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
- III -
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

Version 03/2008 WATERCLEAN 1600
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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
- 1 -
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
- 3 -
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!

WATERCLEAN 1600 Version 03/2008 GENERAL
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1.4 Raw Water
1.4.1 Types of Pollutants
The raw water can generally be polluted by:
1. Biological contamination
• Bacteria, viruses, toxins
2. Chemical contamination
• Inorganic salts (heavy metals, nitrates, asbestos, etc.)
• Organic compounds (benzenes, solvents, etc.)
• Pesticides, herbicides, etc.
3. Salt in sea water and brackish water and other mineral salts and solid
matters
1.4.2 Retention Capabilities of the Waterclean 1600 System
The effective retention capability depends on the grade of contamination.
As standard, the WTC 1600 plant is equipped with reverse-osmosis
(RO) membrane. Optionally, nano-filtration (NF) spiral-wound memb-
ranes can also be installed in the pressure tubes. The retention capa-
city of the two different membrane types is indicated in the following
figure.

GENERAL Version 03/2008 WATERCLEAN 1600
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The degree of purification is not equally good for all pollutants. De-
pending on the degree of contamination, a pre-treatment or a combi-
nation with additional system modules of the KÄRCHER WATER-
CLEAN series is necessary.
1.4.3 Characteristics of Raw Water
Ground Water
Surface Water
Salt Water
• Source
Temperature independent of the time of year, always
a constant temperature
pH value acidic to neutral
pH 5 - 7,5
Hardness 10 - 35 °dH
Organic contamination minimum
Germ contamination low
Pollutants low
• Lake
• River
• Stream
Temperature greatly varying, depending on the time
of year
pH-value alkaline to neutral
pH 9 - 7
Hardness up to approx. 12 °dH
Organic contamination strongly contaminated with small dirt
particles
Germ contamination high
Pollutants medium to high
• Sea
Temperature low variations throughout the year,
greatly varying from region to region
pH-value alkaline to neutral
pH 8,5 - 7
Hardness approx. 12 °dH
Organic contamination average contamination with small par-
ticles, depending on the distance from
the shore.
Germ contamination medium to high
Pollutants low to high, depending on the distance
from the shore.

WATERCLEAN 1600 Version 03/2008 GENERAL
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1.4.4 Physical Operating Principle of the RO-Machine
The machine is operating with the physical principle of the reverse os-
mosis. Osmosis is the concentration equalisation on two liquids with
different densities. A gradual compensation of the concentrations is
produced with a semi-permeable membrane (Fig. 1) until an osmotic
balance sets in.
The reversion of this procedure is called 'Reverse Osmosis'. Machines
working to this principle are called RO-machines.
Due to a pressure which is stronger than the osmotic pressure applied
to the liquid, the flow direction of the water is reversed. The water is
now pressed through the membrane from an upgraded solution. The
purified water produced with this method is called drinking water, the
upgraded residual water is called concentrate.
The reverse osmosis can be economically used for the demineralisa-
tion of waters with salt content. The advantage over conventional ion
exchange procedures is mainly the low environmental pollution. The
reverse osmosis requires no regenerant chemicals for the purifying
procedure.
Fig. 1 Reverse Osmosis Membrane
Inflow
Water-
collector
Net
Porous
support
layer
Membrane
(two layers glued
together)

GENERAL Version 03/2008 WATERCLEAN 1600
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WATERCLEAN 1600 Version 03/2008 DESCRIPTION
- 9 -
2 Description
NOTE Variations of figures/illustrations shown in these oper-
ating instructions to the actual designs are possible
due to the different models.
2.1 Overview
Fig. 2 Module Overview
5
4
1
1
1 Ventilation opening, A/C system
2 Reset button, A(/C system (below cover)
3 Connection box 1 for:
- Raw-water inlet
- Industrial-water outlet
- Concentrate outlet
- Power supply, container
- Power supply, raw-water pump
4 Connection box 2 for:
- Drinking-water outlet for two WBP 700
- Bulk water filling
- Power supply outlet (can be used for communi-
cation between two WTC 1600 C units)
- Power supply inlet (can be used for communica-
tion between two WTC 1600 C units)
5 WTC 1600
2
3

DESCRIPTION Version 03/2008 WATERCLEAN 1600
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2.2 Principle of Operation
Key to the System Flow Diagram (Fig. 3)
Raw Water An external in-feed pressure pump P01 (3/2) conveys the raw water
from the source to the water treatment plant.
Pre-treatment Module The raw water is first conducted through a preliminary filter unit,
which consists of two filter bags F02 and F03 (3/5) arranged parallel to
each other. Only one filter is passed through at a time; thus the filter
bag of the second filter can be changed without having to stop the op-
eration.
The remaining capacity of the active preliminary filter is monitored by
the plant in order to be able to change over automatically to the redun-
dant filter if required.
1 Debris filter
2 Raw water pump
3 Sensor for input pressure, pre-treatment
4 Prefilter switch-over valve
5 Preliminary filter air relief cock
6 Preliminary filter
7 Check valve
8 Solenoid valve, untreated water supply
9 Sensor for input pressure, main module
10 Temperature sensor, untreated water
11 Safety valve, untreated water overpressure
12 Pump unit
13 Sensor for intake pressure of membrane
filter blocks
14 Constant flow regulator
15 Valve, concentrate return line
16 RO filter block I
17 RO-filter block II
18 Safety valve, double pass
19 Flow meter, pass I
20 Pressure maintenance valve, double pass
21 Three-way tap, double pass
22 Valve for drinking water, double pass
23 RO filter block III
24 Pressure maintenance valve,
motor-controlled
25 Sensor for output pressure of membrane
filter blocks
26 Conductivity meter
27 Flow meter, pass II (total)
28 CIP valve, intake
29 Cleaning tank
30 Filling level sensor
31 CIP valve, outlet
32 CIP valve for draining
33 Overflow valve, cleaning tank return line
34 Solenoid valve, concentrate
35 Overflow valve, industrial water
36 UV-irradiator
37 Solenoid valve, drinking water
38 Relief valve
39 Chlorination pump
40 Chlorination container
41 Relief valve
42 Anti scalant pump
43 Anti scalant container
44 Activated carbon filter with instru-
ments/gauges for dechlorination
45 Drinking-water interim storage (V = 4 m3)
with filling-level regulators (regulates the
operation of the WTC 1600 plant and the two
feed pumps (46 and 47); ventilation via ster-
ile filter and overflow valve
46 Feed pump for feeding into two WBP 700
47 Feed pump for supply of the drinking-water
distribution station

WATERCLEAN 1600 Version 03/2008 DESCRIPTION
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Fig. 3
RO-Filter I
3~
RO-Filter III
RO-Filter II
M
3~
M
V03
V04
V02
V22
V05
V24 10 bar
V10
V12
V15
V23
V25
1-5 bar
1-5 bar
V01
V20 V21 V16 T
F
P02 P03
2 m3/h
2 m3/h
1 m3/h
Drain Industrial
Water
Reverse Osmosis Modul
Pre-treatment
F02 0,5μm
F03 0,5μm
F04 F05
F06
B1
B2
P04
MV06 V07
25 bar
M
V08
75 bar 75 bar
Concentrate
Drinking Water
Raw Water
Raw Water Pump
Anti Scalant (option)
P01 B3
P05
UV- Irradiator (option)
Control sensor
10 bar
V = 4 m3
Drinking-water interim storage
Filling pump
bulk water
to bulk water filling
WBP 700
to two WBP 700
LIC
LIC
+
–
46
45
47
Feed pump
PI PI
4
4
35
5
42
2
6 6
43
41
42
7 7
89
10
11
12 12
13
14
16
20 25
21
23
22 28
26 27
29
31
30
32
35
33
24
34
36 37
39
38
19
40
17
15
18
Dechlorination

DESCRIPTION Version 03/2008 WATERCLEAN 1600
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Dechlorination Module
(option)
The dechlorination module, which consists of ten 30"-activated car-
bon filter elements, the pre-filtration. Its purpose is to remove pos-
sibly given chlorine from the raw water (catalytic and adsorptive). This
is absolutely necessary for the protection of the succeeding spiral-
wound membrane modules, as these cannot withstand chlorine con-
centrations in excess of 0.1 mg/l. Therefore, the chlorine concentra-
tion in the raw water is to be determined prior to starting operation.
This is carried out by means of the provided UV spectrometer and the
respective chlorine-indicator chemical. For chlorine concentrations in
the raw water that are in excess of 0.05 mg/l, it is absolutely necessary
that the activated carbon filters are installed into the filter bowls.
The measurement of the chlorine concentration of the activated-car-
bon filtrate must be carried out on each day of operation.
The bottom water-sampling valve of the activated-carbon filter can be
used for this. Also, the pressure loss of the active-carbon filter is to be
determined with the two manometers (Δp = upper manometer rea-
ding - bottom manometer reading).
If the chlorine concentration in the filtrate approaches 0.1 mg/l or if the
pressure loss increases above 0.8 bar, the activated-carbon filter ele-
ments are to be exchanged.
Fig. 4
1 Lid lock (open for exchanging the fil-
ter plugs
2 Filter bowl, dechlorination module
3 Pressure gange, intake pressure
4 Sampling valve (also to be used for
pressure compensation) + draining
5 Pressure gange, outlet pressure
6 Sampling valve (also to be used for
pressure compensation) + draining
7 Bleed valve
1
2
3
5
4
6
7

WATERCLEAN 1600 Version 03/2008 DESCRIPTION
- 13 -
Reverse Osmosis Module After leaving the preliminary filter unit, the raw water is fed to the re-
verse osmosis system.
When exceeding the required admission pressure of approx. 0.1 bar
in the untreated water line, the SPC switches on the two high-pressure
pump units P02 and P03 (3/12). The admission pressure is measured
through the sensor (3/13) and the pressure reading can be called up
via the SPC.
NOTE A minimum in-feed pressure of 0.1 bar is required for
the high-pressure pumps!
The high-pressure pump units (3/12) deliver the water at an increased
pressure (depending on the salt content, up to 69 bar) to the parallel
membrane filter blocks I (3/16) and II (3/17). A safety valve and a mem-
brane pressure reservoir are connected to the output side of each of
both the pumps.
Automatic Operation Mode
(Single Pass)
During the automatic operating mode, the polluted part of the water
(concentrate) of both the membrane filter blocks I and II is fed as raw wa-
ter to the inlet of membrane filter block III (3/23). The filtrate produced
from both these cleaning stages flows to the drinking water outlet.
The concentrate from the second stage is conducted via the motor-
driven pressure maintaining valve V06 (3/24) to the concentrate outlet.
The working pressure and drinking water quantity are regulated by
the pressure maintaining valve.
In order to minimize the raw water requirement of the entire system,
a part of the concentrate of the second stage can be mixed with the
raw water at the inlet of the high-pressure pump. The return flow
quantity is limited by the constant flow regulator V24 (3/14) to 1 m3/h.
If the conductivity of the drinking water exceeds 2 000 µS/cm, or if the
drinking water quantity falls below 1 600 l/h, the return flow must be
shut off at valve V05 (3/15).
Fig. 4a Flow diagram, membrane filter in Single Pass operation
mode
Manual Operation Mode,
Double Pass (Option)
For the manual operation mode the plant must be put into operation
manually. A requirement for this operation mode is a salt content of
the raw water of < 5 000 ppm (conductivity approx. 10 000 µS/cm).
RO-Filter I
RO-Filter III
RO-Filter II V03
V04
V02
V05V24
10 bar
F04
F05
F06
MV06
14 15
16
17
20
21 23
22
24

DESCRIPTION Version 03/2008 WATERCLEAN 1600
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NOTE In case of high salt contents, the drinking water capac-
ity can vary quite heavily from the values mentioned.
During Double Pass operation, the filtrate of both the membrane filter
blocks I and II forms the raw water for the membrane filter block III.
The concentrate of both stages flows to the concentrate outlet; during
this process, the return feed (valve V05) must always be closed. Only
the filtrate of membrane filter block III (3/23) is fed to the drinking wa-
ter outlet.
The Double Pass operating mode is particularly suitable for highly
contaminated water.
Fig. 4b Flow diagram, membrane filter in the Double Pass operating
mode
UV-irradiator (Option) For germ reduction, the drinking water is conducted through the op-
tional UV-irradiator (3/36). In conjunction with the RO filtration, the
UV-irradiator forms an additional security stage of the conditioning
process. Proper functioning of the UV-irradiator is controlled by a sen-
sor which is mounted on the side of the irradiator. Display is indicated
at the UV-irradiator switch cabinet.
Drinking water/
Industrial water
The water quality is tested by means of a conductance measure-
ment (3/26) at the drinking water outlet. For values > 2 000 µS/cm, the
magnetic valve (3/37) automatically closes the drinking water outlet;
the filtrate flows to the industrial water outlet.
In this case the system operator must decide whether the water pro-
duced can be used.
Chlorination/
Remineralisation
By means of the metering pump (3/39), the water can be chlorinated
in accordance with the local regulations.
Chlorination of the depot delays regermination during storage of the
drinking water, and in some countries, is stipulated by law (observe
national guidelines!).
For mixing the chlorinating solution, one container (3/40) is integrated
in the pre-treatment module.
RO-Filter I
RO-Filter III
RO-Filter II V03
V04
V02
F04
F05
F06
MV06
V05
15
16
17
20
21 23
22
24