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Repair instructions
BIO-CIRCLE II G40026-03
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
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.
Picture of the G27226-10 semiconductor control unit (green front). Dismounting as described above (grey front).
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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.
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Attention: When fastening the pump only tighten to the lug, do not apply tension.
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
Picture of the G27226-10 control unit (green front) Replace fuse (T 10A)
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Action
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.
When replacing the temperature limiter stick the new one on directly above the defect one.
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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: Heating has no fault to frame Measured value: > 250 k
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Action
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)
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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).
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
- Temperature sensor (PT100) not connected Error message on the display: F6 - Temperature sensor is short-circuited Error message on the display: F7
Action
Check electrical connection, replace temperature sensor
Fault
- Minimum filling level has been reached Error message on the display: LO
Action
Top up with liquid. If liquid is topped up while in operation, the actual temperature is shown on the display. Clean level switch
- Level switch cant float Error message on the display: - Level switch not connected Error message on the display:
LO Check electrical connection see Ill. 1 (level switch circuit diagram) Check electrical connection, check function of the level switch, replace level switch if necessary
F4
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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.
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)
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 Press the spring down with a screwdriver 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.
NO COM
NC | PT PT | 24V S1
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Action
Replace fuse (Type 5x20 mm 1 A M) 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.
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Action
Check electrical connection, replace pump if necessary 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 grey front)
Cable leading to the washing pump (control unit with green front)
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For pulling out the protective tube push the ring towards the screw connection.
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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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!
Once the replacement is completed, reposition the clamp and press it together hand-tight.
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F2: F3:
F9:
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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Fault
Heating without function Washing pump without function Aerator without function Liquid overheated Other fault:
Note
Level and fuse checked? Level and fuse checked? Fuse checked? Position of the PT100 checked?
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