Repair instructions BIO-CIRCLE II AL_07_2012 EN

Bio-Circle Surface Technology GmbH Berensweg 200 | D-33334 Gtersloh Telefon: +49 (0) 5241 94430 Telefax: +49 (0) 5241 9443-44 E-Mail: service@bio-circle.de | www.bio-circle.de

Repair instructions

BIO-CIRCLE II G40026-03

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Table of contents 1. General information .................................................................................................................................... 3 2. Dismounting the control unit ..................................................................................................................... 3

3. Replacing the control unit .......................................................................................................................... 4

4. Replacing a component (heating, pump, aerator) .................................................................................... 4 5. Aerator troubleshooting (F3) ..................................................................................................................... 5

5.1 Replacing the fuse .................................................................................................................... 5 5.2 Replacing the aerator ............................................................................................................... 6

6. Heating troubleshooting (F1; heating without function; ground fault circuit interrupter trips) ......... 9 6.1 Replacing the fuse .................................................................................................................... 9 6.2 Resetting the temperature limiter ........................................................................................... 10 6.4 Replacing the heating............................................................................................................. 12

7. Pt100 temperature sensor (F6; F7) and float switch (LO; F4; F5) troubleshooting ............................ 14 8. Washing pump troubleshooting (F2) ....................................................................................................... 17

8.1 Replacing the fuse .................................................................................................................. 17 8.2 Replacing the washing pump ................................................................................................. 18

9. Replacing the lid ........................................................................................................................................ 20

10. Replacing the brush or the hose ............................................................................................................. 20

11. Replacing the air stone ............................................................................................................................ 21

12. Terminal diagram of the electrical control unit (grey front) ............................................................... 21 13. Terminal diagram of the electrical control unit (green front) ............................................................. 22 14. Dimension drawing ................................................................................................................................. 23

15. Error messages ........................................................................................................................................ 24

16. Error log................................................................................................................................................... 25

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1. General information Any work on the electrical installation may only be carried out by qualified personnel. Attention! Disconnect the electrical installation from the power supply and disconnect the main power plug prior to commencing any work on the parts washer components! Verify that the device is current less! An electrical connection in conformity with the corresponding regulations (EN 60204-1, VDE 0113-1) has to be provided on site. A ground fault circuit interrupter is stringently required! Please have this verified by a qualified electrician. The device has to be installed in a horizontal and stable position on a suitable surface. Cleaning agents containing flammable substances may not be used. Only use cleaning agents that have been approved for this device.

2. Dismounting the control unit

Please remove the 4 screw cover caps using a screwdriver.

Now unscrew the 4 screws.

Picture of the G27226-10 semiconductor control unit (green front). Dismounting as described above (grey front).

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3. Replacing the control unit

For replacing the control unit of the parts washer please follow the instructions in the special conversion instructions for the Bio-Circle II semiconductor control unit (see Appendix I)

4. Replacing a component (heating, pump, aerator)

Remove the cable ties.

Unloose the screw connection.

Then the screw connection can be taken out.

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5. Aerator troubleshooting (F3) Aerator without function Error message on the display: F3

5.1 Replacing the fuse

Fault Action - Aerator fuse defect Replace fuse (Type 5x20 mm 0.1A M)

The fuse for the diaphragm pump is marked F3 (0.1A). Please unscrew the fuse holder using a screwdriver and then check the fuse. If the fuse is defect, insert a new one and also check the diaphragm pump.

G27226-10 control unit (green front)

Replace fuse (T3, 15A)

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5.2 Replacing the aerator

Fault Action - Aerator disconnected Check electrical connection, or defect replace aerator if necessary

Cable leading to the diaphragm pump

Checking the output voltage for the diaphragm pump: Please check the output voltage of the control unit while the diaphragm pump is still connected. It should be in the range of ~240 V/AC. If the output voltage is correct, the oxygen pump is defect and has to be replaced.

Picture of the G27226-10 control unit (green front)

Unscrew the self-locking nut.

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and disconnect the air hose.

Remove the diaphragm pump and pull out the cables. Position a new diaphragm pump on the retaining plate, reconnect the cables, and connect the device to the control unit.

Mount the air hose on the new diaphragm pump.

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Attention: When fastening the pump only tighten to the lug, do not apply tension.

Image of a device with built-in oxygen pump.

Position of the built-in oxygen pump behind the semiconductor control unit on devices since 09/2011 and on devices that have been retrofitted.

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6. Heating troubleshooting (F1; heating without function; ground fault circuit interrupter trips)

Error message on the display: F1

6.1 Replacing the fuse

Fault Action - Heating fuse defect Replace fuse (Type 6, 3x32 mm, T 10A)

The fuse for the heating is marked F1 (10A). Please unscrew the fuse holder using a screwdriver and then check the fuse. If the fuse is defect, insert a new one and also check the heating.

Picture of the G27226-10 control unit (green front)

Replace fuse (T 10A)

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6.2 Resetting the temperature limiter

Fault Action - Temperature limiter has tripped Reset temperature limiter

Attention: mains voltage! First disconnect the device from the power supply, pull out the plug from the socket. Please remove the control unit. In the cavity underneath the control unit you will find the temperature limiter. In order to switch the temperature limiter on please click the red button.

Position of the temperature limiter

When replacing the temperature limiter stick the new one on directly above the defect one.

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6.3 Checking the heating 1) Checking the resistance range The correct resistance

rage of the heating has to be between 47 and 60

2) Fault to frame

In order to exclude a fault to frame of the heating, measure the electrical resistance between the housing of the heater rod (1) and the heating coil (2). The measured value has to be 250 k.

Example: Defect heating Measured value: < 250 k

Example: Heating has no fault to frame Measured value: > 250 k

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6.4 Replacing the heating

Fault Action - Heating defect Replace heating

Checking the output voltage for the heating: Please check the output voltage of the control unit while the heating is still connected. It should be in the range of ~240 V/AC. If the output voltage is correct, the heating is defect and has to be replaced.

Cable leading to the heating in the G27226-10 semiconductor control unit (green front)

Cable leading to the heating

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In order to do this - Pull the plug apart (1). - Disconnect the second wire of the heating directly on the control unit (2). - Disconnect the earth lug of the heating (3).

Unscrew the fastening nut on the heating.

Remove the heating. Now a new heating can be built in and connected.

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7. PT100 temperature sensor (F6; F7) and float switch (LO; F4; F5) troubleshooting

Fault Action - Temperature sensor (PT100) not connected Check electrical connection, Error message on the display: F6 - Temperature sensor is short-circuited replace temperature sensor Error message on the display: F7

Fault Action - Minimum filling level has been reached Top up with liquid. Error message on the display: LO If liquid is topped up while in operation, the actual temperature is shown on the display. - Level switch cant float Clean level switch Error message on the display: LO

- Level switch not connected Check electrical connection Error message on the display: F4 see Ill. 1 (level switch circuit diagram)

- Short circuit on the level switch Check electrical connection, Error message on the display: F5 check function of the level switch, replace level switch if necessary

7.1 Replacement or conversion to PT100 float switch combination

Cable leading to the temperature sensor

(Image of control unit with grey front for control unit with green front see item 7.4) For checking the temperature sensor disconnect the corresponding wires in the five-pole plug on the control unit. In case of a defect please replace the temperature sensor. Temperature values:

40 C/ 104 F

41 C/ 105.8 F

42 C/ 107.6 F

( -0.4 ) 115.9 ( +0.4 )

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7.2 Dismounting the temperature sensor and the plastic float switch:

Remove the cable ties and pull out the und temperature sensor.

Unscrew the fastening nut.

Remove the level switch by pulling out the cables. Now a new PT100 float switch combination can be built in and connected.

7.3 PT100 float switch combination mounting kit

Stainless steel float switch with M16 PG screw connection and lock nut

Peg for sealing the redundant orifice in the cable bushing

Operating tool for plug contact

7.4 PT100 float switch combination connection (control unit with grey front)

X3 terminal configuration

1 - yellow (Pt100) 2 - grey (Pt100) 3 - white (float switch) 4 - brown (float switch) 5 - green (float switch)

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7.5 PT100 float switch combination connection (control unit with green front)

NO COM NC | PT PT | 24V S1

Optional connection for a foot switch

Please make sure the wires are connected correctly (low voltage). Also refer to the terminal scheme on page 8.

Level switch: 1. White - NO 2. Brown - COM 3. Green - NC

PT100 temperature sensor: 4. Grey PT100 5. Yellow PT100

Attention: If necessary strip the cable ends. When connecting cable insulation may not enter the terminal, nor may open cable strands protrude from the terminal.

Please note: If immediately after completion of the mounting of the control unit error message 5, 6 or 7 is shown on the display, the sequence of wires may have ben mixed up.

7.6 PT100 float switch combination cable duct

Insert the float switch with the cable from below through the orifice and fasten with the lock nut.

Insert the cable through the cable duct and put the included peg in the free orifice. Then fasten in place.

Press the spring down with a screwdriver

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8. Washing pump troubleshooting (F2) Washing pump without function Error message on the display: F2

8.1 Replacing the fuse

Fault Action - Pump fuse defect Replace fuse (Type 5x20 mm 1 A M)

For control units with grey front

The fuse for the washing pump is marked F2, 1 A.

Unscrew the fuse holder using a screwdriver and then check the fuse.

If the fuse is defect, insert a new one and also check the washing pump.

For control units with green front

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8.2 Replacing the washing pump

Fault Action - Pump not connected or defect Check electrical connection, replace pump if necessary

Cable leading to the washing pump (control unit with grey front)

Checking the output voltage for the washing pump:

Please check the output voltage of the control unit while the washing pump is still connected. It should be in the range of ~240 V/AC.

If the output voltage is correct, the washing pump is defect and has to be replaced.

Cable leading to the washing pump (control unit with green front)

Remove the cable ties and unloose the screw connection.

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For pulling out the protective tube push the ring towards the screw connection.

Then pull out the cable.

Please disconnect the pump hose from the pump. For this push the ring in and pull out the lock pin.

Now a new pump can be built in and connected.

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9. Replacing the lid

Please do not tighten the screws but only screw them in to the point where the distance on both sides is the same!

The screws only serve as hinged bearings!

10. Replacing the brush or the hose

For replacing the brush or the hose pull the clamp apart using a pair of tongs and disconnect the hose.

Once the replacement is completed, reposition the clamp and press it together hand-tight.

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11. Replacing the air stone

For replacing the air stone disconnect the hose and attach a new air stone to the hose.

12. Wiring diagram of the electrical control unit (grey front)

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13. Wiring diagram of the electrical control unit (green front)

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14. Scale drawing

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15. Error messages

Any malfunctions that occur will be shown on the display indicating a number between 1 and 8.

LO: Liquid level in the tank is too low. Yellow LED is flashing.

F1: The heating is without function. Possible cause: e.g. cable break, defect fuse, or the temperature sensor has tripped because of overheating.

Actions: Replace fuse (T10A), measure the resistance of the heating (target: 43 to 60 Ohm), eliminate cause of overheating and reset temperature sensor.

F2: The pump is without function. Possible cause: e.g. cable break or defect fuse Actions: Replace fuse (T3, 15A), replace pump

F3: The air pump is without function. Possible cause: e.g. cable break or defect fuse

Actions: Replace fuse (T3, 15A), replace pump

F4: The level switch is not or incorrectly connected, or there is a cable break.

F5: Short circuit in the level switch

F6: The PT100 temperature sensor is not or incorrectly connected, or there is a cable break.

F7: Defect or short circuit in the PT100 temperature sensor.

F8: Overheating alert: The device has been switched of because the temperature measured exceeded 55 C/131 F.

Determine the cause (e.g. additional heating by very hot parts). For restart pull out the plug and plug it in again.

F9: The control unit has to be reset (disconnect the device from the power supply); if the defect persists, the control unit has to be replaced.

F10: No increase of temperature could be measured although the heating was switched on (e.g. because the level switch was jammed). For restart pull out the plug and plug it in again.

Power consumption too low for: F71 heating, F72 liquid pump, F73 oxygen pump

Power consumption too high for: F81 heating, F82 liquid pump, F83 oxygen pump

Overheating In order to avoid damage caused by overheating the device comes with a temperature sensor that switches the heating off if a temperature limit is exceeded. Once the switch has tripped, the cause of the overheating has to be eliminated, and the temperature sensor has to be reset.

Temperature sensor:

It is located in the tank interstice and has been glued to the inner wall in the lower third of the tank. For resetting by all means disconnect the device from the power supply, remove the control unit and click the red button.

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16. Error log

Device type: _____________________ Serial no.: __________________________

Year of manufacture: 2 0 _ _ Please indicate serial number, if available

Component: heating Serial no.: __________________________

Component: aerator Serial no.: __________________________

Component: control unit Serial no.: __________________________

Other component: ______________________________________________________

Fault Note Heating without function Level and fuse checked?

Washing pump without function Level and fuse checked?

Aerator without function Fuse checked?

Liquid overheated Position of the PT100 checked?

Other fault: ________________________________________________________________

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Error messages on the display F1 F6

F2 F7

F3

F4 LO

F5 Temperature display flashing