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600 CD
User Manual
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Karcher 600 CD User Manual

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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.
The texts and pictures can only be copied and duplicated or passed on to third parties after obtaining explicit permission from:
ALFRED KÄRCHER GmbH & Co. CUSTOMER SERVICE TRAINING P. O. Box 160 D-71349 Winnenden www.kaercher.com
2
WTC 600 LP / MP CONTENTS
Contents
1 General..........................................................................................7 - 10
1.1 Introduction ........................................................................................................... 7
1.2 Marking of Instructions ........................................................................................ 7
1.3 Intended Use.......................................................................................................... 7
1.4 Safety Instructions................................................................................................ 8
1.4.1 Quality of the Untreated W ater .................................................................................8
1.4.2 Chlorination of Drinking Water..................................................................................8
1.4.3 Disposal of Chemicals ............................................................................................. 8
1.4.4 Handling Electricity / Protection Class .....................................................................9
1.5 General installation notes .................................................................................. 10
1.6 Units and Designations .......................................................................................11
2 Description ................................................................................ 11 - 20
2.1 Overview .............................................................................................................. 11
2.2 Flow Diagram ...................................................................................................... 13
2.3 Description of the System.................................................................................. 14
2.3.1 Modular Design ......................................................................................................14
2.3.1.1 Pre-chlorination Module......................................................................................... 14
2.3.1.2 Flocculation Module............................................................................................... 14
2.3.1.3 Mediafilter- and Activated Carbon Filter ................................................................ 15
2.3.1.4 RO System, Pump and Fine Filter ........................................................................ 15
2.3.1.5 Control Panel and Display ..................................................................................... 15
2.3.1.6 Anti Scalant and Post Chlorination ........................................................................ 15
2.3.1.7 Pressure-increase Pump ...................................................................................... 16
2.3.2 Safety Installations .................................................................................................16
2.3.3 Operating Modes....................................................................................................17
2.3.3.1 Automatic Operation (Standard Operating Mode) ................................................. 17
2.3.3.2 Manual Operation .................................................................................................. 17
2.4 Technical Data WTC 600 LP/MP ......................................................................... 18
2.5 Consumption Materials ...................................................................................... 20
2.5.1 Chemicals for Metering Container ..........................................................................20
2.5.2 Cleaning Chemicals ...............................................................................................20
2.5.3 Filter .......................................................................................................................20
3 Operation of the System .......................................................... 21 - 43
3.1 Assembly and Starting Operation ..................................................................... 21
3.2 Mixing Chlorine, Flocculation Agent and Antiscalant ..................................... 22
3.2.1 Initial Starting of Operation .....................................................................................22
3.2.2 Pre-chlorination ......................................................................................................22
3.2.3 Antiscalant..............................................................................................................24
3.2.4 Metering Amounts and Mixing of the Post Chlorination ..........................................25
3.2.5 Flocculation Agent..................................................................................................25
3.2.5.1 Mixing of the flocking test solution..........................................................................25
3
CONTENTS WTC 600 LP / MP
Contents
3.2.5.2 Perfor m flocking test...............................................................................................26
3.2.5.3 Evaluate flocking test .............................................................................................26
3.3 Connecting the Equipment ................................................................................ 27
3.3.1 Connections, Valves and Indicators.......................................................................27
3.3.1.1 Pressure-increase Module .................................................................................... 28
3.3.1.2 RO Module with Preliminary Filters....................................................................... 28
3.3.2 Electrical Connections ........................................................................................... 29
3.3.2.1 Pressure-increase Pump ...................................................................................... 29
3.3.2.2 Preliminary Filter ................................................................................................... 29
3.3.2.3 Metering Station .................................................................................................... 29
3.3.2.4 Float Switch........................................................................................................... 31
3.3.2.5 Reverse Osmosis System .................................................................................... 31
3.4 Starting Operation ............................................................................................... 31
3.4.1 Metering Station .....................................................................................................31
3.4.2 Media filter and activated carbon filter ....................................................................32
3.4.2.1 Initial Filling............................................................................................................ 32
3.4.2.2 Starting Operation ................................................................................................. 32
3.4.2.3 Backwashing / Regeneration ................................................................................ 32
3.4.2.4 Programming......................................................................................................... 33
3.4.3 Starting Operation of the RO System ....................................................................35
3.4.3.1 Operating Levels and Passwords ......................................................................... 35
3.4.3.2 Menu Selection...................................................................................................... 35
3.4.3.3 Selection of an Option ........................................................................................... 35
3.4.3.4 Selecting Several Arguments at the Same............................................................ 36
3.4.3.5 Adjusting Operating Parameters and Balancing Values .........................................36
3.4.3.6 Acknowledging Data Inputs .................................................................................. 36
3.4.3.7 Operational Interruptions....................................................................................... 36
3.4.3.8 Initial startup ...........................................................................................................38
3.4.4 Normal Operation ...................................................................................................40
3.4.4.1 Operating Messages for Normal Operation .......................................................... 41
3.4.5 Putting Out of Operation.........................................................................................42
3.4.6 Disinfection.............................................................................................................43
4 Maintenance.............................................................................. 44 - 62
4.1 Fine Filter ............................................................................................................. 44
4.2 Metering Station WTC 600 CD............................................................................ 44
4.3 Reverse Osmosis Module (RO Module) ............................................................ 45
4.3.1 RO Filter Replacement...........................................................................................45
4.4 Cleaning in Case of Malfunction........................................................................ 46
4.4.1 Design of the Flushing and Disinfection Equipment ...............................................47
4.4.2 Disinfection.............................................................................................................49
4.4.3 Acidic and Alkaline Cleaning ..................................................................................50
4.4.3.1 Cleaning Solution for Acidic Cleaning ................................................................... 51
4
WTC 600 LP / MP CONTENTS
Contents
4.4.3.2 Cleaning Solution for Alkaline Cleaning................................................................. 51
4.4.4 Conserving.............................................................................................................51
4.4.4.1 Draining and rinse the metering stations ................................................................51
4.4.4.2 Conserve RO systems ..........................................................................................51
4.4.4.3 Draining the pre-filter ..............................................................................................53
4.4.5 Removing the Preservation After Longer Operational Interruptions.......................53
4.4.6 Rinsing the pre-filter ...............................................................................................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 Maintenance Plan ................................................................................................ 61
4.6.1 Maintenance During Operation...............................................................................61
4.6.2 Maintenance Plan Service .....................................................................................62
Appendix ................................................................................... 63 - 84
RO control manufacture settings .......................................................................... 63
RO control program structure ............................................................................... 65
RO 1000: User manual...........................................................................................67
Operating Record for the WTC 600 LP/MP ........................................................... 84
List of key words .............................................................................86 - 88
5
WTC 600 LP / MP
6
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
NOTE
Instructions that are attached directly to the equipment must be observed under all means and kept in completely readable condition.
Following this symbol are recommendations or tips which make working easier and provide for secure operation.
Following this symbol are recommendations or tips which make working easier and provide for secure operation.
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.
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 main­tained. The chemicals used have a caustic and fire-promoting effect.
Dangers:
- Danger of fire in case of contact with combustible 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:
- In case 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
WTC 600 LP / MP GENERAL
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 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 I).
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 H z Hz (frequency) l Liter l/h 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) µS/cm Microsiemens per cm (spec. conductance value ETL Spare parts list LW Conductance value SLP Circuit Diagram
Table 1 Units and their meaning
NOTE
1000 milliliter = 1 liter; 1000 mg = 1
9
DESCRIPTION WTC 600 LP / MP
2 Description
2.1 Overview
1.2 2.1 4.12, 4.13
f
g
2.2
1.3
4.23 c
b a
d
4.24
4.21
4.14
4.11
4.15
4.17
4.4
4.3
4.7
4.5, 4.6
e
Figure 1 Overview of components
10
WTC 600 LP / MP DESCRIPTION
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
1.6 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
4.11 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
4.8 Input solenoid valve
4.9 Manostat
4.10 High-pressure pump
Items 1.1 to 6.4 are attached to the components as reference numbers.
a Media filter control b Control, activated carbon filter c Control cabinet d Manual / automatic rotary switch e Master switch f Media and activated charcoal
plug sockets
g Power outlets (3x) for metering
stations
6.2 Antiscalant metering
6.3 Post chlorination metering
6.4 Flocculation metering
11
DESCRIPTION WTC 600 LP / MP
2.2 Flow Diagram
Figure 2 Flow diagram of the complete reverse osmosis system (RO system)
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 water 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 pre­chlorination if required.
2
1
Figure 3 WTC 600 CD
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).
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 filter.
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
1
the RO system. The RO pump (4/2) pumps the pre-filtered
water through two RO filters (4/1) which are connected in series.
2
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).
Parameters are entered with the arrow pushbuttons. Data input is acknowledged with the ENTER pushbutton (5/4) and cancelled with the ESC pushbutton (5/3).
Programming conditions, etc., are indicated in the display (5/2).
2.3.1.6 Anti Scalant and Post Chlorination
Figure 4 RO pump
1
Figure 5 Control panel and display
2
3
4
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 pre­chlorination.
14
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
1
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) ⱕ 2 bar.
CAUTION
Observe mechanical protection as well as protection of the connection cable against water!
Figure 6 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 ⱕ 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 4 A MP 400 V 2.2 kW 2.2 kW 5.1 A
LP 230V 2.2 kW 1.5 kW 10 A MP 230 V 2.2 kW 2.2 kW 14 A
Table 2 Setting of motor protection switch
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:
2
1
3
4
5
- 5x20 6,3 A time-delay
- 5x20 0,1 A time-delay.
Figure 7 Switch cabinet and control electronic
6
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 operation.
With the exception of an error acknowledgement (only in case of pre-selection Vw­acknowledgement 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
WTC 600 LP / MP DESCRIPTION
2.4 Technical 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*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 16 A Connected electrical load 2.2 kW 2.2 kW Effective electrical power consumption 1.5 kW 2.2 kW
Mechanical protection / protection against water
1)
1)
Switch cabinet IP44 Pump and valves IP44 Metering pump IP44 Power outlets (plug inserted) < 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 m³/h Capacity range 15000 l/day (±10%) Maximum drinking water capacity 650 l/h
Dimensions: H x W x D
WTC 600 LP/MP 1800 x 660 x 720 mm WTC 600 LP/MP - A 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
Table 3 Technical Data
1)
depending on the system version
17
DESCRIPTION WTC 600 LP / MP
Filter Container
Volume per container 103 l
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 Canal connection (supplied by customer) > DN 50
Hydraulic Data
Maximum allowable flow rate in filteroperation 1,3 m3/h Amount of waste water produced during 2 m³/h, ca. 670 liter per backwashing
backwashing
Allowable Operating Conditions
Maximum pressure 6 bar
Metering Pump
Feed capacity at max. counter-pressure (10 bar) 1 l/h 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 l
Table 4 Technical Data
18
WTC 600 LP / MP DESCRIPTION
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).
NOTE NOTE
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 l 6.294-703.0 RM 5001 Flockulents, 60 l 6.294-716.0
Table 5 Kärcher Original Products
2.5.2 Cleaning Chemicals
Product Item No.
RM Kleen MCT 511 6.294-008.0
Explanations of the units, see Chapter 1.6. A metering container from the WTC 600 CD metering station has a volume of 75 liter.
RM Kleen MCT 103 6.294-009.0 RM P3 Oxonia Active 6.294-010.0 RM 1,2 Propandiol, 5 l 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*
Table 6 Cleaning Chemicals * Attention! Note national variants!
2.5.3 Filter
Product Item No.
Filter element 5µ 6.414-466.0 Replacement set, metering pump 6.762-172.0
Table 7 Filter Elements
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 2.2, 3.3.2.1, 3.3.1
the WTC 600 PI in between, if required (depending on delivery scope) 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
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
- Iron Fe in mg/l
- Manganese Mn in mg/l
- Ammonium NH
or NH3 in mg/l
4
- System yield determined by the sales department (Normal case: 75%, in special cases 50%).
20
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
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
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: ____ x 0,4 = ______
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!
Only use drinking water to dilute the original chlorine product upstream of the chlorination point. This water is taken from the drinking water tap (1/4.21).
Manganese content: ____ x 0,6 = ______ Ammonium content: ____ x 8,0 = ______ Basic requirement: 1,2 Total: ==========
4.For 50% yield: Total x 192 = ____ ml RM 852 per 10 litre metering solution OR T otal x 512 = ____ ml calcium h ypochlorite (1ml corresponds to 1.05g) per 10 litres metering solution
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 T otal x 348 = _____ ml calcium h ypochlorite (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/l
4
Iron content: 1,0 x 0 ,4 = 0 ,4 Manganese content: 1,0 x 0,6 = 0,6 Ammonium content: 0,2 x 8,0 = 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 348 = 129 ml calcium hypochlorite (1ml corresponds to 1.05g) per 10 litres metering solution
22
WTC 600 LP / MP OPERATION OF THE SYSTEM
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. 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 10 l 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 (21°-28° dH) 5 115 214
Table 10 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 10 l Metering Solution
1 (0°-7° 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 11 Metering of antiscalant at 50% yield
1 °dH = 1,79 °frH 1 °dH = 17,9 mg CaCO3/l 1 °frH = 10,0 mg CaCO3/l
23
OPERATION OF THE SYSTEM WTC 600 LP / MP
3.2.4 Metering Amounts and Mixing of the Post Chlorination
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: 4 x 17 = 68 ml
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 clean dropping bottle, close bottle
5. Cast away the remainder.
24
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 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
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
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).
Shake well before measurement in labor atory.
Calculation example:
The flocculation test gave 11 drops of flocculation 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
25
OPERATION OF THE SYSTEM WTC 600 LP / MP
3.3 Connecting the Equipment
3.3.1 Connections, Valves and Indicator s
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 main­tenance of the system, minimum clearances from the walls are to be observed:
Page Minimum clearances [cm] A50 B10 C70 D50
Table 12 Minimum clearances
Figure 8 Minimum clearances WTC 600 LP/MP
2
1
Figure 9 Water connections, WTC 600 PI
3
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 mm WTC 600 CD: width x depth: 500 x 1100 mm WTC 600 PI: width x depth: 600 x 200 mm
26
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)
2
3
1
4
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) Concentrate control valve (11/8)
Figure 10 Connections, rear
3
2
1
Figure 11 Connections, front
4 5
6 7
8
9
27
OPERATION 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)
1
Alarm output
(empty alarm)
Figure 12 Alarm output and digital input of the metering pumps
2
For connection of the control cables in the electrical switching cabinet, the blind connections in the flange plate (13/4) are replaced by the enclosed cable screw fittings (13/3).
Connect the control cables in accordance with T ab le 13.
NOTE
The complete connecting diagrams / plans (13/1) are located in the switch cabinet.
NOTE
The connections for signal inputs that are not required are bridged at the connecting terminal (13/2).
28
1
2
3
4
Figure 13 Connections, metering stations
WTC 600 LP / MP OPERATION OF THE SYSTEM
Metering Type Function Signal Line Connecting Container Terminal,
El. Cabinet
Pre-chlorination Alarm output (12/1 not required white -----
blue -----
Empty signal brown 14
black 15
Digital input (12/2) Release brown 8
blue 9
not required white -----
black -----
Antiscalant Alarm output (12/1) not required white -----
blue -----
Empty signal brown 16
black 17
Digital input (12/2) Release brown 10
blue 11
not required white -----
black -----
Post chlorination Alarm output (12/1) not required white -----
blue -----
Empty signal brown 18
black 19
Digital input (12/2) Release brown 12
blue 13
not required white -----
black -----
Table 13 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.
29
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 bac kwashing (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
Operating mode on “Manual” (14/2)! Change the operating mode by pressing the "Mode" key (14/2).
Modul Lift Frequency Meter-
Pre­chlorination 40% 70% 3.2.2
Pushbutton for venting in “continuous operation” (14/3).
4
(14/1) (14/4) ing
2
3
1
Antiscalant 40% 50% 3.2.3 Post
clorination 40% 70% 3.2.4 Flocculation 40% 70% 3.2.5
Table 14 Checking pump settings
NOTE
30
Adjust the lift only when the pump is running. Danger of damaging!
Figure 14 Metering station
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 T ab le 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 opening 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
31
OPERATION OF THE SYSTEM WTC 600 LP / MP
3.4.2.4 Programming
To start the programming, the covered pushbutton (15/1) to the left 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
43
(15/3).
1
NOTE
If a different adjustment than the factory-setting is required, enter
2
and acknowledge by pressing “MANUAL REGEN” (15/4).
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. 2 00 Media filter back-washing at 02.00 (minutes) 2 Covered pushbutton 0. 2 00 Media filter back-washing at 02.00
(full hours) At the activated carbon filter 1 Covered pushbutton 0. 2 30 Backwashing of activated carbonfilter at
02.30 (minutes)
2 Covered pushbutton 0. 2 30 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
1)
Table 17 Programming table 32
for sand filter and activated carbon filter
WTC 600 LP / MP OPERATION OF THE SYSTEM
Position Indication Description
6 Covered pushbutton 0000. Without function 7 Covered pushbutton 0000. Without function 8 Covered pushbutton AA14 Without function 9 Covered pushbutton AA02 10 Covered pushbutton AA02 11 TIME OF DAY 1C10 Backwashing period 10 minutes 12 Covered pushbutton 2C00 0 minutes 13 Covered pushbutton 3C00 0 minutes 14 Covered pushbutton 4C03 Initial filtration 3 minutes 15 Covered pushbutton 4d10 Leave programming mode
1)
Table 18 Programming table
1)
For changing of any given value from the programming table, the complete menu must be run
for media filter and activated carbon filter
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
Table 19 Statistical indications – diagnosis
NOTE
Briefly pressing the “ADVANCE” pushbutton after selecting runs you through the diagnosis indication.
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
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:     
T echnician 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:   ESC     ESC   
NOTE
NOTE NOTE
The user operates the equipment in normal level. Entering a password is not required.
To enter a password, the respective key sequence must be entered in the normal level within one minute.
For settings and menus of the RO 1000 control system, see figure 22. 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 list. 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 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 pushbutton and the 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
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 pushbutton and the 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 value 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 pushbutton. With help of the pushbutton and the 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 factor y 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 5µ. 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 message 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).
35
OPERATION OF THE SYSTEM WTC 600 LP / MP
Indication:
-Press the pushbutton.
Indication:
Press the RETURN pushbutton.
Indication:
-Press the pushbutton.
Indication:
Press the RETURN pushbutton.
Indication:
-Press the pushbutton.
Indication:
Press the RETURN pushbutton.
> 1 Error ack. <
2 Operating mode
1 Error ack.
> 2 Operating mode <
Operating mode
Operation
Operating mode
Switched off
Execute ?
> no < yes
Execute ?
no > yes <
Indication:
Press the RETURN pushbutton.
Indication:
-Press the pushbutton.
Indication:
System in disinfection operating mode. Set the concentrate flow to 600l/h at the concentrate regulating valve (4.15).
CAUTION CAUTION
During disinfection operating mode, all confirmation queries are switched off! 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!
1 Error ack.
> 2 Operating mode <
Operating mode
Switched off
Operating mode
Disinfection
Leave the system to run in this condition for 20 minutes, then switch to switched off operating mode (cf. 3.4.5).
36
WTC 600 LP / MP OPERATION OF THE SYSTEM
3.4.3.8 Initial startup
- Set the equipment to the operation operating mode (see 3.4.4)
- Set the drinking water capacity to 600 l/h
- 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 l/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 Pump pressure and concentrate pressure increase 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
Untreated Drinking water Concentrade Yield water capacity capacity
1200 l/h 600 l/h 600 l/h 50% 800 l/h 600 l/h 200 l/h 75%
Table 21 Typical yields at maximum drinking water capacity and untreated water temperature
NOTE
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.
of 15 °C
The drinking water capacity must never be set 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 v alve and the pump until the switch of the level float signals empty and the RO system switches on again.
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
- -Press pushbutton
- Use the
- Use the key to change to warn value
- Use
CAUTION
- Press the key: Display jumps back to "6 LF limits"
- Press ESC, display is in initial condition
- System has been checked and is ready for use.
keys to call up menu item "6 LF limits"
keys to set the limiting value (upper limiting value of the drinking water
conductivity): 20% of the untreated water conductivity value
keys to set the warn value (warning value of the drinking water conductivity):
15% of the untreated water conductivity value
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!
38
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:
RO 1000 V 01.34
Switched off
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:
RO 1000 V 01.34
production on
Figure 16 User indication in normal operation
W-Temp:
12.3°C
perm: 12 µS/cm
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 ackn. failure <
Press the pushbutton one time.
2 operat. mode
Indication:
1 ackn. failure
Press the RETURN pushbutton.
> 2 operat. mode <
Indication:
operation mode
Press the pushbutton.
STOP
hours meter
1111 h 11 min
Indication:
Press the RETURN pushbutton.
Indication:
Press the pushbutton.
Indication:
Press the RETURN pushbutton.
Indication:
Press the ESC pushbutton.
operation mode
OPERATION
are you sure ?
>no< yes
are you sure ?
no >yes <
1 ackn. failure
> 2 operat. mode <
39
OPERATION OF THE SYSTEM WTC 600 LP / MP
Indication:
The equipment produces and starts with rejection. Operating conditions:
- „Production“ LED lights.
- “Reject“ LED lights. After the reject period has run off, normal production with rotating indication:
RO 1000 V 01.34
Production on
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:
W-Temp:
12.3°C
perm: 12 µS/cm
RO 1000 V 01.34
Disposal
hours meter
1111 h 11 min
- The “tank full” LED lights at the operating panel.
- Indication: “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 w ater . Cause: Empty sensor 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
WTC 600 LP / MP OPERATION OF THE SYSTEM
3.4.5 Putting Out of Operation
CAUTION
NOTE
NOTE
The system is switched off e. g., when putting out of operation for extended periods. For out-of­operation 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 pushbutton.
Indication:
Press the RETURN pushbutton.
Normally, do not switch off with the main switch (a possibly active flushing program 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.
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.
> 1 ackn. failure <
2 operat. mode
1 ackn. failure
> 2 operat. mode <
Indication:
Press the pushbutton.
Indication:
Press the RETURN pushbutton.
Indication:
Press the pushbutton.
Indication:
Press the RETURN pushbutton.
Indication: Press the ESC pushbutton.
Indication:
operation mode
OPERATION
operation mode
Stop
are you sure ?
>no< yes
are you sure ?
no > yes <
1 ackn. failure
> 2 operat. mode <
RO 1000 V 01.34
Stop
The equipment is switched off now.
41
OPERATION OF THE SYSTEM WTC 600 LP / MP
3.4.6 Desinfection
Enter user password (compare with Chapter 3.4.3.1):
Indication:
Press the 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.
> 1 ackn. failure <
2 operat. mode
1 ackn. failure
> 2 operat. mode <
operation mode
OPERATION
operation mode
STOP
are you sure ?
>no< yes
are you sure ?
no > yes <
Indication:
Press the RETURN pushbutton.
Indication:
Press the pushbutton.
Indication:
System in disinfection operation mode.
CAUTION CAUTION
During the disinfection operation mode, all safety quest are switched off! Observe the pressure after the fine filter: If less than 2 bar, switch off the equipment
immediately. High-pressure pump running dry!
1 ackn. failure
> 2 operat. mode <
operation mode
STOP
operation mode
Desinfection
42
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.
NOTE
Replace the fine filter every 3 months.
NOTE
Use the special filter wrench!
4.2 Metering Station WTC 600 CD
1
Figure 17 Replacing the fine filter
2 3
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 (goggles, 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)! Tighten valve by hand only (danger of damaging!)
1)
Feinfilter 5µ: Art.-Nr. 6.414-466.0
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 water connection (19/3) and carefully lever out using pipe pliers.
1
2
3
4
4
- Remove adapter from lid, clean and insert.
- Take out filter and remove low er lid.
NOTE
1)
Membrane replacement set: Item No. 6.762 172.0
Do not interchange lids.
44
5
Figure 18 RO-Modul
WTC 600 LP / MP MAINTENANCE
1)
- Apply Propandiol
- Insert a new filter (19/7) at the supply opening (end without seal first!).
to the rubber seals.
67
1
- Attach all adapters.
2
- 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
4
connections.
- Fasten module to frame and connect pipe
3
lines.
- Flush the equipment for 10 minutes (3.4.3.7).
5
- Switch to the operation operating mode:
Figure 19 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 following 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 NOTE
Alkali cleaning with RM MCT 511 first, then acid cleaning with RM MCT 103. Only disinfect if cleaning is unsuccessful.
1)
Propandiol: Item No. 6.290-910.0
45
MAINTENANCE WTC 600 LP / MP
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. Pressure switch
5. RO Pump
6. Pressure tube / module
7. Measuring cell
8. Flow meter (drinking water)
9. Pressure control valve
10. Check valve
11. Concentrate control valve
12. Flow meter (concentrate)
13. Electrical control system
14. Drinking water to the flushing tank
15. Concentrate to the flushing tank
16. Flushing tank
17. Sampling valve for drinking water
18. Sampling valve for untreated water
19. Flushing pump
Aids:
- Cleaning tank
- Four connection hoses
- Conductive capacity measuring unit for measurement comparison after flushing
- Protective clothing (goggles, gloves, apron)
- External pump as flushing pump
Starting Position:
- RO equipment set to switched off operating mode and switched off with main switch.
46
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!
47
MAINTENANCE WTC 600 LP / MP
4.4.2 Disinfection
A disinfection 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
1)
- 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. Plug in 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!
Volume of the RM Item No. disinfection solution [l] P3-Oxonia-Active [ml]
30 75 (= ½ bottle) 6.294-010.0
Table 22 Composition of the disinfection solution
1)
Item No. 6.768-354.0
48
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 CAUTION
End the cleaning when a change of the pH-value can no longer be detected. 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,
4. Connect the untreated water supply to the RO equipment again; guide drinking water and concentrate outlet to the canal.
5. Plug in the earthing-contact plugs of the metering pumps
6. Switch the RO equipment to the operating mode
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.
1)
Item No. 6.768-355.0
49
MAINTENANCE WTC 600 LP / MP
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 (6.287-014), until the pH value is approx. 7.
4.4.3.2 Cleaning Solution for Alkaline Cleaning
Volume of the RM Kleen MCT 511 [l] Item No. cleaning solution [l]
30 1,0 6.294-008.0
Table 24 Composition of the cleaning solutions for alkaline cleaning
Neutralise by adding RM V apor apid bio descaling acid (6.290-239), until the pH value is appro x. 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 conservation means must be flushed and renewed, if required.
50
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. Fill 25 litres of chlorine-free drinking water into the flushing tank (20/16).
2. 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.
3 . Switch system to disinfection operating mode and adjust water pressure to 2 bar (manometer
4.7) using the untreated water sampling tap.
4. Disconnect the earthing pin plug of the metering pumps.
5. Add sodium bisulphite to the flushing tank.
6. If the system is to be protected against frost, then slowly add the RM 1,2 propandiol.
7. Allow the conservation solution to circulate for 10 minutes.
8. The more RM 1,2 propandiol is added the lower the drinking water flow. Do not change the pressure regulating valve and concentrate regulating valve settings.
9. Set the system to switched off operating mode and switch off the master switch.
10. 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.
51
MAINTENANCE WTC 600 LP / MP
Preservation solution [l] Sulfite 5kg1) [g] RM 1,2 Propandiol 5l2) [l]
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.
2. Interrupt the untreated water supply, depressurise the filter.
3. Undo hose 6.390-962.0 from the hose nozzle at the outlet of the activated carbon filter.
4. Attach a connection hose to this hose nozzle and screw tight with a hose clamp.
5. Fix the other end of the connection hose to the filter control heads.
6. Keep the untreated water supply open until water comes out of the connection hose.
7. 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 necessar y, 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.
1)
Sulfite 5 kg: Item No. 6.769-040.0
2)
RM 1,2 Propandiol, 5l: Item No. 6.290-910.0
52
WTC 600 LP / MP MAINTENANCE
4.4.6 Flushing the pre-filter
The WTC 600 LP/MP pre-filter must be flushed if the diff erential pressure of the pre-filter immediately after back-washing is more than 0.5 bar .
CAUTION
CAUTION
- 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:
Before flushing the filter, check the manometer for correct display values and exchange if necessary!
Pre-filter blockages are caused above all by changed water constituents. A renewed water analysis must be carried out in order to remove the cause of blockages. Notify sales depar tment! Additional treatment stages possibly required!
- 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
3. Connect the flushing pump to the pre-filter untreated water inlet
4. Start back-washing
5. Switch on flushing pump
6. Leave the flushing solution to circulate until the back-washing is finished (approx. 10 min)
7. Leave the flushing solution to stand for 30 minutes
8. Repeat the procedure from item 4 once again
9. 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.
53
MAINTENANCE WTC 600 LP / MP
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. 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 1.408-151.0
- 4 metal suction pipes, 0.5m 6.902-050.0 (Remove the plastic rings from the metal pipes)
- Filling funnel 4.901-090.0
- Shovel 6.812-049.0
Spare parts required:
- Activated carbon filter bed 6.414-721.0
- Sand filter bed 6.414-714.0
Spare parts possibly required:
- Filter pressure tank 6.414-710.0
- Set of O-rings 6.414-713.0
Initial situation:
- WTC 600 set to switched off operating mode and switched off at the master switch
- Untreated water pipe shut off
54
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
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.
Firmly push the metal pipes together or secure with thin adhesive tape!
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 Pump in metering 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 defective 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
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 Fill up 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.
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 >>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 Replace 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
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 ETL 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 push­rod torn out
Pump does not Air in the suction Bleed pump meter line and in the
metering head Lift adjustment a 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!)
Table 30
58
Injection fitting Check direction of flow blocked and correct, if required,
or eliminate plug (direction of arrow!)
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
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- not initiated incorrectly programming washing” programmed counter
Tabelle 31
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 Weekly 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 everyClean intake and pressure 4.2
4000 hours valves
Metering stations Yearly or everyReplace 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
WTC 600 LP / MP MAINTENANCE
4.6.2 Maintenance Plan – Service
NOTE
Module Work to be Carried Out
Media filter Assess general condition
Activated carbon filter Assess general condition
Fein filter Read differential pressure
Reverse osmosis Assess general condition
Measured and read values are to be entered into the maintenance record.
Differential pressure after backwashing Read adjustment of the differential controller Read amount of backwashings
Differential pressure after backwashing Chlorine measurement in filtrate (1/18 Read amount of backwashings
Amount of used up filters since last service
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 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.
61
APPENDIX WTC 600 LP / MP
Appendix:
RO control factory settings:
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 1 s
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 34
62
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 1 s
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
63
APPENDIX WTC 600 LP / MP
RO control program structure
Figure 21
64
WTC 600 LP / MP APPENDIX
65
APPENDIX WTC 600 LP / MP
RO 1000: Manual
Control System
RO 1000
MANUAL
66
WTC 600 LP / MP APPENDIX
Contents
1 General........................................................................................69 - 74
1.1 General remarks .....................................................................................................69
1.2 Scope of Application..............................................................................................69
1.3 Instructions for Use ...............................................................................................70
1.4 Safety Instructions .................................................................................................70
1.5 Terms and Definitions ............................................................................................71
1.6 Declaration of Conformity .....................................................................................71
2 Installation/Start-up ...................................................................72 - 73
2.1 Basic Requirements ...............................................................................................72
2.2 Start-up....................................................................................................................72
2.3 Function of Terminals.............................................................................................73
3 Operational Scope ..................................................................... 74 - 79
3.1 Operating Settings ................................................................................................. 74
3.2 Operating Parameters............................................................................................75
3.3 Operating Modes ............................................................................................ 76 - 77
3.4 Operating Conditions ............................................................................................ 78
3.5 Operating Failures/Failure messages...................................................................79
4 Operation....................................................................................80 - 88
4.1 User Interface .........................................................................................................80
4.2 Basic Elements .......................................................................................................81
4.2.1 Password Entry ........................................................................................................81
4.2.2 Selection of menu .....................................................................................................81
4.2.3 Selection...................................................................................................................81
4.2.4 Multiselection............................................................................................................82
4.2.5 Numerical Editing......................................................................................................82
4.2.6 Alphanumerical Editing .............................................................................................82
4.2.7 Confirmations ...........................................................................................................82
67
APPENDIX WTC 600 LP / MP
Contents
4.3 Operating Levels ....................................................................................................83
4.3.1 Normal Level ............................................................................................................83
4.3.2 User Level ................................................................................................................ 83
4.3.3 Technician's Level .................................................................................................... 83
4.4 Menu Structure .......................................................................................................85
4.4.1 Main Menu ................................................................................................................86
4.4.2 Calibration Menu.......................................................................................................87
4.4.3 Setting Menu.............................................................................................................88
4.4.4 Diagosis Menu..........................................................................................................88
5 Technical Data ........................................................................... 89 - 90
68
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 operation 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. Its 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 µS/cm, resolution: 0.2%, accuracy: 1%,
temperature 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 – T wo-point calibration – T echnical diagnostic function
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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. It 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) before 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.
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1.5 Terms and Definitions
The following scripts will be used for this manual:
Item Script Examples
keys LED's inlets/outlets
operati ng se tt in gs operati ng p arame t ers
operati ng mo de s operati ng co ndi ti ons operati ng failu re
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
capital letters + bold capital letters + bold capital letters + bold
italics italics
capital s + un der l ign ed capital s + un der l ign ed capital s + un der l ign ed
LEFT, UP, DOWN RINSE, DISPOSAL PUMP FAILURE, INLET VALVE
ps-ha rd wat er, ps-pum ps
LIM, t-rinse
STOP, ON PRODUCTION; DISPOSAL MOTOR FAILURE, FORCED STOP
– 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)
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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 into account).
– All inductive consumers (valves, motors, contactors, transformers) of the unit have to be
provided with suitable interference suppressors (RC element, var istor, 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 è after at most 5 sec a text has to be displayed on the LC
display (otherwise switch off è 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).
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2.3 Function of T erminals
Terminal arrangement and functions are as follows:
No. Code Function adm. max. load terminal
1 2 3
4 5 6
7 8 9
10 11 12
13 14 15 16
17 18 19
PE N L
ENT-PE ENT-N ENT-L
P1-PE P1-N P1-Ls
MV1-PE MV1-N MV1-Ls
MV2-PE MV2-N MV2-Ls MV2-Lo
MV3-PE MV3-N MV3-Ls
Mains sup ply - pr otec tive. conduct Mains supply - neutral condu ctor Mains supply - phase
softener - pr ot ecti ve condu cto r softener - ne utral con du ctor softener - ph ase
pump 1 - prot ect ive con duc tor pump 1 - neut ral co ndu cto r pump 1 - phase
inlet valve - pro tecti ve cond uct inlet valve - neu tral con duct or inlet valve - closer
outlet valve - pr otec tive c ond. outlet valve - neut ral c ondu cto r outlet valve - clos er outlet valve - op eni ng co ntac t
concen trate valve - prot ect ive con d. concen trate valve - neut ral con d. concen trate valve - close r
1000 VA = max.
total ou tput
performance
1000 VA
1000 VA
1000 VA
1000 VA
1000 VA
2,5 mm² 2,5 mm² 2,5 mm²
2,5 mm² 2,5 mm² 2,5 mm²
2,5 mm² 2,5 mm² 2,5 mm²
2,5 mm² 2,5 mm² 2,5 mm²
2,5 mm² 2,5 mm² 2,5 mm²
2,5 mm² 2,5 mm² 2,5 mm²
20 21 22
23 24
25 26
27 28
29 30
31 32
33 34 35 36 37
STO-W STO-S STO-O
REG-M REG-E
MOTL-M MOTL-E
DRS-M DRS-E
NIVU-M NIVU-E
NIVO-M NIVO-E
SEN-S SEN-A SEN-B SEN-C SEN-D
trouble message - central contact trouble message - closer trouble message operning contact
mass - regen erati on input - rege ne rati on
mass - motor protection/limitent input - mo tor pr ot ect ion /lim iten t
mass - pressure switch input - pressure switch
mass - min. top level input - mi n. top level
mass - max. top level input - ma x. top level
sensor pe r m eate s cre en ing sensor pe rmeate A (whi te) sensor pe rmeate B (brown) sensor pe rm eat e C (ye llow sensor pe rm eat e D (gr een ))
230 VAC / 4A
resp. 2 4V DC
/1 A
2,5 mm² 2,5 mm² 2,5 mm²
2,5 mm² 2,5 mm²
2,5 mm² 2,5 mm²
2,5 mm² 2,5 mm²
2,5 mm² 2,5 mm²
2,5 mm² 2,5 mm²
0,5 mm² 0,5 mm² 0,5 mm² 0,5 mm² 0,5 mm²
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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. The standard values (setting after parameter reset) are marked by * in the appropriate field.
ps LIM high function: Preselect if unit is to be switched off if
LIM is exceeded or if a failure
message is sufficient right of access: user/technician possible setting:
ps acknowledgment function: Prelesect if acknowledgment of
* switch off do
not switch off
failures is possible in the normal level
(=without password)
or only in the user/technician level
(=with password). right of access: technician
possible setting:
ps concentrate mode function: Preselect if
right of access: technician possible setting:
ps tank type function: Prelesect if tank is equipped with an
right of access: technician possible setting:
* without password
with password
PRODUCTION has to be followed by (with pump) or DISPLACEMENT (without pump).
* flush displacement
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.
* with without overflow
CONCENTRATE FLUSH
CONCENTRATE
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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 values in brackets are the standard values after system reset (see item 4.4.4).
LIM function: 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 exceeded during PRODUCTION, RINSE or CONCENTRATE DISPLACEMENT/FLUSH for the time defined for t-delay LIM, an ALARM MESSAGE will be
activated. right of access: user/technician possible setting: meas. range 0.5-50µS/cm (40 µS/cm)
Attention: the set value must be above aaLIM
aaLIM function: 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 right of access: user/technician possible setting: 0.5-50µS/cm (10 µS/cm)
Attention: the set value must be lower than LIM
t-delay LIM function: Time delay for wrong permeate limit value
(see above) right of access: technician possible setting: 0-99 min (1 min)
t-delay aaLIM function: Time delay for advance alarm in case of wrong
permeate limit value (see above) right of access: technician possible setting: 0-99 min (5 min)
t-delay lack of pressure function: Time delay to release
PRESSURE SWITCH is inactive. right of access: technician possible setting: 0-99s (1s)
t-delay at start function: Period of time of permanent pressure at start of
operation after opening of the inlet valve before
the pumps begin to work. right of access: technician possible setting: 0-9.9s (0.5s)
PRESSURE FAILURE if
t-pressure available function: Period of time until
released if pumps do not start after opening of
inlet valve. right of access: technician possible setting: 0-99s (5s)
t rinse function: Duration of a
right of access: technician possible setting: 0-99 min (5s)
DISCONTINUOUS RINSE.
PRESURE FAILURE is
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t rinse interval function: Time after which a
process is started provided that the control system was during that time in the operating
condition right of access: technician possible setting: 0-99h (0h)
t concentrate function: Duration of a
DISPLACEMENT/FLUSH process at the end of
a
PRODUCTION (TANK FULL active). right of access: technician possible setting: 0-99min (1 min)
t min disposal funtion: Minimum duration of a
beginning of a minimum time after which the unit passes to
PRODUCTION if the value drops below LIM. right of access: technician possible setting: 0-999s (5s)
Attention: the set value must be less than t max
disposal. (Pay attention to units)
t max disposal function: Maximum duration of a
is the maximum time after which the value has to
be below LIM, otherwise a failure message will be
given. right of access: technician possible setting: 1-99min (60 min)
Attention: the set value must be greater than
t min disposal (Pa y attention to units!)
RINSE INTERVAL.
DISCONTINUOUS RINSE
CONCENTRATE
PRODUCTION. This is the
DISPOSAL process at the
DISPOSAL process. This
t maintenance function: Operating time (hour meter) after which a signal
is given that maintenance has to be carried out
(flashing OPERATION). right of access: technician possible setting: 0-999999h (3500h)
Attention: zero setting means that no
maintenance message is given.
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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 not 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 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.
DISPOSAL, PRODUCTION ON, CONCENTRATE
DISINFECTION
The control system does not carry out any production process, but INLET V ALVE, OUTLET VALVE as well as the PUMP 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.
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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.
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3.5 Operating failures/failure messages
The control system is able to detect operating failures dur ing
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
FORCED STOP MOTO R FAILURE/HARD
WA TER
LACK OF PRESSURE
Cy perm> LIM Unit switches off if ps LIM
high = switch-off
FORCED STOP active MOTO R FAILURE/
LIMITENT CONTACT
active PRESSURE SWITCH active
Unit switches off Unit switches off
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 alar m 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 inf ormed immediately if such f ailures 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.
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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 important 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 Ï, DOWN Ð, LEFT Í, RIGHT Î, ENTER Í 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 Te xt 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 serves for the (menu-assisted) user communication for control system settings (user/technician level).
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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 descr iption 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.
    
For technician's password entry, the following keys have to be actuated in the normal level,
within one minute.    ESC      ESC
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 / keys. 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. ">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 / 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.
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4.2.4 Multiselection
The multiselection allows to select various arguments simultaneously (for the purpose of this paper, argument means an y type of setting). In the lowest line of the text display appears for that purpose a chain of "0" and "1". Each one 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 Í/ Î 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 Ï / Ð key. The current setting of all arguments is accepted/stored with the Í 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 low er line. A flashing block (cursor) always marks the figure which can be modified; this modification (new setting) can be achieved with the Ï / Ð keys. Cursor displacement is achieved with the Í / Î keys, so that other figures can be modified, too. The displayed value is stored as new operating parameter when the Í 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 4.2.4), with the exception that the Ï / Ð 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 Î key (select "yes") followed by the Í 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).
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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) allo ws oper ation and setting of the most important functions and operating settings/parameters respectively as well as the calibration of the conductivity sensors.
T echnician's le vel:
The technician's level is a extended user level: It allows to carry out the functions of the user level, to manipulate Í all operating settings/parameters and to fulfil a hardware test by means of a specific diagnostic function.
The 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:
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.
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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.
If there 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 system 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.
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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).
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APPENDIX WTC 600 LP / MP
4.4.1 Main menu
The details of the different 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).
2 Operat. mode 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).
2 Cy permeate Permanent display of current permeate conductivity. To leave this menu
point press one of the keys.
4 Temp. permeate P ermanent display of current permeat temperature. To leave this menu
point press one of the keys. 5 Hour meter Calling-in (display) of the operating hours meter . 6 Cy limits Numerical entry of LIM and aaLIM. 7 Optional alarm Setting (selection) of ps LIM high 8 Calibration 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. 9 Setting This menu point assures branching to the setting menu (see item 4.4.4).
The modification will be stored of the entered data are acknowledged
before leaving the setting menu. 10 Diagnosis 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.
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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: 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. 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 v alue has to be entered by numerical editing. The entered value is equated with the current conductivity after actuation of the Í key.
2 temp.permeate 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 Í key is then actuated.
3 calibr. reset This menu point allows to reset adjustment of the two measuring inputs
to the internal standard values. ATTENTION !! Inter nal calibration is not a correct adjustment.
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4.4.3 Setting menu
The calibration menu is used to adjust the sensors. The following functions are available:
Menu point: Function:
1 t Cy LIM Numerical editing of t delay LIM 2 t Cy alarm Numerical editing of t delay aaLIM 3 t lack of pressure Numerical editing of t delay lack of pressure 4 t delay at start Numerical editing of t delay at start 5 t press. availabe Numerical editing of t pressure failure 6 t disc. rinse Numerical editing of t rinse 7 t rinse.interval Numerical editing of t rinse interval 8 t concentrate Numerical editing of t concentrate 9 t disposal Numerical editing of t disposal 10 t maintenance Numerical editing of t maintenance 11ps failure alarm Selection of ps acknowledgment 12 ps concentrate Selection of ps concentrate 13 ps type of tank Selection of ps tank type 14 inputs Setting of input types (valve with open rest pos./opener) 15 ps language Selection of ps language 16 system reset As soon as this function is called-in and acknowledged,
the internal hours meter will be deleted (set to 0)
4.4.4 Diagnosis menu
The diagnosis allows direct display/manipulation of the input/output conditions for testing purposes.
ATTENTION!!! Under these conditions, failure detection is not active.
Menu point: Function:
1 digital input 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. 2 digital output Manipulation of the digital circuit outputs (see item 2.3) by means of a
multiselection. 3 lights Manipulation of the lights (item 4.1.1) by means of a multiselection. 4 Cy permeate Permanent display of the current permeate conductivity. This display can
be cancelled by actuating one of the keys. 5 temp. permeate Permanent display of the current permeate temperature. This display can
be cancelled by actuating one of the keys.
88
WTC 600 LP / MP APPENDIX
5 Technical Data
The following table contains all significant technical data of the RO 1000 control.
min. type max. unit
nominal service volta ge main frequ en Cy nominal voltam ps
ambient temperature range (operation) ambient tempe rat ure rang e (s torag e) relative air humidit y
conduc tivity range
- accuraCy of measu reme nt (re f. to range end
200
47
5 0
-10 15
2
–
- value wi tho ut sens or )
- temperature rang e switching c ur rent o f circ u it inpu t s
adm. relay load fo r 230 V AC adm. relay load fo r 24 V DC total installed load total installed load - solen oid valves
0
0 – – – –
protect io n cl ass IP55
230
– –
– – –
–
0.5 –
– – – – –
260
63 10
50 70 85
200
1
40 30
4
1
1000
250
V
Hz
VA ° C
° C
%
µS/cm
%
° C
mA
A
A VA VA
Service Handbook 08.2004
89
APPENDIX WTC 600 LP / MP
Remarks
Conduct-
ing
capacity
[µS/cm]
Through-
flow [l/h]
Activated
carbon filter
Counter Ð Backwash-
Concen-
Pump
Pressure
Operat-
Conduct-
Sand
ings
trate
pressure
[bar]
pressure
[bar]
ahead of
fine filter
[bar]
ing hours
[h]
ing
capacity
[µS/cm]
filter
Temper-
ature [ ¡C]
Hard-
ness
[¡dH]
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 Supply: Date of Starting Operation:
Date Operator Untreated Water Operating Data Drinking Water Malfunctions /
90
This control sheet is to be filled out consciously 1x per week. Please copy after entering the operational start-up values.
Service Handbook 08.2004
WTC 600 LP / MP LIST OF KEY WORDS
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 ......................................................62
Assembly and Starting Operation ................20
Automatic Operation
(Standard Operating Mode)..........................16
B
Backwashing / Regeneration .......................31
Balancing Values .........................................35
Basic elements.............................................81
Basic Requirements for
System Installation.......................................72
C
Calibration menu ..........................................87
Check valve .................................................46
Chemicals for Metering Containe .................19
Chlorination of Drinking Water .......................8
Circuit Breaker ............................................. 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 ...............................................82
Connecting the Equipment ...........................26
Connections, Valves and Indicators ............ 26
Conserve the RO system ............................ 50
Conserving...................................................50
Consumption Materials.................................19
Control, activated carbon filter .....................11
Control cabinet .............................................11
Control Panel and Display............................14
Control System ............................................ 66
D
De-conserving..............................................35
Declaration of Conformity.............................71
Description of the System............................13
Design of the Flushing and
Disinfection Equipment.................................46
Desinfection .................................................42
Diagnosis menu ...........................................88
Differential pressure switch..........................11
Disinfection ..................................................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 .......................................... 15
Evaluate flocking test ...................................25
F
Filter .............................................................19
Fine Filter ...............................................14, 43
Fine filter.......................................................46
Fine filter candle ...........................................11
Fine filter housing .........................................11
First fill of the metering tanks .......................21
Float Switch .................................................30
Flocculation Agent........................................24
Flocculation metering ...................................11
Flocculation metering point...........................11
Flocculation Module .....................................13
Flow Diagram ...............................................12
Flow meter (concentrate) .............................46
Flow meter (drinking water)..........................46
Flushing pump..............................................46
Flushing tank................................................46
Flushing the pre-filter....................................53
Function of Terminals...................................73
G
General ........................................................69
General installation notes...............................9
General Remarks .........................................69
H
Handling Electricity / Protection Class...........9
High-pressure pump ....................................11
91
LIST OF KEY WORDS WTC 600 LP / MP
I
Indicator lights ..............................................80
Initial Filling ...................................................31
Initial startup .................................................37
Input solenoid valve .....................................11
Installation/Start-up ......................................72
Instructions for Use......................................70
K
Keyboard......................................................80
M
Main menu....................................................86
Maintenance.................................................43
Maintenance During Operation ....................60
Maintenance Plan.........................................60
Maintenance Plan – Service ........................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 ...................................................46
Manometer - activated carbon filter
inlet pressur .................................................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 ......................................................11
Manual / automatic rotary switch..................11
Manual Operation.........................................16
Master switch............................................... 11
Measuring cell ..............................................46
Media and Activated Carbon Filter ...............31
Media and activated charcoal
plug sockets ................................................. 11
Media filter ....................................................11
Media filter control ........................................11
Mediafilter- and Activated Carbon Filter .......14
Membrane ....................................................11
Membrane pressure pipe .............................11
Menu Selection.............................................34
Menu structure .............................................85
Metering Amounts and
Mixing of the Post Chlorinati.........................24
Metering Station .....................................28, 30
Metering Station LED and
Indicator LEDs at the Swi.............................56
Metering Station WTC 600 CD.....................43
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 .....................................................80
Operation of the System ..............................20
Operational Scope .......................................74
Other Maintenance.......................................61
Overview of components ............................. 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........................... 27
Pressure-increase Pump ....................... 15, 28
Programming................................................32
Pump............................................................14
Putting Out of Operation...............................41
Q
Quality of the Untreated Water.......................8
92
WTC 600 LP / MP LIST OF KEY WORDS
R
RC Protective Switch................................... 15
Regeneration................................................31
Removing the
Preservation After Longer Operational.........52
Replace 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
RO Pump .....................................................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 the Same ..................................................35
Selection ......................................................81
Selection of an Option ..................................34
Selection of menu.........................................81
Setting menu ................................................88
Solenoid valve..............................................46
Start-up ........................................................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 level.........................................84
Terms and Definitions ..................................71
Text display.................................................. 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
93
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