Page 1 Read this manual carefully before use! Keep for future use!
Page 2 Klingenburg GmbH Brüsseler Straße 77 45968 Gladbeck GERMANY Telephone: +49 2043 96360 E-Mail: info@klingenburg.de Internet: www.klingenburg.de Original operating manual Klin-64121-DE © 2023 Klingenburg GmbH ·KLINGENBURG Rotor Cleaning Device...
Page 3 Information about this manual This manual enables safe and efficient handling of the machine. This manual is part of the machine and must be kept accessible to the staff (Chapter 2.3 Personnel qualification on page 12) at all times. The staff must carefully read and have understood this manual before starting any work on or with the machine.
Page 4: Table Of Contents
Table of Contents Unpacking and checking scope of delivery ..............6 Before you begin – safety ....................10 2.1. Symbols in this manual ..................10 2.2. Intended use ..................... 11 2.3. Personnel qualification ..................12 2.4. Personal protective equipment ................. 14 2.5.
Page 5 6.2.4. High-pressure water supply ............54 6.2.5. Compressed air supply ..............54 6.2.6. Clock sensor .................. 58 6.2.7. Rotor cleaner control ..............60 6.2.8. Rotor cleaner drive ................. 62 6.3. Electrical installation ..................63 6.3.1. Rotor cleaner control ..............63 6.3.2.
Page 6: Unpacking And Checking Scope Of Delivery
1. Unpacking and checking scope of delivery Delivery The rotor cleaning device is delivered with the full scope of delivery in packaging adapted to the transport route and delivery location. Checking the delivery Check delivery for transport damage and ensure it is complete immediately upon receipt.
Page 7 Fig. 3: Cleaning carriage with nozzles Fig. 4: Inductive proximity sensors Fig. 5: Compressed air hose and 3/2-way compressed air solenoid valve ·KLINGENBURG Rotor Cleaning Device...
Page 8 Fig. 6: Drip pan Fig. 7: Cleaning rail cover The scope of delivery includes: • Pre-assembled cleaning rail (Fig. 1/8) with stepper motor (Fig. 1/1), two deflection rollers (Fig. 2/1), toothed belt (Fig. 2/2), cleaning carriage (Fig. 3/1) with high-pressure hot water nozzle (Fig. 3/2) and compressed air nozzle (Fig.
Page 9 Optional: Cross beam for cleaning rail mount • Handling packaging material The individual packages are packed according to the expected transport conditions. The packaging provides protection against transport damage, corrosion and other damage. For this reason, do not destroy the packaging and do not remove it until shortly before use.
Page 10: Before You Begin - Safety
2. Before you begin – safety This chapter provides an overview of all important safety aspects for protecting personnel and for ensuring safe and fault-free operation. Further task-specific safety instructions can be found in the sections of the individual chapters. 2.1.
Page 11: Intended Use
Example: Loosen the screw. CAUTION! Risk of pinching by cover! Close the cover carefully. Tighten the screw. Tips and recommendations This symbol highlights useful tips and recommendations as well as information designed to ensure efficient and smooth operation. Other markings The following markings are used in this manual in order to highlight instructions, outcomes, lists, references and other elements: Marking...
Page 12: Personnel Qualification
Misuse Any use that deviates from the intended use, in particular use on machines other than rotary heat exchangers of the Klingenburg RRS and RRT series and use in potentially explosive environments is misuse. WARNING! Danger from misuse! Misuse of the machine can lead to serious injuries or even death.
Page 13 List of personnel qualifications The qualifications of the personnel required to carry out the activities on the machine are defined below. The definition of personnel qualifications depends on their main focus. A distinction is made here between the personnel who operates the machine (user), the personnel who prepares the machine for operation (service technician, electrician) and the operator, who bears the legal product responsibility for the protection of personnel or third parties.
Page 14: Personal Protective Equipment
Operator: The operator is a natural or legal person who operates the rotor cleaning device for commercial or economic purposes themselves, or makes it available for a third-party to use, and who bears the legal responsibility for the product vis-à-vis protection of personnel and third parties during operation.
Page 15: Working And Danger Areas
2.5. Working and danger areas During normal operation, it is not necessary for personnel to be in the area of the rotor cleaning device. Personnel only needs to be in the area of the rotor cleaning device for adjustment and maintenance work and for troubleshooting.
Page 16: Hazards From Moving Parts
2.6.2. Hazards from moving parts Cleaning carriage WARNING! Danger of being crushed and drawn in by the cleaning carriage! Body parts can be crushed or hair and limbs pulled in on the cleaning carriage. Do not reach into the cleaning carriage when it is running. •...
Page 17: Noise Hazards
Pressurised supply lines WARNING! Risk of injury from pressurised supply lines! During and after operation, the compressed air and water lines are under pressure. Working on pressurised components can lead to serious injuries. • Prior to any work on the compressed air and water lines, depressurise them.
Page 18: Operator's Obligations
2.7. Operator’s obligations The rotor cleaning device is used in the commercial sector. The operator of the rotor cleaning device is therefore subject to the statutory obligations pertaining to occupational safety. In addition to the safety instructions in this manual, the applicable safety, occupational safety and environmental protection regulations for the rotor cleaning device’s area of application must be adhered to.
Page 19: Safety Devices
2.8. Safety devices Location of safety devices The machine does not have its own safety devices. The operator must install emergency stop devices for the rotor cleaning device and integrate them into the safety chain of the higher-level control. Integration in an emergency stop The rotor cleaning device is intended for attachment to rotary heat concept exchangers that are controlled via a higher-level control system at their...
Page 20: Packing
3. Packing Packaging unit cleaning rail The cleaning rail is delivered packed in bubble wrap. The bubble wrap serves to protect the cleaning rail and the components preassembled on it from damage during transport. A red tape on the bubble wrap warns about highly sensitive electronic equipment.
Page 21: Technical Specifications
4. Technical specifications 4.1. Cleaning rail The weight of the cleaning rail Weight depends on the size of the rotary heat exchanger to which the respective cleaning rail is attached. 9.53 kg at 720 mm minimum size of the cleaning rail (design for the smallest available Klingenburg rotary heat exchanger).
Page 22: Control Units
4.2. Control units Rotor Cleaner Control 230 V AC ± 10% @ 50/60 Hz Supply voltage Power consumption 0.5 W @ 230 V AC Ambient air humidity 10-95 %RH, non-condensing Fuse Internal T800 mA, external 16 A Classification Class II Modbus internal 38,400 baud, 8 data bits, 2 stop bits, no parity...
Page 23 Rotor Cleaner Drive Torque 4.0 / 8.0 Nm * Power Size 220 W Efficiency > 90% Power supply Voltage 1 x 230 V AC 50/60 Hz ± 10% Supply current at max. load 2.4 A Power factor (cos-phi) at max. load 0.65 Motor output Nominal motor power...
Page 24 Protection rating IP 54 Enclosure material Plastic Front cover Plastic Weight 900 g Humidity 10-95% rh, non-condensing Cooling Self-cooling Interfaces Modbus RTU interface protocol (Baud rate: 9.6, 19.2, 38.4, 57.6, 115.2 kBaud) Default: 38.4 kBaud, 1 stop bit, non- parity RS-485 interface connection 2 x RJ12 &...
Page 25: Stepper Motor
Functions Technology Sinusoidal back-EMF signal controlled via FOC (field-oriented control) Alarm Alarm reset Via rotor cleaner control Service data log Operating hours, alarms, loads, software version, max. temperature, max. motor voltage, max. motor current, max. ripple voltage, max. ripple current Software updating Yes, via serial interface Short-circuit protection...
Page 26: Media Supply
4.4. Media supply 4.4.1. Compressed Air Compressed air supply Operating pressure 6 – 8 bar 4.4.2. High pressure water High pressure water supply Water pressure 60 bar Temperature Max. 50 °C ·KLINGENBURG Rotor Cleaning Device...
Page 27: Compressed Air Solenoid Valve
4.5. Compressed air solenoid valve 3/2-way compressed air solenoid Valve function 3/2-way, closed, monostable valve Type of actuation Electric Valve size 21mm Standard nominal flow 700 l/min Pneumatic working port G1/8 Operating pressure 0.25MPa – 1 MPa Operating pressure 2.5 bar – 10 bar Design Piston gate valve Type of reset...
Page 28 Corrosion resistance class CRC 2 - Moderate corrosion stress LABS (PWIS) conformity VDMA24364-B1/B2-L Media temperature -10 °C – 60 °C Pilot medium Compressed air to ISO 8573-1:2010 [7:4:4] Ambient temperature -10 °C – 60 °C Product weight 136 g Type of mounting Either: On terminal strip With through-hole...
Page 29: Sensors
4.6. Sensors Inductive proximity sensor AM1/CP- Electrical data Supply voltage 10 - 30 VDC Idle current 10 mA Load current 200 mA Leakage current 10 µA Output voltage drop 1.8 V at 200 mA Switching frequency 2 kHz Nominal sensing distance 4 mm Operating distance 0 - 3.2 mm...
Page 30 Clock Sensor E2E-X8MC1122M Size Mounting type Non-flush Sensing distance 8 mm Overall length 47.1 mm Thread length 26 mm Material housing Brass, nickel-plated Output type Operation Mode Poles Connection method Cable Cable specifications PVC (oil-resistant) Cable length Protection rating IP67/IP67G/IP69K ·KLINGENBURG Rotor Cleaning Device...
Page 31: Layout And Function
5. Layout and function 5.1. Function layout Fig. 10: Function layout of the rotor cleaning device ·KLINGENBURG Rotor Cleaning Device...
Page 32: Functional Description
5.2. Functional description The rotor Cleaning device is used to clean the rotor matrix or rotary heat exchangers of the Klingenburg RRS and RRT series, which are exposed to polluted exhaust air during operation. The cleaning prevents the rotor matrix from becoming clogged, e.g. by sticky or greasy exhaust air components, and thus prevents reduced performance or even failure of the rotary heat exchanger.
Page 33: Operating And Display Elements
5.3. Operating and display elements Rotor Cleaner Control Fig. 11: Rotor cleaner control operating and display elements 1 Start / Cancel / Up / Down / Left / Back 2 OK / Menu / Up 3 Up / Down / Calib / Right 4 Display 5 Red alarm LED The function of the buttons (Fig.
Page 34: Sensors
5.4. Sensors Inductive proximity sensors The inductive proximity sensors are used to monitor the end position (centre and circumference of the rotor) of the cleaning carriage. On the one hand, they prevent the cleaning carriage from colliding with the rotor housing, and on the other hand, the compressed air and high-pressure water supply are switched on or off via their signals.
Page 35 Rotor Cleaner control terminal assignment Fig. 13: Rotor cleaner control terminal assignment 4 +24 V DC power supply inductive proximity sensor rotor circumference 5 Modbus signal line A 6 Modbus signal line B 7 Modbus ground connection 8 Signal line inductive proximity sensor rotor circumference 9 Inductive proximity sensor rotor circumference ground connection 10 Inductive proximity sensor rotor centre signal line 11 Inductive proximity sensor rotor centre ground connection...
Page 36 Rotor Cleaner Drive port openings 1 Modbus 2 Alarm 3 Clock sensor 4 Power supply 5 Stepper motor ·KLINGENBURG Rotor Cleaning Device...
Page 37 Rotor Cleaner Drive terminal assignment Fig. 14: Rotor cleaner drive terminal assignment 1 4-pole DIP switch 2 LED 3 RJ12 RS-485 interface connector (2 x RJ12) 4 A/D control and signal terminals 5 Power supply terminals (L, N, PE) 6 Connection terminals for stepper motor (U, V, W, PE) ·KLINGENBURG Rotor Cleaning Device...
Page 38: Installation
6. Installation 6.1. Safety instructions for the installation Electrical System Danger! Risk of fatal injury from electric current! In case of contact with live parts, there is a risk of fatal injury through electric shock. Before starting work, switch off the electrical supply and •...
Page 39: Mechanical Installation
6.2. Mechanical installation 6.2.1. Cleaning rail The possible position of the cleaning rail on the frame of the rotary heat exchanger depends on the arrangement of the air flow separation. Horizontal air flow separation Fig. 15: Horizontal air flow separation Possible positioning of the cleaning rail with horizontal air flow separation...
Page 40 Vertical air flow separation Fig. 18: Vertical air flow separation Possible positioning of the cleaning rail with vertical air flow separation Fig. 19: Possible positioning of the cleaning rail Fig. 20: Possible positioning of the cleaning rail Unavailable area for attaching the cleaning rail Available area for attaching the cleaning rail ·KLINGENBURG Rotor Cleaning Device...
Page 41 Install cleaning rail Personell qualification: Service technician • Personal protective equipment: Protective clothing • Safety shoes • • Protective gloves Pre-condition: The entire system is switched off and secured against being switched • on again Operating manual for the building control system. The position of the cleaning rail was determined depending on the air •...
Page 42 Fig. 22 Align the crossbeam ( /2) on the housing of the rotary heat exchanger (Fig. 22/3) so that the mitres of the crossbeam (Fig. 22/1) Fig. 22 are parallel to the housing frame ( /4). Fig. 22: Crossbeam alignment Screw the crossbeam (Fig.
Page 43 Hold the cleaning rail (Fig. 25/2) with two persons on the frame (Fig. 25/1) of the rotary heat exchanger. The end of the cleaning rail on the engine side must be at the outer end of the rotary heat exchanger. Make sure that the cleaning carriage can run over the entire rotor area.
Page 44 Transfer the position (Fig. 30/2) of the deflection roller (Fig. 30/1) to the back side of the cleaning rail (Fig. 29/1) that is in contact with the horizontal beam of the housing. Mark a drilling point on the central axis (Fig. 29/2) of the cleaning rail within the marked area.
Page 45 Move the deflection roller back to its original position. Tighten the wing nut (Fig. 33/1) to tension the toothed belt (Fig. 33/2) until both belt strands are parallel to each other. Tighten both screws (Fig. 32/1) of the deflection roller. Position the motor-side end of the cleaning rail (Fig.
Page 46 Set the travel path of the cleaning carriage Move the cleaning carriage (Fig. 36/1) to the very top position by hand. Avoid contact of the cleaning carriage (Fig. 36/1) with the horizontal beam (Fig. 36/2) of the rotor frame. Fig. 36: Cleaning carriage top position Ensure that the maximum switching distance of 4 mm between the proximity sensor (Fig.
Page 47 Move the cleaning carriage (Fig. 38/1) to the very bottom position at the rotor circumference by hand. Avoid contact of the cleaning carriage (Fig. 38/1) with the cross beam (Fig. 38/2) of the rotor frame. Fig. 38: Cleaning carriage bottom position Set the distance between the centre point of the high-pressure water nozzle (Fig.
Page 48 Measure the distance between the high-pressure water nozzle (Fig. 41/2) and the rotor surface (Fig. 41/1). Fig. 41: Distance between water nozzle and rotor surface If the distance is less or more than 2.5 cm, loosen the setscrew (Fig. 42/2) and adjust the high pressure water nozzle (Fig. 42/1) moving it away from or onto the rotor surface (Fig.
Page 49 If the distance is less or more than 2.5 cm, loosen the supply-side locknuts (Fig. 44/2) and the rotor-side locknut (Fig. 45/1) and adjust the compressed air nozzle (Fig. 44/1) by moving it away or onto the rotor surface (Fig. 44/3) to a distance of 2.5 cm from the rotor surface (Fig.
Page 50 Manually move the cleaning carriage to the centre of the cleaning rail (Fig. 47). In the event of an error reset, this ensures a response time for reaching an emergency stop switch before the cleaning carriage collides with the rotor housing. Fig.
Page 51: Drip Pan
6.2.2. Drip pan Install drip pan The drip pan must be installed on the extract air side of the rotary heat exchanger. If the rotor cleaning device is retrofitted and the rotary heat exchanger does not have a crossbeam (Fig. 48/1) for mounting the drip pan on the extract air side, the crossbeam (Fig.
Page 52 Hold the drip pan (Fig. 51/1) on the rotor frame (Fig. 51/4) on the exhaust air side. Align the drip pan (Fig. 51/1) parallel to the rotor segment (Fig. 51/6). The distance to be set (Fig. 51/5) results from the distance measured in step 2 (Fig.
Page 53: Cleaning Rail Cover
Fig. 54: Drip pan drill holes 6.2.3. Cleaning rail cover Install cleaning rail cover Place the cleaning rail cover (Fig. 56/1) on the cleaning rail so that the drill holes in the cover (Fig. 55/1) line up with the holes in the cleaning rail.
Page 54: High-Pressure Water Supply
6.2.4. High-pressure water supply Connect high-pressure hot water supply Connect the high-pressure water nozzle (Fig. 57/1) using a suitable connection technique with an electromagnetic hydraulic valve and with the on-site high-pressure water supply (Fig. 57/3). Klingenburg recommends using a Parker Ermeto hydraulic screw connection (Fig.
Page 55 Slide the union nut (Fig. 60/1) onto one end of the compressed air hose (Fig. 60/2). Fig. 60: Slide union nut on compressed air hose Push the compressed air hose (Fig. 61/3) onto the screw-in stud (Fig. 61/2) on the compressed air nozzle (Fig. 61/1). Fig.
Page 56 Slide the union nut (Fig. 64/1) onto the other end of the compressed air hose (Fig. 64/2). Fig. 64: Slide the union nut on the other end of the compressed air hose Push the valve-side end of the compressed air hose (Fig. 65/1) onto the screw-in stud on connection 2 (Fig.
Page 57 Slide the union nut (Fig. 67/1) onto the compressed air supply hose (Fig. 67/2). Push the compressed air supply hose onto the screw-in stud on connection 1 of the 3/2-way solenoid valve similar to the connection of connection 2 in step 8. Secure the compressed air supply hose on connection 1 of the 3/2- way solenoid valve by screwing the union nut onto the screw-in stud similar to step 9.
Page 58: Clock Sensor
6.2.6. Clock sensor Installing the clock sensor Personnel qualification: • Service technician Personal protective equipment: • Protective clothing • Safety shoes If the rotor of the rotary heat exchanger is controlled with an OJ Electronics controller, an inductive rotor guard with associated sensor holder (Fig.
Page 59 Fig. 71: Drill holes Fasten the clock sensor holder to the rotor housing with the screws (Fig. 73/2) and the associated nuts (Fig. 72/2). Use washers under the screw heads (Fig. 73/1) and washers under the nuts (Fig. 72/1). Fig. 72: Fasten clock sensor holder Screw the nut (Fig.
Page 60: Rotor Cleaner Control
Screw a screw (Fig. 76/1) with washers (Fig. 76/2) into the rotor (Fig. 76/4) in line with the clock sensor (Fig. 76/3). The washers act as contactor (Fig. 77/2) for the clock sensor. Fig. 75: Lock nut Adjust the clock sensor (Fig. 77/2) via the nuts (Fig. 77/3 and Fig. 75/2) to maintain the required switching distance of 10 –...
Page 61 Install rotor cleaner control Personell qualification: Electrician • Personal protective equipment: Protective clothing • • Safety shoes Loosen all 6 housing screws (Fig. 78/1) by a quarter turn to the left and remove the front cover. Fig. 78: Housing screws Fasten the rotor cleaner control to the rotor housing using the 4 existing drill holes (Fig.
Page 62: Rotor Cleaner Drive
6.2.8. Rotor cleaner drive Incorrect mechanical installation NOTICE! Incorrect mechanical installation can cause damage to the rotor cleaner drive! Only have the rotor cleaner drive installed by qualified • electricians. Only mount the rotor cleaner drive in such a way that a •...
Page 63: Electrical Installation
6.3. Electrical installation 6.3.1. Rotor cleaner control Connect rotor cleaner control Personnel qualification: • Electrician Personal protective equipment: • Protective clothing Safety shoes • Requirements: • The entire system is switched off and secured against being switched on again Operating manual for the building control system. The cleaning rail is installed and adjusted.
Page 64 Removing the front cover Fig. 82: Housing screws Loosen all 6 housing screws (Fig. 82/1) by a quarter turn to the left and remove the front cover. Internal modbus Fig. 83: Terminals internal modbus ·KLINGENBURG Rotor Cleaning Device...
Page 65 Fig. 84: Modbus cable Insert the modbus wires (Fig. 84/1-3) through the cable socket (Fig. 83/4) Connect the brown-white wire (Fig. 84/1) to terminal 5 (Fig. 83/1, A). Connect the brown wire (Fig. 84/2) to terminal 6 (Fig. 83/2, B). Connect the red-white wire (Fig.
Page 66 Rotor centre proximity sensor Fig. 86: Cable socket and terminals rotor centre proximity sensor Insert the wires of the rotor centre proximity sensor connection cable through the cable socket (Fig. 86/4). Connect the black signal wire to terminal 10 (Fig. 86/1, DI InnSens) of the rotor cleaner control.
Page 67 Insert the wires of the external 0-10 V signal cable through the cable socket (Fig. 87/3) Connect external 0-10 V input signal wire to terminal 17 (Fig. 87/1, 0- 10V in). Connect the ground wire of the external 0-10 V input signal to terminal 18 (Fig.
Page 68 Power supply for the relays and valves Fig. 89: Terminals for the relay and valve power supply Insert a 230 V power supply cable through the cable socket (Fig. 89/3). This cable is used to supply power to the water relay and the compressed air relay as well as the corresponding solenoid valves.
Page 69 Fig. 90: Terminals water relay Insert the wires of the water relay (power supply wire and neutral wire) through the cable socket (Fig. 90/2). Connect the power supply wire of the water relay to terminal 24 (Fig. 90/1, NO). Connect the neutral wire of the water relay to the cable terminal to which the N wire of the 230 V power supply cable is connected.
Page 70 Insert the wires of the compressed air relay (power supply wire and neutral wire) through the cable socket (Fig. 91/2). Connect the power supply wire of the compressed air relay to terminal 27 (Fig. 91/1, NO). Connect the neutral wire of the compressed air relay to the cable terminal to which the N wire of the 230 V power supply cable is connected.
Page 71 Fig. 93: Terminals power supply Insert the power supply cable through the cable socket (Fig. 93/4). Connect the phase wire to terminal 28 (Fig. 93/1, L). Connect the neutral wire to terminal 29 (Fig. 93/2, N). Close front cover Connect the protective wire to terminal 30 (Fig. 93/3, PE). Fig.
Page 72: Rotor Cleaner Drive
6.3.2. Rotor cleaner drive Connect rotor cleaner drive Personnel qualification: Electrician • Personal protective equipment: • Protective clothing Safety shoes • Requirements: The entire system is switched off and secured against being switched • on again Operating manual for the building control system. The cleaning rail is installed and adjusted.
Page 73 Connect power supply Fig. 96: Terminals Power supply Loosen the nut (Fig. 96/2) of the cable entry (Fig. 96/1). Slide the nut (Fig. 96/2) of the cable entry (Fig. 96/1) over the power cable. Insert the power cable through the cable entry (Fig. 96/1) into the rotor cleaner drive.
Page 74 Fig. 97: Power supply wires Connect phase wire (Fig. 97/1), neutral wire (Fig. 97/2) and protective wire (Fig. 97/3) to the voltage source. Connect stepper motor Fig. 98: Terminals stepper motor ·KLINGENBURG Rotor Cleaning Device...
Page 75 Fig. 99: Motor cable Loosen the nut (Fig. 98/1) of the cable entry (Fig. 98/2). Slide the nut (Fig. 98/1) of the cable entry (Fig. 98/2) over the stepper motor extension cable. Insert the wires (Fig. 99/1-4) of the stepper motor cable through the cable entry (Fig.
Page 76 The cable connection is properly made when the pawls on both sides of the connector on the stepper motor cable are firmly connected to the sockets on the connector of the stepper motor extension cable. Establish equipotential bonding Fig. 101: Equipotential bonding Fasten the potential equalization of the rotor cleaner drive with a ring cable lug (Fig.
Page 77 Connect clock sensor Fig. 102: Terminals clock sensor Fig. 103: Clock sensor cable Insert the wires of the clock sensor (Fig. 103/1-3) through the cable entry (Fig. 102/3) into the rotor cleaner drive. Connect the blue wire (Fig. 103/2) to terminal 5 (Fig. 102/1, GND). Connect the brown wire (Fig.
Page 78 Fig. 105: Modbus cable RJ12 connector Connect the modbus cable via the RJ 12 connector (Fig. 105/1) to RJ12 sockets A (Fig. 104/1). When installing the RJ12 connectors, note that the connectors must be aligned so that the colour sequence in the connectors is the same at both cable ends.
Page 79: Commissioning And Operation
7. Commissioning and operation 7.1. Menu structure and menu navigation Menu structure The menu of the control software is structured hierarchically. The menu consists of a main menu from which several submenus can be selected. The individual menu items are numbered consecutively. The menu is structured as follows: •...
Page 80: Basic Settings And Calibration
7.2. Basic settings and calibration Set language Personnel qualification: • User Pre-conditions: The cleaning rail is installed. • • The rotor cleaner drive is installed and connected to the power supply. All necessary electrical connections between the cleaning rail, the rotor •...
Page 81 Start the calibration with [OK] (Fig. 110/1).  The calibration status indicator appears, showing the actual status of the calibration (Fig. 111/1). Fig. 110: Start calibration  After the calibration has started, the cleaning carriage first moves to its starting position on the rotor circumference (Fig. 111/1). Fig.
Page 82  The cleaning carriage then moves to the centre of the rotor. After detecting a signal from the rotor circumference proximity sensor, the display shows “Outer Sensor OK’’ (Fig. 113/1). Fig. 113: Calibration outer sensor check  As soon as the cleaning carriage has reached the centre of the rotor and has detected a signal from the rotor centre proximity sensor, the display shows “Inner sensor OK’’...
Page 83  Once the maximum rotor speed is reached, the calibration is complete. The rotor slows down to a standstill and the display shows the status “Standby’’ (Fig. 116/1) and the calculated estimated cleaning time (Fig. 116/2). Now the cleaning can be started via [Start] (Fig.
Page 84: Settings
7.3. Settings 7.3.1. Open submenu “setup” Personnel qualification: Open submenu “setup” User • Pre-conditions: The cleaning rail is installed. • The rotor cleaner drive is installed and connected to the • power supply. • All necessary electrical connections between the cleaning rail, the rotor cleaner drive and the rotor cleaner control are installed.
Page 85 Enter the password (Fig. 121/2) by using the arrow keys [up] (Fig. 121/4), [left] (Fig. 121/3) and [right] (Fig. 121/5). The password to be entered is “1112”. The password is factory set and cannot be changed. Use the arrow key [right] (Fig. 121/5) after you have selected the last password digit.
Page 86: Change Language
7.3.2. Change language Change language Pre-condition: • The “2 Setup” submenu is open. Select the “Language’’ submenu (Fig. 123/2) with the arrow keys [up] (Fig. 123/3) and [down] (Fig. 123/5). Confirm the selection with [OK] (Fig. 123/4).  The “21 Language’’ submenu appears on the display (Fig. 124/1) Fig.
Page 87: Set Carriage Step Size
7.3.3. Set carriage step size Set carriage stepsize Select the “Carriage stepsize’’ submenu (Fig. 125/2) with the arrow keys [up] (Fig. 125/3) and [down] (Fig. 125/4). Fig. 125: Select submenu “carriage Open the “Carriage stepsize’’ submenu with [OK] (Fig. 126/1). stepsize”...
Page 88: Set Maximum Rotor Speed
 The “2 setup’’ submenu appears on the display again (Fig. 128/1). Fig. 128: Submenu “2 setup” 7.3.4. Set maximum rotor speed Select the “Max. rotor speed’’ submenu (Fig. 129/2) with the arrow keys [up] (Fig. 129/3) and [down] (Fig. 129/5) in “2 Setup’’ submenu (Fig.
Page 89: Set Minimum Rotor Speed
7.3.5. Set minimum rotor speed Select the “Min. rotor speed’’ submenu (Fig. 131/2) with the arrow keys [up] (Fig. 131/3) and [down] (Fig. 131/5) in “2 Setup’’ submenu (Fig. 131/1). Confirm the selection with [OK] (Fig. 131/4).  The “24 Min. rotor speed’’ submenu appears on the display (Fig. 132/1).
Page 90: Set Length Tolerance
7.3.6. Set length tolerance Select the “Length tolerance’’ submenu (Fig. 133/2) with the arrow keys [up] (Fig. 133/3) and [down] (Fig. 133/5) in “2 Setup’’ submenu (Fig. 133/1). Confirm the selection with [OK] (Fig. 133/4).  The “25 Length tolerance’’ submenu appears on the display (Fig. 134/1).
Page 91: Set Drying Cycles
7.3.7. Set drying cycles Select the “Drying cycles’’ submenu (Fig. 135//2) with the arrow keys [up] (Fig. 135//3) and [down] (Fig. 135//5) in submenu “2 Setup’’ (Fig. 135//1). Confirm the selection with [OK] (Fig. 135//4).  The “26 Drying cycles’’ submenu appears on the display (Fig. 136/1).
Page 92: Perform Calibration
7.3.8. Perform calibration To perform a renewed calibration, select the “Calibration’’ submenu (Fig. 137/2) with the arrow keys [up] (Fig. 137/3) and [down] (Fig. 137/5) in “2 Setup’’ submenu (Fig. 137/1). Confirm the selection with [OK] (Fig. 137/4).  The “27 Calibration’’ submenu appears on the display (Fig. 138/1). Fig.
Page 93: Perform Hardware Test
7.3.9. Perform hardware test Open submenu “Hardware test” Select the “Hardware test’’ submenu (Fig. 139/2) with the arrow keys [up] (Fig. 55/3) and [down] (Fig. 139/5) in “2 Setup’’ submenu (Fig. 139/1). Confirm the selection with [OK] (Fig. 139/4).  The “28 Hardware test’’ submenu (Fig. 140/1) appears on the display.
Page 94  The “28 Hardware test’’ submenu (Fig. 142/1) appears on the display again and the rotor turns when the electrical installation is correct. The change in the resulting speed can be read on the control unit of the rotor. Alternatively, the voltage at the rotor control unit can be measured and compared with the set voltage signal.
Page 95 Check compressed air relay Select the “Air relay’’ submenu (Fig. 144/2) with the arrow keys [up] (Fig. 144/3) and [down] (Fig. 144/5). Confirm the selection with [OK] (Fig. 144/4).  The “282 Test air relay’’ submenu (Fig. 145/1) appears on the display.
Page 96 Select “Off’’ (Fig. 147/2) with the arrow keys [up] (Fig. 147/3) and [down] (Fig. 147/5). Confirm the selection with [OK] (Fig. 147/4).  The “28 Hardware test’’ submenu (Fig. 148/1) appears again on the display, the air relay opens and compressed air no longer flows out of the compressed air nozzle.
Page 97 After checking the water relay, open the “Water relay’’ submenu (Fig. 150/2) again with [OK] (Fig. 150/4).  The “283 Test water relay’’ submenu (Fig. 151/1) appears on the display. Fig. 150: Open submenu “water relay” Select “Off’’ (Fig. 151//2) with the arrow keys [up] (Fig. 151//3) and [down] (Fig.
Page 98: Scheduler
7.4. Scheduler The scheduler enables automatic cleaning on preselected days of the week. Open scheduler submenu Select the “Scheduler” submenu (Fig. 152/2) in “1 Main menu” menu (Fig. 152/1) with the arrow keys [up] (Fig. 152/3) and [down] (Fig. 152/5). Confirm the selection with [OK] (Fig.
Page 99 Press the arrow key [up] (Fig. 154/5) on the days you want the rotor cleaning device to perform an automatic cleaning. If the rotor cleaning device shall not perform an automatic cleaning on the selected day confirm the selection [Off] (Fig.
Page 100 Set the actual date and time analogous to chapter 7.2 Basic settings and calibration on page 80. Fig. 157: "Set date and time" submenu ·KLINGENBURG Rotor Cleaning Device...
Page 101: Starting And Stopping Cleaning
7.5. Starting and stopping cleaning Start the cleaning process Requirements: • The basic settings have been made and the calibration has been completed. If the calibration has been carried out successfully, the cleaning process start screen appears on the display showing the status indication “Standby’’...
Page 102  As soon as the cleaning carriage has reached the centre of the rotor, the water and air relay both close, the associated solenoid valves are released and the cleaning with water and compressed air begins. The status indication switches to “Cleaning’’ (Fig. 160/1). Fig.
Page 103  After the cleaning carriage has reached its starting position on the rotor circumference, the cleaning process is complete. The status indication switches to “Standby’’ (Fig. 163//1). Press [Start] (Fig. 163/2) to start the cleaning process again or [Menu] (Fig. 163/3) to open the “1 Main menu’’ menu. Fig.
Page 104 Abort cleaning process Press [Abort] (Fig. 166/1) to abort the cleaning process.  The cleaning process start screen appears on the display showing the status indication “Standby’’ (Fig. 167/1). Pressing [Start] (Fig. 167/2) restarts the cleaning process. Pressing [Menu] (Fig. 167/3) calls up the “1 Main menu’’...
Page 105: Status Indicators
Fig. 169: Cleaning process status screen – cleaning 7.6. Status indicators Open submenu “status” Press [Menu] (Fig. 170/1) to open the “1 Main menu’’ menu (Fig. 171/1).  The “1 Main menu’’ menu appears on the display (Fig. 171/1). Fig. 170: Open main menu ·KLINGENBURG Rotor Cleaning Device...
Page 106 Select the “Status’’ submenu (Fig. 171/2) with the arrow keys [up] (Fig. 171/3) and [down] (Fig. 171/5). Confirm the selection with [OK] (Fig. 171/4).  The “4 Status’’ submenu appears on the display (Fig. 172/1). Fig. 171: Open submenu “Status” Open submenu “Software versions”...
Page 107 Open submenu “System info” Select the “System info’’ submenu (Fig. 174/2) with the arrow keys [up] (Fig. 174/3) and [down] (Fig. 174/5). Confirm the selection with [OK] (Fig. 174/4).  The “42 System info’’ submenu appears on the display (Fig. 175/1) showing the values “Rail length’’...
Page 108 The input signals “Start Input’’ (Fig. 177/2), “Inner Sensor’’ (Fig. 177/3) and “Outer Sensor’’ (Fig. 177/4) show “Yes’’ if there is an input signal. The “0-10V Input’’ (Fig. 177/5) shows the currently applied voltage in a range from 0 to 10 V. Press [OK] (Fig.
Page 109: Fault Indications
Fig. 180: Submenu “4 Status” 7.7. Fault indications Open submenu “Alarms” Press [Menu] (Fig. 181/1) to open the “1 Main menu’’ menu (Fig. 182/1).  The “1 Main menu’’ menu appears on the display (Fig. 182/1). Fig. 181: Open main menu Select the “Alarms’’...
Page 110 Open submenu “Active alarms” Select the “Active alarms’’ submenu (Fig. 183/2) with the arrow keys [up] (Fig. 183/3) and [down] (Fig. 183/5). Confirm the selection with [OK] (Fig. 183/4).  The “51 Active alarms’’ submenu appears on the display (Fig. 184/1) showing a “listing of the active alarms’’...
Page 111 Open submenu “Alarm log” Select the “Alarm log’’ submenu (Fig. 186/2) with the arrow keys [up] (Fig. 186/3) and [down] (Fig. 186/5). Confirm the selection with [OK] (Fig. 186/4).  The “52 Alarms’’ submenu appears on the display (Fig. 187/1) showing a “listing of the registered alarms’’...
Page 112 Alarm messages popping up during The alarm messages described below are also displayed in operation abbreviated form in submenu “51 Active alarms’’ and saved in submenu “52 Alarms’’. To rectify the alarms described, see chapter 9 Troubleshooting on page 118. If an alarm message appears, that is not described below, read chapter 9 Troubleshooting on page 118 or contact Klingenburg GmbH Manufacturer's contact details on page 4.
Page 113 Modbus communication alarm The alarm message “Cleaner Drive communication alarm!’’ (Fig. 191/2) occurs during the cleaning process if there is a problem with the modbus communication between the rotor cleaner control and the rotor cleaner drive. The red alarm LED (Fig.
Page 114 Motor phase alarm The alarm message “Cleaner Drive motor phase alarm!’’ (Fig. 193/2) is displayed during the cleaning process if there is a problem with the connection of stepper motor of the cleaning rail. The red alarm LED (Fig. 193/1) lights up. Refer to chapter 9 Troubleshooting on page 118 and rectify the ...
Page 115 Outer sensor signal alarm The alarm message “Outer sensor signal is missing!’’ (Fig. 195/2) is displayed during the cleaning process if there is a problem with the proximity sensor on the circumference of the rotor. The red alarm LED (Fig. 195/1) lights up. Refer to chapter 9 Troubleshooting on page 118 and rectify the ...
Page 116: Maintenance
8. Maintenance 8.1. Maintenance safety instructions Electrical voltage DANGER! Risk of fatal injury from electric current! In case of contact with live parts, there is a risk of fatal injury through electric shock. Only qualified electricians may work on electrical •...
Page 117: Maintenance Table
8.2. Maintenance table The table below indicates the maintenance operations required for optimum and trouble-free operation of the machine. The operator is responsible for carrying out the maintenance work and complying with the minimum maintenance intervals. If you have any questions about maintenance work and intervals, contact the manufacturer ...
Page 118: Troubleshooting
9. Troubleshooting Error description Display indication Cause Solution Personnel Motor does not Stepper motor is not Check stepper motor Eletrician ,,Inner or Outer rotate/cleaning sensor error!’’ connected to the cleaner connection, replace or repair carriage does not drive. if necessary Chapter 6.3.2 move Rotor cleaner drive on page...
Page 119 Error description Display indication Cause Solution Personnel Inner sensor ,,Inner sensor Stepper motor defective. Check the stepper motor, Electrician cannot be reached replace if necessary. signal is missing!’’ or does not switch. Reset alarm message. Foreign objects on the Check the cleaning rail for Service cleaning rail.
Page 120 Error description Display indication Cause Solution Personnel Defective terminals for 0- Replace rotor cleaner Electrician 10 V voltage output signal control, contact Klingenburg on the rotor cleaner for replacement. control. Reset alarm message. Rotary heat exchanger Check rotary heat Electrician motor defective.
Page 121 Error description Display indication Cause Solution Personnel No connection between Connect the output of the Service water solenoid valve and water solenoid valve with technician high-pressure hot water the high-pressure hot water nozzle. nozzle. Lack of function of the Check the water solenoid Service water solenoid valve.
Page 122 Error description Display indication Cause Solution Personnel Overvoltage alarm ,,Cleaner Drive Input voltage too high. Check connections L, N and Electrician triggered. PE on the the rotor cleaner overvoltage alarm!’’ control, correct if necessary. Reset alarm message. Undervoltage alarm Input voltage too low. Check connections L, N and Electrician ,,Cleaner Drive...
Page 123 Error description Display indication Cause Solution Personnel Motor phase alarm ,,Cleaner Drive Stepper motor cable not Check connection of the Electrician triggered. motor phase properly connected to the stepper motor cable on the rotor cleaner drive. rotor cleaner drive, correct if alarm!’’...
Page 124: Disassembly And Disposal
Disassembly and disposal Electrical system DANGER! Danger to life due to electric current! There is a danger to life in case of contact with live components. Electrical components which are switched on can perform uncontrolled movements and lead to serious injuries. Before starting disassembly, switch off and permanently •...
Page 125 Personnel: Service technician • Electrician • Protective equipment: • Protective clothing Safety shoes • Safety gloves • Requirements: • The machine is switched off and secured against being switched on again Operating manual for the building control system.  Disassembling Physically disconnect the entire system from all energy sources.

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