Kärcher WATERCLEAN 1600 User manual

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

WATERCLEAN 1600 Version 03/2008
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Contents
1 General
1.1 EU Declaration of Conformity ................................................. 1
1.2 Use in Accordance with the Regulations ................................ 2
1.3 Safety Instructions .................................................................... 3
1.3.1 Operation and Maintenance of the WTC 1600 ......... 3
1.3.2 Operation and Maintenance of the UV Irradiator .... 4
1.4 Raw Water .................................................................................. 5
1.4.1 Types of Pollutants ..................................................... 5
1.4.2 Retention Capabilities of the
Waterclean 1600 System ............................................ 5
1.4.3 Characteristics of Raw Water ..................................... 6
1.4.4 Physical Operating Principle of the RO-Machine ..... 7
2 Description
2.1 Overview .................................................................................... 9
2.2 Principle of Operation ............................................................. 10
2.3 Description of the System ...................................................... 17
2.3.1 Safety Installations ................................................... 17
2.3.2 Submergible Raw Water Pump ............................... 18
2.3.3 Raw Water Pump (Option) ....................................... 18
2.3.4 Container Outside ..................................................... 19
2.3.4.1 Connection Box 1 ..................................................... 19
2.3.4.2 Connection Box 2 ..................................................... 19
2.3.5 Container Inside ........................................................ 20
2.3.5.1 Preliminary Filter Module ........................................ 20
2.3.6 Reverse Osmosis Module (RO Module) ................. 23
2.3.6.1 Connection Panel ...................................................... 24
2.3.6.2 Control Panel for the "Double Pass" (Option) ........ 25
2.3.6.3 Motor-driven Pressure Maintaining Valve
(Pressure-/Rate Control) .......................................... 25

Version 03/2008 WATERCLEAN 1600
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2.3.6.4 Panel for Return Feed of Concentrate .................... 26
2.3.6.5 Cleaning, Disinfecting, Preserving and Frost
Protection Function (Cleaning In Place, CIP) .......... 27
2.3.6.6 Electrical Connection ............................................... 28
2.3.7 Switch Cabinet RO Module ..................................... 29
2.3.7.1 Automatic Circuit Breaker ....................................... 30
2.3.7.2 Safety Fuses ............................................................. 31
2.3.8 Operating Panel ....................................................... 32
2.3.9 UV Treatment (Option) ............................................ 37
2.4 Specifications .......................................................................... 38
2.4.1 Complete System ..................................................... 38
2.5 Accessories .............................................................................. 40
2.5.1 WTC 1600 .................................................................. 40
2.5.2 Generator Accessories ............................................ 41
2.6 Consumption Materials .......................................................... 41
3 Operation
3.1 Note for Maintenance and Care ............................................. 43
3.2 Assembly and Installation ...................................................... 43
3.2.1 Container Flaps ........................................................ 43
3.2.2 Protective Grounding/Earthing ............................... 43
3.2.3 Power Supply Via External Line Entry .................... 44
3.2.4 A/C / Heating System ............................................... 45
3.2.5 Hydraulic Connections ............................................ 46
3.2.5.1 Raw Water Feed Inlet ............................................... 46
3.2.5.2 Concentrate Outlet ................................................... 47
3.2.5.3 Drinking Water Outlet .............................................. 48
3.2.5.4 Industrial Water Outlet ............................................ 48
3.2.6 List of Chemicals ...................................................... 49

WATERCLEAN 1600 Version 03/2008
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3.3 Disinfecting the Plant (RO Module) ....................................... 50
3.3.1 Standard Disinfection ............................................... 50
3.3.2 Disinfection after Contamination or Continuous
Operation with Biologically-polluted
Untreated Water ....................................................... 51
3.4 Water Treatment ...................................................................... 52
3.4.1 Putting into Operation .............................................. 52
3.4.1.1 Inserting the Filter Bag in the Preliminary Filter .... 52
3.4.1.2 Installation of activated carbon filter elements
into dechlorination module ..................................... 53
3.4.1.3 Adding Chlorine ........................................................ 53
3.4.1.4 Anti-scalant (Option) ................................................ 55
3.4.1.5 UV Treatment (Option) ............................................. 56
3.4.2 Automatic Operation (Standard Operating Mode) 56
3.4.2.1 Switching on in Automatic Operation Mode .......... 57
3.4.2.2 Switching OFF in Automatic Operation Mode ....... 59
3.4.3 Manual Operation Mode, Double-Pass (Option) .... 59
3.4.3.1 Switching ON in Manual Operation Mode ............. 60
3.4.3.2 Switching OFF in Manual Operation Mode ............ 62
3.4.3.3 Switching ON in Manual Operation Mode
as Emergency Function ............................................ 62
3.4.3.4 Switching OFF in Manual Operation as
Emergency Function ................................................ 63
3.4.4 Checking the Membrane Condition ........................ 63
3.5 Measures for Protecting the Membrane ............................... 64
3.5.1 Washing out procedure ............................................ 64
3.5.2 Cleaning .................................................................... 65
3.5.3 Preserving ................................................................. 66
3.5.4 Frost Protection ........................................................ 67
3.5.5 Emptying/Draining the Drinking-water Interim
Storage, the Dechlorination Module and
Distribution ............................................................... 69

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3.6 Monitoring during Operation ................................................. 70
3.7 Winter Operation .................................................................... 72
3.8 Putting out of Operation ........................................................ 73
4 Malfunctions and Maintenance
4.1 Malfunction, Causes and Corrective Measures .................... 77
4.1.1 Displays on the Switch Cabinet .............................. 77
4.1.2 Operational Faults .................................................... 78
4.1.3 Fault Indications on the Control Panel ................... 79
4.1.4 Faults on the UV Treatment (Option) ..................... 82
4.1.5 Other Malfunctions .................................................. 82
4.2 Maintenance Work Schedule ................................................. 83
4.3 Maintenance ............................................................................ 85
4.3.1 Cleaning and Surface Treatment of the
Complete System ..................................................... 85
4.3.1.1 Cleaning and Surface Protection ............................ 85
4.3.2 RO Module ................................................................ 86
4.3.2.1 Oil Level Control on the High-Pressure Pump ....... 86
4.3.2.2 Changing the Oil of the High Pressure Pump ........ 86
4.3.2.3 Changing the Membrane Filters ............................. 87
4.3.2.4 Post-preservation of Non-installed,
Originally-packed Membranes ................................ 90
4.3.3 Preliminary Filter Module ........................................ 91
4.3.4 UV Irradiator (Option) .............................................. 94
4.3.4.1 Changing the UV Irradiator ..................................... 94
4.3.4.2 Cleaning/Changing the Protective Quartz Tube ..... 95
4.3.4.3 Cleaning the UV Sensor .......................................... 96
Appendix
Operating Log for WTC 1600 C ............................................ 101

WATERCLEAN 1600 Version 03/2008 GENERAL
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1 General
1.1 EU Declaration of Conformity
We hereby declare that the equipment described below conforms to the relevant fundamental safety
and health requirements of the appropriate EU Directive, both in its basic design and construction as
well as in the version marketed by us. This declaration will cease to be valid if any modifications are
made to the machine without our express approval.
Winnenden
Product: Waterclean
Model: 1.237-101.0
1.237-102.0
1.237-103.0
1.237-106.0
Relevant EU Directives: EU - Machinery Directive (98/37/EU)
EU - Low-Voltage Equipment Directive (73/23/EEC)
amended by 93/68/EEC
EU - Directive on Electromagnetic Compatibility (89/336/EEC)
amended by 91/263/EEC, 92/31/EEC, 93/68/EEC
Harmonized standards applied: DIN EN 60 204 – 1
DIN EN 55 081 – 1
DIN EN 55 082 – 2
National standards applied: –
Appropriate internal measures have been taken to ensure that series-production units conform at all times to the
requirements of current EU Directives and relevant standards. The signatories are empowered to represent and act
on behalf of the company management.
Alfred Kärcher Kommanditgesellschaft. Sitz Winnenden. Registergericht: Waiblingen, HRA 169.
Persönlich haftende Gesellschafterin: Kärcher Reinigungstechnik GmbH. Sitz Winnenden, 2404 Registergericht Waiblingen, HRB
Geschäftsführer: Dr. Bernhard Graf, Hartmut Jenner, Georg Metz
5.957-690.0
11/02

GENERAL Version 03/2008 WATERCLEAN 1600
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1.2 Use in Accordance with the Regulations
The equipment is designed for the producing drinking water from raw
water (contaminated water).
The retention degree of for chemical pollutants and biological patho-
gens or contamination is very high (for information on the reduction of
chemical contamination contents, see the Data Sheets of the membrane filters
used). However, the quality of the drinking water produced depends
on the degree of contamination of the raw water.
• Before putting into operation for the first time, we recommend that
a raw water analysis be performed.
• Continuous drinking water quality is ensured only when the equip-
ment undergoes regular supervision.
• The respective national and international directives concerning
drinking water must be observed.
The water produced with this equipment can be classified as drinking
water without reservation if these rules have been taken into conside-
ration.

WATERCLEAN 1600 Version 03/2008 GENERAL
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1.3 Safety Instructions
1.3.1 Operation and Maintenance of the WTC 1600
Warning! Dangerous electrical voltages!
When working on assemblies marked with this symbol, safety measu-
res must be taken:
• Switch off
• Secure against being switched on again
• Check for voltage-free condition
The connection to the mains should be made only by a qualified elec-
trician. The power supply cable must be equipped with a protective
conductor.
The switch cabinet should be opened only by a qualified electrician.
An adequate quality of the raw water must be guaranteed! Flawless
drinking water is only achieved with regular maintenance of all the fil-
ters belonging to this system.
For any work involving the use of chemicals (e. g. for cleaning purpo-
ses/disinfection measures) the information, measures and instruc-
tions in the material safety data sheets (MSDS) of the respective che-
micals are to be observed and met under all conditions. This applies
partical arly for R/S statements (Risk and Safety Statements) and the
regulations on exposure limitation and personal protective equip-
ment (PPE).
The operator of the system is responsible that the MSDS meet the cur-
rent state. The operator must further ensure that employees/personel,
which come into contact with chemicals, are awara of the contents of
the corresponding MSDS, understand and can implement the con-
tents.
Provide for good ventilation of operating area/container.
Store chemicals in a cool and dry location, not below 5 °C.
Keep chemicals out of the reach of children.
In case of accidents:
The measures described in the corresponding MSDS are to be strictly
observed.

GENERAL Version 03/2008 WATERCLEAN 1600
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1.3.2 Operation and Maintenance of the UV Irradiator
• Never operate the UV irradiator outside of its housing.
Danger for eyes and skin!
Prolonged reaction of UV light causes reddening/burns to the skin.
• Danger of glass-breakage!
- Protect the UV irradiator against water blasts as well as
against intense vibrations.
- Careful handling is required when changing the UV lamp.
• Ensure unrestricted flow through the UV irradiator. Danger in case
of overpressure!
• When cleaning UV-irradiator components, the data sheets on
safety of the cleaning agents being used are to be observed!
• Be careful during cleaning and maintenance!
- Before any cleaning and maintenance, the complete system is
to be de-energized and secured against restarting. Danger of
electric shock!
- -The UV irradiator can be very hot after operation. Allow it to
cool down prior to dismounting!
• Operation of the UV irradiator with defective protective quartz tube
is prohibited!
• The relevant regulations for prevention of accidents are to be
observed!