Hydrotec HY-MAG INTEGRAL Series User manual

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HY-MAG
INTEGRAL
DN100
Serial number: ..............................
HYDROTEC
Hydrotec House
4-5 Manor Courtyard
Hughenden Avenue
High Wycombe
HP13 5RE
Tel. 01494 / 796040 Fax 01494 / 796049

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Operating Instruction HY-MAG®INTEGRAL
General
The HY-MAG Integral is a high-quality menu- and micro-processor driven control box
providing maximum efficiency for the HY-MAG Water Conditioning Units sizes DN20 to
DN100. The control box is pre-programmed ex works to the individual water conditioning
units.
The instructions render a survey on the menu guide and the individual programming
possibilities for the operator.
The specific technical data for the HY-MAG Water Conditioning Unit are shown on the type
plate. Below some information:
Mains voltage: 230V, 50cps a.c.
Protection class: IP 65
Ambient temperature
Control box: max. 40°C
Flow capacity water part: dependent on nominal width
Max. operating temperature: 80°C
Nom. Pressure: PN 16
CAUTION: The HY-MAG Integral control box is designed in protection class IP65.
The feed line with power supply plug for mains supply does not meet the
requirements. Mains supply line and plugs must rather be positioned
outside the possible spray water range or be protected by appropriate
means.
NOTE: The HY-MAG Integral control box is provided with a transparent
plastic glass. To be able to change or set control operations, the plastic
cover must be opened with the right-hand closure.
Once setting has been finished, the cover must be closed again with an
audible sound.
NOTE: The water parts of the DN 100 have, contrary to the water parts series
DN25-DN65, an additional thermal protection to avoid overheating. The
units are supplied ex works with appropriate connections.

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Connection of Water Part
The HY-MAG Water Conditioning Units are supplied ex works in 2 components, that means
water part and control box.
Connection between control box and water part must be provided by expert plumbers as
follows:
HY-MAG DN25 –DN65
The control box includes a mains connection cable and a load cable for the connection of the
water part. Such load cable is provided with a Harting plug. To guarantee a correct
connection of the water part, it is necessary to insert the Harting plug into the Harting
bushing on the water part and to fix it by the safety bracket. A code bar on the plug / bushing
guarantees a correct connection.
It is only possible and allowed to start or put the control box in operation if the Harting plug
between control box and water part has been closed!
The connection cable between control box and water part is a spiral cable. Max. distance
between both unit components shall not exceed 1.5 m!
HY-MAG DN100
The control box for the HY-MAG DN100 does include a mains connection cable, a load cable
and a cable to connect the thermal protection.
The connection box (terminal strip) provided on the water part is necessary to make the
appropriate connection at plant installation:
Connection coil: load cable
Connection thermal
protection: thermal protection cable
To guarantee a correct connection of the water part, it is necessary to fix the corresponding
cable ends in the specific and marked terminals.
It is only possible and allowed to start or put the control box in operation if the connection is
properly made correctly and the terminal or connection box closed!
The connection cable between control box and water part is a spiral cable. Max. distance
between both unit components shall not exceed 1.5 m!

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Initiation Phase
Once the control box was connected to the mains power and switched on, the initiation
phase and an initial system check is started automatically. Every individual and actually
running operating sequence is shown in the LCD-display.
Standard display:
Control box test:
Short-circuit test:
Operation - test: Technical operation check of complete HY-MAG system (control box
and water conditioning unit). The below individual sequences are
shown
Test thermal protection
Actor –test
Temp. test: OK
Test current to water conditioning unit
See list of individual current rates for
units (nom. width)
Pre-set water conditioning unit –
example HY-MAG DN100
Check remanence clearance
H Y D R O T E C
Integral V. 1.00
Short-circuit - test
Test OK
Control box - test . . . .
Control box OK
Actor –test
current: xxx mA
Actor –test
Hydromag type: DN 100
Actor –test
Time reman. clearance: OK

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Normal Operation
The control box automatically switches to normal operation once the initiation phase has
elapsed, whereby the individual actual operation sequences are shown in the display and by
the LED lights.
The individual operation phases are shown optically. The below display monitoring is shown
during continuous operation.
LED –Light Sequence Display Monitor
All 8 LED’s light successively (GREEN phase),
positive d.c. (approx. 100 V) is released to the
water part
Duration about 26 s
LED : GREEN
Monitoring of day, date and time
Operation state Monitoring current rate
The current ratings for the corresponding HY-MAG types are
shown in the below list
REFIT®–Phase
Duration about 4 s (magnetic remanence
clearing, LED extinguishes successively to the
left within 4 seconds –GREEN LED)
LED : GREEN
LED REFIT Phase : YELLOW
All 8 LED’s light successively (RED), negative
d.c. (approx. 100 V) is released to the water
part
Duration about 26 s
LED : GREEN
REFIT®–Phase
Duration about 4 s (magnetic remanence
clearing, LED extinguishes successively to the
left within 4 seconds –RED LED)
LED : GREEN
LED REFIT PHASE : YELLOW
Thu 11.10.2003 10:30
Cont. operation + xxx mA
Thu 11.10.2003 10:30
Cont. operation + 0mA
Thu 11.10.2003 10:30
Cont. operation - xxx mA
Thu 11.10.2003 10:30
Cont. operation - 0mA

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The shown current rating is dependent on the type of water conditioning unit.
HY-MAG DN20 / 25 235 mA ± 10%
HY-MAG DN32 / 40 345 mA ± 10%
HY-MAG DN50 / 65 465 mA ± 10%
HY-MAG DN100 3.25 A ± 10%
Menu Sequences
Input and programming of HY-MAG Integral control box by pressing the front foil buttons
(behind transparent cover) as below:
Retrieval of menu.
Return from the individual menu levels.
Clear parameters.
Selection of individual menu sequences in menu levels, modification
and setting of parameters.
Selection of individual menu sequences in menu levels, modification
and setting of parameters.
Retrieval of individual menu sequences,
confirmation/acknowledgement of settings
NOTE : The monitoring returns to Standard Mode if input is delayed for more than 30
seconds and standard operation is shown in the display again.
Main Programme Menu
The individual sub-menus are selected in the main menu. The main menu is reached by
pressing the button once.

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The below menu sequences can be retrieved by the buttons
Operation mode
Operation hours
Date / Time
Time zones
Language
Service
The corresponding menu sequence is retrieved via the button and the respective sub-
menu is shown.
Mode of Operation
The operator can select between 2 different operation modes for the HY-MAG water
conditioning units.
Continuous
operation HY-MAG operates on a continuous 24 hour/day basis
Timer control The control box is in standby mode (LED standby: YELLOW). Switch-
on and –off times are controlled by the internal timers.
One switch-on and –off time per day can be programmed.
The above operation modes can be selected by subsequent pressing the buttons
and the correct mode can then be confirmed and acknowledged by pressing the button
once.
The control box and/or monitoring returns automatically to main menu after the setting has
been confirmed.
Main menu
Operation mode
Main menu
Operation hours
Main menu
Date / Time
Main menu
Time zones
Main menu
Language
Main menu
Service
Operation mode
Continuous operation
Operation mode
Timer control

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Operating Hours
The operating hours of the HY-MAG unit are registered by 2 separate counters.
Absolute value: Total operation time of HY-MAG unit in the actual installation.
(Operation hours since start-up). Standby-times are not registered and
thus, not shown.
Relative value: Operating hours of unit counted from a certain period of time.
The counter can be reset by the operator. (Operating hours since
last reset).
The below display is shown after the main menu sequence “operating hours” is retrieved:
The operator is in a position to reset the relative operating hours by pressing the button
once and the relative operating hours since the last reset are shown in the display.
The operating hours can be cleared by pressing the button once and the same button
also is used to return to the previous display.
Clearing the relative operating hours results in an automatic store and monitoring of the
actual time of clearing in line 2.
Date / Time
The operator can alter the internal timer and the date as described below. The main menu
Date / Time must initially be retrieved, whereby the display shows the actual setting.
If the setting is to be altered, press the button . Should no modification be requested,
the sub-menu can be left by pressing the button .
The active field that can be altered is marked with a line underneath. Change the setting by
pressing the buttons or until the desired figure is visible in the display. The setting
is finished once the Cursor is not flashing anymore. The mode is achieved by pressing the
corresponding button . The menu can be left by pressing the button once.
Oper. hours abs 000250
Oper. hours rel 000015
000015 oper. hours since
08.10.2003 14:50
000000 oper. hours since
10.10.2003 09:40
Date: Wed 10.10.2003
Time: 09:45
Date: Wed 10.10.2003
Time: 09:45

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NOTE: If the button is pressed during the modification phase, the input is
interrupted and the changed figures not registered.
Time Zones
The switch-on and –off times of the unit can be programmed in the menu „Time zones“ after
the operation mode „Timer control“ was retrieved. One such setting is possible per day.
A group of several days or also individual days can be programmed by the operator. Switch-
on and switch-off times are controlled and initiated by the internal timer.
Groups: Mo ... Su
(several days)
Mo ... Fr
Sa ... Su
Individual days: Mo, Tue, Wed, Thu, Fr, Sa, Su
and so on –for every day in the week.
An initial selection of the desired menu is possible via the Cursor buttons , the
menu is then retrieved by pressing the button once and the switching times can then be
altered via the Cursor buttons. The figure that can actually be altered is marked with a line
underneath. Once the correct setting is achieved, the button must be pressed until the
line underneath is no longer visible. If the total switch settings for the selected and retrieved
group of days /individual day are to be cleared, press the button once.
The times for switch-on and switch-off can be selected right on the dot. Below is an example
for setting switch time - group of days Mo-Su, switch-on 6.00 a.m., switch-off 10.00 p.m.
NOTE: If times different to the individual days than provided in the corresponding
group of days are set, the display for the group of days show **:**-**:** and the
actual switch time is set in the day monitoring.
If the switch-off time is set earlier than the switch-on time or if the times were
reset (00:00-00:00), the water conditioning unit is not activated that day(s).
Select time zone:
Mo .. Su: **:** - **:**
Select time zone:
Mo .. Fr: **:** - **:**
Select time zone:
Sa .. Su: **:** - **:**
Select time zone:
Mo: **:** - **:**
Alter time zone:
Mo .. Su: 06:00 - 22:00

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Language
The service menu of the HY-MAG Integral control box provides 2 languages. Operation and
setting is possible in both languages.
The menu language is initially selected by means of the button . The corresponding
language is then selected and confirmed by the buttons or . Once the correct
language is shown, confirm by pressing the button and setting is finished.
Service
The service menu is code protected and can be retrieved from authorised service personnel
only.
NOTE: If the customer or plant operator retrieves the service menu by mistake, and
no buttons shall be pressed for 30 seconds, after such time period the HY-
MAG Integral control box returns automatically to standard mode.
Failure Indication
The Integral control box is provided with an automatic failure recognition, whereby the failure
type is shown.
In case of failure, the total LED-scale flashes red and the display shows the type of failure.
Moreover, it is possible to signal a failure via a potential-free contact. The correct connection
is shown in the terminal plan and such relay-contact can be charged as below:
Rated (nom.) current: 6A
Rated (nom.) voltage: 250V AC
max. switching capacity: 1500W (class AC1 –Ohm load)
max. switching capacity: 300W (class AC15 –electro-magnetic load)
min. switching capacity: 500mW / 12V / 10mA
Language:
German
Language:
English
Code : . . . . .

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Failure 1: Undercurrent
Coil not closed, faulty connection control box → water unit
Failure 2: Overload
Short cut of coil, faulty coil
Failure 3: Short cut
Short cut in coil connection (visible during initiation)
Failure 4,5: Control box failure
failure in any electrical component of the control box
Failure 6: Thermal protection
Thermal switch in the coil of the HY-MAG DN100 was released
ATTENTION: If the button is pressed during a failure record, the acoustic alarm is
switched-off, the record contact shows failure and the display: “Conditioning off”. A new start
of the control box and initiation is released automatically about 60 seconds after a button has
been pressed last.
Failure: Undercurrent
Thu 11.10.2003 16:17
Failure: Overload
Thu 11.10.2003 16:17
Failure: Short cut
Thu 11.10.2003 16:17
Failure: Control box
Thu 11.10.2003 16:17
Failure: Overheating
Do 11.10.2003 16:17

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Failure –Remedial Action
General:
If there is no display or should no sign for any operation be visible, initially check the
following:
Check whether or not the unit is switched on and mains voltage 230V/50 cps available. If that
is all correct, check the fuse as per the below instruction:
The fuse is provided in the terminal unit on the ledge for the water part connections and
mains supply. Please take care that the mains plug is removed prior to opening the unit!
Open the lower front cover and replace fine fuse (3.15 AT).
If there is still no LED scale visible, inform the technical department of Hydrotec.
Fault Types:
Failure 1: Undercurrent
Check connection and correct fit between water part and control box, i.e. fit of
Harting coupling.
Failure 2: Overload
Failure in magnet (solenoid) coil in water unit. Inform Hydrotec immediately in
that case since no further local steps are possible.
It is necessary to note the time the failure had been recognised first.
Disconnect unit from mains voltage
Failure 3: Short cut
Short cut (external) of coil circuit.
Disconnect unit from mains supply. Check for foreign particles in connection
(spiral cable of control box and connection socket of water unit).
Restart unit. Hydrotec have to be informed immediately if the failure arises
again. There are no further local measures necessary. Disconnect the unit
from mains supply.
Water Part
Connection
Mains
Connection
VFC Contact
Fuse 3.15 AT
Thermal
Protection

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Failure 4, 5: Control box
Faulty control box. Internal communication or between control box and water
part may be faulty or disturbed. Switch-off plant and start again. Return box for
inspection to Hydrotec along with corresponding failure report or other
information should the fault happen again.
Failure 6: Overheating
- For HY-MAG DN100 only -
Temperature safety control was released, i.e. the solenoid coil in the water
part is overheated. Check whether or not exterior influences or stagnation of
water may be the reason.
If there is no exterior influence visible, control operation and check whether
cooling takes place. The operation mode starts automatically again once the
coil temperature is cooling down and the contact switching accordingly.
Inform Hydrotec accordingly should that not be the case.