Kärcher WATERCLEAN 1600 Operating Instructions Manual
  1. Manuals
  2. Brands
  3. Kärcher Manuals
  4. Cleaning Equipment
  5. WATERCLEAN 1600
  6. Operating instructions manual
Kärcher WATERCLEAN 1600 Operating Instructions Manual

Kärcher WATERCLEAN 1600 Operating Instructions Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Operating Instructions
WATERCLEAN 1600
1.237-117.0 WTC 1600 C
BTA 5.971-044.0
ETL 5.970-924.0
A 2025042

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the WATERCLEAN 1600 and is the answer not in the manual?

Questions and answers

Related Manuals for Kärcher WATERCLEAN 1600

Summary of Contents for Kärcher 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 3: Table Of Contents

    Operation and Maintenance of the UV Irradiator ..4 Raw Water .................. 5 1.4.1 Types of Pollutants ............. 5 1.4.2 Retention Capabilities of the Waterclean 1600 System ..........5 1.4.3 Characteristics of Raw Water ........6 1.4.4 Physical Operating Principle of the RO-Machine ..7 Description Overview ..................
  • Page 4 WATERCLEAN 1600 Version 03/2008 2.3.6.4 Panel for Return Feed of Concentrate ....26 2.3.6.5 Cleaning, Disinfecting, Preserving and Frost Protection Function (Cleaning In Place, CIP) ..27 2.3.6.6 Electrical Connection ..........28 2.3.7 Switch Cabinet RO Module ........29 2.3.7.1 Automatic Circuit Breaker ........
  • Page 5 WATERCLEAN 1600 Version 03/2008 Disinfecting the Plant (RO Module) ........50 3.3.1 Standard Disinfection ..........50 3.3.2 Disinfection after Contamination or Continuous Operation with Biologically-polluted Untreated Water ............51 Water Treatment ..............52 3.4.1 Putting into Operation ..........52 3.4.1.1 Inserting the Filter Bag in the Preliminary Filter ..
  • Page 6 WATERCLEAN 1600 Version 03/2008 Monitoring during Operation ..........70 Winter Operation ..............72 Putting out of Operation ............73 Malfunctions and Maintenance Malfunction, Causes and Corrective Measures ....77 4.1.1 Displays on the Switch Cabinet ......77 4.1.2 Operational Faults ............ 78 4.1.3...

  • Page 7: General

    WATERCLEAN 1600 GENERAL Version 03/2008 General EU Declaration of Conformity We hereby declare that the equipment described below conforms to the relevant fundamental safety and health requirements of the appropriate EU Directive, both in its basic design and construction as well as in the version marketed by us.

  • Page 8: Use In Accordance With The Regulations

    GENERAL WATERCLEAN 1600 Version 03/2008 Use in Accordance with the Regulations The equipment is designed for the producing drinking water from raw water (contaminated water). The retention degree of for chemical pollutants and biological patho- gens or contamination is very high (...

  • Page 9: Safety Instructions

    WATERCLEAN 1600 GENERAL Version 03/2008 Safety Instructions 1.3.1 Operation and Maintenance of the WTC 1600 Warning! Dangerous electrical voltages! When working on assemblies marked with this symbol, safety measu- res must be taken: • Switch off • Secure against being switched on again •...

  • Page 10: Operation And Maintenance Of The Uv Irradiator

    GENERAL WATERCLEAN 1600 Version 03/2008 1.3.2 Operation and Maintenance of the UV Irradiator • Never operate the UV irradiator outside of its housing. Danger for eyes and skin! Prolonged reaction of UV light causes reddening/burns to the skin. • Danger of glass-breakage! - Protect the UV irradiator against water blasts as well as against intense vibrations.

  • Page 11: Raw Water

    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.

  • Page 12: Characteristics Of Raw Water

    GENERAL WATERCLEAN 1600 Version 03/2008 The degree of purification is not equally good for all pollutants. De- pending on the degree of contamination, a pre-treatment or a combi- nation with additional system modules of the KÄRCHER WATER- CLEAN series is necessary.

  • Page 13: Physical Operating Principle Of The Ro-Machine

    WATERCLEAN 1600 GENERAL Version 03/2008 1.4.4 Physical Operating Principle of the RO-Machine The machine is operating with the physical principle of the reverse os- mosis. Osmosis is the concentration equalisation on two liquids with different densities. A gradual compensation of the concentrations is produced with a semi-permeable membrane (Fig.
  • Page 14 GENERAL WATERCLEAN 1600 Version 03/2008 - 8 -...

  • Page 15: Description

    WATERCLEAN 1600 DESCRIPTION Version 03/2008 Description NOTE Variations of figures/illustrations shown in these oper- ating instructions to the actual designs are possible due to the different models. Overview Ventilation opening, A/C system Reset button, A(/C system (below cover) Connection box 1 for:...

  • Page 16: Principle Of Operation

    DESCRIPTION WATERCLEAN 1600 Version 03/2008 Principle of Operation Key to the System Flow Diagram (Fig. 3) Debris filter Flow meter, pass II (total) Raw water pump CIP valve, intake Sensor for input pressure, pre-treatment Cleaning tank Prefilter switch-over valve Filling level sensor Preliminary filter air relief cock...
  • Page 17 WATERCLEAN 1600 DESCRIPTION Version 03/2008 Fig. 3 - 11 -...
  • Page 18 DESCRIPTION WATERCLEAN 1600 Version 03/2008 Dechlorination Module The dechlorination module, which consists of ten 30"-activated car- (option) bon filter elements, the pre-filtration. Its purpose is to remove pos- sibly given chlorine from the raw water (catalytic and adsorptive). This is absolutely necessary for the protection of the succeeding spiral- wound membrane modules, as these cannot withstand chlorine con- centrations in excess of 0.1 mg/l.
  • Page 19 WATERCLEAN 1600 DESCRIPTION Version 03/2008 Reverse Osmosis Module After leaving the preliminary filter unit, the raw water is fed to the re- verse osmosis system. When exceeding the required admission pressure of approx. 0.1 bar in the untreated water line, the SPC switches on the two high-pressure pump units P02 and P03 (3/12).
  • Page 20 DESCRIPTION WATERCLEAN 1600 Version 03/2008 NOTE In case of high salt contents, the drinking water capac- ity can vary quite heavily from the values mentioned. During Double Pass operation, the filtrate of both the membrane filter blocks I and II forms the raw water for the membrane filter block III.
  • Page 21 WATERCLEAN 1600 DESCRIPTION Version 03/2008 The reverse osmosis procedure extracts minerals from the water dur- ing treatment. If this water is the sole drinking water source for ex- tended periods, Kärcher recommends the metered addition of rem- ineralisation chemicals in order to avoid deficiency symptoms for the effected persons resulting thereof.
  • Page 22 DESCRIPTION WATERCLEAN 1600 Version 03/2008 Cleaning/Disinfecting/Pre- The cleaning tank (3/29) in the RO module is filled with water, and a serving/Protecting against cleaning agent, disinfectant or anti-freeze is added according to the Frost working procedure to be carried out. The fluid flows from the cleaning tank via the valve V12 (3/31) to the inlet of the high-pressure pump units.

  • Page 23: Description Of The System

    WATERCLEAN 1600 DESCRIPTION Version 03/2008 Description of the System The system is a mobile water treatment plant for producing drinking water with an output of approx. 1 600 l/h. It is a modular assembly and can be fitted according to the conditions for application.

  • Page 24: Submergible Raw Water Pump

    DESCRIPTION WATERCLEAN 1600 Version 03/2008 2.3.2 Submergible Raw Water Pump The raw water pump (7/1) is designed as a submergible pump with an integrated debris filter (7/6). It pumps the raw water from the source to the water connection panel on the system.

  • Page 25: Container Outside

    WATERCLEAN 1600 DESCRIPTION Version 03/2008 2.3.4 Container Outside 2.3.4.1 Connection Box 1 Connection box 1 is used for the raw water inlet (8/1) industrial water (8/2) and concentrate outlet (8/3) the power supply for the WTC 1600 C (8/4) and the power supply for the raw water pump (8/5).

  • Page 26: Container Inside

    DESCRIPTION WATERCLEAN 1600 Version 03/2008 2.3.5 Container Inside 2.3.5.1 Preliminary Filter Module The preliminary filter unit and the holder for a chlorinating container (11/6) and the anti-scalant mixing tank (11/5) are built into the prelim- inary filter module. Raw Water Connection Panel...
  • Page 27 WATERCLEAN 1600 DESCRIPTION Version 03/2008 The preliminary filter comprises: • an automatically controlled 3/2-way valve (11/2) for changing over from one filter to the other • one removable cover (11/1) each for changing the filter bag • one air relief cock (11/3) each Chlorinating/Remineralisa- The chlorination container (11/6) is secured in the holder by a fixation...
  • Page 28 DESCRIPTION WATERCLEAN 1600 Version 03/2008 Fig. 13 Anti-scalant mounting kit - 22 -...

  • Page 29: Reverse Osmosis Module (Ro Module)

    WATERCLEAN 1600 DESCRIPTION Version 03/2008 2.3.6 Reverse Osmosis Module (RO Module) The main part of the RO Module comprises the high-pressure pumps, the membrane filters and the motor-driven pressure maintaining valve. Both the high-pressure pumps (14/1 and 14/2) are switched in parallel and pump the raw water through the membrane filter blocks...

  • Page 30: Connection Panel

    DESCRIPTION WATERCLEAN 1600 Version 03/2008 2.3.6.1 Connection Panel The water connection panel of the RO module consists of four connec- tions. They are mounted on the base plate on the switch cabinet side. • Industrial water outlet (15/1), D coupling •...

  • Page 31: Control Panel For The "Double Pass" (Option)

    WATERCLEAN 1600 DESCRIPTION Version 03/2008 2.3.6.2 Control Panel for the "Double Pass" (Option) The control panel for the "Double Pass" operating mode is located above the water connection panel. It consists of two levers (16/1 and 16/2) and a hand wheel (16/3) enabling different valves to be actuated.

  • Page 32: Panel For Return Feed Of Concentrate

    DESCRIPTION WATERCLEAN 1600 Version 03/2008 2.3.6.4 Panel for Return Feed of Concentrate The return feed for the concentrate conducts 1 000 l/h of the concen- trate back to the suction side of the high-pressure pumps. By supple- menting with 3 000 l/h of untreated water, the required 4 000 l/h at the intake of the high-pressure pumps are maintained again.

  • Page 33: Cleaning, Disinfecting, Preserving And Frost Protection Function (Cleaning In Place, Cip)

    WATERCLEAN 1600 DESCRIPTION Version 03/2008 2.3.6.5 Cleaning, Disinfecting, Preserving and Frost Protection Function (Cleaning In Place, CIP) For cleaning, disinfecting, preserving and protecting against frost the system is respectively built into a cleaning tank (19/1) in the RO mod- ule. It is secured to the holder (19/5) by a fixation strap.

  • Page 34: Electrical Connection

    DESCRIPTION WATERCLEAN 1600 Version 03/2008 2.3.6.6 Electrical Connection The electrical 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).

  • Page 35: Switch Cabinet Ro Module

    WATERCLEAN 1600 DESCRIPTION Version 03/2008 2.3.7 Switch Cabinet RO Module The switch cabinet is built into the frame of the RO module. It houses all the electrical assemblies for operating and monitoring the system. Fig. 21 Switch cabinet Phase rotation indicator "Preliminary filter F03 in...

  • Page 36: Automatic Circuit Breaker

    DESCRIPTION WATERCLEAN 1600 Version 03/2008 2.3.7.1 Automatic Circuit Breaker Fig. 22 Fuses in the switch cabinet Main fuse: supply 400 V Residual current device: supply 400 V Fuse: plug - external Fuse: switch cabinet fan Fuse: volume-controlling pump P04 Fuse: control transformer 230 V...

  • Page 37: Safety Fuses

    WATERCLEAN 1600 DESCRIPTION Version 03/2008 2.3.7.2 Safety Fuses The safety fuses are located on the inside of the left switch cabinet wall. The integrated LED illuminates when the fuse is defective. Fig. 23 Safety fuses Fuse phase control lamp 1...

  • Page 38: Operating Panel

    DESCRIPTION WATERCLEAN 1600 Version 03/2008 2.3.8 Operating Panel The operating panel provides the operator with relevant information during operation, e.g.: • The name of the program in progress, • The remaining running times of active programs (e.g. preserva- tion, disinfecting, cleaning.
  • Page 39 WATERCLEAN 1600 DESCRIPTION Version 03/2008 Menu Information 01 Automatic • Output (l/h) • Pressure (bar) O u t p u t : _ _ _ _ _ _ l / h Display P r e s s u r e :...
  • Page 40 DESCRIPTION WATERCLEAN 1600 Version 03/2008 Menu Information 05 Temperature limits • Raw water temperature limit • Raw water temperature R a w w a t e r t e m p . Display m i n 3 / m a x 4 0 °...
  • Page 41 WATERCLEAN 1600 DESCRIPTION Version 03/2008 Menu Information 09 Cleaning • Cleaning time C l e a n i n g t i m e : Display a c t . _ _ _ _ / s e t 2 0 m i n 10 Preservation •...
  • Page 42 DESCRIPTION WATERCLEAN 1600 Version 03/2008 Menu Information 13 Malfunction times • Wait PISA –1 min • Wait PISA +1 min • Wait PISA –1 max • Wait PISA +1 max • Wait PISA +2 max • Wait PICSA +1 max...

  • Page 43: Uv Treatment (Option)

    WATERCLEAN 1600 DESCRIPTION Version 03/2008 Menu Information 17 Working hours • Time since maintenance • Working hours T i m e s i n c e m a i n t e - Display n a n c e _ _ _ _ h...

  • Page 44: Specifications

    DESCRIPTION WATERCLEAN 1600 Version 03/2008 Specifications 2.4.1 Complete System Modules of the System WTC 1600 (Pre-cleaning module, dechlorination, membrane module, drinking- water intermim storage and drinking-water distribution). ISO ICC container (standard 20") Dimensions for Transport WTC 1600 C < 10.000 kg...
  • Page 45 WATERCLEAN 1600 DESCRIPTION Version 03/2008 Other Performance Character- • Integrated volume-controlling pump for subsequent chlorination istics • UV treatment for germ reduction (optional) • Control displays for conductivity and temperature • Control displays for operating pressures • Operating panel • External control via filling-level sensors in the drinking-water tank •...

  • Page 46: Accessories

    DESCRIPTION WATERCLEAN 1600 Version 03/2008 Accessories NOTE Order standard accessory spare parts from the current spare parts list! (not according to the following listings.) The spare parts list is updated continuously. 2.5.1 WTC 1600 Designation Quantity Order No.: Raw water pump including swim ring 1 pc 4.540-081.0...

  • Page 47: Generator Accessories

    WATERCLEAN 1600 DESCRIPTION Version 03/2008 2.5.2 Generator Accessories Designation Quantity Order No.: Earthing rod 1 pc 6.600-131.0 Earthing cable 1 pc 6.600-157.0 Consumption Materials NOTE Order consumption materials from the current spare parts list! The spare parts list is updated continuously.
  • Page 48 DESCRIPTION WATERCLEAN 1600 Version 03/2008 - 42 -...

  • Page 49: Operation

    WATERCLEAN 1600 OPERATION Version 03/2008 Operation Note for Maintenance and Care The system primarily consists of stainless steel components. Some of the components are additionally painted/coated. It is nonetheless re- quired that the system is rinsed regularly with drinking water.

  • Page 50: Power Supply Via External Line Entry

    OPERATION WATERCLEAN 1600 Version 03/2008 3.2.3 Power Supply Via External Line Entry • The power supply (29/1) at the container must be established. • Set the main switch (29/3) at the main switch cabinet to "I" (ON) . • If indicator (29/2) lights up after switching on, switch the phase- shifter switch (29/4) to the other position.

  • Page 51: A/C / Heating System

    WATERCLEAN 1600 OPERATION Version 03/2008 3.2.4 A/C / Heating System At low temperatures, ensure that the A/C / heating system is set to "HEAT" and switched on. The requested temperature is to be pre-se- lected via the temperature regulator of the A/C / heating system. When the plant is in operation, the water-carrying modules must be kept frost-free.

  • Page 52: Hydraulic Connections

    OPERATION WATERCLEAN 1600 Version 03/2008 3.2.5 Hydraulic Connections 3.2.5.1 Raw Water Feed Inlet Connect raw water hose to the coupling "raw water inlet" (32/2) at the container side. Unwind the raw water hose to the raw water source. Connect the raw water pump to the RW tank by hoses (the water level in the RW tank must be higher than the pump level).

  • Page 53: Concentrate Outlet

    WATERCLEAN 1600 OPERATION Version 03/2008 NOTE Forvertical operation of the pump, a minimum water depth of 75 cm is required so that the pump does not get to the bottom and has suf- ficient clearance to particles that have possibly deposited on the ground.

  • Page 54: Drinking Water Outlet

    OPERATION WATERCLEAN 1600 Version 03/2008 3.2.5.3 Drinking Water Outlet Couple the drinking water hose to the respective coupling at the connection panel (34/1). Fig. 34 Drinking-water outlet NOTE Do not connect the drinking water hose yet to the drinking water tank or to the depot location, as the system must be disinfected first and then flushed...

  • Page 55: List Of Chemicals

    WATERCLEAN 1600 OPERATION Version 03/2008 3.2.6 List of Chemicals Work step Chemicals Quantity per application Standard disinfec- RM P3 Oxonia 150 ml tion Disinfecting after RM P3 Oxonia 250 ml per 100 l ext. con- contamination tainer content Cleaning RM Kleen MCT 511...

  • Page 56: Disinfecting The Plant (Ro Module)

    OPERATION WATERCLEAN 1600 Version 03/2008 Disinfecting the Plant (RO Module) 3.3.1 Standard Disinfection The system must undergo a standard disinfection: • before being put into operation, if the system has not been in oper- ation for longer than 60 hours •...

  • Page 57: Disinfection After Contamination Or Continuous Operation With Biologically-Polluted Untreated Water

    WATERCLEAN 1600 OPERATION Version 03/2008 10. After the required time has elapsed, the high-pressure pump switches off. NOTE The procedure can be interrupted by pressing the "Stop" button (49/8). 11. Turn the valve levers V12 and V10 into the vertical position (close).

  • Page 58: Water Treatment

    OPERATION WATERCLEAN 1600 Version 03/2008 Water Treatment Connect the system as described under Section 3.2. The working steps must be strictly adhered to and carried out consecutively. WARNING The equipment may only be operated by qualified or trained staff. Operating errors can cause dam-...

  • Page 59: Installation Of Activated Carbon Filter Elements Into Dechlorination Module

    WATERCLEAN 1600 OPERATION Version 03/2008 Fill the housing with drinking water to enable trouble-free, auto- matic switching-over between the prefilters. NOTE Place the lid such that it is centred exactly on the filter housing and tighten the winged nuts evenly.
  • Page 60 OPERATION WATERCLEAN 1600 Version 03/2008 WARNING Do not adjust knob (38/1) and (38/4). These are fac- tory-set. NOTE Standard setting (target concentration: 0.3 ppm chlorine-free): • Displacement: 100% • Ratio (frequency): 1:1 The operating mode must be set to "External" in order to have the amount-proportional addition of chlorine switched on.

  • Page 61: Anti-Scalant (Option)

    WATERCLEAN 1600 OPERATION Version 03/2008 3.4.1.4 Anti-scalant (Option) Dosing Amount With use of the following table, the adjustment of the Anti Scalant dosing amount can be determined with very good proximity. The op- timum dosing could be calculated only after an exact water analysis and with the help of a calculation program.

  • Page 62: Uv Treatment (Option)

    OPERATION WATERCLEAN 1600 Version 03/2008 3.4.1.5 UV Treatment (Option) Switch on the UV irradiator with the switch (39/1); the LEDs (39/2, 3, 4) flash briefly. During the switching-on phase (1 to 2 minutes) the LEDs light up in the sequence red (39/2), yellow (39/3), and green (52/4).

  • Page 63: Switching On In Automatic Operation Mode

    WATERCLEAN 1600 OPERATION Version 03/2008 If the drinking-water flow of 1 600 l/h is not reached or if the conduc- tivity value of the drinking water exceeds the allowable limit values, then the concentrate return line must definitely be shut.
  • Page 64 OPERATION WATERCLEAN 1600 Version 03/2008 ➜ On the operating panel (49/7) the system output and pressure data valid at the given time are shown ➜ "Control valve V06 closed" lamp (49/15) flashes, the control valve automatically controls the system to the rated opera-...

  • Page 65: Switching Off In Automatic Operation Mode

    WATERCLEAN 1600 OPERATION Version 03/2008 3.4.2.2 Switching OFF in Automatic Operation Mode Press "Stop" button (49/8). ➜ Control valve V06 opens, lamp "Control valve V06 open" (49/14) flashes. If the valve is open, the lamp illuminates con- tinuously. NOTE The opening time can last up to 3 minutes.

  • Page 66: Switching On In Manual Operation Mode

    OPERATION WATERCLEAN 1600 Version 03/2008 3.4.3.1 Switching ON in Manual Operation Mode DANGER When putting into operation for the first time, after disin- fecting, cleaning, preserving or applying anti-freeze, reject the drinking water for at least 30 minutes and after the system has stood still for between 24 - 60 hours, reject for 15 minutes.
  • Page 67 WATERCLEAN 1600 OPERATION Version 03/2008 Turn hand-wheel (43/1) slowly in the "CLOSE" direction until the first adjustment value for Pass 1 is reached on the "Pass 1” menu of the control panel. Fig. 43 Hand-wheel Using button "▼" (44/3) on the operating panel, switch to menu "Pass 2".

  • Page 68: Switching Off In Manual Operation Mode

    OPERATION WATERCLEAN 1600 Version 03/2008 3.4.3.2 Switching OFF in Manual Operation Mode Fully turn the hand-wheel (43/1) slowly in the "OPEN" direction. Press the "Stop" button (49/8). ➜ Control valve V06 opens; "Control valve V06 open" lamp (49/14) flashes. When the valve is open, the lamp lights con- tinuously.

  • Page 69: Switching Off In Manual Operation As Emergency Function

    WATERCLEAN 1600 OPERATION Version 03/2008 NOTE From the drinking-water capacity of approx. 1 000 l/h on, the control procedure takes place very slowly as internal control parameters change. NOTE If due to failure of certain sensors the respective values are not indicated, then these must be deter- mined manually (e.g., by reading the pressure...

  • Page 70: Measures For Protecting The Membrane

    OPERATION WATERCLEAN 1600 Version 03/2008 Measures for Protecting the Membrane The following protective measures safeguard the function of the membrane filter and maximize its service life: • Washing out The work step ”washing out” is to be carried out: • After each operation, •...

  • Page 71: Cleaning

    WATERCLEAN 1600 OPERATION Version 03/2008 Press luminous button "Start" (49/11). ➜ a high-pressure pump starts ➜ the operating panel (49/7) indicates "Maintenance - Washing Out" ➜ the cleaning tank is emptied via the concentrate and drinking water connection WARNING Reject the water.

  • Page 72: Preserving

    OPERATION WATERCLEAN 1600 Version 03/2008 From an external source, fill the cleaning tank (50/1) to the upper mark with drinking water. Add cleaning chemicals to the cleaning tank according to Table 1, page 49. Turn valve levers V12 (50/9) and V10 (50/7) into the horizontal position (open).

  • Page 73: Frost Protection

    WATERCLEAN 1600 OPERATION Version 03/2008 ➜ operating panel indicates "Maintenance - Preservation" and then the preservation time begins. The subsequent procedure corresponds with the working steps 7 to 10 of Section 3.5.2. Make sure that all the water-conducting components of the sys- tem that are not preserved, are emptied.
  • Page 74 OPERATION WATERCLEAN 1600 Version 03/2008 11. Let the system sit for approx. 15 minutes to enable the concen- tration on the inside to compensate. 12. Open valve V05 of the concentrate return line. 13. Shut valve V10. 14. Press the luminous "Start" button (72/11).

  • Page 75: Emptying/Draining The Drinking-Water Interim Storage, The Dechlorination Module And Distribution

    WATERCLEAN 1600 OPERATION Version 03/2008 3.5.5 Emptying/Draining the Drinking-water Interim Storage, the Dechlorination Module and Dis- tribution Empty 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.

  • Page 76: Monitoring During Operation

    OPERATION WATERCLEAN 1600 Version 03/2008 Monitoring during Operation The WTC 1600 is monitored by an SPS (storage programmable control) system. If a fault occurs it is indicated on the operating panel (49/7) and the lamp "Fault reset" (49/9) illuminates on the switch cabinet.
  • Page 77 WATERCLEAN 1600 OPERATION Version 03/2008 Filling Level, Chlorinating-/ • Check the filling level of the chlorinating (46/1) and Anti Scalant Anti Scalant Container container (46/2). (Option) ➜ If necessary replenish and prepare mixture Fig. 46 Chlorinating and Anti Scalant container Filling Level, Remineralisation •...

  • Page 78: Winter Operation

    OPERATION WATERCLEAN 1600 Version 03/2008 Winter Operation During winter operation it is necessary to heat the water treatment plant. For heating 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.

  • Page 79: Putting Out Of Operation

    WATERCLEAN 1600 OPERATION Version 03/2008 Putting out of Operation Put out of operation in the following sequence: Empty the chlorinating-, Anti Scalant and remineralisation con- tainers. • Release the fastening strap (46/2) of the chlorinating container (46/1). • Pour the contents of the chlorination- and Anti Scalant con- tainers into a suitable collecting container and dispose of in accordance with national regulations.
  • Page 80 OPERATION WATERCLEAN 1600 Version 03/2008 Disconnect, empty 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...
  • Page 81 WATERCLEAN 1600 OPERATION Version 03/2008 Key Fig. 49 Phase control lamps Phase rotation indicator Float switch Conductivity indicator DW Temperature indicator DW Lamps, preliminary filters Control panel SPC "Stop" button "Fault reset" button 10 Selector switch for main- tenance functions 11 "Start"...
  • Page 82 OPERATION WATERCLEAN 1600 Version 03/2008 - 76 -...

  • Page 83: Malfunctions And Maintenance

    WATERCLEAN 1600 MALFUNCTIONS AND MAINTENANCE Version 03/2008 Malfunctions and Maintenance 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.

  • Page 84: Operational Faults

    MALFUNCTIONS AND MAINTENANCE WATERCLEAN 1600 Version 03/2008 4.1.2 Operational Faults Fault Cause Remedy WTC 1600 unit starts again Float switch is set to "ON" Set switch to "OFF" although "Stop"-button has been pressed Drinking water, industrial water Wrong program selected Start the correct program or concentrate flow is faulty...

  • Page 85: Fault Indications On The Control Panel

    WATERCLEAN 1600 MALFUNCTIONS AND MAINTENANCE Version 03/2008 Fault Cause Remedy Drinking water interim storage Level sensor cable not pluged in Plug in cable gets overfilled Float switch is set to "OFF" Set switch to "ON" Level sensor "maximum" defect Replace with new one 4.1.3...
  • Page 86 MALFUNCTIONS AND MAINTENANCE WATERCLEAN 1600 Version 03/2008 Fault Cause Remedy Fault, raw water temperature Raw water temperature too high Look for suitable raw water too high source Sensor defective Replace sensor Signal converter defective Replace signal converter Fault, raw water temperature...
  • Page 87 WATERCLEAN 1600 MALFUNCTIONS AND MAINTENANCE Version 03/2008 Fault Cause Remedy Membrane input pressure too Regulation fault Inform customer service high Incorrect handling during manual Check valve settings operation Cleaning tank filling level too No filling level, or filling level too...

  • Page 88: Faults On The Uv Treatment (Option)

    MALFUNCTIONS AND MAINTENANCE WATERCLEAN 1600 Version 03/2008 4.1.4 Faults on the UV Treatment (Option) Malfunction/Fault Cause Remedy 1 UV irradiator and LEDs at the Fuse defective/tripped Check fuse and replace if nec- switchbox do not illuminate essary Power supply disconnected Check power supply 2 Yellow LED "Pre-alarm"...

  • Page 89: Maintenance Work Schedule

    WATERCLEAN 1600 MALFUNCTIONS AND MAINTENANCE Version 03/2008 Maintenance Work Schedule Consec. Test Point/Description Time Schedule Reference to Section Complete System Cleaning For low salt content Section 4.3.1.1 (RW < 5 000 ppm): weekly For brackish and salt water Section 4.3.1.1 (RW >...
  • Page 90 MALFUNCTIONS AND MAINTENANCE WATERCLEAN 1600 Version 03/2008 Consec. Test Point/Description Time Schedule Reference to Section UV System (option) Check the display of the UV daily Section 3.6 switch cabinet (UV capa- city) Check the protective quartz after indication of the yellow Section 4.3.4.2...

  • Page 91: Maintenance

    WATERCLEAN 1600 MALFUNCTIONS AND MAINTENANCE Version 03/2008 Maintenance ☞ The system is to be checked annually by an authorized KÄRCHER dealer. WARNING If the system is subject to waste water/salt water during maintenance work, then the system must be rinsed thoroughly with drinking water.

  • Page 92: Ro Module

    MALFUNCTIONS AND MAINTENANCE WATERCLEAN 1600 Version 03/2008 4.3.2 RO Module 4.3.2.1 Oil Level Control on the High-Pressure Pump Check the oil level of the high-pressure pump through the oil sight glass (52/2). If necessary, fill up with oil to the upper edge of the oil level gauge. To do this, unscrew the Screw (52/1) on the housing cover and pour in SAE 50 oil.

  • Page 93: Changing The Membrane Filters

    WATERCLEAN 1600 MALFUNCTIONS AND MAINTENANCE Version 03/2008 4.3.2.3 Changing the Membrane Filters WARNING Make sure the system has been depressurized before opening the filter unit! • Drain the water from the system. • Turn off the power supply and safeguard it from being switched on again.
  • Page 94 MALFUNCTIONS AND MAINTENANCE WATERCLEAN 1600 Version 03/2008 • Mount the membrane detachment facility (55/3); to do this - Place the membrane detachment facility, spacing pins (55/1) first, over the respective pair of pressure tubes. - Screw both of the membrane detachment screws to the stop nut (55/2) into the thread of the permeate nipple (54/3).
  • Page 95 WATERCLEAN 1600 MALFUNCTIONS AND MAINTENANCE Version 03/2008 • Pull the membrane filters (57/1) individually out of the pressure tubes. Fig. 57 • Assembly is effected in the reverse sequence. NOTE Check the permeate collecting pipes for damage. Apply grease to the permeate collecting pipes and to the O-rings.

  • Page 96: Post-Preservation Of Non-Installed, Originally-Packed Membranes

    MALFUNCTIONS AND MAINTENANCE WATERCLEAN 1600 Version 03/2008 4.3.2.4 Post-preservation of Non-installed, Originally-packed Membranes Originally packed membranes can be stored in their packaging for up to 12 months. As a protective measure, however, renewal of the pre- servation solution after 6 months is recommended.

  • Page 97: Preliminary Filter Module

    WATERCLEAN 1600 MALFUNCTIONS AND MAINTENANCE Version 03/2008 4.3.3 Preliminary Filter Module Changing the Filter Bag • For relieving the pressure of the preliminary filters, briefly open the venting cocks (60/1), place a suitable collecting container underneath. • Loosen the three winged nuts in each case (60/3) on the respective lid of the two preliminary filters and remove lid.
  • Page 98 MALFUNCTIONS AND MAINTENANCE WATERCLEAN 1600 Version 03/2008 WARNING Clean the prefilter housing before inserting the filter bag. Wipe particles out of the prefilter housing using a cloth or similar so that these do not fall down to the bottom of the housing and make their way to the membranes.
  • Page 99 WATERCLEAN 1600 MALFUNCTIONS AND MAINTENANCE Version 03/2008 Dechlorination Module WARNING The housing of the active carbon filter is under pressure! Observe the following: Before opening the housing of the active carbon filter, the inlet ball valve is to be shut.

  • Page 100: Uv Irradiator (Option)

    MALFUNCTIONS AND MAINTENANCE WATERCLEAN 1600 Version 03/2008 4.3.4 UV Irradiator (Option) 4.3.4.1 Changing the UV Irradiator • Switch off the UV irradiator with the 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.

  • Page 101: Cleaning/Changing The Protective Quartz Tube

    WATERCLEAN 1600 MALFUNCTIONS AND MAINTENANCE Version 03/2008 4.3.4.2 Cleaning/Changing the Protective Quartz Tube • Depressurize and empty the UV unit. • Remove the UV irradiator according the Section 4.3.4.1. Fig. 65 • Loosen the clamping socket (65/1) together with the threaded socket (65/2) and unscrew.

  • Page 102: Cleaning The Uv Sensor

    MALFUNCTIONS AND MAINTENANCE WATERCLEAN 1600 Version 03/2008 4.3.4.3 Cleaning the UV Sensor • Depressurize and empty the 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.

  • Page 103: Appendix

    WATERCLEAN 1600 APPENDIX Version 03/2008 Appendix Salt Content of Water Sources Quantity values for the contents present in the water are given in dif- ferent units; therefore, conversion to the measuring units of the sys- tem is necessary. In the case of the WTC 1600 the presence of salt ions is deduced from the continual measurement of the conductivity.
  • Page 104 APPENDIX WATERCLEAN 1600 Version 03/2008 µS/cm ppm µS/cm ppm µS/cm ppm µS/cm ppm µS/cm ppm µS/cm 1700 2600 1315 4500 2356 7800 4206 12000 6607 1000 1725 2650 1344 4600 2412 7900 4262 12200 6728 1020 1750 2700 1371 4700...
  • Page 105 WATERCLEAN 1600 APPENDIX Version 03/2008 µS/cm ppm µS/cm ppm µS/cm ppm µS/cm ppm µS/cm ppm µS/cm 19750 11323 25000 14550 28500 16702 39500 23465 60000 37205 81000 51443 20000 11476 25500 14858 29000 17010 40000 23773 61000 37883 82000 52121...
  • Page 106 APPENDIX WATERCLEAN 1600 Version 03/2008 - 100 -...
  • Page 107 WATERCLEAN 1600 APPENDIX Version 03/2008 - 101 -...
  • Page 109 WATERCLEAN 1600 APPENDIX Version 03/2008 - 103 -...

Table of Contents