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WATERCLEAN 1600

Version 03/2008

MALFUNCTIONS AND MAINTENANCE

- 77 -

Malfunctions and Maintenance

4.1

Malfunction, Causes and Corrective Measures

If an electrical consumer fails to function, the corresponding fuse in
the switch cabinet and E-distributor should always be checked first.

If the fuse cuts out again after resetting it, the operation is to be halted
and an electrician consulted.

4.1.1

Displays on the Switch Cabinet

Fig. 51

Fault

Cause

Remedy

Rotating field display (51/1) on
the electrical connection panel
illuminates, red

Reverse phase rotation direction

A qualified electrician must
reverse the direction of phase
rotation by changing the
phases in the system plug
(Use phase inverter in the plug)

One or several phase control
lamps (51/5) fails to illuminate

Bulb of the lamp defective

Replace electric bulb

Interference in the 400 V supply

For external supply:
Check plug and cable

For electric generator unit
operation:
Check generator

"Fault reset" button (51/2) illu-
minates

Fault as indicated on the operat-
ing panel

Remedy fault and press "Fault
reset" button

Summary of Contents for WATERCLEAN 1600

Page 1: ...Operating Instructions WATERCLEAN 1600 1 237 117 0 WTC 1600 C BTA 5 971 044 0 ETL 5 970 924 0 A 2025042 ...

Page 2: ......

Page 3: ... Raw Water 6 1 4 4 Physical Operating Principle of the RO Machine 7 2 Description 2 1 Overview 9 2 2 Principle of Operation 10 2 3 Description of the System 17 2 3 1 Safety Installations 17 2 3 2 Submergible Raw Water Pump 18 2 3 3 Raw Water Pump Option 18 2 3 4 Container Outside 19 2 3 4 1 Connection Box 1 19 2 3 4 2 Connection Box 2 19 2 3 5 Container Inside 20 2 3 5 1 Preliminary Filter Module ...

Page 4: ...on 37 2 4 Specifications 38 2 4 1 Complete System 38 2 5 Accessories 40 2 5 1 WTC 1600 40 2 5 2 Generator Accessories 41 2 6 Consumption Materials 41 3 Operation 3 1 Note for Maintenance and Care 43 3 2 Assembly and Installation 43 3 2 1 Container Flaps 43 3 2 2 Protective Grounding Earthing 43 3 2 3 Power Supply Via External Line Entry 44 3 2 4 A C Heating System 45 3 2 5 Hydraulic Connections 46...

Page 5: ...matic Operation Standard Operating Mode 56 3 4 2 1 Switching on in Automatic Operation Mode 57 3 4 2 2 Switching OFF in Automatic Operation Mode 59 3 4 3 Manual Operation Mode Double Pass Option 59 3 4 3 1 Switching ON in Manual Operation Mode 60 3 4 3 2 Switching OFF in Manual Operation Mode 62 3 4 3 3 Switching ON in Manual Operation Mode as Emergency Function 62 3 4 3 4 Switching OFF in Manual ...

Page 6: ... Schedule 83 4 3 Maintenance 85 4 3 1 Cleaning and Surface Treatment of the Complete System 85 4 3 1 1 Cleaning and Surface Protection 85 4 3 2 RO Module 86 4 3 2 1 Oil Level Control on the High Pressure Pump 86 4 3 2 2 Changing the Oil of the High Pressure Pump 86 4 3 2 3 Changing the Membrane Filters 87 4 3 2 4 Post preservation of Non installed Originally packed Membranes 90 4 3 3 Preliminary F...

Page 7: ...pment Directive 73 23 EEC amended by 93 68 EEC EU Directive on Electromagnetic Compatibility 89 336 EEC amended by 91 263 EEC 92 31 EEC 93 68 EEC Harmonized standards applied DIN EN 60 204 1 DIN EN 55 081 1 DIN EN 55 082 2 National standards applied Appropriate internal measures have been taken to ensure that series production units conform at all times to the requirements of current EU Directives...

Page 8: ...the membrane filters used However the quality of the drinking water produced depends on the degree of contamination of the raw water Before putting into operation for the first time we recommend that a raw water analysis be performed Continuous drinking water quality is ensured only when the equip ment undergoes regular supervision The respective national and international directives concerning dr...

Page 9: ...ving the use of chemicals e g for cleaning purpo ses disinfection measures the information measures and instruc tions in the material safety data sheets MSDS of the respective che micals are to be observed and met under all conditions This applies partical arly for R S statements Risk and Safety Statements and the regulations on exposure limitation and personal protective equip ment PPE The operat...

Page 10: ...nrestricted flow through the UV irradiator Danger in case of overpressure When cleaning UV irradiator components the data sheets on safety of the cleaning agents being used are to be observed Be careful during cleaning and maintenance Before any cleaning and maintenance the complete system is to be de energized and secured against restarting Danger of electric shock The UV irradiator can be very h...

Page 11: ...es herbicides etc 3 Salt in sea water and brackish water and other mineral salts and solid matters 1 4 2 Retention Capabilities of the Waterclean 1600 System The effective retention capability depends on the grade of contamination As standard the WTC 1600 plant is equipped with reverse osmosis RO membrane Optionally nano filtration NF spiral wound memb ranes can also be installed in the pressure t...

Page 12: ...ic contamination minimum Germ contamination low Pollutants low Lake River Stream Temperature greatly varying depending on the time of year pH value alkaline to neutral pH 9 7 Hardness up to approx 12 dH Organic contamination strongly contaminated with small dirt particles Germ contamination high Pollutants medium to high Sea Temperature low variations throughout the year greatly varying from regio...

Page 13: ... a pressure which is stronger than the osmotic pressure applied to the liquid the flow direction of the water is reversed The water is now pressed through the membrane from an upgraded solution The purified water produced with this method is called drinking water the upgraded residual water is called concentrate The reverse osmosis can be economically used for the demineralisa tion of waters with ...

Page 14: ...GENERAL Version 03 2008 WATERCLEAN 1600 8 ...

Page 15: ...tilation opening A C system 2 Reset button A C system below cover 3 Connection box 1 for Raw water inlet Industrial water outlet Concentrate outlet Power supply container Power supply raw water pump 4 Connection box 2 for Drinking water outlet for two WBP 700 Bulk water filling Power supply outlet can be used for communi cation between two WTC 1600 C units Power supply inlet can be used for commun...

Page 16: ...Sensor for intake pressure of membrane filter blocks 14 Constant flow regulator 15 Valve concentrate return line 16 RO filter block I 17 RO filter block II 18 Safety valve double pass 19 Flow meter pass I 20 Pressure maintenance valve double pass 21 Three way tap double pass 22 Valve for drinking water double pass 23 RO filter block III 24 Pressure maintenance valve motor controlled 25 Sensor for ...

Page 17: ...5μm F03 0 5μm F04 F05 F06 B1 B2 P04 M V06 V07 25 bar M V08 75 bar 75 bar Concentrate Drinking Water Raw Water Raw Water Pump Anti Scalant option P01 B3 P05 UV Irradiator option Control sensor 10 bar V 4 m 3 Drinking water interim storage Filling pump bulk water to bulk water filling WBP 700 to two WBP 700 LIC LIC 46 45 47 Feed pump PI PI 4 4 3 5 5 42 2 6 6 43 41 42 7 7 8 9 10 11 12 12 13 14 16 20 ...

Page 18: ...bsolutely necessary that the activated carbon filters are installed into the filter bowls The measurement of the chlorine concentration of the activated car bon filtrate must be carried out on each day of operation The bottom water sampling valve of the activated carbon filter can be used for this Also the pressure loss of the active carbon filter is to be determined with the two manometers Δp upp...

Page 19: ...of membrane filter block III 3 23 The filtrate produced from both these cleaning stages flows to the drinking water outlet The concentrate from the second stage is conducted via the motor driven pressure maintaining valve V06 3 24 to the concentrate outlet The working pressure and drinking water quantity are regulated by the pressure maintaining valve In order to minimize the raw water requirement...

Page 20: ...al security stage of the conditioning process Proper functioning of the UV irradiator is controlled by a sen sor which is mounted on the side of the irradiator Display is indicated at the UV irradiator switch cabinet Drinking water Industrial water The water quality is tested by means of a conductance measure ment 3 26 at the drinking water outlet For values 2 000 µS cm the magnetic valve 3 37 aut...

Page 21: ... chemi cal to adapt the pH value The set up design of the dosage station is identical with the station previously described However it is better accessible for the operator so that this dosage station can also be used for permanent chlorination remineralization Fig 5 Anti Scalant Option Using the second dosing pump 3 42 an anti scalant chemical can be added to the raw water Scaling is known as the...

Page 22: ...e two connected WBP 700 units and into a 4 m3 drinking water inte rim storage The drinking water interim storage is fitted with a venti lation system with installed sterile filter and an overflow valve The container is also fitted with two level indicators and regulators mini mum and maximum When the red and green control lamps are lit the minimum level is either fallen below or the maximum level ...

Page 23: ...rklift stacking slits are availa ble for stowing the modules 2 3 1 Safety Installations Emergency OFF Switches The emergency OFF switch for the WTC 1600 module is located on the switch cabinet door When operating the emergency OFF switch all the power circuits of the WTC 1600 module are cut off The emergency OFF switch for the whole container including the WTC 1600 module is located at the main sw...

Page 24: ...es a float 7 5 that prevents the pump from sinking to the ground and sucking in any mud a safety cord 7 2 for fixation to the shore a 20 m long connection cable 7 4 for the power supply a coupling 7 3 for connecting the raw water hose As an accessory a pump is provided for blowing up the float 2 3 3 Raw Water Pump Option If a raw water tank is available which has a higher water level than the leve...

Page 25: ... and the power supply for the raw water pump 8 5 Fig 8 Connection box 1 2 3 4 2 Connection Box 2 Connection box 2 is used for the drinking water outlets of the two WBP 700 units 9 1 and 9 2 and the bulk water filling 9 3 It is also used for the communication drinking water demand from the two WBP 700 units 9 4 and 9 5 and the communication raw water demand bet ween second WTC 1600 C unit Fig 9 Con...

Page 26: ...er Connection Panel WTC 1600 unit The raw water connection panel 10 1 is located on the right side of the pre treatment module 10 2 Preliminary Filter Unit The preliminary filter unit consists of two separate filter pots 11 4 with a filter bag inserted in each one Only one filter operates at a time In this way the filter bag of the redundant filter can be changed with out interrupting the operatio...

Page 27: ...ents germs from forming in a drinking water storage tank connected on the output side of the system and in the pipe system Fig 12 Volume controlling pump Anti scalant Option RM 5 000 is a fluid anti scalant which has been developed to avoid anorganic scaling At the same time it also works as a dispersing agent against colloids and particles The anti scalant mounting kit consists of a mixing tank 1...

Page 28: ...DESCRIPTION Version 03 2008 WATERCLEAN 1600 22 Fig 13 Anti scalant mounting kit 1 2 ...

Page 29: ...ve three membrane filters 14 5 switched one after the other which are arranged one underneath the other in a stand Filter block III 14 3 is built in over the filter blocks I and II and has two membrane filters After switching off the system pumps the solenoid valves of the main module remain open for a certain time approx 5 min in order to enable internal pressure compensation This is indicated by...

Page 30: ... the base plate on the switch cabinet side Industrial water outlet 15 1 D coupling Drinking water outlet 15 2 D coupling Concentrate outlet 15 3 D coupling Raw water inlet 15 4 D coupling for operation without the pre liminary filter module or for emptying the preliminary filter for operation with the preliminary filter module Fig 15 Water connection panel 3 1 2 4 ...

Page 31: ...ifferent valves to be actuated Fig 16 Control panel Double Pass 2 3 6 3 Motor driven Pressure Maintaining Valve Pressure Rate Control The motor driven pressure maintaining valve V06 is integrated on the right next to the cleaning tank 17 4 The motor 17 1 is driven by the SPS storage programmable control and controls the valve V06 17 3 via the shaft 17 2 The output of the system is set using valve ...

Page 32: ...refilter but at the same time also increases the total salt content at the membrane intake The panel for the return feed is located behind the Double Pass con trol panel For operating the valve lever 18 3 it must be actuated from underneath behind the control panel The valve V05 18 1 is integrated in the return feed pipe In the posi tion illustrated Fig 18 the return feed is closed WARNING Do neve...

Page 33: ...e con tainer as well as for activating the cleaning disinfecting preservation and anti freeze procedure respectively For disinfection and the frost protection preserving combination the drinking water and industrial water outlets are conducted back into the cleaning tank This is done with use of the respective hoses as re turn flow lines to the two couplings 19 2 WARNING Do not fill chlorinated wa...

Page 34: ...connection for the WTC 1600 C is established via the 400 V 63 A 5 pole socket at connection box 1 The main switch 20 1 with emergency off function for the whole container is located at the main switch cabinet left hand side of the container close to the entrance Fig 20 Connecting plug 400 V 1 ...

Page 35: ... drinking water 3 Temperature indicator drinking water 4 Operating panel SPC 5 Lamp Raw water pump ON 6 Luminous Start button 7 Luminous Fault reset button 8 Stop button 9 Maintenance function selector switch 10 Program selector switch 11 Preliminary filter F03 in operation lamp 12 Control valve V06 activa tion open lamp 13 Socket 230 V 10 A 14 Control valve V06 activa tion closed lamp 15 Prelimin...

Page 36: ...urrent device supply 400 V 1F2 3 Fuse plug external 3F1 4 Fuse switch cabinet fan 3F3 5 Fuse volume controlling pump P04 7F1 6 Fuse control transformer 230 V 8F1 7 Fuse control voltage 230 V AC 8F4 8 Fuse power supply unit 24 V DC 14F1 9 Fuse raw water pump P01 4Q1 10 Fuse high pressure pump P02 5Q1 11 Fuse high pressure pump P03 5Q3 1 2 3 4 5 6 7 8 9 10 11 ...

Page 37: ...se tilt the respective fuse holder 24 1 down to the front and remove the fuse from behind Fig 24 Changing a safety fuse 1 Fuse phase control lamp 1 XF1 200 mA 2 Fuse phase control lamp 2 XF2 200 mA 3 Fuse phase control lamp 3 XF3 200 mA 4 Fuse 230V input in Siemens module EM 223 XF4 1 A 5 Concentrate outlet valve V07 XF5 1 6 A 6 Drinking water outlet valve V08 XF6 1 6 A 7 Inlet magnetic valve V16 ...

Page 38: ...as the temperature pressure flow and con ductivity for the various programs In order to access this information the following operating steps must be carried out 1 Press the Enter button 25 5 2 At the same time press the Shift button 25 6 and button 5 25 7 3 Press either the button 25 4 or 25 2 until the desired menu item 01 to 18 is reached on the display 25 1 4 Press the Enter button 25 5 the di...

Page 39: ... r a n e s _ _ _ _ _ b a r O u t l e t p r e s s u r e M e m b r a n e s _ _ _ _ _ b a r D i f f e r e n t i a l p r e s s P r e f i l t e r _ _ _ _ _ b a r 03 Flow Volume flow pass 1 Volume flow total Display V o l u m e f l o w P a s s 1 _ _ _ _ _ _ l h V o l u m e f l o w T o t a l _ _ _ _ _ _ l h 04 Pressure limits Pre pressure HP pumps Inlet pressure pre clean Outlet pressure membrane Inlet p...

Page 40: ...et pressure membrane Display F l o w t o t a l l h m i n 1 5 5 0 m a x 1 6 5 0 I n l p r e s s m e m b r a n e m i n 6 5 0 m a x 6 8 0 b a r 08 Difference pressure Difference pressure pre filter change over Difference pressure pre filter switch off Change pre filter wait V06 open at turn off wait Turn off delay Display D i f f p r p r e f i l t e r C h a n g e o v e r 2 0 b a r D i f f p r p r e f...

Page 41: ...s e p e r i o d 1 0 s e c 12 Times Delay raw water pump Delay HP pumps Start delay autocontrol Turn off time pumps Delay stop Pulse period pause V06 Delay V16 closed Display D e l a y r a w w a t e r p u m p 1 s e c D e l a y H P p u m p 1 3 0 s e c D e l a y H P p u m p 2 5 s e c S t a r t d e l a y a u t o c o n t r o l 1 s e c T u r n o f f t i m e p u m p s V 0 6 o p e n 3 0 s e c D e l a y S ...

Page 42: ...1 5 0 s e c W a i t P I S A 1 m a x I n l p r P r e c l 5 0 s e c W a i t P I S A 2 m a x M e m b r O u t l e t 5 0 s e c W a i t P I C S A 1 m a x M e m b r I n l e t 5 0 s e c 14 Rinsing Delay stop Delay HP pump on Display D e l a y S t o p A t L S 1 m i n 2 s e c D e l a y H P p u m p o n w a s h o u t 5 s e c 15 Hand Pass 1 l h bar Pass 2 l h bar Display P a s s 1 _ _ _ _ _ _ l h _ _ _ _ _ b a...

Page 43: ...ation panel 26 2 of the UV switch cabinet The UV switch cabinet is installed in the RO mo dule next to the cleaning tank For operation switch 26 3 must be set to Auto Fig 26 UV irradiator switch cabinet 17 Working hours Time since maintenance Working hours Display T i m e s i n c e m a i n t e n a n c e _ _ _ _ h W o r k i n g h o u r s _ _ _ _ h 18 Disinfection Disinfection times Disinfection ind...

Page 44: ... Frequency 50 Hz kW Connect load max 35 kW Connection CEE plug 400 V 63 A 5 pole 3P N PE Raw water quantity 3 000 to 4 000 l h Raw water pressure pre cleaning inlet 3 to 10 bar Raw water temperature 0 to 40 C Rated drinking water capacity depending on salt content water temperature 1 600 see Fig 27 l h Drinking water pressure max 2 bar Working pressure max 69 bar Yield dependent upon membrane type...

Page 45: ...rs in the drinking water tank Container for cleaning disinfecting anti freeze and chlorination Drinking water storage and distribution Plant Capacity with Standard Equipping RO Module Fig 27 Drinking water output Fig 28 Drinking water quality 0 200 10000 20000 30000 40000 50000 400 600 800 1000 1200 1400 1600 1800 Salt concentration mg l Flow of drinking water l h 40 C 20 C 15 C 5 C 0 200 10000 20...

Page 46: ...2 860 112 0 Silicone grease 5 g 3 pcs 6 288 072 0 Accessory repair kit 1 set 6 369 737 0 Float switch 1 pc 4 744 149 0 Bypass device Draining device for membrane change 1 pc 5 049 567 0 Scale 1 pc 6 369 424 0 Membrane tool 1 pc 4 901 085 0 Filter bag 1 set 10 pcs 6 414 546 0 Gloves 1 pair 6 547 126 0 Protective glasses 1 pc 7 816 001 0 Drinking water industrial water hose 2 pcs 2 x 5 m 4 440 633 0...

Page 47: ...embrane option Membrane maintenance Preserving chemicals Sodium metabisulphite 5 kg 6 769 040 0 Membrane cleaning RM Kleen MCT 511 20 l 4 x 1l 6 290 338 0 6 294 008 0 RM Kleen MCT 103 20 l 4 x 1l 6 290 339 0 6 294 009 0 RM P3 Oxonia disinfectant 30 l 6 x150 ml 6 290 834 0 6 294 010 0 Anti freeze 1 2 Propandiol 5 l 6 290 910 0 Metered addition Chlorinated lime 1 x 0 9 kg 6 291 513 0 Chlorinated lim...

Page 48: ...DESCRIPTION Version 03 2008 WATERCLEAN 1600 42 ...

Page 49: ...r the relevant surfaces are to be cleaned inten sively with drinking water as a precaution 3 2 Assembly and Installation Operating personnel must be trained by an authorized KÄRCHER Dealer Raw Water Source Clean water is to be used as far as possible as a raw water source Op tically clean water preserves the water treatment plant WARNING The system is not designed as a sewage water clarification p...

Page 50: ...itch cabinet to I ON If indicator 29 2 lights up after switching on switch the phase shifter switch 29 4 to the other position Connect the units equipment in the container to the corresponding power outlets e g feed pump for drinking water distribution sta tion to power outlet 29 5 and feed pump of the WBP 700 to power outlet 29 6 Fig 29 Power supply via external line entry 2 3 5 6 4 1 ...

Page 51: ...mperature must be pre selected This also applies when the plant is not running for as long as the frost protection measures have not been carried through NOTE Before the A C heating system is disconnected from the power supply it should be switched off This must be done latest before re establishing the power supply If this is not done operation of the A C heating system also when in switched on c...

Page 52: ...s the water level in the RW tank must be higher than the pump level 4 Connect the hose coming from the raw water inlet of the WTC 1600 C to the pressure side of the raw water pump 5 Remove the bonnet from the pump 6 Open the venting screw on the pump As soon as water comes out of the venting screw close the venting screw again 7 Insert plug of power supply cable for the raw water pump into socket ...

Page 53: ...materials is avoided as far as possible 2 Connect the raw water hose to the coupling 31 1 of the pump 3 Insert the raw water pump into the raw water source and secure to the shore using the safety cord 4 Insert plug of the cable into socket 32 1 Fig 32 Raw water pump socket 3 2 5 2 Concentrate Outlet 1 Couple the hose for the concentrate return feed to the coupling 33 1 on the connection panel 2 U...

Page 54: ...ll the drinking water hose to the drinking water tank or a similar container 3 2 5 4 Industrial Water Outlet If the conductivity of the drinking water produced exceeds 2 000 µS cm the system automatically switches over from the drink ing water to the industrial water outlet 35 1 Fig 35 Industrial water outlet 1 Connect the industrial water hose at the respective coupling 33 1 of the connection pan...

Page 55: ...ntent Cleaning RM Kleen MCT 511 RM Kleen MCT 103 1l 1l Preserving Sodium metabisul phite 700 g 500 ml Protecting against frost 1 2 Propandiol 15 l Chlorination is user defined and thus within the responsibility of the operator spe cific laws and regulations are to be observed Chlorinated lime 60 10 g in 10 l of run down tank contents 20 g in 20 l of run down tank contents 30 g in 30 l of run down ...

Page 56: ...rding to Table 1 page 49 WARNING An over dose causes damage to the membrane and an under dose results in insufficient disinfection 3 Ventil valve V05 36 1 on the concentrate return feed 4 Turn the valve lever V12 50 9 into a horizontal posi tion open V10 and V15 are shut verti cal position 5 Connect the free ends of the industrial water hose and drinking water hose to the couplings 50 3 and 50 4 o...

Page 57: ...ction after Contamination or Continuous Operation with Biologically polluted Untreated Water During this disinfecting procedure the entire system including the raw water pump and preliminary filter unit are disinfected Depending on the untreated water this procedure is useful to reduce the biological strain on the system in continuous operation The biological strain can be detected by the formatio...

Page 58: ... check of the system for leakages and damage 3 4 1 Putting into Operation 3 4 1 1 Inserting the Filter Bag in the Preliminary Filter 1 For relieving the pressure in the preliminary filters briefly open the relief cocks 37 1 place a suitable collecting container under neath 2 Loosen each of the three winged nuts 37 2 on the respective lid 37 3 of both of the preliminary filters and remove the lid F...

Page 59: ...prior to water treatment 3 4 1 3 Adding Chlorine Chlorination is necessary if drinking water is to be stored in a supply tank It prevents germ formation in the supply tank and in the succeed ing distribution system When using the drinking water immediately fill the chlorinating con tainer with drinking water WARNING Always read the MSDS prior to use of the calcium hypochlorite NOTE The national li...

Page 60: ...er period of time Kärcher recommends an addition of remineral ising chemicals in order to avoid resulting deficiency symptoms amongst the persons involved The addition is to be carried out only after consulting Kärcher For remineralisation calcium chloride is additionally dissolved in the chlorine solution The addition depends on the composition of the conditioned water and the required objective ...

Page 61: ...andard adjustment of the dosing pump Stroke length 30 Frequency 20 The operating mode must be set to Manual A service life of approx 120 h per 30 l of mixture results NOTE When the concentrate return line is open select the metered addition of the next higher hardness classification For the classification Very hard the metered addi tion remains the same Starting Operation 1 Fill the anti scalant t...

Page 62: ...sinks be low 50 the red Main alarm LED 39 2 illuminates The irradiator must be replaced then according to Section 4 3 3 The upper section 39 5 of the hour meter indicates the irradiation du ration the bottom section 39 6 the switching cycle of the UV irradia tor 3 4 2 Automatic Operation Standard Operating Mode Before switching on make sure that the levers and the hand wheel of the Double Pass con...

Page 63: ...9 4 and conductivity display 49 5 are active the control lamp 49 6 of the active preliminary filter illumi nates NOTE If an emergency shut off was performed the con trol valve V06 is automatically opened In the nor mal condition the valve is open and the lamp 49 14 lights up continuously Luminous button Start 49 11 illuminates NOTE The indicator Cleaning tank filling level too low on the operating...

Page 64: ...located next to the socket 41 3 for the raw water pump This connection must always be plugged in 4 Insert plug of the level sensor cable 41 1 into socket 41 2 on the RO side Fig 41 Connecting cable for float switch 5 Turn float switch 49 3 to position ON 6 Press Start button 49 11 The system is switched ON and OFF via the float switch NOTE Before turning the WTC 1600 unit off the switch 49 3 has t...

Page 65: ...n O OFF All displays and lamps go out NOTE For short term operational interruptions e g over night the Washing out work step in accordance with Section 3 5 1 must be performed WARNING If the system stands still for a longer period 60 h preservation measures are to be taken according to Section 3 5 3 3 4 3 Manual Operation Mode Double Pass Option WARNING Only use this operating mode for fresh water...

Page 66: ...Procedure In order to adjust the system to the operating point it is necessary to switch back and forward several times between the menus Pass 1 and Pass 2 so that the specified flow rate values can be adjust or cor rected Setting values WARNING The reference value for Pass 1 is always 1 000 l h The reference value for 2 is 20 bar of pressure or a flow rate of 600 l h max NOTE In most cases the ma...

Page 67: ...44 4 to reduce the output value Lamps Control valve V06 closed 49 15 and Control valve V06 open 49 14 flash during the control procedure NOTE The adjusting procedure runs very slowly Fig 44 Operating panel 4 Using button 44 2 on the operating panel switch to menu Pass 1 and check correct the output value Turn hand wheel 43 1 in the CLOSE direction to increase the output value Turn hand wheel 43 1 ...

Page 68: ...er switching on the system in Emergency operation is possible as fol lows 1 Before switching on make sure that the levers and the hand wheel of the double pass operating panel are in position I Single pass see Fig 43 2 Leave the concentrate return line as in automatic operation 3 Set the main switch 49 16 to position I ON The reactions are the same as in Section 3 4 2 1 Switching ON in automatic o...

Page 69: ...begun the condition of the membranes and the cleaning performance are to be checked respec tively To do this the conductivity of the raw water and the drinking water produced must be determined 1 Determine the conductivity of the raw water using a manual con ductivity measuring instrument 2 Read off the conductivity of the drinking water on the display of the switch cabinet 3 Calculate the measuri...

Page 70: ...se or during operating intervals 60 h Preservation has two aims to prolong the service life of the system components by removing waste water from the system to avoid biological contamination of the system Protect against frost if there is danger of frost occurring 3 5 1 Washing out procedure For the washing out procedure the membrane filters are operated with clean water instead of raw water WARNI...

Page 71: ... 3 5 2 Cleaning Since in most cases the cause of the membrane filter becoming clogged cannot be determined with complete certainty it is recom mended by the manufacturer that the cleaning procedure always be carried out in two stages Preparation Perform the Washing out work step according to Section 3 5 1 Stage 1 Step 1 Clean with RM Kleen MCT 511 in the sequence described below Step 2 Carry out t...

Page 72: ...op button 49 8 8 Turn the valve levers V12 50 9 and V10 50 7 into the vertical position close 9 Turn valve lever V15 50 10 to the horizontal position open The cleaning tank is emptied at the connection 50 11 WARNING Dispose of the chemical solution according to the national regulations 10 Open the cleaning tank and wash it out with drinking water to remove any remaining chemical solution 3 5 3 Pre...

Page 73: ...ings apply 1 Perform the Washing out work step according to Section 3 5 1 NOTE Stop the Washing out procedure when the 40 l level in the cleaning tank is reached 2 Fill anti freeze into the cleaning tank according to Table 1 page 49 3 Shut valve V05 of the concentrate return line 4 Set the valve lever V12 50 9 to the horizontal position open V10 is shut 5 Connect the industrial and drinking water ...

Page 74: ... the measuring cup according to Table 1 page 49 16 After 20 minutes the operating panel 49 7 indicates Open V10 Open valve V10 manually 17 Add the dissolved preserving chemical into the cleaning tank 18 After the required time has elapsed the high pressure pump switches off 19 Turn the valve levers V12 50 9 and V10 50 7 into the vertical position close 20 Open lid of both pre filters 21 Evenly dis...

Page 75: ... the drinking water interim storage and the hose lines as far as possible with the two feed pumps The dechlorination module has to be emptied via the two sampling valves Afterwards disconnect the hose connections at the lowest point each in the system and allow re maining water to drain Completely drain the two feed pumps via the respective drain screws ...

Page 76: ...o the redundant filter On the operating panel 49 7 Renew filter bag F02 or F03 is indicated Lamp 49 6 for the switched off filter bag flashes 2 Change the filter bag according to Section 4 3 3 3 Press luminous lamp Fault reset 49 9 Lamp goes out Fault signal on the operating panel goes out Operating Record The following values are to be entered into the operating record From the SPC Prefilter inta...

Page 77: ... the chlorinating 46 1 and Anti Scalant container 46 2 If necessary replenish and prepare mixture Fig 46 Chlorinating and Anti Scalant container FillingLevel Remineralisation Tank Check the filling level of the remineralisation tank Refill if required Fig 47 Remineralisation tank 1 2 1 Run down tank for dosing 2 Dosage pump 1 2 ...

Page 78: ...the container inside of the WTC 1600 C the built in A C must be used Additionally frost protection measures are to be taken outside of the container WARNING It must be ensured that system when filled with water is not subject to freezing also during operating intermissi ons at any point of time Otherwise considerable dama ges are possible due to frost ...

Page 79: ... 2 or 3 4 3 2 4 Carry out washing out procedure according to Section 3 5 1 5 If required carry out the preserving and frost protection accord ing to Sections 3 5 3 and 3 5 5 NOTE If there is danger of freezing carry out the frost protection and preserving together 6 Drain water from the system components that are not preserved Empty prefilters and dechlorination module DANGER To prevent any germs ...

Page 80: ...y and clean all the external accessories and stow them according to the loading layout plan Raw water pump Raw water concentrate drain hose Drinking water hose all other loose component parts NOTE Hang all the hoses up to dry unwound as soon as possible after use ...

Page 81: ...anel SPC 8 Stop button 9 Fault reset button 10 Selector switch for main tenance functions 11 Start button 12 Operating mode selector switch 13 Lamp raw water pump 14 Lamp valve V06 open 15 Lamp valve V06 closed 16 Main switch 1 Cleaning tank 2 Lid 3 Coupling return line 4 Coupling return line 5 Upper marking cleaning washing out 6 Fixation strap 7 Valve lever V 10 8 Lower marking disinfection pres...

Page 82: ...OPERATION Version 03 2008 WATERCLEAN 1600 76 ...

Page 83: ... 4 5 Fault Cause Remedy Rotating field display 51 1 on the electrical connection panel illuminates red Reverse phase rotation direction A qualified electrician must reverse the direction of phase rotation by changing the phases in the system plug Use phase inverter in the plug One or several phase control lamps 51 5 fails to illuminate Bulb of the lamp defective Replace electric bulb Interference ...

Page 84: ...float switch on the switch cabinet is activated but not elec trically connected Connect float switch cable Feed pump for WBP 700 does not start after start up of the system Water level in the drinking water interim storage has never reached the minimum level sen sor Wait till water level in the stor age tank has reached the mini mum level Feed pump for bulk water fill ing does not start after star...

Page 85: ...n inform a qualified electrician Pump is damaged Repair pump Fault drinking water flow too low Drinking water flowmeter 3 27 defective Replace drinking water flowm eter Electric lead on flowmeter or switch cabinet loose or damaged Repair fault or replace cable Fault engine protection high pressure pump No 2 Fuse 5Q3 has cut out Check fuse 5Q3 if necessary activate if it cuts out again inform a qua...

Page 86: ...essure Sensor defective Replace sensor Signal converter defective Replace signal converter Input pressure of pre treatment too low Raw water pump is not deep enough in the water or is working without pumping water Shake pump during operation under water Reduce air pressure in the float Raw water pump wrongly posi tioned Check position of pump in water Raw water pump defective Repair pump Raw water...

Page 87: ... outlet the operator or the responsible authority must decide if the water can be used Drinking water conductivity 2 000 µS cm Switch system off Shut concentrate return line Switch system on Membranes defective Change membranes if neces sary Raw water conductivity too high Look for suitable raw water source Renew filter bag F02 Preliminary filter F02 is full Change F02 Renew filter bag F03 Prelimi...

Page 88: ... at the pro tective quartz tube and or UV sensor Check for deposits or coatings and clean according to Sections 4 3 4 2 and 4 3 4 3 3 Red LED Main alarm illumi nates UV irradiator failed Change UV irradiator accord ing to Section 4 3 4 1 Deposits or coating at the pro tective quartz tube and or UV sensor Check for deposits or coatings and clean according to Sections 4 3 4 2 and 4 3 4 3 Malfunction...

Page 89: ... 4 3 2 1 4 Oil Change every 3 000 operating hours Section 4 3 2 2 5 Completely replace pres sure and suction valve replace all seals in the pump head every 3 000 operating hours Spare parts catalogue RO Module 6 Check membrane filter weekly Section 3 4 4 7 Cleaning the Membrane Filters every 4 weeks or according to Section 3 5 Section 3 5 2 8 Changing the Membrane Filters Section 3 4 4 Section 4 3...

Page 90: ...ow Pre alarm LED at the UV switch cabinet Section 4 3 4 2 15 Check sensor sensor win dow and clean if required after indication of the yellow Pre alarm LED at the UV switch cabinet Section 4 3 4 3 16 Change UV lamp every 8 000 operating hours or after indication of the red Main alarm at the UV switch cabinet Section 4 3 4 1 17 Change UV sensor every 15 months Section 4 3 4 3 Consec No Test Point D...

Page 91: ...accordingly longer The equipment is delivered ex factory with a preservation coating to protect against surface corrosion This coating uses off with time and must therefore be renewed periodically The time intervals can be found in the maintenance plan 4 3 1 1 Cleaning and Surface Protection For cleaning purposes drinking water conditioned water is to be used CAUTION Switch off the system disconne...

Page 92: ... do this unscrew the Screw 52 1 on the housing cover and pour in SAE 50 oil 1 Screw 2 Oil level gauge glass 3 Oil drain plug 4 3 2 2 Changing the Oil of the High Pressure Pump Remove the housing cover of the high pressure pump according to Section 4 3 2 1 Place an oil pan under the high pressure pump amount of oil approx 2 l Unscrew the oil drain plug 52 3 and drain oil Clean oil drain plug and se...

Page 93: ...the filter unit Drain the water from the system Turn off the power supply and safeguard it from being switched on again Loosen all the nuts evenly on the end plates 53 1 of the pressure tubes and then unscrew Remove end plates Fig 53 Loosen screwing 54 1 and pull off flexible metal tube 54 2 Loosen the two screwings 54 5 land remove tubular bar 54 4 Fig 54 1 1 3 4 2 5 ...

Page 94: ...chment screws to the stop nut 55 2 into the thread of the permeate nipple 54 3 Turn both winged nuts 55 5 evenly in a clockwise direction thus pulling the end caps 55 4 out of the pressure tubes Fig 55 Detach the end caps of the other pressure tubes in the same way observing the following pair wise arrangement Fig 56 NOTE Both the two lower end caps 56 4 and 56 5 must each be pulled individually u...

Page 95: ...nce NOTE Check the permeate collecting pipes for damage Apply grease to the permeate collecting pipes and to the O rings NOTE Apply suitable grease to the lip seal and O rings at the end caps WARNING When assembling the membrane filters make sure that the lip seal 57 2 is properly positioned see Fig 58 re rear lip seal rear fr front lip seal front Fig 58 1 2 re re re fr fr fr fr fr ...

Page 96: ...me packaging again later 1 Remove the membranes out of the packaging 59 1 Bild 59 Membrane originally packed 2 Prepare the post preserving solution 100 g natriumhydrogensul fit 2 kg 1 2 propandiol and fill up with approx 7 9 l of drinking water to 10 l in total The total quantity depends on the number of membranes NOTE The consumable materials are listed in Section 2 6 3 Insert the membranes in a ...

Page 97: ...rneath Loosen the three winged nuts in each case 60 3 on the respective lid of the two preliminary filters and remove lid Fig 60 Take out pressure plate 60 2 and supporting basket 61 2 remove old filter bag from the supporting basket Fig 61 Insert a new filter bag 61 1 in the supporting basket WARNING The sealing ring on the filter bag must lie completely inside the sealing groove of the supportin...

Page 98: ...e bottom of the housing and make their way to the membranes Parti cles at the intake to the membranes can damage these or decrease the capacity of the system NOTE For expected downtime up to 5 days see operating record the filter housing must be filled with drink ing water in order to ensure a trouble free switch over procedure Sterile Filters The sterile filters used for ventilation of the drinki...

Page 99: ...ure in the housing of the acti vated carbon filter 3 Open the housing of the activated carbon filter 4 Remove the used 30 active carbon filter elements ten in total and replace with new ones 5 Mount filter housing together again 6 Open intake ball valve again Fig 62 1 Lid lock open for exchanging the fil ter plugs 2 Filter bowl dechlorination module 3 Pressure gange intake pressure 4 Sampling valv...

Page 100: ...he switch at the UV switch cabi net and secure against switching on again Fig 63 Loosen cable connector 63 1 until the cable is no longer clamped Pry off the cap 63 2 Fig 64 Unscrew the two machine screws 64 1 Pull the socket 64 2 with the irradiation bulb out of the housing Pull the bulb 64 3 from the socket Reassembly is carried out in reverse order 1 2 1 2 3 ...

Page 101: ...65 1 together with the threaded socket 65 2 and unscrew Remove the O ring 65 3 Carefully turn and pull out the protective tube CAUTION Do not damage the protective tube Clean the protective tube or replace if required NOTE Use a sponge and commercially available cleaner for cleaning Afterwards rinse clear and dry with a leather cloth Carefully insert the cleaned or a new protective tube Further as...

Page 102: ...he UV unit Fig 66 Unscrew sensor 66 1 with cable Clean the glass surfaces 66 2 of the sensor and sensor adapter NOTE Use a sponge and commercially available cleaner for cleaning Afterwards rinse clear and dry with a leather cloth Apply food grease to the sensor thread Further assembly is carried out in reverse order 1 2 ...

Page 103: ...try specific and can differ from the above mentioned value The following table enables making an approximate assessment for converting ppm to µS cm Conversion table µS cm ppm µS cm ppm µS cm ppm µS cm ppm µS cm ppm µS cm ppm µS cm ppm 10 5 180 85 340 165 500 247 670 333 830 414 20 9 190 90 350 171 510 252 680 338 840 419 30 14 200 95 360 176 520 257 690 343 850 424 40 19 210 100 370 181 530 262 70...

Page 104: ...5 1047 3350 1726 6000 3197 9216 5000 15000 8425 1320 662 2125 1073 3400 1753 6100 3253 9300 5047 15250 8576 1340 672 2150 1085 3450 1781 6200 3309 9400 5103 15500 8728 1360 682 2175 1098 3500 1808 6300 3365 9500 5159 15750 8879 1380 692 2200 1111 3550 1835 6400 3421 9600 5215 16000 9031 1400 702 2225 1124 3600 1863 6500 3477 9700 5271 16250 9182 1420 713 2250 1137 3650 1899 6600 3533 9800 5327 165...

Page 105: ...00 12705 29500 17317 33000 19469 48000 29069 69000 43307 90000 57545 22250 12860 30000 17624 34000 20084 49000 29747 70000 43985 91000 58223 22500 13013 30500 17932 34500 20391 50000 30425 71000 44663 92000 58901 22750 13167 24500 14243 35000 20698 51000 31103 72000 45341 93000 59579 23000 13321 24750 14397 35500 21006 52000 31781 73000 46091 94000 60257 23250 13474 25000 14550 36000 21313 53000 3...

Page 106: ...APPENDIX Version 03 2008 WATERCLEAN 1600 100 ...

Page 107: ...r Date Raw Water Operating Data Drinking Water Malfunctions Remarks Pre filter replaced yes no Hardness dH Temperature C Turbidity NTU Conductivity µS cm Houres of operation SPC h Intake pressure pre cleaning bar Intake pressure main module bar Intake pressure membranes bar Output pressure membranes bar Differential pressure prefilter bar Differential pressure membranes bar Drinking Water capacity...

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Page 109: ... replaced yes no Hardness dH Temperature C Turbidity NTU Conductivity µS cm Houres of operation SPC h Intake pressure pre cleaning bar Intake pressure main module bar Intake pressure membranes bar Output pressure membranes bar Differential pressure prefilter bar Differential pressure membranes bar Drinking Water capacity l h Conductivity µS cm Chlorine content ppm Temperature C ...

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Kärcher WATERCLEAN 1600, Operating Instructions Manual

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