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JRG 9800.002, Instruction Manual

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JRG 9800.002 Instruction Manual Download Page 13

Design and function 

Operating instructions 

 

 

 

6 

 

 

5.2

 

Design versions 

5.2.1

 

Hycleen Des 30 Standard version 

 

 

1 

Control cabinet with control panel  

 

Controls 

2 

Process cabinet 

4 

Main switch I = ON / O = OFF 

3 

Cover (removable) 

5 

Production Start/Stop rotary switch 

9 

Storage tank 60 L Calzid-Ex 

6 

Illuminated 

push-button 

Operation 

status 

10  Storage tank 100 L Salisol 

7 

Illuminated push-button Reset 

11  Storage tank 60 L Anolyte 

8 

Rotary selector switch ECA: Anolyte & 
Catholyte / anolyte neutral 

 
 
 
 
 

Summary of Contents for 9800.002

Page 1: ...Hycleen Des 30 Instruction manual Standard version 9800 030 Industrial design 9800 002 Mobile system 9800 003 Version 2 4...

Page 2: ...instruction manual The instruction manual is part of the product and an important component in the safety concept Read and follow the instruction manual Keep the operating manual always available on...

Page 3: ...rage 4 5 Design and function 5 5 1 Peripherals of the Hycleen Des 30 5 5 2 Design versions 6 5 2 1 Hycleen Des 30 Standard version 6 5 2 2 Hycleen Des 30 Industrial version 7 5 2 3 Hycleen Des 30 Mobi...

Page 4: ...4 8 2 1 Preliminary checks 24 8 2 2 Wiring diagram 25 8 2 3 Installing the flow meter with impulse transmitter 25 8 2 4 Assembly instructions for the dosing unit with dosing lance 26 8 2 5 Cutting the...

Page 5: ...10 9 Acknowledging fault messages 58 10 10 Viewing messages on the PLC 59 11 Maintenance 60 11 1 Maintenance schedule 60 11 2 Maintenance work 61 11 2 1 Preparatory steps 61 11 2 2 Refilling operating...

Page 6: ...Operating instructions Intended Use...

Page 7: ......

Page 8: ...ary for installing commissioning maintaining and decommissioning the Hycleen Des 30 system 2 1 Warnings This instruction manual contains warning signs that draw attention to risks of fatal or physical...

Page 9: ...version and types Type Code No Item No Property Hycleen Des 30 351 120 030 9800 030 Standard version Hycleen Des 30 Industrial 351 120 260 9800 002 Industrial version Hycleen Des 30 Mobile 351 120 25...

Page 10: ...diately leave the room and breathe fresh air for more than 1 h Always operate the Hycleen Des 30in a well ventilated room as production can give off small amounts of hydrogen and chlorine vapours In r...

Page 11: ...luences Transport and or store the Hycleen Des 30in its unopened original packaging After transport always check the Hycleen Des 30 for transport damage Protect the Hycleen Des 30 from dust dirt moist...

Page 12: ...rain outlet 11 Monitoring e g monitoring the concentration of free chlorine or other drinking water parameters ORP pH value conductivity or total chlorine content We recommend using a limescale sensor...

Page 13: ...el Controls 2 Process cabinet 4 Main switch I ON O OFF 3 Cover removable 5 Production Start Stop rotary switch 9 Storage tank 60 L Calzid Ex 6 Illuminated push button Operation status 10 Storage tank...

Page 14: ...ntrol panel 2 Main switch I ON O OFF 7 Process cabinet 3 Production Start Stop rotary switch 8 Storage tank 60 L Calzid Ex 4 Illuminated push button Operation status 9 Storage tank 100 L Salisol 5 Ill...

Page 15: ...Main switch I ON O OFF 8 Anolyte dosing pump 3 Production Start Stop rotary switch 9 Casters 4 Illuminated push button Operation status 10 Storage tank 25 L Salisol 5 Illuminated push button Reset 11...

Page 16: ...t large 8 Valve block 3 Power supply unit small 9 Static mixer 4 PLC 10 Manometer system pressure 5 Circuit breaker relays fuses terminal blocks 11 Pressure reducing valve 12 Solenoid valves 6 Cabinet...

Page 17: ...meter impulse transmitter bushing 7 Softened water inlet 2 Salisol level sensor bushing 8 Salisol tank outlet 3 Anolyte level sensor bushing 9 Calzid Ex inlet 4 Calzid Ex level switch connection 10 S...

Page 18: ...nstallation diagram 1 Tap water 2 Softened water 2 dH from the softening unit ion exchanger 3 Control cabinet 4 Process cabinet 5 Calzid Ex tank 6 Salisol tank 7 Anolyte Anolyte neutral tank 8 Dosing...

Page 19: ...ted push button indicating Operation status of descale function EO4 1 2 Salisol pump OUT1 2 Solenoid valve V1 4 Illuminated push button Reset OUT2 2 Solenoid valve V2 5 Flow meter OUT3 1 Solenoid valv...

Page 20: ...Ex tank C Anolyte tank 1 Calzid Ex tank 60 L 8 Anolyte tank 60 L 2 Lid 9 Level sensor 3 Suction pipe 10 Lid 4 Run dry float switch 11 Degassing pipe connection 12 Dosing pump connection B Salisol tan...

Page 21: ...micro bubbles develop which produce the desired physical destruction hence disinfective effect on the cell membranes of bacteria and amoeba The interaction of all these factors results in an extremel...

Page 22: ...y releasing it into the waste water in accordance with applicable disposal guidelines In this production mode a maximum of 20 L h of Anolyte and Catholyte are produced 5 5 2 Anolyte neutral The produc...

Page 23: ...l System control automatic process control 5 control elements PLC Anolyte dosing pumps can be connected Max 2 Disinfectant solution Calzid Ex level monitoring Inductive switch Process unit cleaning wi...

Page 24: ...nsumption depends on the quality of the inlet water The higher the conductivity of the water the more often the process unit has to be cleaned and the higher the consumption of Calzid Ex see Chapter 1...

Page 25: ...marks 80 mm 470 mm Level monitoring Capacitive System inlet Use softened water drinking water quality with carbonate hardness 2 dH to minimise Calzid Ex consumption External pre filter 5 m Flow pressu...

Page 26: ...neutral 2 Catholyte 2 Calzid Ex 2 2 Frame Subassemblies Piece s Included with delivery Piece s Frame half 1 Wall mounting set 1 Composite panel 2 Screws M8 x 60 7 Magnetic catch 2 Washers M8 7 Wall m...

Page 27: ...PE LD length 3 m 4 6 mm colourless 1 4 Salisol tank 100 L Including Piece s Filling level sensor 1 Suction filter connection 4 6 mm 1 Hose PE LD length 0 2 m 6 8 mm colourless 1 Hose PE LD length 3 m...

Page 28: ...zid Ex 2 2 Calzid Ex tank 60 L Including Piece s Filling level sensor float switch 1 Suction filter connection 4 6 mm 1 Hose PE LD length 3 m 4 6 mm colourless 1 3 Salisol tank 100 L Including Piece s...

Page 29: ...2 2 Calzid Ex tank 14 L Including Piece s Hose PE LD length 1 m 4 6 mm colourless 1 Suction filter connection 4 6 mm 1 Filling level sensor float switch 1 3 Salisol tank 25 L Including Piece s Hose PE...

Page 30: ...ling the dosing pump on page 34 Subassemblies Piece s Accessories Piece s Dosing pump 1 Wall mounting set 1 Wall console 1 Screws M6 x 50 3 Power supply cable 1 Rawlplugs 8 mm x 38 mm 3 Cable to PLC 1...

Page 31: ...m Spirit level Allen key M8 Vacuum cleaner Open end wrench M8 M6 Screwdriver Pipe cutter 8 2 Installation 8 2 1 Preliminary checks Risk of injury from drilling through electric cables or water pipes B...

Page 32: ...pipe since this unit regulates the proportional dosing of the disinfectant solution See the Installation diagram on page 11 Install the flow meter DN 32 40 50 with impulse transmitter 1 impulse L ups...

Page 33: ...5 200 are connected accordingly 8 2 4 Assembly instructions for the dosing unit with dosing lance The dosing unit injects the quantity of disinfectant solution supplied by the dosing pump into the dri...

Page 34: ...er D Using a pipe cutter cut the supplied dosing lance 2 to the required length L Before installing deburr the edges of the cut pipe See assembly instructions for the dosing unit There are different w...

Page 35: ...8 2 6 Assembly instructions Hycleen Des 30 No Subassembly Piece s 1 Frame top section 1 2 Wall mounts 2 3 Calzid Ex tank 1 4 Salisol tank 1 5 Anolyte tank 1 6 Drip tray 1 7 Wall mounting bracket 1 8 W...

Page 36: ...ll holes as indicated on the drilling template Risk of injury from drilling through electric cables or water pipes Before drilling check the area at or around the planned drill holes for embedded elec...

Page 37: ...th the washers and M8 x 60 screws in the lower holes 3 Tighten all three M8 x 60 screws In the base frame 2 insert a M8 x 45 screw in each of the holes 1 and secure them on the back with washers and n...

Page 38: ...If the three wall mounts do not engage properly loosen the mounting screws of the wall mounting bracket 1 and move it until the wall mounts 3 engage The following work is easier if carried out by two...

Page 39: ...ttach it after filling up when doing so pay attention to the sensors Place the empty Calzid Ex tank 1 in the drip tray and fill with Calzid Ex Place the empty Salisol container 2 in the drip tray fill...

Page 40: ...template Risk of injury from drilling through electric cables or water pipes Before drilling check the area at or around the planned drill holes for embedded electrical cables or pipes Drill all 4 ho...

Page 41: ...d the planned drill holes for embedded electrical cables or pipes Mark the position of the drill holes as indicated on the drilling template Drill all 3 holes Push a rawlplug into each of the 3 holes...

Page 42: ...ry low consumption rates of Anolyte Anolyte neutral 60 L per day the filling level sensor should be modified so that always fresh Anolyte is supplied The Anolyte Anolyte neutral production 1 productio...

Page 43: ...output hose 6 mm with filter into the pipe 4 of the Salisol tank 1 until the filter reaches the bottom of the tank Connect the output hose 6 mm to the connection 5 on the process cabinet 6 and tighte...

Page 44: ...on the Anolyte tank 6 and tighten Attach the hose 8 mm from the Anolyte inlet 5 to the Anolyte outlet 8 of the process cabinet 7 and tighten Attach the hose 8 mm from the Anolyte outlet 3 to the inle...

Page 45: ...he illustration shows dosing pump 60 dosing pump 12 is connected accordingly If the Catholyte is not used connect the Catholyte outlet 2 on the process cabinet 1 and the drain outlet with hose 8 mm an...

Page 46: ...f cable 3 into the level sensor 1 of the Salisol tank and fasten the terminal to screw 4 Fasten the white wire from the Salisol level sensor cable in the DC INPUT 7 connection of the PLC Fasten the br...

Page 47: ...able cable 4 into the level sensor 1 of the Anolyte tank and fasten the terminal to screw 3 Fasten the white wire from the Anolyte level sensor cable in the DC INPUT 8 connection of the PLC Fasten the...

Page 48: ...cted in the same way as the flow meter Run the cable 2 from the dosing pump 1 through the dosing pump connection 4 on the control cabinet 3 and fix the cable in position Please note Use pliers to prop...

Page 49: ...es are suitable for 24 V Risk of electric shock caused by loose cables It is necessary to check whether all cables of the system are fastened correctly before connecting to the power supply Possible d...

Page 50: ...the enclosed hoses 2 Water inlet of Salisol tank 3 Salisol hose to the system 4 Calzid Ex hose to the system 5 Anolyte from the system inlet 6 Anolyte to the dosing outlet Level sensor cable connecti...

Page 51: ...ssioning the system On the control cabinet control panel turn the Production rotary switch to Stop Switch on the main switch 1 on the control cabinet control panel If necessary open the door of the co...

Page 52: ...nt outlet 3 of the dosing pump 1 Venting the Salisol piping system On the PLC press the and buttons at the same time The dosing pump starts pumping Salisol Slowly open the vent screw 2 on the dosing p...

Page 53: ...by pressing the illuminated Operation status button until Calzid Ex comes out of the vent outlet 3 of the dosing pump Slowly close the vent screw 2 on the dosing pump Press the illuminated Reset butt...

Page 54: ...o the I ON position The power supply is turned on The display on the PLC 1 shows the following message If a different message appears refer to Chapter 12 Troubleshooting on page 65 In the process cabi...

Page 55: ...he PLC 1 display After the production values have levelled off the following average values should appear on the PLC display Flow Flow rate 40 L h Crnt Current consumption 12 13 A If the flow rate is...

Page 56: ...t 2 minutes while noting the exact time Switch off the system see Chapter 10 4 Switching off the system on page 54 Measure the amount of solution collected in both measuring cylinders 1 and 2 Compare...

Page 57: ...ssed to start a manual descaling cycle see Chapter 10 8 Manual descaling cycle on page 58 2 Illuminated Reset button Lit red Malfunction Chapter 12 Troubleshooting on page 65 provides information on h...

Page 58: ...PLC All messages during production are shown on the PLC display The two buttons and are active to display error messages and the amounts of the initial solutions produced Any changes to the process pa...

Page 59: ...rned on The display on the PLC 1 shows the following message Selecting the operating mode On the control panel turn the ECA rotary switch to the Anolyte Catholyte position and after the production val...

Page 60: ...After the production values have levelled off the following average values should appear on the PLC display Flow Flow rate per hour L Crnt Current consumption 12 13 A Flow rate limits for Anolyte neu...

Page 61: ...oduction is stopped Check whether the PLC 1 display shows the following message If a different message appears refer to Chapter 12 Troubleshooting 65 On the control panel turn the main switch to the 0...

Page 62: ...T manual set toggle switch in the direction of the rear wall and turn off rotary control 2 on the pump 1 it should already be on 0 Turn the Production rotary switch to Start The system will now be ri...

Page 63: ...d Ex This increases the service lifetime of the system and particularly of the reactor The system should always be cleaned at least once a day The default settings of the PLC intensive cleaning perfor...

Page 64: ...percentage indicator shows the progress of the descaling cycle The descaling cycle is complete after about 25 min The illuminated Operation status button flashes green 2 Hz A rinsing cycle with water...

Page 65: ...hold for at least 5 secs An additional manual descaling cycle is initiated This runs in exactly the same way as the automatic descaling cycle See Chapter 10 7 Automatic descaling cycle on page 57 10...

Page 66: ...lowing error messages nn Number of messages SalUL Salisol overflow SalTL Salisol run dry CrLow Current too low CrHigh Current too high Use the button to scroll through the following error messages nn...

Page 67: ...ay recommended limit value 10 to 13 A Check the system for leaks and spills monthly Visual inspection of the pre filter for dirt and sludge accumulation If necessary clean it as described in the OEM d...

Page 68: ...le residues Take the appropriate measures to ensure that the medium is collected safely Possible spillage of media harmful to health and the environment These media pose a risk of physical injury or d...

Page 69: ...full unscrew the cap 4 and refill up to the Max mark with Calzid Ex Order new Calzid Ex see Chapter 13 2 Accessories required on page 73 Check the fill level in the Salisol tank 5 If there is only lit...

Page 70: ...the system off see Chapter 10 4 Switching off the system on page 54 Open the door of the process cabinet using the key Push the reactor 2 back slightly to release the couplings 3 on the plate 1 Carefu...

Page 71: ...Salisol level sensor Switch off the system see Chapter 10 4 Switching off the system on page 54 Remove the cover 2 from the Salisol tank 1 Pull off the connecting cable 3 from the level sensor 4 Pull...

Page 72: ...the softening unit ion exchanger Check whether water is present at the inlet Check whether the regulating valve is closed Acknowledge the fault message see Chapter 10 9 Acknowledging fault messages pa...

Page 73: ...er service CzdTL Calzid Ex run dry The fill level in the Calzid Ex tank is below minimum The run dry float switch in the Calzid Ex container is crusted caked faulty or not connected properly Further p...

Page 74: ...ty wrongly set or not connected properly Check the Salisol fill level Check the condition of the float switch If necessary clean with a soft cloth Check the connections of the float switch Check water...

Page 75: ...y Further production is not possible Start a manual descaling cycle see Chapter 10 8 on page 58 Acknowledge the fault message see Chapter 10 9 Acknowledging fault messages on page 58 Resume production...

Page 76: ...ructions Spare parts list 69 13 Spare parts list 13 1 Hycleen Des 30 Control cabinet Designation Code No Power supply unit large 351 120 132 Power supply unit small 351 120 131 Mitsubishi controller A...

Page 77: ...ial version No Designation Code No A Calzid Ex tank 60 L 351 120 018 B Salisol tank 100 L 351 120 019 C Anolyte tank 60 L 351 120 017 Mobile device Designation Code No Calzid Ex tank 25 L 351 120 225...

Page 78: ...and Calzid Ex 351 120 055 Mixer 351 120 049 Flow meter Reactor Designation Code No Designation Code No Flow meter 351 120 052 Reactor 351 120 025 Screw in connection straight 351 120 061 Coupling with...

Page 79: ...ion Code No Designation Code No Flow unit complete 351 120 289 Valve block complete 351 120 001 3 2 way solenoid valve 351 120 069 Filling level sensor Designation Code No Designation Code No Anolyte...

Page 80: ...4 kg 351 111 012 9811 012 Dosing pump max 60 L h with wall bracket w 283 mm h 230 mm d 123 mm 5 kg 351 111 060 9811 060 Flow meter DN 32 40 50 Cold water meter with impulse transmitter DN 32 40 50 1...

Page 81: ...0 9815 080 Water meter DN 100 flange connection d 4 h 105 mm l 250 mm H 150 mm 18 2 kg 351 115 100 9815 100 Water meter DN 125 flange connection d 5 h 118 mm l 250 mm H 160 mm 20 7 kg 351 115 125 9815...

Page 82: ...max 30 C The fine filter already contains a 100 m fine filter element which however must be replaced by a 5 m fine filter cartridge The fine filter cartridge must be replaced periodically at least twi...

Page 83: ...d2 8 mm l 287 mm h 240 mm 1 65 kg 351 112 032 9812 032 Dosing unit with dosing lance DN 40 d1 G 13 4 d2 8 mm l 292 mm h 237 mm 2 1 kg 351 112 040 9812 040 Dosing unit with dosing lance DN 50 d1 G 23...

Page 84: ...l 99 8 is needed The grain should be between 0 1 0 9 mm and the average grain size should be 0 4 0 7 mm Designation Code No Item No High purity salt 25kg refill bag 351 118 010 9818 010 Cleaning agent...

Page 85: ...ree and must not be emptied the reactor must be stored wet See Chapter 10 5 Decommissioning during prolonged periods of non use downtime 3 days on page 55 Empty the operating fluid tanks Disconnect th...

Page 86: ...ith national regulations standards and guidelines Collect any spilled media and dispose of according to the local regulations Refer to the safety data sheet Neutralise any operating fluid residues and...

Page 87: ..._______________________________________________ Date Device works perfectly Produced volume of Anolyte see PLC in the control cabinet L Drinking water volume Flow meter L Monitoring parameters Filling...

Page 88: ...nance log template Internal contact person name and phone number ___________________________________________________________________________________ Date Commissioned by company and name Annual mainte...

Page 89: ...chnical documents Georg Fischer GmbH Johannes Meierbeck 65 N rdliche Gr nauer Strasse 86633 Neuburg Germany We hereby confirm that the partly completed machine Hycleen Des 30 is a system for producing...

Page 90: ...rementioned partly completed machine is to be incorporated fully complies with the provisions of Machinery Directive 2006 42 EC The partly completed machine also meets the requirements of the followin...

Page 91: ...ms 463 824 Seoul Phone 82 31 8017 1450 3 Fax 82 31 8017 1454 kor ps georgfischer com www gfps com kr Malaysia George Fischer M Sdn Bhd 40460 Shah Alam Selangor Darul Ehsan Phone 60 0 3 5122 5585 Fax 6...

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