GF JRG Coral force 8000 Operating Manual
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GF JRG Coral force 8000 Operating Manual

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JRG Coral force 8000
JRG Coral force 11000
JRG Coral force 14000
JRG Coral force 3.5D
JRG Coral force 5D
Coral force 14000
Operating Manual
EN
FailSafe
Rev.: 1113803-1

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Summary of Contents for GF JRG Coral force 8000

  • Page 1 JRG Coral force 8000 JRG Coral force 11000 JRG Coral force 14000 JRG Coral force 3.5D JRG Coral force 5D Coral force 14000 Operating Manual FailSafe Rev.: 1113803-1...
  • Page 2 Seite 2 von 68 Rev.: 1113803-1...

  • Page 3: Table Of Contents

    Contents Preface ......................... 5 Safety Information ......................... 5 Warranty ..........................6 Duty of Care of the Operator ....................6 Safety Information and Prerequisites for Installation ............7 CE-Marking ..........................9 Product description ....................10 Intended Use........................10 Principle of Operation ......................12 Control and Monitoring Module .................
  • Page 4 Water Treatment (WT) ......................41 Thermal Disinfection (TD) ....................42 Backflush (RS) ........................43 Service Display ........................44 Fault Messages/Malfunctions ....................45 Manual Decommissioning if Ball Valve is Defective ............. 48 Errors E00 to E05 – Ball Valve Positioning ................49 Error E06 –...

  • Page 5: Preface

    1 Preface These operating instructions contain all the important information you will need for proper operation of the device described. Observing these instructions helps avoid dangers, reduce repair costs and downtime, and increase the reliability and service life of the unit. Always keep this operating manual available at the site of use.

  • Page 6: Warranty

    Warranty The warranty shall be honoured under our General Terms of Sale and Delivery only if: • the device is installed by a qualified professional, • the device is used as instructed in this operating manual, • the device is properly deployed, •...

  • Page 7: Safety Information And Prerequisites For Installation

    Safety Information and Prerequisites for Installation Attention • Use the device only in its proper working condition and for its intended use and in full awareness of safety issues and potential hazards. • Observe the installation and operating instructions. • Ensure that any faults that may affect safety are rectified immediately by a specialist.
  • Page 8 Affix or position a sign indicating that maintenance or repair work is in progress. Unplug and depressurise the unit and secure it against inadvertent reactivation. Before undertaking maintenance or repair work, ensure that all device and system parts have cooled to room temperature. •...

  • Page 9: Ce-Marking

    CE-Marking The manufacturer Georg Fischer JRG AG declares that the following products and models JRG Coral force 8000 JRG Coral force 11000 JRG Coral force 14000 JRG Coral force 3.5D JRG Coral force 5D DIRECTIVE 2006/42/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL...

  • Page 10: Product Description

    2 Product description Intended Use The JRG Coral force 8000, 11000, 14000, 3.5D, 5D limescale conditioning units are designed to provide long-term reductions in limescale formation in potable water installations and sanitary systems. The biomineralisation process is based on a...
  • Page 11 Installation example with JRG Coral force 14000 in the main potable water system inlet, fitted after the water meter and a domestic water station with filter, RV and pressure control valve. Any other or additional use of this equipment is deemed to be NOT FOR INTENDED PURPOSE.

  • Page 12: Principle Of Operation

    Principle of Operation JRG Coral force limescale conditioners function on the basis of patented WATERCRYST catalyser technology. This leaves the valuable minerals in the potable water and does not alter its natural composition. The stainless steel tank (1) contains a loose bed of active, fine-grained polymer catalyst granulate (2), above which are filter granules of lower specific weight (3) in polypropylene and filter stars (4, 5) in the water inlet and outlet.
  • Page 13 Regular thermal disinfection (TDI) is performed automatically to prevent harm to the unit being caused by microbiological action. During this process the catalyst cartridge is isolated from the drinking water supply by means of a valve, while a bypass in the valve ensures that the supply of drinking water continues unaffected.

  • Page 14: Control And Monitoring Module

    3 Control and Monitoring Module The control and monitoring module is based on an industrial programmable logic controller (PLC) and offers the following functions: • Monitoring Functions Granulate change interval via operating hours counter Time interval for automatic thermal disinfection Control valve positions for thermal disinfection and backflushing Heating function for thermal disinfection Temperature in all operating phases...
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  • Page 16 The controller is operated via the 4 cursor keys (1), the OK button (2) and the ESC button (3), which are positioned to the right of the display (4). Nach dem Einstecken des Netzsteckers erscheint im Display der Steuerung das in der Abbildung oben zu sehende Menü.
  • Page 17 ANZAHL Counts the number of thermal disinfections successfully completed. LETZTE TD Time in hours since the last thermal disinfection successfully completed. Timeout The maximum time available for the ball valve drives to reach their defined positions TD-heiz Maximum heating time for the temperature to reach TD…78°C TD-halt TD temperature holding time...

  • Page 18: Scope Of Delivery And Setting Up

    4 Scope of Delivery and Setting Up Units are supplied on a euro pallet, ready for installation. Seite 18 von 68 Rev.: 1113803-1...
  • Page 19 Item Component Description Filter stars Filter stars in food-safe plastic Isolating non-return valve Stopcock with integral backflow inhibitor, complies with EN 1717 Catalyst granulate fine-grained, polymer catalyst granulate Stainless steel vessel and PN10 stainless steel vessel with maintenance flange pipework Filter granulate Floating polypropylene filter granulate for retention of catalyst granulate...

  • Page 20: Technical Data

    5 Technical Data Hydraulic 8000 11000 14000 3.5D Coral force Residential units max. up to VDI 3807-T3 Short-term peak flow rate, Qs [l/h] 7.900 10.100 11.800 12.500 13.500 Continuous flow rate [l/h] 1.500 2.500 3.500 5.000 Nominal pressure Operating pressure (min. - max.) [bar] Pressure loss at peak flow [bar]...

  • Page 21: Installation Options

    6 Installation Options JRG Coral force unit is fitted to domestic water inlet immediately after the meter, non-return valve, filter and pressure regulator. (1) Water meter; (2) domestic water station; (3) JRG Coral force limescale conditioner; (4) free outlet into drain (ensure adequate dimensioning and temperature tolerance);...

  • Page 22: Filling And Bleeding The Unit

    7 Filling and Bleeding the Unit Commissioning should be performed by JRG Coral force's customer support team in the exact sequence described below. Any failure to properly bleed the JRG Coral force unit may result in malfunctioning. Remove thermal insulation Seite 22 von 68 Rev.: 1113803-1...

  • Page 23: Filling And Bleeding

    Filling and bleeding Seite 23 von 68 Rev.: 1113803-1...
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  • Page 25 Seite 25 von 68 Rev.: 1113803-1...

  • Page 26: Fitting Thermal Insulation And Thermometer

    Fitting thermal insulation and thermometer C heck for Leaks Before fitting the insulation, check installation and unit for any leaks, including the base of the vessel. Fit the thermal insulation: 1. Close the sealing rail on one of the two sides of the valves.

  • Page 27: Signal Contact For Building Management System (Optional)

    Signal Contact for Building Management System (optional) The unit features a 2-pole signal input with chassis socket and cable connector provided plus a potential- free fault signal contact that can be connected via a 4-pole chassis plug on the controller housing and the cable socket provided, so enabling a connection into the building management system.

  • Page 28: Commissioning

    8 Commissioning Ensure that the maintenance cocks are fully open and that the unit is completely filled with water and all air is bled out. The controller requires a three-phase fused mains supply of 400 V, 50Hz, min. 10A, max. 16A. Switch unit on When the key-switch is turned on, the controller automatically initiates a full hygiene program to ensure the intrinsic safety of the system before the JRG Coral force limescale conditioning...
  • Page 29 Seite 29 von 68 Rev.: 1113803-1...

  • Page 30: Initialisation And Settings - Automatic Hygiene Program

    8.1.1 Initialisation and Settings - Automatic Hygiene Program Seite 30 von 68 Rev.: 1113803-1...
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  • Page 32 Seite 32 von 68 Rev.: 1113803-1...
  • Page 33 Seite 33 von 68 Rev.: 1113803-1...

  • Page 34: Set Date And Time

    Set date and time The date and time must be set during commissioning (see next page). When the date and time are set, the time clock of the controller is activated. The date and time must be set again after extended power outages (over 80 hours).

  • Page 35: Setting Device Parameters (Optional)

    Setting Device Parameters (OPTIONAL) Leaving the Component Level: Start the limescale conditioning unit by switching it off, waiting 10 seconds and then switching back on. Seite 35 von 68 Rev.: 1113803-1...

  • Page 36: Linking To Pumping System (Optional)

    8.3.1 Linking to pumping system (OPTIONAL) The software need only be enabled by changing the S_Hebe switch, as described below, if the signal contact is connected to the pumping system. (With contact connected, ON. With pumping system not connected, OFF.) Leaving the Component Level: Start the limescale conditioning unit by switching it off, waiting 10 seconds and then switching back on.

  • Page 37: Setting The Time For Thermal Disinfection (Td) (Optional)

    8.3.2 Setting the time for thermal disinfection (TD) (OPTIONAL) The start time for TD is factory set to Mondays and Thursdays at 00:05. Should it be necessary, for reasons specific to the building or installation, for these TD times to be changed, proceed as follows. Leaving the Component Level: Start the limescale conditioning unit by switching it off, waiting 10 seconds and then switching back on.

  • Page 38: Changing The Service Interval (Optional)

    8.3.3 Changing the Service Interval (OPTIONAL) A service interval is preset by the factory of 43,800 hours (= 5 years). Should it be necessary, for reasons specific to the building or installation, for this interval to be different or to change the operating hour counter reading, proceed as follows.

  • Page 39: Initiating A Manual Thermal Disinfection (Td)

    Initiating a Manual Thermal Disinfection (TD) For reasons of hygiene and to test the correct operation of the system, thermal disinfection must be performed whenever a limescale treatment unit is commissioned. Seite 39 von 68 Rev.: 1113803-1...

  • Page 40: Operating States And Indications

    9 Operating States and Indications Operational signalling and indications, maintenance requests and fault messages are conveyed via the following elements: Operating status lamp (green) Service/Fault lamp (red) Legend: Lamp on Lamp off Lamp flashing slowly (about every 3 sec.) Lamp flashing fast (about once per sec.) Display Acoustic alarm signal: No alarm sounds during normal water treatment operation...

  • Page 41: Water Treatment (Wt)

    Water Treatment (WT) In water treatment, the incoming water passes downwards through the pipework via the backflow inhibitor. The contents of the vessel containing the catalyst granulate moves upwards at the same rate. The treated water then passes through the two-way ball valve into the downstream installation.

  • Page 42: Thermal Disinfection (Td)

    Thermal Disinfection (TD) To ensure continued supply to the installation during thermal disinfection, water passes through a bypass in the overflow valve. The main ball valve is set to the shut-off position. The water is heated using an electric heater rod and transported into the vessel by the charging pump.

  • Page 43: Backflush (Rs)

    Backflush (RS) Once thermal disinfection is complete, the small 2-way ball valve opens the backflushing line. Part of the flow rinses the hot water upwards from beneath, to exit the vessel. Flush volume flow: approx. 60-100 l/min (depending on line pressure) Rinse duration: approx.

  • Page 44: Service Display

    Service Display When cartridge replacement is imminent, this is indicated by flashing of the yellow LED as per the following combinations: On continuously during water treatment (WT); flashes during TD or RS On  SERVICE Date: Current date Message: 'Service required' open Seite 44 von 68 Rev.: 1113803-1...

  • Page 45: Fault Messages/Malfunctions

    Fault Messages/Malfunctions If faults or malfunctions occur that cannot be rectified immediately, the system should be taken out of service. • Unplug mains plug to isolate unit from electrical power. • In the event of power failure, the fail-safe drives of both ball valves move them automatically into their respective shut-off positions.
  • Page 46 Green operating status indicator off Red fault lamp on The error number E(NN)/date and time are displayed in the main menu. Error messages can also be read from the display. They indicate which component of the system has issued the error. open Deactivate/Reset Alarm: •...
  • Page 47 Retrieving Error Messages in the Error Log The up and down arrow buttons can be used to display the error log. Caution: Switch the unit off only if there is an imminent hazard. If the unit is switched off or unplugged, all error messages will be lost. In this case it will no longer be possible to read the error log.

  • Page 48: Manual Decommissioning If Ball Valve Is Defective

    Manual Decommissioning if Ball Valve is Defective If a fault occurs in the ball valve drive following a power failure during backflush mode, the rinsing water is not automatically cut off; instead, KH2 must be manually operated to cut off the rinsing supply.

  • Page 49: Errors E00 To E05 - Ball Valve Positioning

    Errors E00 to E05 – Ball Valve Positioning The controller does not receive feedback from the position sensing of the drive units of either KH1 or KH2. The error message is issued in combination with E04 'KH1 Error' or E05 'KH2 Error' and provides, as extra information, the operating status in which the error occurred.
  • Page 50 open Signal contact Possible Causes • Ball valve will not move • Fault in cabling between controller and valve drive • Cam switch for position sensing out of place or faulty • Ball valve drive fault • Cam switch for position sensing out of place or faulty •...

  • Page 51: Error E06 - Heating Time Exceeded During Td

    Error E06 – Heating time exceeded during TD During thermal disinfection (5/8 h) the PT100 temperature element detects when the required disinfection temperature of at least 78°C is not achieved. Display Lamp green Lamp red Alarm The alarm can be deactivated by pressing the appropriate button Signal contact open...
  • Page 52 Possible Causes • Dry running • Heating circuit fault Phase (of supply power) failed Heater fault Heater protection fault (off continuously) LOGO! output Q5 faulty (off continuously) Pump fault Wiring fault to pump or heater • STL heater over-temperature protection activated Dry running Pump fault PT100 fault...
  • Page 53 Actions/Checks • Check whether another error is also present • Check power supply • Check inputs via input menu • Check heater over-temperature protection • Check heater resistance • Check temperature switch • Check pump • Check cabling • Check ball valve positions •...

  • Page 54: Error E07 - Backflush Failed

    Error E07 – Backflush failed The PT100 temperature element detects during backflushing (15/45 min) that the temperature could not be reduced below 35°C. Display Lamp green Lamp red Alarm The alarm can be deactivated by pressing the appropriate button Signal contact open Possible Causes Seite 54 von 68...

  • Page 55: Error E08 - Backflush Not Possible, Pumping System

    Actions/Checks • Check whether another error is also present • Check water supply • Check proper drainage via backflush line • Check ball valve settings • Check inputs via input menu • Check cabling • Check temperature switch • Check controller •...

  • Page 56: Error - Date And Time Settings Missing

    Possible Causes • Pumping system fault • Signal input not connected to pumping system • Fuses on signal input blown Actions/Checks • Check signal input • Check pumping system 9.11 Error - Date and time settings missing The time and date have not been set for the LOGO! controller unit. The weekly time switch for user-differentiated TD settings only functions if the time is set.

  • Page 57: Maintenance And Service

    10 Maintenance and Service In addition to the usual periodic inspections of the technical systems in accordance with the regulations and standards valid in this field of application, the catalyst granulate in JRG Coral force limescale conditioners must be replaced every five years. Georg Fischer JRG offers a service kit for this purpose.

  • Page 58: Safety When Replacing The Catalyst Granulate

    10.2 Safety when Replacing the Catalyst Granulate Risk of slipping from spilled granulate. Erect a warning sign Risk of scalding! from escaping hot water. Wait until system parts have cooled to room temperature and isolate the system from supply pressure Unplug the unit and secure against restarting Before undertaking granulate replacement, secure the work area to ensure that no unauthorised persons can gain access to the unit.

  • Page 59: Behälter Entleeren

    11 Behälter entleeren Kugelhahn 1 in Bypass- Stellung bringen • KH1 geht bei Stromausfall durch den montierten FailSafe-Antrieb automatisch in Bypassstellung. • Bei Störung des Kugelhahnantriebes muss der KH1 durch manuelles Bewegen (siehe Kap. 8.6 „Manuelle Einstellung KH1“ Seite Fehler! Textmarke nicht definiert.) in die Stellung Bypass gebracht werden, Wasserversorgung...
  • Page 60 Schlauch an Entleerungshahn anschließen und Entleerungshahn öffnen (Druckentlastung) Behälter über Entlüftungsventil belüften Seite 60 von 68 Rev.: 1113803-1...

  • Page 61: Remove Thermal Insulation

    11.1 Remove Thermal Insulation • Open snap-in clamps at top and bottom • Remove PS covers from top of unit and from maintenance flange • Open the lateral locking rails of the jacket • Carefully remove the 2-part insulation jacket 11.2 Emptying Out Granulate Place empty collecting vessel (supplied with service kit) under the...

  • Page 62: Replacing Filter Stars

    11.3 Replacing Filter Stars Remove the filter nozzle stars (top and bottom) including the filter arms. Replace. Ensure accurate fit in threaded sleeve and screw in by hand until firmly seated. Seite 62 von 68 Rev.: 1113803-1...

  • Page 63: Filling With New Catalysing And Filter Granulate

    11.4 Filling with New Catalysing and Filter Granulate Coat bolts with ceramic paste Replace maintenance flange sealing ring (clean the seal surface thoroughly) Fit a new O-ring from the service kit Close maintenance flange Open the filler plug OBSERVE THE CORRECT SEQUENCE Add catalyst granulate via the funnel.
  • Page 64 Close filler plug tightly Seite 64 von 68 Rev.: 1113803-1...

  • Page 65: Commissioning The Unit

    11.5 Commissioning the Unit See the separate 'Commissioning' manual provided with the unit. 11.6 Documentation Note 1. Commissioning must be entered into the maintenance history. 2. Complete the commissioning report and send it to Georg Fischer JRG. Excpl. In the view shown above commissioning on 15/04/2015 was made. Accordingly, the recommended granules exchange is carried out in April 2020th Seite 65 von 68 Rev.: 1113803-1...

  • Page 66: Resetting The Operating Hours Counter

    11.7 Resetting the Operating Hours Counter To acknowledge the message or error message once service has taken place, reset the service timer R esetting the Service Timer The imminent need for service is indicated by the red signal lamp lighting up and the message 'KAT Service Required' appearing on the display.

  • Page 67: Service Set

    See the separate 'Commissioning' manual provided with the unit. 12 Service Set Service-Set Description Item no. Service-Set JRG Coral force 8000 9699.008 Service-Set JRG Coral force 11000 9699.011 Service-Set JRG Coral force 14000 9699.014 Service-Set JRG Coral force 3.5D...

  • Page 68: Seite 3 Von

    Commissioning & Service JRG Coral force 8000 / 11000 / 14000 / 3.5D / 5D Subject to technical changes; mistakes and printing errors excepted. Postal address / stamp of installing company Georg Fischer JRG AG Hauptstraße 130 4450 Sissach Switzerland +41 61 975 23 77 info.jrg.ps@georgfischer.com...

This manual is also suitable for:

Jrg coral force 11000Jrg coral force 14000Jrg coral force 3.5dJrg coral force 5d

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