4 1 Design of the Flushing and Disinfection Equipment WTC 600 LP MP 15 Trink wasser O W 7 Konzentrat Figure20 Diagram of connection principle for cleaning conserving and disinfection of the RO equipment 1 Manometer 8 2 Fine filter 9 3 Solenoid valve 10 4 Pressure switch 11 5 RO Pump 12 6 Pressure tube 13 module 14 7 Measuring cell Aids Cleaning tank Four connection hoses Flow meter drinking water Pressure control valve Check valve Concentrate control valve Flow meter concentrate Electrical control system Drinking water to the flushing tank 15 16 17 18 19 Concentrate to the flushing tank Flushing tank Sampling valve for drinking water Sampling valve for untreated water Flushing pump Conductive capacity measuring unit for measurement comparison after flushing Protective clothing goggles gloves apron External pump as flushing pump
76. p running dry 42 Service Handbook 08 2004 WTC 600 LP MP MAINTENANCE 4 Maintenance 4 1 Fine Filter The manometers 17 1 and 17 3 are located in front of and behind the fine filter unit 17 2 If the differential pressure is more than 0 8 bar the fine filter is to be cleaned or replaced Stop the untreated water supply until the system is in the lack of pressure operating condition Switch off the main switch Release the pressure in the equipment open the sampling valve for untreated water Replace filter Figure17 Replacing the fine filter NOTE Replace the fine filter every 3 months NOTE Use the special filter wrench 4 2 Metering Station WTC 600 CD Every 4 weeks Clean the inside of the metering tank and thoroughly rinse with chlorine free drinking water When working on the metering head or on the connections and lines wear protective clothing googles gloves Before any maintenance disconnect the pump from mains pull mains plug Every 12 months or when malfunctions occur Cleaning the suction and pressure valves Unscrew valve and take out inner part of valve With a thin wire pin nail or similar carefully remove the valve inner part in flow direction see arrow mark on valve body Disassemble the inner part seat O ring balls ball cages and clean replace if necessary Reassemble valve again and screw in CAUTION Observe direction of flow arrow Tight
77. portant operating conditions of the unit The control system has the following indicator lights OPERATION Active if the control system is in the operating mode OPERATION and if at least one pump is switched on This indicator light will be a flashing light instead of a continous light if the set maintenance interval has run out FAILURE Active if there is an operating trouble In this case the reason is displayed In case of Cy alarm the failure LED flashes Should the trouble light flash immediately after having the control system switched on the reason is an internal system failure see item 3 5 DISINFECTION Active if the control system is in the operating mode DISINFECTION DISPOSAL Active if the control system is in the operating condition DISPOSAL FORCED STOP Active if the FORCED STOP input is activated and if the control system is in the operating mode OPERATION TANK FULL Active if the TANK FULL input is activated 4 1 2 Keyboard The control system has keys for the functions UP A DOWN y LEFT RIGHT gt ENTER as well as ESC on the equipment keyboard symbols arrows are used to identify some of them They allow to call via the menu all functions and to modify the system settings parameters 4 1 3 Text display The purpose of the LC text display is to indicate besides the indicator lights the current operating mode or the current unit condition respectively normal level it also serve
78. r at most 5 sec a text has to be displayed on the LC display otherwise switch off repair 3 Carry out diagnostic program see item 3 3 and test all inputs and outputs of the control unit Should the fuse on the pc board become active one of the valve outputs is short circuited 4 Set operating modes and parameters see item 4 5 Calibrate sensors see item 4 4 2 72 Service Handbook 08 2004 WTC 600 LP MP APPENDIX 2 3 Function of Terminals Terminal arrangement and functions are as follows we Fm oam mar oas romina PE Mains supply protective conduct 1000 VA max Mains supply neutral conductor total output Mains supply phase performance softener protective conductor softener neutral conductor 1000 VA softener phase pump 1 protective conductor pump 1 neutral conductor 1000 VA pump 1 phase inlet valve protective conduct inlet valve neutral conductor 1000 VA inlet valve closer outlet valve protective cond outlet valve neutral conductor 1000 VA outlet valve closer outlet valve opening contact concentrate valve protective cond concentrate valve neutral cond 1000 VA concentrate valve closer o o TENES III 20 STO W trouble message central contact 230 VAC 4A 21 STO S trouble message closer resp 24V DC 22 STO O trouble message operning contact 1 A 23 REG M mass regeneration 24 REG E input regeneration 25 MOTL M mass m
79. r connection 19 3 and carefully lever out using pipe pliers Remove adapter from lid clean and insert Take out filter and remove lower lid NOTE Do not interchange lids Figure 18 RO Modul Membrane replacement set Item No 6 762 172 0 II Service Handbook 08 2004 WTC 600 LP MP MAINTENANCE Apply Propandiol to the rubber seals a D t a 6 Insert a new filter 19 7 at the supply opening end without seal first Attach all adapters Insert lid 19 4 in such a manner that the threads of the openings are flush with the nuts of the clamp 19 5 Install securing rings and screw in connections Fasten module to frame and connect pipe lines Flush the equipment for 10 minutes 3 4 3 7 Switch to the operation operating mode I Figure19 Assembly and disassembly of the RO The equipment values must correspond with filter those of the initial start up 4 4 Cleaning in Case of Malfunction The following measured variables or their change from the original values cf operating certificate are indicators for the need for cleaning or disinfecting the system The WTC 600 service kit 2 901 044 0 is intended for cleaning the WTC 600 Apart from the cleaning chemicals and a wet dry vacuum it contains all the equipment needed for cleaning and conserving the WTC 600 LP and MP The cleaning chemicals must be ordered separately The system should be cleaned if the foll
80. r with a salt content up to 2000 ppm WTC 600 LP respectively up to 5000 ppm WTC 600 MP The design of the system is modular and can be adapted accordingly to the local conditions depending on the application conditions as well as the composition of the untreated water Media filter and flocculation module 1 Activated carbon filter module 2 Reverse osmosis system module 4 Pressure increase pump module 5 Metering stations The RO system is designed for stationary use 2 3 1 1 Pre chlorination Module The WTC 600 CD metering station consisting of metering container 3 1 and pump 3 2 is connected to the sand filter module for pre chlorination if required Figure3 WTC600CD 2 3 1 2 Flocculation Module The WTC 600 CD metering station see figure 3 with injection adapter is connected to the sand filter module for pre flocculation if required The exact requirement of flocculation agent is to be determined when starting operation see Section 3 2 5 Service Handbook 08 2004 13 DESCRIPTION WTC 600 LP MP 2 3 1 3 Mediafilter and Activated Carbon Filter The pre filter units of the RO system consist of the media filter and the activated carbon filter The filter fillings consist of support pebbles and filter sand according to DIN 19623 as well as activated carbon The filters are each controlled by means of a central control valve with microprocessor control and located at the top of the fi
81. rried out in order to remove the cause of blockages Notify sales department Additional treatment stages possibly required Composition of the pre filter flushing service kit Auxiliaries Flushing tank Four connection hoses Conductivity measuring device for comparative measurement after flushing Goggles gloves apron Flushing pump Initial situation RO system set to switched off operating mode and with master switch switched on Work steps 1 Add 30 litres drinking water to the flushing tank and add 2 2 litres RM Kleen MCT 103 2 Dismantle the back washing hoses at the pre filters connect the service kit hoses and feed to the flushing tank Connect the flushing pump to the pre filter untreated water inlet Start back washing Switch on flushing pump Leave the flushing solution to circulate until the back washing is finished approx 10 min Leave the flushing solution to stand for 30 minutes Repeat the procedure from item 4 once again D E NE COD OM ub 0 Reinstate the original piping and carry out a complete backwash If this cleaning is unsuccessful the media filter must be disinfected The service kit contents and the flushing sequence is the same as for flushing the pre filter however the chemicals used are those given in table 26 Service Handbook 08 2004 53 MAINTENANCE WTC 600 LP MP System Volume of RMP3 Oxonia active Art No output 1 h disinfectant 15 I soluti
82. s for the menu assisted user communication for control system settings user technician level 80 Service Handbook 08 2004 WTC 600 LP MP APPENDIX 4 2 Basic elements The whole user surface of the control system is composed by basis functions such as password entry menu selection selection of settings numerical entries etc The description of the basic functions will be followed by the operating elements of the menus for users techniciens 4 2 1 Password entry The entry of the password is the only way to gain access from the normal level to the user technician level User and technician have different passwords For user s password entry the following keys have to be actuated in the normal level within one minute A gt V e For technician s password entry the following keys have to be actuated in the normal level within one minute A gt ESC V gt ESC Y d A For technician s password entry the following keys have to be actuated in the normal level within one minute 4 2 2 Selection of menu A menu is used to select or call specific functions It consists of several numerical menu points lines listed one below the other The text display of the control system always shows two of these menu lines that means it always displays a two line section window of the whole menu If a function or a menu point has to be called in the desired menu point has to be selected first using the Y keys
83. s ii 74 3 2 Operating Parameters e is 75 3 3 e EE EE 76 77 3 4 Operating Conditions l de 78 35 Operating Failures Failure messages u nnne 79 4 SOperTatllohuu S sn 80 88 4 1 User Interface aniones id A er la ais 80 4 2 Basic Elements ti aaa 81 4 21 Password ERY inea e dais 81 A L SS Sua Qu G el gru aN au ee eee sus sa 81 42 37 SBIBGIIO Pager pee eve A 81 4 2 4 Ee EE 82 4 2 5 Numerical Edi u y Rer iine Roper ebd ue entis utes d te dob lee papapas 82 4 2 6 Alphanurmierical Editing criadas 82 4 2 7 Confirmations ta cad ces 82 Service Handbook 08 2004 67 APPENDIX WTC 600 LP MP Contents 4 3 Operating Levels ii o ioci parecen 83 43 1 Normal Level ibo ale ida 83 ASD User Eevel Scc ls dicitis Swa cad ee 83 42 3 3 TECHNICIAN S RT ME 83 AA Meru SIruclUre uuu e Ec ox cec ask occa aV e TER EE RR EI RAY E EROR CUI 85 4 4 Mad ISP aa kaaman ee ahua Saati aa eve tO edad test a eyak aN a huq Rees 86 2 2 Calibration Meni uuu u uu a ie 87 4 4 3 Setting Menu PT 88 4 44 Diagosis Men usina 88 5 Technical Data ue ee 89 90 68 Service Handbook 08 2004 WTC 600 LP MP APPENDIX 1 General 1 1 General Remarks The present Manual is the technical documentation of the RO 1000 control system for reverse osmosis units When studying this manual it would be useful to have the control system ready for operat
84. sor in the metering container delivers signal Corrective action Refill metering container with chemical and acknowledge NOTE The malfunction indication can be acknowledged by pressing the ESC pushbutton the rotating indications for normal operation appear again see above 40 Service Handbook 08 2004 WTC 600 LP MP 3 4 5 Putting Out of Operation OPERATION OF THE SYSTEM CAUTION Normally do not switch off with the main switch a possibly active flushing program may be interrupted NOTE The RO system working in normal operation is switched off only via the float switch when the drinking water tank is full NOTE The current operating mode is also maintained in the switched off condition meaning after switching on again the control system is in the same operating mode as before switching off last with the main switch The system is switched off e g when putting out of operation for extended periods For out of operation periods exceeding 14 days the equipment must be conserved see Chapter 4 4 4 Enter user password for this compare with Chapter 3 4 3 1 Indication Press the Y pushbutton Indication Press the RETURN pushbutton Indication Press the pushbutton Indication Press the RETURN pushbutton Indication Press the gt pushbutton Indication Press the RETURN pushbutton Indication Press the ESC pushbutton Indication The equipment is switched off now
85. ssage must be indicated on the display RO 1000 V 01 34 Stop Otherwise press the ESC pushbutton 5 times Then enter user password cf Chap 3 4 3 1 Service Handbook 08 2004 35 OPERATION OF THE SYSTEM WTC 600 LP MP Indication gt 1 Error ack lt wk Dress the pushbutton 2 Operating mode Indication 1 Error ack Press the RETURN pushbutton gt 2 Operating mode lt Indication Operating mode ah Press the pushbutton Operation Indication Operating mode Press the RETURN pushbutton Switched off Indication Execute 3 Press the pushbutton gt no lt yes Indication Execute Press the RETURN pushbutton no gt yes lt Indication 1 Error ack Press the RETURN pushbutton gt 2 Operating mode lt Indication Operating mode wk Dress the pushbutton Switched off Indication Operating mode Disinfection System in disinfection operating mode Set the concentrate flow to 600l h at the concentrate regulating valve 4 15 CAUTION During disinfection operating mode all confirmation queries are switched off CAUTION Observe the pressure downstream of the fine filter manometer 4 7 As soon as it is less than 2 bar pressure immediately switch off the system High pressure pump running dry Leave the system to run in this condition for 20 minutes then switch to switched off operating mode cf 3 4 5 36 Service Handbook 08 2004 WTC 600 LP
86. st Two menu lines each are depicted on the display of the control In order to call up the function of a menu point first select the desired menu point with help of the pushbutton and the Y pushbutton By pressing the RETURN pushbutton the function of this menu point is called up A menu is ended by pressing the ESC pushbutton returning you to the normal level For nested menus the ESC pushbutton brings you back to the previous menu 3 4 3 3 Selection of an Option Options are selected with the A pushbutton and the Y pushbutton By pressing the RETURN pushbutton the current option is stored as the new operating setting A selection can be cancelled by pressing the ESC pushbutton 34 Service Handbook 08 2004 WTC 600 LP MP OPERATION OF THE SYSTEM 3 4 3 4 Selecting Several Arguments at the Same For this a series of 0 argument inactive and 1 argument active appears on the bottom line of the display With help of the pushbutton and the pushbutton a cursor can be moved between the individual characters The activation inactivation of an argument is carried out with the 4 pushbutton and the Y pushbutton respectively Storing is carried out through pressing the RETURN pushbutton Example See Chapter 3 4 3 7 3 4 3 5 Adjusting Operating Parameters and Balancing Values For adjustment of operating parameters e g via a menu the name of the operating parameter appears in the upper line and the current val
87. stem automatically returns to the normal level for safety reasons 4 3 3 Technician s level The technician s level is an expanded user level It allows to fulfill the functions at user s level to manipulate all operating settings parameters and to fulfill a hardware test by means of a diagnostic function The functional scope covers all menus and sub menus see 4 4 Access to the technician s level is similar to that to the user s level that means a specific password has to be entered see 4 2 1 If there is no key actuation for more than 10 min and provided that current function does not correspond to the display of measured values or a diagnostic process the control system returns to the normal level 84 Service Handbook 08 2004 WTC 600 LP MP APPENDIX 4 4 Menu structure The menu structure of the user surface is shown below Access to the main menu is achieved by entering a pass word see item 4 2 1 main menu 1 ackn failure operat mode Cy permeate Cylimits temp s options alarm 2 3 4 5 operat hours 6 7 8 calibration 9 settings 10 diagnosis calibration menu setup menu diagnosis menu 1 Cy permeate 1 tCy LIM 1 digital input 2 temp permeate 2 digital output 3 calibr reset 3 lights 4 Oy permeate 5 permeate temp 7 trinse interval 8 t concentrate 9 tdisposal 1
88. t registered OPERATION The control system fulfills the production in accordance with the respective operating conditions in the unit As long as the unit status is DISPOSAL PRODUCTION ON CONCENTRATE DISPLACEMENT FLUSH or DISCONTINUOUS RINSE the current operating data conductivity temperature etc are displayed one after the other rolling Failures are registered processed and displayed DISINFECTION The control system does not carry out any production process but INLET VALVE OUTLET VALVE as well as the PUNP are switched on so that a disinfection can be carried out No failures are registered DIAGNOSIS The DIAGNOSIS is called via the main menue see item 4 4 1 For diagnosis purposes all control outputs can be manipulated via the keyboard and the input status analog digital can be displayed see item 4 4 5 Attention Failures are not registered displayed The current operating mode is maintained when the system is switched off that means the control system will be in the same operating mode which was running when the system was switched off Service Handbook 08 2004 77 APPENDIX WTC 600 LP MP 3 4 Operating conditions When the unit is in OPERATION the control system performs one of the seven possible operating conditions The following diagram shows the various conditions as well as the reasons for status changes For that purpose an error free sequence of operations is assumed Start OPERATION or
89. ting function right of access possible setting WTC 600 LP MP Time after which a DISCONTINUOUS RINSE process is started provided that the control system was during that time in the operating condition RINSE INTERVAL technician 0 99h Oh Duration of a CONCENTRATE DISPLACEMENT FLUSH process at the end of a PRODUCTION TANK FULL active technician 0 99min 1 min Minimum duration of a DISPOSAL process at the beginning of a PRODUCTION This is the minimum time after which the unit passes to PRODUCTION if the value drops below LIM technician 0 999s 5s Attention the set value must be less than t max disposal Pay attention to units Maximum duration of a DISPOSAL process This is the maximum time after which the value has to be below LIM otherwise a failure message will be given technician 1 99min 60 min Attention the set value must be greater than t min disposal Pay attention to units Operating time hour meter after which a signal is given that maintenance has to be carried out flashing OPERATION technician 0 999999h 3500h Attention zero setting means that no maintenance message is given Service Handbook 08 2004 WTC 600 LP MP APPENDIX 3 2 Operating parameters When the control system is switched on the following four operating modes exist STOP The control system does not carry out any production process All outputs remain inactive Failures are no
90. ture compensation with integrated sensor Self explanatory menu assisted operator environment All settings and adjustments via keyboard text display no mechanical adjustments potentiometers trimmers switches plug in bridges Any process time can be set Preselection for tank type with without overflow hardwater production admissible not admissible concentrate displacement disposal Hour meter with maintenance interval message Protection against improper acknowledgement of failures Permanent display of measured values Two point calibration Technical diagnostic function Service Handbook 08 2004 69 APPENDIX WTC 600 LP MP 1 3 Instructions for Use The following instructions should be followed when operating the control system Do not switch on off the control system in quick succession Wait at least 5 seconds between switching the main switch on and off The control system should only be operated under the ambient conditions temperature humidity mentioned in the technical data see item 5 It is particularly important to protect the control system against water and humidity lt must not come into contact with splash water or condensed water Manufacturer s seals trimmer fixation EPROM labels must not be damaged Otherwise the right to assert claims for defect shall lapse Should the control system become defective take note of the type of problem consequences bef
91. ue is shown in the bottom line A flashing cursor marks the respective changeable figure which can be adjusted to the desired value by pressing the pushbutton and the Y pushbutton With help of the pushbutton and the gt pushbutton the marking can be slid to the respective other figure Storing is carried out through pressing the RETURN pushbutton the input can be cancelled by pressing the ESC pushbutton 3 4 3 6 Acknowledging Data Inputs To avoid input errors acknowledgments are required at various menu locations They request the user again to acknowledge changes of operational settings parameters and adjustments as correct For acknowledgment the pushbutton and afterwards the RETURN pushbutton must be pressed 3 4 3 7 De conserving The RO system leaves the factory conserved Therefore the conservation liquid must be flushed out before the initial startup Initial situation The pre filters have been put into service The filter insert has been inserted at the fine filter 5p After all the water pipes and float switch have been connected the drinking water pipe to the tank must be undone and temporarily fed to the wastewater sewer Work steps Master switch on system is in switched off operating mode Temporarily lay the drinking water pipe in the sewer Flush purge system Pressure regulating valve 4 17 fully open lever horizontal Concentrate regulating valve 4 15 half open 45 The following me
92. ushbutton 0 230 Backwashing of activated carbonfilter at 02 30 minutes 2 Covered pushbutton 0 230 Backwashing of activated carbonfilter at 02 30 full hours At both filters 3 Covered pushbutton FF01 Time interval in days between 2 backwa shings FF01 means one backwashing per day 4 Covered pushbutton 200 0 Without function 5 Covered pushbutton 200 0 Without function Table 17 Programming table for sand filter and activated carbon filter 32 Service Handbook 08 2004 WTC 600 LP MP OPERATION OF THE SYSTEM Position Indication Description 6 Covered pushbutton Without function 7 Covered pushbutton Without function 8 Covered pushbutton Without function 9 Covered pushbutton 10 Covered pushbutton 11 TIME OF DAY Backwashing period 10 minutes 12 Covered pushbutton 0 minutes 13 Covered pushbutton 3C00 0 minutes 14 Covered pushbutton 4C03 Initial filtration 3 minutes 15 Covered pushbutton 4d10 Leave programming mode Table18 Programming table for media filter and activated carbon filter 1 For changing of any given value from the programming table the complete menu must be run through The enter position flashes and the value is changed with the ADVANCE pushbutton Indication Description 02 30 Day time F 00 Days since the last regeneration 0 0 0 0 Number of regeneration Table19 Statistical indications diagnosis NO
93. ustible materials Toxic gas develops when coming in contact with acids Heat or direct sunlight decomposes the chemical Chlorine and oxygen are released Caustic effects to the eyes skin and respiratory system result Safety Instructions Wear acid resistant protective equipment goggles gloves and when dust is produced breathing mask protection with a filter Keep an eye wash bottle small readily available Provide for adequate room ventilation and a washing facility Store the chemicals in a cool dry place not below 5 C Store chemicals in a location out of the reach of children In Case of Accidents Incase of contact with the eyes rinse immediately and thoroughly with fresh water and consult a doctor Use water to extinguish avoid impact and friction If solutions are spilt flush the area with a sufficient amount of fresh water 1 4 3 Disposal of Chemicals It is generally recommended to admit resulting disinfection solutions preservation solutions etc into a neutralizing system If this should not be possible the disinfection solution after clarification with the relevant authority mayor s office district administration office etc is to be neutralized and can afterwards be led into the public sewer system 8 Service Handbook 08 2004 WTC 600 LP MP GENERAL 1 4 4 A Handling Electricity Protection Class Be aware of dangerous electrical voltage For work on compo
94. ve Check switch replace if necessary Table 27 Malfunction indications at the switch cabinet and their causes Indication Malfunction Cause Corrective Action Chap Fig Green LED at LED does not No power supply Have fuse Q2 metering station flash when checked from pump does not high pressure electrician flash pump runs Operating mode Set operating mode switch 1 10 contact to manual Electrical defect Replace pump ETL Red LED at Pump blocked Metering Refill check float switch 3 2 metering container empty 3 3 2 4 station pump lights red Cable that Have cable checked 3 3 2 3 indicates empty is broken Auxiliary Have auxiliary contactor ETL SLP contactor in replaced by electrician switch cabinet defective Table 28 Metering station and metering pump LED 56 Service Handbook 08 2004 WTC 600 LP MP MAINTENANCE 4 5 2 Malfunction Indication at the Operating Panel The control system detects operational malfunctions only while in operation operating mode these are indicated on the display The occurrence of an error usually leads to the complete system being switched off production is interrupted Indication Malfunction Cause Corrective Action Chap Fig Motor Metering containe Fillup 3 2 hard water empty Lack of pressure PI station gene No water Establish the flow of rates no pressure available untreated water again Air in the pump Bleed the pump connect pump directly in canal run for 30 sec
95. washing 3 4 2 De conserve reverse osmosis 3 4 3 7 Fill metering container and start operation 3 4 1 Start the operation of the reverse osmosis 3 4 3 8 3 4 1 Metering Station NOTE Pushbutton for venting in continuous operation 14 3 Operating mode on Manual 14 2 Change the operating mode by pressing the Mode key 14 2 Modul Lift Frequency Meter 14 1 14 4 ing Pre chlorination 40 70 3 2 2 Antiscalant 40 50 3 2 3 Post clorination 40 70 3 2 4 Flocculation 40 70 3 2 5 Table14 Checking pump settings Figure 14 Metering station NOTE Adjust the lift only when the pump is running Danger of damaging 30 Service Handbook 08 2004 WTC 600 LP MP OPERATION OF THE SYSTEM 3 4 2 Media and Activated Carbon Filter 3 4 2 1 Initial Filling Remove the central control valve and position the central pipes with the lower nozzle in the middle of the tank floor Fill the tank up to a third with water Place the filling funnel 4 901 090 0 in the opening and fill the filter bed with a shovel 6 812 049 0 in accordance with Table 15 Filter Support pebbles Filter sand Activated carbon Media filter 15 kg Grain size 2 0 3 15 mm 100 kg Grain size 0 4 0 8 mm Activated carbon 15 kg Grain size 1 2 mm 32 kg Actvated carbon grain F100 Table 15 Completely fill the tank with water Align the central pipe in the middle of the container open
96. water conductivity 15 of the untreated water conductivity value CAUTION The upper limiting value must not exceed the statutorily permissible drinking water conductivity In case of doubt take the statutory limiting value as the limiting value and enter the warning as half the statutory limiting value Press the l key Display jumps back to 6 LF limits Press ESC display is in initial condition System has been checked and is ready for use 38 Service Handbook 08 2004 WTC 600 LP MP OPERATION OF THE SYSTEM 3 4 4 Normal Operation Switch on the RO 1000 control the following message appears on the display Ge m iud witched o NOTE The system has been switched off in the user or technician level Switching on without password is not possible When the following rotating masks appear W Temp 12 3 perm 12 uS cm RO 1000 V 01 34 production on hours meter 1111h 11 min Figure16 User indication in normal operation The system is ready to start meaning the equipment can produce Otherwise enter the user password compare with Chapter 3 4 3 1 Indication 1 gt 1 ackn failure lt Press the Y pushbutton one time 2 operat mode Indication 1 ackn failure Press the RETURN pushbutton gt 2 operat mode lt Indication operation mode Press the pushbutton STOP Indication operation mode Press the RETURN pushbutton OPERATION In
97. white black Antiscalant Alarm output 12 1 not required white blue Digital input 12 2 Empty signal Release brown not required Post chlorination Alarm output 12 1 notrequired white Empty signal black Digital input 12 2 Release brown 12 blue 13 not required white black Table13 Connection assignment Empty message and releasing of the metering containers at the RO control CAUTION Electrically insulate cable ends that are not used with insulating terminals Service Handbook 08 2004 OPERATION OF THE SYSTEM WTC 600 LP MP 3 3 2 4 Float Switch Connect the signal lines of the enclosed float switch to clamps 6 7 8S3 option of the connecting terminal compare wiring diagram in the switching box Upon installation adjust a switching hysteresis of at least 300 liters between the switching on and switching off point 3 3 2 5 Reverse Osmosis System The WTC 600 LP MP is connected to the following power supply 400 V 50Hz 3Ph N PE or 230 V 50Hz 1Ph N PE depending on type of system Fuse protection 16 A RC protective switch 30 mA from source of power supply check if in existence or have confirmed in writing 3 4 Starting Operation Operation of the individual equipment components is started in the following sequence Fill the preliminary filter and start operation by back

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