JETPAK Contents Contents Introduction Documentation Conventions Safety Intended use General safety instructions Safety instructions specific to the JETPAK system 11 Description Structure Technical data Requirements to the activated carbon Installation Transport and storage Unpacking and erection Mounting the stirrer shaft Connections Level measuring Connection of water supply...
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JETPAK Contents Connecting PROFINET IO-Device Connecting PROFIBUS DP Connecting MODBUS TCP Changing the IP address of the CPU Connecting Process Monitoring System (PMS) Data formats Reference list Operation HMI Control panel System scheme Operator menus Calculation of the dosage quantity Replenishing activated carbon Switching on the dosing points Switching off dosage...
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JETPAK Contents Maintenance parts kits Spares Dismantling and disposal Typical installation 10. Wiring diagrams 11. Annex 11.1 Requirements to the filter 11.2 Dosage diagram 11.3 Time sequence of the dosing process 12. Declaration of conformity...
The entitled „Installation and commissioning“ and „Maintenance...“ chapters are intended exclusively for Evoqua-authorized technici- ans. These sections contain important information on assembling, configuring, and commissioning the system and on maintenance and repair work.
JETPAK Introduction Conventions This Instruction manual contains a number of notes with different Notes priorities marked with symbols. Picto- Note Meaning gram Danger to life and limb! If the Warning! situation is not handled properly, death or serious injury may be the result.
JETPAK Safety 2. Safety Intended use The plant may be used for the preparation and dosing of a water and activated carbon suspension for the treatment of swimming, drinking, cooling, process and waste water. Other or excess use is not intended. The operational safety of the system can only be guaranteed if it is used in accordance with its intended purpose.
"Authorized and qualified personnel" include: by the operator, by Evoqua or by personnel who have been trained Operation and instructed by the service partner.
JETPAK Safety Safety instructions specific to the JETPAK system Warning of caustic substances! Danger due to chemicals! The solution contains sulphuric acid that is dangerous to the skin and face, particularly the eyes! During all work involving acid keep an eye-bath close at hand! To avoid acid burns put on closely sealing protective goggles and protective clothing before starting any work involving sulphuric acid.
19 Filter nozzles 9 Suction line 20 Pure water 10 Diaphragm valve 21 Pure water outlet 11 Vent line with solenoid valve The items 14 - 21 are not supplied by Evoqua. For requirements concerning the filter refer to the annex.
JETPAK Description Technical data Dimensions (W x D x H) 1.10 m x 0.85 m x 1.5 m Space 1.5 m x 1.5 m Weight, installed, empty approx. 56 kg (with 3 dosage lines) operative approx. 516 kg Tank volume 460 ltr up to overflow Usible volume 300 ltr...
JETPAK Description Requirements to the activated carbon • Only moistened and acidic powdered activated carbon (to EN 12903 (potable water), EN 15977 (swimming pool water), DIN 19643-2) • Surface >900 m /g, calculated by BET • Low fluctuations in quality depending on production •...
JETPAK Installation 4. Installation Transport and storage • Protect the system from tilting during transport and storage. • Remove the transport fixing devices only on arriving at the ins- tallation site. • Load the system with an elevating truck or forklift. •...
JETPAK Installation Mounting the stirrer shaft 1 Open the filling hole of the tank. 2 Fix the stirrer shaft to the stirrer motor (see figure). 3 Fix the screws A with the Allen key 3 mm.. Connections 4.4.1 Mains connection Also refer to the technical data in chapter 3.2 and the wiring dia- grams enclosed.
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JETPAK Installation • Get instructions from the operator! • Harmonise your work with the surroundings. • Use only licensed and properly functioning tools and measu- ring equipment, and personal protection devices. • The system must be properly earthed. No freely accessible part of the system may be under mains voltage or any other dangerous voltage.
JETPAK Installation Level measuring Installed is a non-contact, contiuously measuring ultrasonic level sensor. The limit levels have been programmed at the factory and cannot be changed. Level Height Reaction EMPTY approx. 50 mm Failure approx. 150 mm Tank is filled approx.
JETPAK Installation 4.6.2 Tank overflow and drainage 1 Connect the tank overflow (DN25) and drainage (DN20) by a hose or pipe with a suitable outlet (for the disposal of the suspension refer to the national regulations and those of sewage disposal). Note The overflow must not be closed by a valve.
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• Downstream from the sample water take-off point • Only use original Evoqua - injection points! Order no. W3T166154 • If possible insert the injection pipe from above or diagonally from above, but not from the side or below (risk of blockage) •...
JETPAK Installation Commissioning 4.8.1 Switching-on 1 Open the operating water. 2 Switch-on the main switch. 3 Acknowledge the fault messages „Tank empty“ and „Power fai- lure“ with ACK. 4 Enter the service code. 5 Touch F1 to start the automatic mode. 6 Touch F4, menu is displayed.
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JETPAK Installation 4.8.2 Parameter settings The following parameters must be modified or adjusted: (refer to the operator and service menus) • Date, time • Switching times (chapter 6.10) • Mode: AUTO, ON, OFF, chapter 6.6 • Activated carbon feed rate: (Factory setting1 g/m³), chapter dosing •...
JETPAK Installation Service menus 4.9.1 Setup menus The Setup menus are used for the setting of: • AutoSTART, PROFIBUS address, W&T RS485 bus, maintenance interval • Circulation capacity, flushing time • Concentration, cycle duration, dosing range • Ethernet interface (PROFINET-IO, MODBUS TCP) •...
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JETPAK Installation the control unit is replaced during servicing, set the previous type 3RG6013 if necessary. Set diaphragm valve types 1 - 3 depending on the valves installed. As of software version 2.0, type R629 is installed. 10 Touch „next”. 11 „Setup: ETERNET internet”...
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JETPAK Installation 4.9.2 Function test The following menus serve to activate/deactivate or open/close the following components (service password necessary): • Stirrer • Solenoid valves injector, filling, venting • Membrane valves 1, 2, 3 • Booster pump (when installed) 1 Touch F4. 2 If necessary enter the service password.
JETPAK Installation 4.10 Select the language 1 Touch F4. If necessary enter the operator code. 2 Touch „Language” 3 Select the language. The display is immediately switched to the new language. WT.350.210.000.DE.IM.0223...
JETPAK Installation 4.11 Settings Factory setting Display Commissioning Modification (in bold) Plant name Location AutoSTART Maintenance intervall 365 days = 1 year ETHERNET IP address 192.168.178.100 PROFIBUS address 125 (3-125) RS485 address 2 (0-31) 50 m³/h (10-1500 m³/h) Circulation 50 m³/h (10-1500 m³/h) 50 m³/h (10-1500 m³/h) Flushing time 60 s (10-150 s)
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JETPAK Installation Factory setting Display Commissioning Modification (in bold) Diaphragm valve 1 type 629 (24 V DC) R613 (230 V AC) R629 (24 V DC) Diaphragm valve 1 type R613 (230 V AC) Diaphragm valve 1 type R629 (24 V DC) R613 (230 V AC) WT.350.210.000.DE.IM.0223...
JETPAK Interfaces 5. Interfaces The controller provides interfaces for PROFINET IO-Device, PROFIBUS DP or MODBUS TCP. The corresponding hardware can be installed during commissioning or retrofitted later. Note The status LED „ERROR” on the SIMATIC S7 flashes if the system is not connected to a master fieldbus system (PROFIBUS DP or PROFINET IO).
JETPAK Interfaces Connecting PROFINET IO-Device (Optional) This chapter provides software developers and assembly personnel with information on programming and installation for connection to a PROFINET system. The control of the generator, the Siemens SIMATIC S7-1200, is geared for data exchange over PROFINET IO-Device on a superordinate PROFINET network.
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JETPAK Interfaces 5.2.2 Wiring PROFINET Note Follow the setup guidelines for PROFINET networks such as on network topology, the properties of the bus lines, line termination, max. segment lengths, max. number of stations, transmission rate, use/number of repeaters etc. For information, contact the PROFINET User Organization, the manufacturer or the manufacturer of the automation system you are using.
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JETPAK Interfaces PROFINET IO-Device A Display B CPU C Communication with IO-Master Note The status LED „ERROR” on the SIMATIC S7 flashes if the system is not connected to a master fieldbus system (PROFIBUS DP or PROFINET IO). In such case, the communication partner (PROFIBUS master or IO-controller) is not available.
JETPAK Interfaces 5.2.3 Configuring PROFINET-IO-Controller In order for the data on a automation system to be read, it must know the configuration for the data transfer. Data exchange configuration: The PROFINET IO-Controller is configured with the aid of the device master data file (GSDML file): GSDML-V2.32-#Siemens-PreConf_Basic8880-V1-20180720- 085016.xml 192 (6 x 32) bytes of user data are transferred over the PROFINET...
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JETPAK Interfaces 5.3.1 Technical data Hardware SIMATIC S7-1200 CPU1242-5 PROFIBUS DP Slave V1.0 Siemens part no 6GK7242-5DX30-0XE0 Transmission technology RS-485 in accordance with the PROFIBUS specifications Baud rate 1.5 MBit/s Bus address default 125 Bus connection 9 pin D-Sub socket on site: 9-pole PROFIBUS DP plug Communication Cyclic I/O data exchange between the DP master and...
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JETPAK Interfaces 1 Shut-down the generator. Installing the communication module 2 Open control cabinet. 3 Remove the interface cover at the left side of the PLC using a screwdriver. 4 Snap the communication module CM1242-5 Slave onto the rail. 5 Connect the communication module by carefully moving it towards the PLC.
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JETPAK Interfaces 1 Enter the Service password, see chapter 6.1.5. Setting the PROFIBUS DP address 2 Press F4 “Menu”. 3 Touch “Setup”. The present PROFIBUS DP address is displayed. 4 Enter the new PROFIBUS address. The new address is active after a reboot of the system. To reboot, switch the main switch off and on (or separate the sys- tem from the mains).
JETPAK Interfaces Connecting MODBUS TCP This chapter provides software developers and assembly personnel with information on programming and installation for connection to a MODBUS system. The control of the generator, the Siemens SIMATIC S7-1200, is geared for data exchange over MODBUS on a superordinate MODBUS network.
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JETPAK Interfaces 5.4.2 Connecting MODBUS Note Follow the setup guidelines for MODBUS networks such as on network topology, the properties of the bus lines, line termination, max. segment lengths, max. number of stations, transmission rate, use/number of repeaters etc. For information, contact the MODBUS User Organization, the manufacturer or the manufacturer of the automation system you are using.
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JETPAK Interfaces PROFINET IO-Device A Display B CPU C Communication with IO-Master 5.4.3 Configuring MODBUS client In order for the data on a automation system to be read, it must know the configuration for the data transfer. MODBUS functions for the data exchange: MODBUS Data length Function and data type...
JETPAK Interfaces Changing the IP address of the CPU For PROFINET and MODBUS Note The Ethernet interface of the CPU is used for the communication with an external automation system. This Ethernet interface of the CPU is also used for the communication with the HMI.
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JETPAK Interfaces 7 Touch „Settings“. 8 Touch the symbol „Service and Commissioning”. 9 Swipe until „Assign IP Address” is displayed. 10 Touch „Assign IP Address” and then 11 Swipe upward until „Accessible devices in target subnet” is displayed. 12 Touch to activate. 13 Touch „>”...
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JETPAK Interfaces If the change was successful, „Station name and IP suite set- tings could be assigned!” is displayed. In case of a failure: „Station name and IP suite settings could not be assigned!” is displayed. Touch „close” to close the message. Touch to close the window.
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JETPAK Interfaces 26 Touch „>” to go to the next step 2/3. 27 Enter the new IP address of the PLC as of step 12. 28 Swipe upward until the slide switch „Override” is displayed. 29 The slide switch must be set to „ON”, swipe if necessary. 30 Touch „>”...
JETPAK Interfaces Connecting Process Monitoring System (PMS) (Optional) The serial RS485 bus interface is used for data transfer to the visualisation system Process Monitoring System (PMS). The visualisation system Process Monitoring System is used for archiving and monitoring of process data, for remote diagnosis and remote access using a standard browser with internet and E- mail capability.
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JETPAK Interfaces 5.6.2 Connecting RS485 1 Shut-down the generator. Installing the communication board 2 Open control cabinet. 3 Carefully remove the two terminal covers of the PLC and lift the blind covers. 4 Connect the communication board CB1241 RS485 from the top to the PLC and close the terminal covers.
JETPAK Interfaces Data formats The following table contains data formats used during the transfer of process data: Data type Size Typical names Initials Value range (Bit) BOOL Bit, Bool BYTE unsigned Char, Byte WORD unsigned Integer, FFFF Word STRING (n*8) + 16 ASCII, String, Character string n = number of characters...
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JETPAK Interfaces BYTE Example: 7B = 123 BYTE 0 WORD Example: 3039 = 12345 BYTE 0 BYTE 1 3039 STRING Example: ‚AB‘ STRING [2] BYTE 0 BYTE 1 BYTE 2 BYTE 3 max. length of string actual length of string ASCII value A ASCII value b...
JETPAK Interfaces Reference list The following reference list contains the data that were made available by the generator. „n” starting address of the master input area. „R” read access right. "n" starting address of the master input area JETPAK (EN) "R"...
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JETPAK Interfaces "n" starting address of the master input area JETPAK (continuation) "R" read access right MODBUS Byte Length Value Format Access Description Register addr. addr. (byte) Value range BOOL Perform maintenance! 1 = Warning message active 40075 n+148 BOOL Tank MIN! 1 = Warning message active BOOL...
JETPAK Operation 6. Operation HMI Control panel 6.1.1 General information The default input unit on the controller is the touch screen. All of the control objects required for control after starting the controller are displayed on the touch screen. Note Damage to the system! Never use pointed or sharp instruments to operate the touch screen or press it abruptly with hard objects, as this can severely...
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JETPAK Operation 6.1.2 Operating the control unit Fig. 1 Basic display A Type of plant B Login symbol C Date, time D Message indicator E Scheme F Function keys F1-F4 G Messages H Level in the tank Status WT.350.210.000.DE.IM.0223...
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JETPAK Operation Function keys Switch Dosing on and off (refer to 6.1.4). Acknowledge fault messages. Display the present fault message when the message indicator is displayed. Select the menu, leave a menu, return to the menu level above. Message indicator The message indicator is displayed in case of a fault.
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JETPAK Operation 6.1.5 Login, entering the password The programme menus are protected against unauthorised operation by passwords. • Operator password: Protects all operating functions. The operator password is 9040. • Service password: Protects the specific system settings and is only given to authorised specialised personnel.
JETPAK Operation System scheme A Stirrer green = operating white = stopped B Membrane valves green = open white = closed C Filling level in the tank: EMPTY 0%: orange, <50 mm MIN <8%, blue, <150 mm MAX ≤100%, blue, <760 mm OVERFILLED >100%: red, >760 mm D Booster pump green = operating...
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JETPAK Operation 6.2.1 Displays Suspension tank EMPTY • Filling level 0%, < 50 mm • Dosing OFF • Stirrer OFF • Message Tank MIN • Add water and powdered activated carbon Fill the suspension tank • Filling level 0%, < 50 mm •...
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JETPAK Operation Suspension tank FULL • Filling level 100%, < 760 mm • Dosing in AUTO mode, presently dosing is not active • Water pressure OK • Stirrer ON Operation off • Filling level 55%, < 760 mm • Dosing OFF •...
JETPAK Operation Operator menus 1 Touch F4. The operator menus are displayed. If necessary enter the operator password. 6.3.1 Operating menus 1 Touch „Operation”. 2 The operation menu „Signal relay” is displayed. Activate the function(s) of the signal relay. Select the function by pressing the symbol. ...
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JETPAK Operation 6.3.2 Info menu 1 Touch „Info”. The Info menus are displayed. Info: Operating data • Operating hours of JETPAK (switched on with F1), • Operating hours of the injector (corresponding to dosing hours), • Dosing times of the individual dosing points 2 Touch „next”.
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JETPAK Operation 6.3.3 Diagnosis menu 1 Touch „Diagnosis”. The Diagnosis menus are displayed. Diagnosis I Passed and calculated dosing and flushing times of the indi- vidual dosing points are displayed as well as the time of the last finished dosing. 2 Touch „next”.
JETPAK Operation 6.3.4 Message menu All the messages are stored in the message buffer. 1 Touch F4. 2 Touch „Messages”. 3 Display of the saved messages with date and time C: Message has come A: Message has been acknowledged G: Message has gone Scroll in the message buffer by moving your finger on the screen.
JETPAK Operation Replenishing activated carbon When the suspension has been consumed to a remainder of ap- prox. 70 l (filling level approximately 150 mm), “Level MIN, fill tank!” appears on the display. Dosage is automatically switched off, the injector and the used dosage line are flushed through.
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JETPAK Operation 4 Pour activated powder carbon into the suspension tank: for a concentration of 2 portion bags = 6 kg weight content of dried powder carbon 20 g/ltr.: 30 g/ltr.: 3 portion bags = 9 kg weight content of dried powder carbon 4 portion bags = 12 kg weight content of dried powder carbon 40 g/ltr.: 5 Replace the cover and lock in place.
JETPAK Operation Switching on the dosing points The parameters of the automatic control are set in the menu Dos- ing and Timer. 1 Touch F4. Touch „Dosing”. If necessary enter the operator password. Touch the symbol of the membrane valve 2 Touch the „Mode”...
JETPAK Operation Note During dosage of activated powder carbon, flocculant dosage should not be switched off. As long as hygiene parameters are met, it is not necessary to add activated powder carbon and flocculant after pool closure until the next morning. Switching off dosage •...
JETPAK Operation Interruptions to operation Note As long as the activated carbon suspension is in the tank, the stir- rer should not be switched off for longer than half an hour, as the activated carbon otherwise separates and settles. Schedule longer phases of having the system switched off so that you can empty the system during normal operation (if necessary mix in small quantities of activated carbon or increase dosage).
7 Empty hose pipes, injectors and valves. Note Protect the system against frost! Setting the operational parameters All operational parameters were set by Evoqua personnel during commissioning. The following operational parameters can be modified by the op- erator if required: •...
JETPAK Operation 6.10 Weekly switching programme (Timer) The control unit contains a weekly programme for control of PAC dosage. One or two times can be set for each weekday for automatic acti- vation and deactivation of activated carbon dosage. 1 Touch F4. 2 Touch „Timer”.
JETPAK Operation 6.11 Setting the signal relay This menu is used to set when the signal relay is activated. 1 Touch F4. 2 Touch „Operation”. „Operation: Siganl relay” is displayed. 3 Set the function of the signal relay: Touch symbol or text drückento activate/deactivate the func- tions.
Reaction of the Cause What is to do? system Effect maintenance The LED is on Service interval is over Inform the Evoqua service until maintenance personnel. has been perfor- med and confirmed Pre-warning Tank Filling level below set level Fill the tank...
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Warning of dangerous voltage! Risk of injury due to electric current! Electrical work on the system may only be performed by qualified electricians. If a repair is necessary commission Evoqua to perform the repair.
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JETPAK Operation Fault Possible causes Fault rectification Filling time of tank exceeded Supply too low Check supply Drain open Close drain Tank overfilled Level sensor dirty or defect Clean the sensor, replace if neces- sary Solenoid valve not tight Check the valve, replace if necessa- Entered value not allowed Value out of limits correct the value...
JETPAK Operation 6.13 Message buffer All the messages are stored in the message buffer. 1 Press F4. 2 Press „Messages”. Display of the saved messages with date and time C: Message has come A: Message has been acknowledged G: Message has gone Scroll in the message buffer by moving your finger on the screen.
JETPAK Maintenance 7. Maintenance Warning! Risk of injury by the rotating stirrer shaft! Do not put your hands through the tank opening! Switch off the main switch before any repair or maintenance work or before opening the tank cover. Warning of dangerous voltage! Risk of injury due to electric current! Electrical work on the system may only be performed by qualified electricians.
JETPAK Maintenance Maintenance by the operator 7.2.1 Replace the sieve at the end of the suction line 1 Switch-off the injection points. Wait for the end of the flushing time. 2 Switch off the main switch. 3 Remove the suction line from the injector and pull it out of the tank.
JETPAK Maintenance 7.2.2 Clean the tank, clean the ultra-sonic level sensor 1 Remove the two screws at the level switch cover. Lift the level switch together with the cover. 2 Wipe the active surface of the sensor (within the colored ring) with a clean dry cloth.
JETPAK Maintenance Maintenance parts kits BZ-1433.002 (05/2022) WT.350.210.000.DE.IM.0223...
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JETPAK Maintenance 7.5.1 Maintenance parts for 6 months (SIMATIC S7-200) Item no. Description W3T420458 W3T420632 W3T420636 system with system with system with one dosing two dosing three point points dosing points W2T505968 Filter 1 each 1 each 1 each W3T158491 Injector outlet 1 each 1 each...
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JETPAK Maintenance 7.5.3 Maintenance parts for 2 years (SIMATIC S7-200) Item no. Description W3T420460 W3T420634 W3T420638 system with system with system with one dosing two dosing three point points dosing points W2T505968 Filter 2 each 2 each 2 each W3T158491 Injector outlet 2 each 2 each...
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JETPAK Maintenance 7.5.4 Maintenance parts for 1 year (SIMATIC S7-1200) Item no. Description W3T420640 W3T420643 W3T420646 system with system with system with one dosing two dosing three point points dosing points W2T505968 Filter 1 each 1 each 1 each W3T158491 Injector outlet 1 each 1 each...
JETPAK Maintenance Item no. Description W3T420641 W3T420644 W3T420647 system with system with system with one dosing two dosing three point points dosing points W3T171965 Spare diaphragm 2 each 4 each 6 each W2T505422 Hose, PVC, 13 x 3,5 1,2 m 1,2 m 1,2 m W2T507155...
JETPAK Dismantling and disposal 8. Dismantling and disposal Dismantling Note Only authorized, qualified and trained technicians may dismantle the system for disposal. 1 Prior to disposal, delete any personal data stored on the old equipment. 2 Disconnect the system from the power supply. 3 Dismantle the system into practical units.
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Where such central collection systems are not available, used equipment purchased from us can be returned to us. Please see our website at www.evoqua.com. for details. You can access the necessary information directly via the QR code. 8.2.3...
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JETPAK Wiring diagrams example application Booster pump Three-phase motor control JETPAK (W3T374766 | WAE8880) 40 41 42 Power supply to be provided locally L1 L2 L3 PE -KM1 1 3 5 I 0 II 2 4 6 I 0 II -KM1 Motorstarter 88x150mm...
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JETPAK Wiring diagrams example application Booster pump Single-phase motor control JETPAK (W3T374766 | WAE8880) 40 41 42 Power supply to be provided locally -KM1 1 3 5 I 0 II 2 4 6 I 0 II -KM1 Motorstarter 88x150mm IP65 /2.C5 /2.C5 Consider module voltage !
JETPAK Annex 11.Annex 11.1 Requirements to the filter Filtration is used to remove the added powdered carbon and the flocculated dirt out of the water. 11.1.1 Quick-run filters according DIN 19605 For filtration, quick-run filters according DIN 19605 are used or precoated filters.
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JETPAK Annex Multi-layer filters To remove activated carbon, multi-layer filters can also be used. The requirements are listed in the following table: Grain size, layer thickness and rate of filtration for multi-layer filters with filter sand used with powdered carbon to DIN 19643-2. Parameters open quick-run closed quick-run...
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JETPAK Annex Standard values for the air-water back-wash of one-layer filters with filter sand, examples for the grain size 0,71 mm to 1,25 mm. Program sequence time in speed in m/h minutes phase venting of the filter vessel and reducing of the water level down to the upper edge of the drain funnel phase...
JETPAK Annex 11.2 Dosage diagram The following diagram shows the timing sequence of dosage on dosage lines 1 ... 3. Within one dosage period all enabled injection points are served once consecutively. The respective diaphragm valve opens to this purpose. The dosage periods start at each full and half hour.
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All information presented herein is believed reliable and in accordance with accepted engineering practices. Evoqua makes no warranties as to the completeness of this information. Users are responsible for evaluating individual product suitability for specific applications. Evoqua assumes no liability whatsoever for any special, indirect or consequential damages arising from the sale, resale or misuse of its products.
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