Karcher 600 CD - Manuals - manualsarea.com

Page 3 - CONTENTS; Contents

3 WTC 600 LP / MP CONTENTS Service Handbook 08.2004 Contents 1 General .......................................................................................... 7 - 10 1.1 Introduction ........................................................................................................... 7 1.2 ...

Page 7 - GENERAL; General; Introduction; CAUTION

7 WTC 600 LP / MP GENERAL Service Handbook 08.2004 1 General 1.1 Introduction This service manual contains basic instructions and information which are to be observed uponset-up, operation and maintenance.Therefore, it is imperative that the service manual is read by the installer as well as by ther...

Page 8 - Safety Instructionse; Quality of the Untreated Water

8 GENERAL WTC 600 LP / MP Service Handbook 08.2004 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 aremaintained regularly. 1.4.2 Chlorination of Drink...

Page 9 - General installation notes; NOTE

9 WTC 600 LP / MP GENERAL Service Handbook 08.2004 1.4.4 Handling Electricity / Protection Class Be aware of dangerous electrical voltage!For work on components/assemblies which are marked with this symbol, protectivemeasures are to be taken: - Switch off the power - Secure against restarting - Chec...

Page 10 - DESCRIPTION; Description; Overview; Figure 1

10 DESCRIPTION WTC 600 LP / MP Service Handbook 08.2004 2 Description 2.1 Overview Figure 1 Overview of components 1.3 e 2.2 a b 1.2 2.1 4.12, 4.13 f g 4.23 c d4.24 4.214.14 4.114.15 4.17 4.44.3 4.7 4.5, 4.6

Page 12 - Flow Diagram; Figure 2

12 DESCRIPTION WTC 600 LP / MP Service Handbook 08.2004 2.2 Flow Diagram Figure 2 Flow diagram of the complete reverse osmosis system (RO system)

Page 13 - Description of the System; Modular Design; - Media filter and flocculation – module 1; Pre-chlorination Module; Figure 3

13 WTC 600 LP / MP DESCRIPTION Service Handbook 08.2004 2.3 Description of the System 2.3.1 Modular Design The installation is a drinking water conditioning system. Its core application is theemineralization of brackish water with a salt content up to 2000 ppm (WTC 600 LP), respectivelyup to 5000 pp...

Page 14 - Figure 5; RO System, Pump and Fine Filter

14 DESCRIPTION WTC 600 LP / MP Service Handbook 08.2004 2.3.1.3 Mediafilter- and Activated Carbon Filter The pre-filter units of the RO system consist of the media filter and the activated carbon filter. The filter fillings consist of support pebbles and filter sand according to DIN 19623, as well a...

Page 15 - Figure 6

15 WTC 600 LP / MP DESCRIPTION Service Handbook 08.2004 2.3.1.7 Pressure-increase Pump If required, the WTC 600 PI pressure-increasepump (6/1) is connected between untreatedwater supply and RO system. It is used forpressure increase of the untreated water. A pressure-increase pump shouldbe used for ...

Page 17 - Technical Data WTC 600 LP/MP; Parameter

17 WTC 600 LP / MP DESCRIPTION Service Handbook 08.2004 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) 1*230V 50 Hz 1) Pre-filter controls: prim / sec. 230...

Page 19 - Consumption Materials

19 WTC 600 LP / MP DESCRIPTION Service Handbook 08.2004 2.5 Consumption Materials Swear protective equipment and observe safety instructions! 2.5.1 Chemicals for Metering Container For mixing of the metering solution, use the measuring cup with the handle (250 ml or 1000 ml). Explanations of the uni...

Page 20 - OPERATION OF THE SYSTEM; Operation of the System; Assembly and Starting Operation; Assembly

20 OPERATION OF THE SYSTEM WTC 600 LP / MP Service Handbook 08.2004 3 Operation of the System 3.1 Assembly and Starting Operation Assembly Chapter Checking the scope of delivery (delivery note) Placing the equipment in the set-up location and positioning Connecting the untreated water to the WTC 600...

Page 21 - Mixing Chlorine, Flocculation Agent and Antiscalant; First fill of the metering tanks; from the untreated water analysis.

21 WTC 600 LP / MP OPERATION OF THE SYSTEM Service Handbook 08.2004 3.2 Mixing Chlorine, Flocculation Agent and Antiscalant 3.2.1 First fill of the metering tanks The first time they are filled, the metering tanks are filled with 30 litres of chlorine-free water.This is taking from the reverse osmos...

Page 22 - O R

22 OPERATION OF THE SYSTEM WTC 600 LP / MP Service Handbook 08.2004 5. For 75% yield: Total x 128 = _____ ml RM 852 per 10 litre metering solution O R Total x 34 8 = _____ ml calcium hypochlorite (1ml corresponds to 1.05g) per 10 litres metering solution These values are entered in the customer's op...

Page 24 - Give 25 ml flocculent RM 5001 into measuring cup

24 OPERATION OF THE SYSTEM WTC 600 LP / MP Service Handbook 08.2004 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 ...

Page 25 - Measure pH-value of water, has to be between 6 and 9; Evaluate flocking test; Adjustment of dosing pump flocking means:

25 WTC 600 LP / MP OPERATION OF THE SYSTEM Service Handbook 08.2004 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...

Page 26 - Connecting the Equipment; Connections, Valves and Indicators; The following constructional measures must be observed:; Figure 8

26 OPERATION OF THE SYSTEM WTC 600 LP / MP Service Handbook 08.2004 3.3 Connecting the Equipment 3.3.1 Connections, Valves and Indicators Depending on the local untreated water supply, the WTC 600 LP/MP is connected directly to theoff-site supply or supplemented through a WTC 600 PI pressure-increas...

Page 27 - Figure 10 Connections, rear

27 WTC 600 LP / MP OPERATION OF THE SYSTEM Service Handbook 08.2004 3.3.1.1 Pressure-increase Module Connection to the RO system (9/2) Hose shank d25Connection to the untreated water (9/3) Hose shank d25 Observe mechanical protection of the electrical connection cable (9/1) as wellas protection agai...

Page 28 - Figure 12 Alarm output and digital input of the metering pumps; Alarm output; Figure 13 Connections, metering stations

28 OPERATION OF THE SYSTEM WTC 600 LP / MP Service Handbook 08.2004 3.3.2 Electrical Connections 3.3.2.1 Pressure-increase Pump 230 V external, via connection cable. 3.3.2.2 Preliminary Filter In delivery condition, the preliminary filters are connected to the power outlets (1/f) on the rearside of ...

Page 30 - Starting Operation; Antiscalant; Figure 14 Metering station

30 OPERATION OF THE SYSTEM WTC 600 LP / MP Service Handbook 08.2004 3.3.2.4 Float Switch Connect the signal lines of the enclosed float switch to clamps 6/7 (8S3 option) of theconnecting terminal – compare wiring diagram in the switching box. Upon installation, adjust aswitching hysteresis of at lea...

Page 32 - Figure 15 XP Controller; Position

32 OPERATION OF THE SYSTEM WTC 600 LP / MP Service Handbook 08.2004 3.4.2.4 Programming To start the programming, the coveredpushbutton (15/1) to the left of the “TIME OFDAY” pushbutton (15/2) is to be pressed (acircular indentation can be felt under the frontfoil).The changing of the flashing posit...

Page 34 - Technician password:; ESC; For settings and menus of the RO 1000 control system, see figure 22.

34 OPERATION OF THE SYSTEM WTC 600 LP / MP Service Handbook 08.2004 3.4.3 Starting Operation of the RO System 3.4.3.1 Operating Levels and Passwords Normal Level: In this level, the operating mode, the operating condition as well as the current measuring andoperating values are indicated on the disp...

Page 39 - Figure 16 User indication in normal operation

39 WTC 600 LP / MP OPERATION OF THE SYSTEM Service Handbook 08.2004 3.4.4 Normal Operation Switch on the RO 1000 control; the followingmessage appears on the display: The system has been switched offin the user or technician level.Switching on without password isnot possible! When the following rota...

Page 43 - MAINTENANCE; Maintenance; Fine Filter; - Stop the untreated water supply until the; Figure 17 Replacing the fine filter; Metering Station WTC 600 CD; Cleaning the suction and pressure valves; - Unscrew valve and take out inner part of valve.

43 WTC 600 LP / MP MAINTENANCE Service Handbook 08.2004 4 Maintenance 4.1 Fine Filter The manometers (17/1 and 17/3) are locatedin front of and behind the fine filter unit (17/2). Ifthe differential pressure is more than 0.8 bar,the fine filter is to be cleaned or replaced: - Stop the untreated wate...

Page 44 - - Select the switching off operating mode and

44 MAINTENANCE WTC 600 LP / MP Service Handbook 08.2004 Replacing the membrane - Set the pump lift adjustment knob (8/1) to 100 %. - Unscrew the 4 screws, size 6 mm, at the metering head and remove the metering head. - Unscrew the membrane to the left. - Reattach the sealing membrane1), intermediate...

Page 45 - Cleaning in Case of Malfunction

45 WTC 600 LP / MP MAINTENANCE Service Handbook 08.2004 - Apply Propandiol 1) to the rubber seals. - Insert a new filter (19/7) at the supply opening (end without seal first!). - Attach all adapters. - Insert lid (19/4) in such a manner that the threads of the openings are flush with thenuts of the ...

Page 46 - - Four connection hoses

46 MAINTENANCE WTC 600 LP / MP Service Handbook 08.2004 4.4.1 Design of the Flushing and Disinfection Equipment Figure 20 Diagram of connection principle for cleaning conserving and disinfection of the RO equipment 1. Manometer 2. Fine filter 3. Solenoid valve 4. Pressure switch 5. RO Pump 6. Pressu...

Page 47 - Close the untreated water inlet depressurise system:

47 WTC 600 LP / MP MAINTENANCE Service Handbook 08.2004 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: - ...

Page 49 - - Chemicals for cleaning and for neutralization.; Switch the RO equipment to the operating mode; Leave the RO system to run for 30 minutes.

49 WTC 600 LP / MP MAINTENANCE Service Handbook 08.2004 4.4.3 Acidic and Alkaline Cleaning If the original drinking water capacity and quality can not be reached, an acidic cleaning or analkaline cleaning of the equipment is to be carried out. Aids: - Universal indicator paper1) pH 0-14 - Chemicals ...

Page 50 - - RO system switched off

50 MAINTENANCE WTC 600 LP / MP Service Handbook 08.2004 4.4.3.1 Cleaning Solution for Acidic Cleaning Volume of the RM Kleen MCT 103 [l] Item No. cleaning solution [l] 30 1,0 6.294-009.0 Table 23 Composition of the cleaning solution for acidic cleaning Neutralise by adding soda (6.287-014), until th...

Page 52 - Chemicals for conserving solutions; Interrupt the untreated water supply, depressurise the filter.

52 MAINTENANCE WTC 600 LP / MP Service Handbook 08.2004 1) Sulfite 5 kg: Item No. 6.769-040.0 2) RM 1,2 Propandiol, 5l: Item No. 6.290-910.0 Preservation solution [l] Sulfite 5kg 1) [g] RM 1,2 Propandiol 5l 2) [l] 30 300 5,0 Table 25 Chemicals for conserving solutions 4.4.4.3 Drain the pre-filter If...

Page 54 - Composition of the disinfectant solution

54 MAINTENANCE WTC 600 LP / MP Service Handbook 08.2004 System Volume of RMP3 Oxonia active Art.-No. output [l/h] disinfectant 15% [l] solution [l] 600 30 0,75 6.294-010.0 Table 26 Composition of the disinfectant solution 10. Flush the service kit with drinking water 11. Switch the RO system to run ...

Page 55 - Unscrew the controller from the control head and place to the side; Switch the WTC 600 to Run operating mode

55 WTC 600 LP / MP MAINTENANCE Service Handbook 08.2004 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 subme...

Page 56 - Malfunction, Cause and Corrective Action; Malfunction indications at the switch cabinet and their causes

56 MAINTENANCE WTC 600 LP / MP Service Handbook 08.2004 4.5 Malfunction, Cause and Corrective Action 4.5.1 Metering Station LED and Indicator LEDs at the Switch Cabinet Indication Malfunction Cause Corrective Action Chap./Fig. Red fault LED Pump in metering Metering Refill, check float switch 2.3.1....

Page 60 - Maintenance Plan; Maintenance During Operation

60 MAINTENANCE WTC 600 LP / MP Service Handbook 08.2004 4.6 Maintenance Plan 4.6.1 Maintenance During Operation Module Cycle / Time Activity Chap./Fig. 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 pr...

Page 61 - Maintenance work to be carried out during service; Other Maintenance

61 WTC 600 LP / MP MAINTENANCE Service Handbook 08.2004 4.6.2 Maintenance Plan – Service Measured and read values are to be entered into the maintenance record. Module Work to be Carried Out Media filter Assess general condition Differential pressure after backwashing Read adjustment of the differen...

Page 62 - APPENDIX; RO control factory settings:; Operating mode

62 APPENDIX WTC 600 LP / MP Service Handbook 08.2004 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 Sett...

Page 66 - Control System

66 APPENDIX WTC 600 LP / MP Service Handbook 08.2004 RO 1000: Manual Control System RO 1000 MANUAL

Page 69 - General Remarks

69 WTC 600 LP / MP APPENDIX Service Handbook 08.2004 1 General 1.1 General Remarks The present Manual is the technical documentation of the RO 1000 control system for reverseosmosis units. When studying this manual, it would be useful to have the control system ready for operation sothat you can dir...

Page 70 - Instructions for Use; switching the main switch on and off.; Safety Instructions; The following safety instructions are imperative:

70 APPENDIX WTC 600 LP / MP Service Handbook 08.2004 1.3 Instructions for Use The following instructions should be followed when operating the control system: – Do not switch on/off the control system in quick succession. Wait at least 5 seconds between switching the main switch on and off. – The co...

Page 71 - Terms and Definitions; Item; Declaration of Conformity

71 WTC 600 LP / MP APPENDIX Service Handbook 08.2004 1.5 Terms and Definitions The following scripts will be used for this manual: Item Script Examples keys LED's inlets/outlets capital letters + boldcapital letters + boldcapital letters + bold LEFT, UP, DOWNRINSE, DISPOSALPUMP FAILURE, INLET VALVE ...

Page 72 - Basic Requirements for System Installation; – The clamps must not be actuated with too much force.

72 APPENDIX WTC 600 LP / MP Service Handbook 08.2004 2 Installation/Start-up 2.1 Basic Requirements for System Installation The following remarks have to be observed during installation and connection of the RO 1000unit: – The connected consumers must not exceed the max. admissible loads of the circ...

Page 73 - Function of Terminals; Terminal arrangement and functions are as follows:; total output

73 WTC 600 LP / MP APPENDIX Service Handbook 08.2004 2.3 Function of Terminals Terminal arrangement and functions are as follows: No. Code Function adm. max. load terminal 1 2 3 PENL Mains supply - protective. conductMains supply - neutral conductorMains supply - phase 1000 VA = max. total output pe...

Page 74 - Operational Scope; ps LIM high

74 APPENDIX WTC 600 LP / MP Service Handbook 08.2004 3 Operational Scope 3.1 Operating settings The control system allows to preselect the following operating settings (realization see item 4).The resulting control behaviours are described in the chapter Operating Conditions. Thestandard values (set...

Page 75 - Operating parameters; LIM; Attention: the set value must be above aaLIM; aaLIM; Attention: the set value must be lower than LIM; Time delay for wrong permeate limit value

75 WTC 600 LP / MP APPENDIX Service Handbook 08.2004 3.2 Operating parameters The control system allows the following operating parameter settings (realization see item 4).The resulting behaviours are described in the chapter operating conditions. The values inbrackets are the standard values after ...

Page 76 - t rinse interval

76 APPENDIX WTC 600 LP / MP Service Handbook 08.2004 t rinse interval function: Time after which a DISCONTINUOUS RINSEprocess is started provided that the controlsystem was during that time in the operatingcondition RINSE INTERVAL. right of access: technicianpossible setting: 0-99h (0h) t concentrat...

Page 78 - Operating conditions

78 APPENDIX WTC 600 LP / MP Service Handbook 08.2004 3.4 Operating conditions When the unit is in OPERATION the control system performs one of the seven possibleoperating conditions. The following diagram shows the various conditions as well as the reasonsfor status changes. For that purpose an erro...

Page 79 - Denomination

79 WTC 600 LP / MP APPENDIX Service Handbook 08.2004 3.5 Operating failures/failure messages The control system is able to detect operating failures during OPERATION and DISINFECTIONand to display them. Usually, the unit will be stopped if a failure occurs. However, operatingsettings exist for the f...

Page 80 - Active, if the TANK FULL input is activated.; The control system has keys for the functions UP

80 APPENDIX WTC 600 LP / MP Service Handbook 08.2004 4 Operation 4.1 User interface The user interface of the RO 1000 consists of a text display (16x2 characters), a keyboardcovered with a protective film (6 keys) and 7 indicator lights. 4.1.1 Indicator lights The indicator lights correspond to the ...

Page 81 - Basic elements; Selection of menu; key is pressed, the currently displayed

81 WTC 600 LP / MP APPENDIX Service Handbook 08.2004 4.2 Basic elements The whole user surface of the control system is composed by basis functions such aspassword entry, menu selection, selection of settings, numerical entries etc. The description ofthe basic functions will be followed by the opera...

Page 82 - keys between the different characters; Numerical editing; keys. Cursor displacement is achieved with the; Alphanumerical editing; and special characters.; Confirmations

82 APPENDIX WTC 600 LP / MP Service Handbook 08.2004 4.2.4 Multiselection The multiselection allows to select various arguments simultaneously (for the purpose of thispaper, argument means any type of setting).In the lowest line of the text display appears for that purpose a chain of "0" and...

Page 83 - a specific diagnostic function.; Normal level

83 WTC 600 LP / MP APPENDIX Service Handbook 08.2004 4.3 Operating levels Similar to the operating modes, the user surface has different operating levels: Normal level: In this level, the text display shows the operating mode, the operating condition, the currentmeasured values and operating values ...

Page 87 - Cy permeate; ATTENTION !! Internal calibration is not a correct adjustment.

87 WTC 600 LP / MP APPENDIX Service Handbook 08.2004 4.4.2 Calibration menu The calibration menu is used to adjust the sensors. The following functions are available: Menu point: Function: 1 Cy permeate Calibration of permeate sensor. If the menu point '1 Cy permeate' ischosen, a submenu appears wit...

Page 90 - Operating Record for the WTC 600 LP/MP; Location of Installation:

90 APPENDIX WTC 600 LP / MP Service Handbook 08.2004 Operating Record for the WTC 600 LP/MP Equipment Data: Works/Plant No.: Type: 1.024- Page No.: Location of Installation: Type of Untreated Water Supply: Date of Starting Operation: D a te Operator U n tr e a te d W a te r Operating Data D rinking ...

Page 91 - LIST OF KEY WORDS

91 WTC 600 LP / MP LIST OF KEY WORDS Service Handbook 08.2004 A Acidic and Alkaline Cleaning ........................ 49Acknowledging Data Inputs ......................... 35Activated Carbon Filter ................................. 31Activated carbon filter .................................. 11Adjus...