ProMinent ProMaqua Dulcodes A, Assembly And Operating Instructions Manual

Page 1: ...ing instructions 2006 42 EC Part no 985175 Version BA DS 064 09 19 EN Please carefully read these operating instructions before use Do not discard The operator shall be liable for any damage caused by...

Page 2: ...des detailed descriptions of the haz ardous situation see Chapter 3 1 Labelling of Warning Informa tion on page 10 The following symbols are used to highlight instructions links lists results and othe...

Page 3: ...odes A control 20 6 4 Display 23 6 4 1 Functions of the keys in Unit Off status 23 6 4 2 Functions of the keys in PAUSE status 24 6 4 3 Functions of the keys in COOLING status 26 6 4 4 Functions of th...

Page 4: ...after dismantling the UV lamp protection tube 64 9 2 3 Cleaning with Cleaning Solution by Filling the UV System 67 9 2 4 Cleaning the UV Sensor 68 9 3 Maintenance of the wearing parts 69 9 3 1 Tools...

Page 5: ...ance data can be found in the data sheet enclosed with the Dulcodes UV system Scope of supply n Radiation chamber n Lamp with lamp protection tube n UV C sensor n Temperature switch n Automatic wiper...

Page 6: ...display for the current oper ating status is displayed The menu is set to the corresponding operating statuses that is to say when the UV system is running all events are monitored and treated accordi...

Page 7: ...char acters are shifted one position to the left HELP Display help text Displays the planned help text for the selected operating object If no help text is planned no help is displayed TAB Switch bet...

Page 8: ...to the corresponding menu entry 2 To execute a menu command press ENTER The next menu level is displayed 3 If a menu level contains an input field use the function keys to enter the corresponding val...

Page 9: ...limit values for variables If you enter a value that is outside these limits the value is not applied If a message window has been planned for the project a system message is emitted and the original...

Page 10: ...will result in fatal or very serious injuries WARNING Nature and source of the danger Possible consequence Fatal or very serious inju ries Measure to be taken to avoid this danger Denotes a possibly...

Page 11: ...tion Hints on use and additional information Source of the information Additional measures Denotes hints on use and other useful informa tion It does not indicate a hazardous or dam aging situation Sa...

Page 12: ...authorised distribution partner Trained qualified per sonnel A trained qualified employee is deemed to be a person who is able to assess the tasks assigned to him and recognize possible hazards based...

Page 13: ...sufficient water treatment Possible consequence Illness or disease Please read the technical data sheet for your UV system Ensure that the maximum permissible water flow rate is not exceeded and the U...

Page 14: ...diation UV C UV C radiation is harmful to the eyes and skin The UV lamps may only be operated when installed The UV system should be installed in accordance with all pertinent regulations prior to com...

Page 15: ...humidity non condensing Other No dust no direct sunlight Permissible ambient temperature 5 C 40 C Humidity maximum 92 relative air humidity non condensing Other ambient conditions No dust no direct su...

Page 16: ...ivery of the UV system and are provided by the operator on site A0917 1 2 3 4 5 7 6 2 2 Fig 3 Typical installation layout for a UV system 1 Shut off valve 2 Shut off valve 3 Rinse valve 4 Sampling tap...

Page 17: ...value to the control The UV setpoint is either entered directly in the control operating mode control internal INT or using a variable 4 20 mA standard signal operating mode con trol external EXT 5 4...

Page 18: ...before the power failure 40 seconds are needed to ramp up the HMI The PLC Program mable Logic Controller is ready for operation considerably faster To avoid ambiguous operating indicators and operati...

Page 19: ...epending on the applica tion Often 600 J m is used to reduce combined chlorine and 400 J m for disinfection The UV dose is calculated from the trans mission of water and the water flow refer to the da...

Page 20: ...intensity Rinsing valve open 600 J m2 UV dose Fig 4 Display of UV dose and radiation intensity UV intensity In UV systems with connected flow measurement via the 0 4 20 mA input the current flow appea...

Page 21: ...e the control parameters have been entered the UV system calculates the setpoint 3 EXT control UV sensor signal a UV sensor signal in W m depending on the control variable analogue input signal Specif...

Page 22: ...e 00 01 Lamp power 1x979 W Lamp ON Wiper Trend UV intensity 2 UV intensity Rinsing valve open UV dose 600 J m2 Fig 8 INT control UV sensor signal in W m of the maximum UV sensor signal The display cor...

Page 23: ...erating time since last switched on 8 Information on the wiping cycle rinsing pro cesses UV dose flow 6 4 1 Functions of the keys in Unit Off status A running wiping cycle cannot be interrupted The UV...

Page 24: ...nctions of the keys in PAUSE status A1182 06 12 2012 10 06 53 STOP FAULTS MENU PAUSE Wiper Fig 12 The UV system display in PAUSE status Tab 4 The following functions can be selected Key Function Upon...

Page 25: ...Description Function ESC ACK Reset the fault TAB Selection of display fields DEL HELP Operating tips ENTER Entry Arrow keys Selection of display fields Control 25...

Page 26: ...ion Upon selection of the function and subsequent pressing of Enter the following occur F1 STOP The UV system is switched off F3 Wiper A wiper cycle is triggered F4 Fault Display of warnings and error...

Page 27: ...AND WARM UP LAMP Lamp is starting WIPER FAULTS Fig 14 The UV system display in Startup status Tab 6 The following functions can be selected Key Function Upon selection of the function and subsequent...

Page 28: ...UV intensity Trend Wiper Rinse valve open Fig 15 The UV system display in Commissioning rinse mode Tab 7 The following functions can be selected Key Function When the function is selected and Enter i...

Page 29: ...wiper fault the wiping cycle is omitted and the free rinse time starts immediately If during the Free rinse a further wiping cycle is trig gered then the free rinsing period does not continue during t...

Page 30: ...pressed F5 Menu Switches to the Menu display F2 F3 F5 F10 Designation Function ESC ACK Reset the fault TAB Select display fields and numbers DEL Delete numbers HELP Operating information ENTER Entry...

Page 31: ...tted Tab 9 The following functions can be selected Key Function When the function is selected and Enter is pressed F1 STOP Switches off the UV system F2 TREND Display of the development of the lamp po...

Page 32: ...ff A1192 06 12 2018 10 06 53 STOP Fault Menu 498 W m2 Control INT Time 0000 01 Lamp power 1x979 W Lamp ON Wiper Trend UV intensity 500 W m2 UV intensity Post burn Fig 19 The UV system display in Post...

Page 33: ...and restart the UV system The UV system restarts here automatically unless the power supply has failed A1193 Faults 24 12 2012 12 10 48 Fault Fault wiper counter 24 12 2012 12 15 26 Fault Breaker 1F6...

Page 34: ...wiper cycle To avoid error messages due to shading of the UV sensor by the wiper elements the status of the warning and safety threshold is frozen at the status prior to the start of the wiper cycle d...

Page 35: ...0 days Archive Faults warnings and events System operation data NEXT MENU PAGE 1 Fig 21 The first operating and display level 6 5 1 1 Trend view UV intensity Up to 192 hours 8 days can be written Use...

Page 36: ...ger for 400 days An operating day is deemed to have occurred if the UV lamp is operated for a minimum of 10 minutes After these 10 minutes the current data for the UV sensor signal and the electrical...

Page 37: ...12 2012 24 12 2012 24 12 2012 24 12 2012 Fig 25 Archive Faults warnings and events 6 5 1 5 Operating Data Operating hours and connections are displayed You can reset the UV lamp operating hours count...

Page 38: ...n the type of control selected n The UV sensor signal is monitored in W m2 with internal control by specification of the electrical lamp power Limits are abso lute values and remain constant when the...

Page 39: ...s the F5 MENU key The entered value is saved and the display again shows the selection of the second operating and display level Use F3 to switch between AUTO and MANUAL MANUAL sets the position of th...

Page 40: ...pears you can now enter the desired value using keys 0 9 3 Enter a value between 0 100 for the lamp power 4 Enter the maximum flow 5 Enter UVT 10 cm for the transmission 6 Confirm the value with ENTER...

Page 41: ...stage 1 A2909 Menu Control and setpoint of UV Automatic Nominal dose 2 HOME Manual mode 400 J m2 activated 335 W m2 Setpoint m3 h Aut Lev1 Aut Lev2 Fig 32 Control and setpoint of UV in control mode au...

Page 42: ...stage 2 is deactivated in this control mode Pause YES or NO Analogue output 0 20 mA or 4 20 mA for the processed UV sensor signal A1206 Menu Internal or remote control INT NO Control INT EXT Setpoint...

Page 43: ...95 Home Max flow Back 30 00 m3 h m3 h GPM m3 h Fig 35 UV dose calculation externally EXT With the EXT control mode the maximum flow corresponds to the 20 mA value of the external input flow signal UV...

Page 44: ...ithout a cool down The length of the cooling down period is pre set and cannot be changed If the water has to be treated while the shut off valve is closed and the pump is stopped then a post burn tim...

Page 45: ...12 Password These menus are password protected therefore please contact the Service partner for your UV system A1208 Sensor calibration Date and time Software and hardware information System informat...

Page 46: ...tensity You can calibrate the unit sensor in this menu should the unit sensor deviate from a reference measurement with a calibrated UV sensor The UV signal must not change again before the calibratio...

Page 47: ...herefore please contact the Service partner for your UV system Pressing Reset resets all operating parameters and settings and the default values are used Only reset the UV system when it is switched...

Page 48: ...ncorrect settings can result in damage to the UV system Please note the configuration and read the data sheet for your UV system A1214 MENU Configuration HOME SENSOR START Fig 42 Changing the system c...

Page 49: ...Setting the display contrast n Setting the language Stop Runtime has no function A1217 MENU _ Contrast Stop Runtime Language HOME Fig 44 Setting the language and contrast A1439 Transfer Info Settings...

Page 50: ...treatment of the water cannot be guaranteed CAUTION Unauthorised operating parameters Possible consequence Material damage Ensure that The installation place is dry and frost free There is guaranteed...

Page 51: ...installation of the UV system I Side view II Front view 1 Bleed valve provided on site 2 Flow of water to pool 3 Shut off valve open in normal operation 4 UV System 5 UV feed and drain pipe has to be...

Page 52: ...5 Service area keep free of obstacles 6 Shut off valve open in normal operation 7 Flow of water from filter 8 Shut off valve closed in normal operation 1 2 3 I II A2141 Fig 48 Electrical wiring diagra...

Page 53: ...ion tube 12 Inlet 16 Temperature switch 17 Support plate for UV lamp protection tube 18 Safety switch 7 2 1 Assembly Maintenance work Leave adequate room for maintenance work The clearance required ca...

Page 54: ...maging the lamp radiation chamber and wiper element It must therefore be ensured that the radiation chamber cannot run empty when the pump is switched off NOTICE Provide valves upstream and downstream...

Page 55: ...uous power supply by means of a suitable fault current protection Only an authorised electrical technician may open the control cabinet Do not lengthen the connecting cable for the UV lamp or the UV s...

Page 56: ...n tube is sitting correctly The UV lamp protection tube may not project out more than 13 mm and may not be offset at an angle 5 Screw the UV lamp protection tube bracket into the chamber cover until h...

Page 57: ...this reason always clean the lamp thor oughly with a cloth moistened with alcohol before installing it Then wipe the UV lamp with a soft dry cloth Also thoroughly clean the glass of the UV lamp return...

Page 58: ...e the UV lamp cover onto the UV lamp protection tube bracket and using the fixing bolts provided screw in and tighten using the Allen key supplied 10 Re fit the safety switch 7 6 Assembly and installa...

Page 59: ...he UV transmission does not fall below the permissible level as otherwise adequate treatment of the water cannot be guaranteed because the radiation dose is too low NOTICE Warning threshold Failure to...

Page 60: ...s from the bleed valve 4 Close the bleed valve 5 Check the reactor for leaks 6 Open the shut off valve downstream of the reactor only nec essary with a manual shut off valve 8 3 Switching on the UV sy...

Page 61: ...it Disconnect damaged and defective devices or devices that have been tampered with from the power supply CAUTION General precautionary measures Ensure that the radiation chamber is at atmos pheric p...

Page 62: ...included in the Appendix 9 1 Maintaining and caring for the KP 300 The operating device is designed for low maintenance operation You should keep the film keyboard clean For cleaning use a moist clea...

Page 63: ...ance with the pertinent guidelines and regulations Deposits of for example iron manganese or limescale can form on the UV lamp protection tubes during operation As these deposits absorb UV radiation...

Page 64: ...of the UV lamp with cotton gloves Fingerprints or impurities burn into the glass and can result in premature failure For this reason always clean the lamp thor oughly with a cloth moistened with alco...

Page 65: ...protection tube with cleaning solution or immerse it in cleaning solution until the film has been removed without leaving a trace 13 Rinse the UV lamp protection tube with clean water and dry thorough...

Page 66: ...e aid of a slotted head screw driver 20 Insert the UV lamp fully into the UV lamp protection tube 21 Place the UV lamp cover onto the UV lamp protection tube bracket and using the fixing bolts provide...

Page 67: ...iation chamber 4 Drain the reactor 5 Screw in the water drain screw again and tighten using min imal force 6 Fill the reactor with the cleaning solution through the vent opening Allow the cleaning sol...

Page 68: ...in the UV sensor again and tighten very little effort is needed for this 7 Connect the sensor connection cable to the UV sensor 8 Slowly open the shut off valve upstream of the radiation chamber 9 Fil...

Page 69: ...Tools Tools n 17 mm open ended spanner n 24 mm open ended spanner n 1 5 mm Allen key n 2 mm Allen key n 5 mm Allen key n 6 mm Allen key n 300 gramme hammer n Plastic hammer n Face spanner for 14 100 m...

Page 70: ...per 316 318 362 365 2x 901 364 900 A1444 Fig 51 Replace these components after an operating period of one year The number of components varies depending on the type of the spare parts kit 316 X ring 3...

Page 71: ...V lamp when wearing cotton gloves Fingerprints or impurities burn into the glass and can result in premature failure For this reason always clean the lamp thor oughly with a cloth moistened with alcoh...

Page 72: ...52 Upper sealing stopper A1877 Fig 53 Lower sealing stopper 3 Drain the radiation chamber by removing the upper and lower sealing stoppers A1875 Fig 54 Earthing cable 4 Remove the earthing cables Main...

Page 73: ...nge plate 5 Dismantle the flange plate with the wiper motor A1879 Fig 56 Safety switch 6 Remove the UV lamp cover safety switch A1880 Fig 57 UV lamp cover 7 Loosen the fixing bolts on the UV lamp cove...

Page 74: ...r and the UV lamp A1882 Fig 59 Tool 9 Loosen and remove the UV lamp protection tube bracket Place the toll on the holes and not on the threads A1883 Fig 60 UV lamp protection tube 10 Remove the UV lam...

Page 75: ...ction tube with a soft cloth Chemically clean the UV lamp protection tube if necessary refer to the Operating Instructions A1884 Fig 61 Wiper limit switch 12 Remove the cable from the wiper limit swit...

Page 76: ...g Slip washer 14 Remove the spacer ring and the slip washer A1887 Fig 64 Bearing cover 15 Unscrew the screws on the bearing cover A1889 Fig 65 Bearing cover 16 Remove the bearing cover from the chambe...

Page 77: ...ring using CARBAFLO 2371 and insert the new X ring into the chamber cover A1891 Fig 67 Checks 19 Check and if necessary replace the adapter shaft The shaft should not have any grooves or unevenness A...

Page 78: ...A1893 Fig 69 Chamber cover 21 Remove the chamber cover A1894 Fig 70 Wiper assembly with spindle 22 Remove the wiper assembly with spindle Maintenance 78...

Page 79: ...A1895 Fig 71 Wiper spindle A1896 Fig 72 Wiper spindle 23 Remove the wiper assembly from the wiper spindle Maintenance 79...

Page 80: ...A1447 Fig 73 Tool for the threaded sleeve in the wiper mounting part number 1037738 A1897 Fig 74 Checking the threaded sleeve A1898 Fig 75 Unscrewing the threaded sleeve Maintenance 80...

Page 81: ...ed sleeve 24 Check and if necessary replace the threaded sleeve in the wiper mounting A1901 Fig 77 Plastic slide bearing A1902 Fig 78 Plastic slide bearing 25 Check and if necessary replace the plasti...

Page 82: ...A1903 Fig 79 Bearing cover 26 Open the bearing cover to obtain access to the slide bearing Maintenance 82...

Page 83: ...ig 80 Tool for pressing in and out the plastic slide bearings part number 1036907 A1904 Fig 81 Bearing cover slide bearing A1905 Fig 82 Bearing cover slide bearing 27 Replace the slide bearing of the...

Page 84: ...Wiper element 1 29 Check and if necessary replace the wiper element 1 The wiper lip points away from the chamber cover to simplify the insertion of the UV lamp protection tube When assembled the wipe...

Page 85: ...earing 31 Remove the counter bearing by pressing it out from inside A1910 Fig 87 Bearing cover chamber cover 32 Use the screw to screw the bearing cover to the chamber cover The flat area points towar...

Page 86: ...rod 33 Push the wiper rod through the UV chamber cover into the counter bearing A1937 Fig 89 Chamber cover 34 Push the chamber cover onto the radiation chamber The wiper rod has to site in the bearin...

Page 87: ...the UV lamp protection tube using a new O ring Screw the UV lamp protection tube bracket into the chamber cover until hand tight A1941 Fig 91 Tightening torque 90 5 36 Tighten the UV lamp protection...

Page 88: ...sensor The shadow of the lamp return cable could otherwise distort the measurement of the UV intensity Fit the UV lamp 38 Fit the safety switch A1940 Fig 93 Coupling 39 Attach the slip washer the spac...

Page 89: ...Connect up all electrical connections 43 Seal the radiation chamber by screwing in the upper and lower sealing stoppers 44 Slowly open the shut off valves upstream and downstream of the radiation cha...

Page 90: ...the respective UV system Re ace the UV lamps with new lamps at the very latest when The UV sensor signal approaches the safety threshold without this being due to other causes such as the formation o...

Page 91: ...Loosen the fixing bolts of the lamp cover using an Allen key remove the lamp cover and pull out the lamp by approxi mately 100 mm 7 Loosen the UV lamp at the cable clamp with the aid of a slotted hea...

Page 92: ...the UV lamp is replaced Only a correctly adjusted safety threshold will guar antee adequate treatment Calibration of the UV sensor Calibrate the UV sensor once the UV system has been switched on 9 5 C...

Page 93: ...at the UV lamp has not yet warmed up sufficiently Allow the activated UV system to warm up for a short while The calibration process can be terminated at any time by pressing F1 F2 and F5 The UV syste...

Page 94: ...3 Remove the fan cover 4 Remove the dirty filter mat and insert a new filter mat 5 Replace the filter mat on the air outlet filter as described above 6 Switch on the main switch Maintenance 94...

Page 95: ...cation on page 12 Display background lighting To ensure easy monitoring of the UV system ope ration the background lighting of the display changes according to the UV system operating status Normal op...

Page 96: ...eck power supply Lamp driver 1 2 3 Lamp open UV lamp defective Replace the UV lamp Lamp driver 1 2 3 Lamp short circuit UV lamp defective Replace the UV lamp Lamp driver 1 2 3 Error Lamp driver not re...

Page 97: ...is not calibrated Calibrate wiper Wiper not at HOME posi tion Wiper does not reach the HOME position within the maximum run time n Move wiper to the HOME position n Check the position of the wiper and...

Page 98: ...n tube n Clean the UV sensor replace UV sensor UV intensity below warning threshold n UV intensity below the warning threshold n UV lamp has aged and UVC power too low n Poor transmission of the water...

Page 99: ...18 GPM DN 150 ANSI 6 1x3A 180 m3 h 794 GPM DN 200 ANSI 8 2x2A 241 m3 h 1059 GPM DN 200 ANSI 8 2x3A 361 m3 h 1588 GPM DN 250 ANSI 10 3x3A 541 m3 h 2382 GPM DN 300 ANSI 12 95 cm transmission 600 J m2 Ty...

Page 100: ...nt temperature 5 40 C Operating pressure The maximum permissible operating pressure is possibly lower with systems that have a non standard design see data sheet for the UV system Requirements for the...

Page 101: ...mp systems Type 1 kW ANSI 1 kW DIN DN 4 100 D1 6 63 168 3 L1 27 56 700 0 L2 13 66 347 L3 6 81 173 L4 18 5 470 L6 9 06 230 0 LA 26 14 664 k 7 5 180 l 0 75 18 b 0 87 20 I ANSI 150 lbs compatible or DIN...

Page 102: ...or DIN 2576 Drawings not true to scale All dimensions in mm unless otherwise indicated Type 3 kW ANSI 3 kW DIN DN 8 200 D1 12 75 323 9 L1 31 5 800 L2 21 54 547 L3 10 75 273 L4 26 38 670 L6 11 02 280...

Page 103: ...ype 2x2 kW ANSI 2x2 kW DIN DN 8 200 k 11 75 295 l 0 88 22 Number I 8 8 b 0 94 24 I ANSI 150 lbs compatible or DIN 2576 II Cable length approx 9 metres 354 III Wall clearance at least 300 mm 12 IV ANSI...

Page 104: ...1 02 26 I ANSI 150 lbs compatible or DIN 2576 II Cable length approx 9 metres 354 III Wall clearance at least 300 mm 12 IV ANSI 150 lbs compatible or DIN 2576 Drawings not true to scale All dimension...

Page 105: ...k 17 400 l 1 22 I ANSI 150 lbs compatible or DIN 2576 II Cable length approx 9 metres 354 III Wall clearance at least 300 mm 12 Drawings not true to scale All dimensions in mm unless otherwise indica...

Page 106: ...Type Voltage Frequency 3x3A 85 264 V AC 3 phases 320 575 V AC 3 phases 50 60 Hz Observe the supplied system circuit diagram Technical data 106...

Page 107: ...180 181 182 105 150 158 304 363 114 340 123 121 124 320 327 153 154 153 318 122 316 357 367 101 653 328 368 304 117 501 655 180 181 182 II A A B B C D D I II II 1 2 5 A A 1 5 A 1 1 B B C 1 2 5 D D A1...

Page 108: ...2 791792 3 120 Locking screw DIN 910 G 3 4 1002753 as necessary 2 121 Complete cable clamp 34 5 x 36 1035011 as necessary 1 122 Bearing plate 1041183 1 123 Cheese head screw DIN 7985 M4x25 A2 468607 2...

Page 109: ...tective cover UVA 50x3 7x71 1041847 1 357 Coupling TX1 series 10 D8 1041484 1 362 Slide bearing F 8x10x10 IGLIDUR 1037033 1 year 1 363 Counter bearing spindle UVA 1041827 5 years 1 364 Threaded sleeve...

Page 110: ...parts number Replacement interval No Lamp cable LFLEX 2x2 5 mm2 10 metres 1041533 as necessary 1 Shaft 14 8 for the X ring 1041758 as necessary 1 is part of the spare parts kit UVA 1x3 kW part number...

Page 111: ...cking screw DIN 910 G 3 4 1002753 as necessary 2 121 Complete cable clamp 34 5 x 36 1035011 as necessary 2 3 122 Bearing plate 1042183 1 130 UV sensor A G 3 4 1 4539 1041449 as necessary 1 131 UV sens...

Page 112: ...91038 1 2 1 year 2 900 Wiper element 1027879 1 year 2 3 901 Holding ring 62 45 x 4 1028100 as necessary 2 3 Filter mat SK 3172 200 Filter for the fan 791039 1 2 1 year 1 Filter mat SK for the small fa...

Page 113: ...12 3 UV system operating log Date Turn ons UV lamp Operating hours UV lamp Signal dis play Sensor w m2 J m2 UV trans mission 1 cm Flow m3 h Conducted maintenance work Signature Appendix 113...

Page 114: ...or repair To do so remove all traces of hazardous substances Refer to the Material Safety Data Sheet for your feed chemical A current Declaration of Decontamination is available to download on the Pro...

Page 115: ...Wipers Designation of the product Dulcodes UV disinfection system Product type UVCb X X 4 5 Serial number see nameplate on the unit Relevant EU directives EU Machinery Directive 2006 42 EC EU EMC Dire...

Page 116: ...ore symbols 2 N Non discriminatory approach 2 Normal operation 16 O Operating error 5 Operating mode Control external 17 Operating mode Control internal 17 Operating Parameters 14 Operating pressure 1...

Page 117: ...17 Relevant EC directives 115 S Serial number 115 Sound pressure level 100 Spare parts kit 70 Standard signal output 106 T The function keys F1 F10 6 U Ultraviolet radiation 14 Use 5 User qualificati...

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Page 120: ...985175 6 en_GB 2019 ProMinent GmbH Im Schuhmachergewann 5 11 69123 Heidelberg Germany Telephone 49 6221 842 0 Fax 49 6221 842 419 Email info prominent com Internet www prominent com...