KarcherメーカーWATERCLEAN 600 CDの使用説明書/サービス説明書
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Service Handbook 5.905-521 08.2004 W ater c lean 600 CD , LP/MP , PI 1.024-....
2 FOREWORD WTC 600 LP / MP Service Handbook 08.2004 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.
3 WTC 600 LP / MP CONTENTS Service Handbook 08.2004 Contents 1 General .......................................................................................... 7 - 10 1. 1 Introduction ................................................................
4 CONTENTS WTC 600 LP / MP Service Handbook 08.2004 Contents 3.2.5.2 P erf orm flocking test ............................................................................................... 2 6 3.2.5.3 Evaluate flocking test ...........................
5 WTC 600 LP / MP CONTENTS Service Handbook 08.2004 4.4.3.2 Cleaning Solution for Alkaline Cleaning ................................................................. 51 4.4.4 Conserving .................................................................
WTC 600 LP / MP 6 Service Handbook 08.2004.
7 WTC 600 LP / MP GENERAL Service Handbook 08.2004 1 General 1.1 Introduction This service manual contains basic instructions and information which are to be observed upon set-up , operation and maintenance.
8 GENERAL WTC 600 LP / MP Service Handbook 08.2004 1.4 Safety Instructionse 1.4.1 Quality of the Untreated W ater Sufficient quality of the untreated water must be ensured! F aultless drinking water is achiev ed only when all filters of the equipment are maintained regularly .
9 WTC 600 LP / MP GENERAL Service Handbook 08.2004 1.4.4 Handling Electricity / Protection Class Be aware of dangerous electrical voltage! For work on components/assemblies which are marked with this symbol, protective measures are to be taken: - Switch off the power - Secure against restar ting - Check and assess that no voltage is given.
10 DESCRIPTION WTC 600 LP / MP Service Handbook 08.2004 2 Description 2.1 Overview Figure 1 Overview of components 1.3 e 2.2 a b 1. 2 2. 1 4.12, 4.13 f g 4.
11 WTC 600 LP / MP DESCRIPTION Service Handbook 08.2004 Legend for figure 1 and figure 2: 1. 1 Pre-chlorination metering point 1. 2 Manometer - media filter inlet pressure 1. 3 Media filter 1. 4 Differential pressure switch 1. 5 Concussion restrictor 1.
12 DESCRIPTION WTC 600 LP / MP Service Handbook 08.2004 2.2 Flow Diagram Figure 2 Flow diagram of the complete reverse osmosis system (RO system).
13 WTC 600 LP / MP DESCRIPTION Service Handbook 08.2004 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 water with a salt content up to 2000 ppm (WTC 600 LP), respectively up to 5000 ppm (WTC 600 MP).
14 DESCRIPTION WTC 600 LP / MP Service Handbook 08.2004 2.3.1.3 Mediafilter- and Activated Carbon Filter The pre-filter units of the RO system consist of the media filter and the activ ated carbon filter . The filter fillings consist of suppor t pebbles and filter sand according to DIN 19623, as well as activated carbon.
15 WTC 600 LP / MP DESCRIPTION Service Handbook 08.2004 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 .
16 DESCRIPTION WTC 600 LP / MP Service Handbook 08.2004 Microfuses T wo microfuses (7/6) f or 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-dela y . Figure 7 Switch cabinet and control electronic 2.
17 WTC 600 LP / MP DESCRIPTION Service Handbook 08.2004 2.4 T echnical Data WTC 600 LP/MP Parameter WTC 600 LP WTC 600 MP Ambient temperature +1°C - +50°C Storage temperature (delivery) to -10°C Humidity <100% r.F. Supply voltage 3*400V 50 Hz 1) 1*230V 50 Hz 1) Pre-filter controls: prim / sec.
18 DESCRIPTION WTC 600 LP / MP Service Handbook 08.2004 Filter Container Volume per container 103 l Filling capacities, Mediafilter Support pebbles 2.0 - 3.
19 WTC 600 LP / MP DESCRIPTION Service Handbook 08.2004 2.5 Consumption Materials Swear protective equipment and observe safety instructions! 2.5.1 Chemicals for Metering Container For mixing of the metering solution, use the measuring cup with the handle (250 ml or 1000 ml).
20 OPERA TION OF THE SYSTEM WTC 600 LP / MP Service Handbook 08.2004 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 2.
21 WTC 600 LP / MP OPERA TION OF THE SYSTEM Service Handbook 08.2004 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 .
22 OPERA TION OF THE SYSTEM WTC 600 LP / MP Service Handbook 08.2004 5. For 75% yield: T otal x 128 = _____ ml RM 852 per 10 litre meter ing solution OR T otal x 34 8 = _____ ml calcium h ypochlor ite (1ml corresponds to 1.05g) per 10 litres metering solution These values are entered in the customer's operating instructions.
23 WTC 600 LP / MP OPERA TION OF THE SYSTEM Service Handbook 08.2004 3.2.3 Antiscalant 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 .
24 OPERA TION OF THE SYSTEM WTC 600 LP / MP Service Handbook 08.2004 3.2.4 Metering Amounts and Mixing of the P ost Chlorination The chlorine quantity given matches a chlorine content of 0.
25 WTC 600 LP / MP OPERA TION OF THE SYSTEM Service Handbook 08.2004 3.2.5.2 Perform flocking test Auxiliaries: - T ransparent 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.
26 OPERA TION OF THE SYSTEM WTC 600 LP / MP Service Handbook 08.2004 3.3 Connecting the Equipment 3.3.1 Connections, V alves 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.
27 WTC 600 LP / MP OPERA TION OF THE SYSTEM Service Handbook 08.2004 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 shan.
28 OPERA TION OF THE SYSTEM WTC 600 LP / MP Service Handbook 08.2004 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.
29 WTC 600 LP / MP OPERA TION OF THE SYSTEM Service Handbook 08.2004 Metering Type Function Signal Line Connecting Container Terminal, El. Cabinet Pre-chlorination Alarm output (12/1 not required whit.
30 OPERA TION OF THE SYSTEM WTC 600 LP / MP Service Handbook 08.2004 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.
31 WTC 600 LP / MP OPERA TION OF THE SYSTEM Service Handbook 08.2004 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 .
32 OPERA TION OF THE SYSTEM WTC 600 LP / MP Service Handbook 08.2004 3.4.2.4 Programming T o star t the progr amming, the cov ered pushbutton (15/1) to the left of the “TIME OF D A Y” pushb utton (15/2) is to be pressed (a circular indentation can be felt under the front foil).
33 WTC 600 LP / MP OPERA TION OF THE SYSTEM Service Handbook 08.2004 Position Indicati on Description 6 Covered pushbutton 0000. Without function 7 Covered pushbutton 0000.
34 OPERA TION OF THE SYSTEM WTC 600 LP / MP Service Handbook 08.2004 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, t.
35 WTC 600 LP / MP OPERA TION OF THE SYSTEM Service Handbook 08.2004 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 displa y .
36 OPERA TION OF THE SYSTEM WTC 600 LP / MP Service Handbook 08.2004 > 1 Error ack. < 2 Operating mode Indication: -Press the pushbutton. Indication: Press the RETURN pushbutton. Indication: -Press the pushbutton. Indication: Press the RETURN pushbutton.
37 WTC 600 LP / MP OPERA TION OF THE SYSTEM Service Handbook 08.2004 3.4.3.8 Initial startup - Set the equipment to the operation operating mode (see 3.
38 OPERA TION OF THE SYSTEM WTC 600 LP / MP Service Handbook 08.2004 Checking the pressure control device (shut the untreated water supply for this): The RO system m ust s witch off after a shor t time. THE “F ault” LED must light at the operating panel – Lack of pressure is indicated on the display (5/2).
39 WTC 600 LP / MP OPERA TION OF THE SYSTEM Service Handbook 08.2004 3.4.4 Normal Operation Switch on the RO 1000 control; the following message appears on the display: The system has been switched off in the user or technician level.
40 OPERA TION OF THE SYSTEM WTC 600 LP / MP Service Handbook 08.2004 RO 1000 V 01.34 Disposal RO 1000 V 01.34 Production on hours meter 1111 h 11 min W -T emp: 12.3°C perm: 12 µS/cm When the RO equipment starts, the intake v alve f or untreated water is opened and the RO pump star ts after the preset time and given pressure.
41 WTC 600 LP / MP OPERA TION OF THE SYSTEM Service Handbook 08.2004 3.4.5 Putting Out of Operation Normally , do not switch off with the main s witch (a possibly active flushing prog ram may be interrupted). The RO system working in normal operation is switched off only via the float switch when the drinking water tank is full.
42 OPERA TION OF THE SYSTEM WTC 600 LP / MP Service Handbook 08.2004 > 1 ackn. failure < 2 operat. mode Indication: Press the pushbutton one time. Indication: Press the RETURN pushbutton. Indication: Press the pushbutton. Indication: Press the RETURN pushbutton.
43 WTC 600 LP / MP MAINTENANCE Service Handbook 08.2004 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).
44 MAINTENANCE WTC 600 LP / MP Service Handbook 08.2004 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.
45 WTC 600 LP / MP MAINTENANCE Service Handbook 08.2004 - Apply Propandiol 1) to the rubber seals. - Inser t a new filter (19/7) at the supply opening (end without seal first!). - Attach all adapters. - Inser t lid (19/4) in such a manner that the threads of the openings are flush with the nuts of the clamp (19/5).
46 MAINTENANCE WTC 600 LP / MP Service Handbook 08.2004 4.4.1 Design of the Flushing and Disinfection Equipment Figure 20 Diagram of connection principle for cleaning conserving and disinfection of the RO equipment 1. Manometer 2. Fine filter 3. Solenoid valve 4.
47 WTC 600 LP / MP MAINTENANCE Service Handbook 08.2004 W ork Steps: 1. Fill 30 liters of chorine-free drinking water into the flushing container (20/16).
48 MAINTENANCE WTC 600 LP / MP Service Handbook 08.2004 4.4.2 Disinfection A disinfection of the RO equipment becomes necessary when acidic and alkaline cleaning was not successful. The metering containers, supply lines, etc. should also be disinfected.
49 WTC 600 LP / MP MAINTENANCE Service Handbook 08.2004 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.
50 MAINTENANCE WTC 600 LP / MP Service Handbook 08.2004 4.4.3.1 Cleaning Solution for Acidic Cleaning Volume of the RM Kleen MCT 103 [l] Item No. cleaning solution [l] 30 1,0 6.294-009.0 Table 23 Composition of the cleaning solution for acidic cleaning Neutralise by adding soda (6.
51 WTC 600 LP / MP MAINTENANCE Service Handbook 08.2004 Aids: - Conserving tank - Four connection hoses - Chemicals f or conser vation (compare with T able 25) and f or neutralization - Conductive capacity measuring unit, for measurement comparison after flushing - Protective clothing (goggles, gloves, apron) - External pump.
52 MAINTENANCE WTC 600 LP / MP Service Handbook 08.2004 1) Sulfite 5 kg: Item No. 6.769-040.0 2) RM 1,2 Propandiol, 5l: Item No. 6.290-910.0 Preservation solution [l] Sulfite 5kg 1) [g] RM 1,2 Propandiol 5l 2) [l] 30 300 5,0 Table 25 Chemicals for conserving solutions 4.
53 WTC 600 LP / MP MAINTENANCE Service Handbook 08.2004 4.4.6 Flushing the pre-filter The WTC 600 LP/MP pre-filter m ust be flushed if the diff erential pressure of the pre-filter immediately after back-w ashing is more than 0.
54 MAINTENANCE WTC 600 LP / MP Service Handbook 08.2004 System Volume of RMP3 Oxonia active Art.-No. output [l/h] disinfectant 15% [l] solution [l] 600 30 0,75 6.294-010.0 Table 26 Composition of the disinfectant solution 10 . Flush the service kit with drinking water 11 .
55 WTC 600 LP / MP MAINTENANCE Service Handbook 08.2004 W ork steps: 1. Unscrew the controller from the control head and place to the side 2. Unscrew the untreated water , filtrate and bac k-washing pipes from the control head 3. Unscrew the control head from the pressure tank and pull of off the submersed pipe 4.
56 MAINTENANCE WTC 600 LP / MP Service Handbook 08.2004 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 Pump in metering Metering Refill, check float switch 2.
57 WTC 600 LP / MP MAINTENANCE Service Handbook 08.2004 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 displa y . The occurrence of an error usually leads to the complete system being switched off (production is interrupted).
58 MAINTENANCE WTC 600 LP / MP Service Handbook 08.2004 4.5.3 Malfunctions of the RO Control and Metering Pump Indication Malfunction Cause Corrective Action Chap.
59 WTC 600 LP / MP MAINTENANCE Service Handbook 08.2004 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.
60 MAINTENANCE WTC 600 LP / MP Service Handbook 08.2004 4.6 Maintenance Plan 4.6.1 Maintenance During Operation Module Cycle / Time Activity Chap./Fig.
61 WTC 600 LP / MP MAINTENANCE Service Handbook 08.2004 4.6.2 Maintenance Plan – Service Measured and read values are to be entered into the maintenance record.
62 APPENDIX WTC 600 LP / MP Service Handbook 08.2004 Appendix: RO control factory settings: WTC 600 LP , LP-A, LP-AM in v oltages 230 V and 400 V Operating mode Switched off LF limits GW : 600 GWV: 1 .
63 WTC 600 LP / MP APPENDIX Service Handbook 08.2004 WTC 600 MP , MP-A, MP-AM in v oltages 230 V and 400 V Operating mode Switched off LF limits GW : 1500 GWV: 4 0 0 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 1 s t-Press.
64 APPENDIX WTC 600 LP / MP Service Handbook 08.2004 RO control program structure Figure 21.
65 WTC 600 LP / MP APPENDIX Service Handbook 08.2004.
66 APPENDIX WTC 600 LP / MP Service Handbook 08.2004 RO 1000: Manual Control System RO 1000 MANU AL.
67 WTC 600 LP / MP APPENDIX Service Handbook 08.2004 Contents 1 General ........................................................................................ 69 - 74 1. 1 General remarks .............................................................
68 APPENDIX WTC 600 LP / MP Service Handbook 08.2004 Contents 4. 3 Operating Levels .................................................................................................... 83 4.3.1 Normal Level ............................................
69 WTC 600 LP / MP APPENDIX Service Handbook 08.2004 1 General 1.1 General Remarks The present Manual is the technical documentation of the RO 1000 control system for reverse osmosis units.
70 APPENDIX WTC 600 LP / MP Service Handbook 08.2004 1.3 Instructions for Use The following instructions should be followed when operating the control system: – Do not s witch on/off the control system in quick succession. W ait at least 5 seconds between switching the main switch on and off.
71 WTC 600 LP / MP APPENDIX Service Handbook 08.2004 1.5 T erms and Definitions The following scripts will be used for this manual: It em Sc rip t Exam pl es keys LED 's inlets/out lets cap it al.
72 APPENDIX WTC 600 LP / MP Service Handbook 08.2004 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.
73 WTC 600 LP / MP APPENDIX Service Handbook 08.2004 2.3 Function of T erminals T e rminal arrangement and functions are as follows: No. Code Func tion adm . max. load term inal 1 2 3 PE N L Ma ins s uppl y - pr otec ti ve. cond uct Mains sup ply - neutral con ductor Mains su pply - pha se 1000 V A = ma x.
74 APPENDIX WTC 600 LP / MP Service Handbook 08.2004 3 Operational Scope 3.1 Operating settings 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.
75 WTC 600 LP / MP APPENDIX Service Handbook 08.2004 3.2 Operating parameters The control system allows the following operating parameter settings (realization see item 4). The resulting behaviours are described in the chapter operating conditions. The v alues in brackets are the standard values after system reset (see item 4.
76 APPENDIX WTC 600 LP / MP Service Handbook 08.2004 t rinse interval function: Time after which a DISCONTINUOUS RINSE process is star ted provided that the control system was during that time in the operating condition RINSE INTER V AL.
77 WTC 600 LP / MP APPENDIX Service Handbook 08.2004 3.2 Operating parameters When the control system is switched on, the following four operating modes exist: ST OP The control system does not carry out any production process. All outputs remain inactive.
78 APPENDIX WTC 600 LP / MP Service Handbook 08.2004 3.4 Operating conditions When the unit is in OPERA TION the control system performs one of the se ven possib le operating conditions. The f ollowing diagr am shows the v arious conditions as well as the reasons for status changes.
79 WTC 600 LP / MP APPENDIX Service Handbook 08.2004 3. 5 Operating failures/failure messages The control system is able to detect oper ating f ailures dur ing OPERA TION and DISINFECTION and to displa y them. Usually , the unit will be stopped if a f ailure occurs.
80 APPENDIX WTC 600 LP / MP Service Handbook 08.2004 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 impor tant operating conditions of the unit.
81 WTC 600 LP / MP APPENDIX Service Handbook 08.2004 4.2 Basic elements The whole user surface of the control system is composed by basis functions such as pass word entr y , menu selection, selection of settings, numerical entries etc.
82 APPENDIX WTC 600 LP / MP Service Handbook 08.2004 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".
83 WTC 600 LP / MP APPENDIX Service Handbook 08.2004 4.3 Operating levels Similar to the operating modes, the user surface has different operating levels: Normal level: In this level, the text display.
84 APPENDIX WTC 600 LP / MP Service Handbook 08.2004 4.3.2 User's Level Access to the user le vel is achie ved b y entering a user's password (see 4.2.1). This le vel allo ws operation and setting of the most impor tant functions and operating settings/parameters respectively .
85 WTC 600 LP / MP APPENDIX Service Handbook 08.2004 4. 4 Menu structure The menu structure of the user surf ace is shown below . Access to the main menu is achie ved by entering a pass word (see item 4.
86 APPENDIX WTC 600 LP / MP Service Handbook 08.2004 4.4.1 Main menu The details of the diff erent menu points of the main menu are described below . Menu point: Function: 1 Ackn. failure This menu point allows to acknowledge an operating failure (the only possibility if ps acknowledgement = with password).
87 WTC 600 LP / MP APPENDIX Service Handbook 08.2004 4.4.2 Calibration menu The calibration menu is used to adjust the sensors . The follo wing functions are a vailable: Menu point: Function: 1 Cy permeate Calibration of permeate sensor . If the menu point '1 Cy permeate' is chosen, a submenu appears with two items: ' 1 min.
88 APPENDIX WTC 600 LP / MP Service Handbook 08.2004 4.4.3 Setting menu The calibration menu is used to adjust the sensors . The follo wing functions are a vailable: Menu point: Function: 1 t Cy LIM N.
89 WTC 600 LP / MP APPENDIX Service Handbook 08.2004 5 Tec hnical Data The following table contains all significant technical data of the RO 1000 control.
90 APPENDIX WTC 600 LP / MP Service Handbook 08.2004 Operating Record for the WTC 600 LP/MP Equipment Data: Works/Plant No.: Type: 1.024- Page No.: Location of Installation: Type of Untreated Water Su.
91 WTC 600 LP / MP LIST OF KEY WORDS Service Handbook 08.2004 A Acidic and Alkaline Cleaning ........................ 49 Acknowledging Data Inputs ......................... 3 5 Activated Carbon Filter ................................. 3 1 Activated carbon filter .
92 LIST OF KEY WORDS WTC 600 LP / MP Service Handbook 08.2004 I Indicator lights .............................................. 80 Initial Filling ................................................... 3 1 Initial startup ................................
93 WTC 600 LP / MP LIST OF KEY WORDS Service Handbook 08.2004 R RC Protective Switch ................................... 1 5 Regeneration ................................................ 31 Removing the Preservation After Longer Operational ......... 52 Replace the activated carbon or filter sand .
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