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📋 Test Protocol / Prüfprotokoll

Article No.

0A465916

Customer Order

AF20-008099

Designation

HP5500D 1000 P 60Hz

Mfg. Order

FA21-000279

Customer

UMS Ezdihar

1. Electrical Inspection / Elektrische Prüfung

According to EN 60204-1, EN 62353

1.1 Visual & Mechanical Checks

Check	Status	Remark
1.1 Blind plugs + cabinet key present	✓ OK
1.2 Covers for main terminals present	✓ OK
1.3 Cabinet labelled with lightning arrow	✓ OK
1.4 Type plate present	✓ OK
1.5 Wire colours according to wiring diagram	✓ OK
1.6 IP rating maintained	✓ OK
1.7 Cover / insulation of live parts	✓ OK
1.8 Cover & marking of mains terminals	✓ OK
1.9 Separation of N and PE terminals	✓ OK
1.10 Cable & fuse sizing per wiring diagram	✓ OK
1.11 PE sticker at protective conductor terminals	✓ OK
1.12 Earthing of control circuits	✓ OK
1.13 Earthing of cabinet, door, frame	✓ OK
1.14 Sticker "Screw contacts tightened" present	✓ OK
1.15 Screw contacts tightened	✓ OK
1.16 Functional test of fuses / motor protectors	✓ OK	Motor protector: 1gch SLP

1.2 Electrical Measurements

Measurement	Target	Tolerance	Actual
1.20 Protective conductor continuity	< 0.3 Ω	—	0.060 Ω
1.21 Insulation resistance	> 2 MΩ	—	> 3.10 MΩ
1.22 Equipment leakage current	< 5 mA	—	0.028 mA
1.24 Residual voltage protection	1s < 60V	—	9 V

1b. Electrical Inspection (Hot Sanitization Cabinet)

According to EN 60204-1, EN 62353 – Additional checks for hot sanitization

Check	Status
1.1 Blind plugs + cabinet key	✓ OK
1.2 Covers for main terminals	✓ OK
1.3 Lightning arrow marking	✓ OK
1.4 Type plate	✓ OK
1.5 Wire colours per diagram	✓ OK
1.6 IP rating	✓ OK
1.7 Cover/insulation of live parts	✓ OK
1.8 Cover & marking mains terminals	✓ OK
1.9 Separation N / PE	✓ OK
1.10 Cable/fuse sizing per diagram	✓ OK
1.11 PE stickers	✓ OK
1.12 Earthing control circuits	✓ OK
1.13 Earthing cabinet/door/frame	✓ OK
1.24 Functional test of fuses	✓ OK

Measurements (Hot Sanitization)

Measurement	Target	Tolerance	Actual
1.20 Protective conductor continuity	< 0.3 Ω	—	0.085 Ω
1.21 Insulation resistance	> 2 MΩ	—	134 MΩ
1.22 Equipment leakage current	< 5 mA	—	0.0002 mA
1.24 Residual voltage	1s < 60V	—	9 V

2. Parameterization / Functional Check (Components)

Check	Status
2.1 Motor protector setting per wiring diagram	✓ OK
2.2 Jumper settings Diatron 5500	✓ OK
2.4 Parameter settings Diatron 5500 per parameter list	✓ OK
2.5 SD card inserted and formatted	✓ OK
2.6 Remote monitoring PC parameterization per checklist	✓ OK
2.7 Visualization parameterization per checklist	✓ OK
2.8 Teamviewer ID entered in circuit diagram	✓ OK

3. Functional Test – Safety Relevant Devices

Check	Status
3.1 LF and temperature measurements calibrated/checked	✓ OK
3.3 Sensor fault simulation Q02 / T02	✓ OK
3.4 Sensor fault simulation Q03 / T03	✓ OK
3.5 Watchdog simulation	✓ OK
3.8 W2 shutdown trigger	✓ OK
3.15 Empty alarm simulation (transfer tank)	✓ OK
3.16 Hard water alarm simulation	✓ OK
3.17 Position error simulation G02, G03 (normal mode)	✓ OK
3.18 Moisture detector simulation	✓ OK
3.19 Ring line leakage	✓ OK
3.20 Heater – temperature sensor assignment	✓ OK
3.21 Subloop check (if present)	✓ OK
3.22 Universal digital I/O check	✓ OK
3.23 Measure all heater currents during hot sanitization	✓ OK
3.24 Check 230VAC at all power terminals of additional/intermediate heaters during hot sanitization	✓ OK

4. Hydraulic Adjustments

Check	Target	Tolerance	Actual
4.1 Setting DV02	6.5 bar	±0.2	6.6
4.2 Setting DV01 (permeate basic setting without reduction)	1.5 bar	+1.0	2.4
4.4 Feed water quantity transfer tank (orifice at feed inlet after V01)	1600 l/h @ 2 bar	+200 / +0.5	1600 l/h / 2.5 l/s
4.5 Concentrate control valve stage 1 (V17) normal mode	50% of 6.7	±10%	200 l/h
4.6 Concentrate control valve stage 2 (V15) normal mode	50% of 6.15	±10%	-120 l/h
4.7 Pressure maintenance in ring line (Pr04) at system stop	0.2 bar	+1.0	0.64
4.8 Setting DV03 (concentrate amount constant regardless of V09 state)	per 6.7	±10%	380 / 400

5. Functional Sequence Tests

Check	Status
5.1 Normal mode manual/automatic	✓ OK
5.2 Temperature rejection V09	✓ OK
5.3 LF-dependent concentrate rejection via V09	✓ OK
5.4 Temperature rejection V03	✓ OK
5.5 Winter mode	—
5.6 Emergency mode level 1	✓ OK
5.7 Emergency mode level 2	✓ OK
5.8 Emergency control mode	✓ OK
5.10 Hot sanitization: ring + devices	✓ OK
5.11 USB interface function: protocol saved to USB stick	✓ OK

6. Hydraulic Test – Stage 1 & Stage 2

Stage 1

Measurement	Target	Tolerance	Actual
6.1 Inlet pressure	> 2.0 bar	—	3.5
6.2 Raw water temperature	10–35 °C	—	11.3
6.3 Raw water conductivity	100–1600 µS/cm	—	36.1
6.4 Conductivity transfer tank (concentrated) Q01	1600–2000 µS/cm	per test	1500
6.5.1 Operating pressure (1PR05)	max 22 bar	—	11.8
6.6 Concentrate pressure (PR06)	max 22 bar	—	10.2
6.7 Concentrate flow (FL03)	390 l/h	±10%	350
6.8 Permeate flow (FL04)	1180 l/h	±10%	1180
6.9 Permeate conductivity (Q02)	3% of 6.4	—	13.5 µS/cm
6.10 Permeate temperature (T02)	10–35 °C	—	24.5
6.15 Return pressure ring line (1Pr04)	1.5–2 bar	+1.0 bar	32.4

Stage 2

Measurement	Target	Tolerance	Actual
6.11 Supply pressure (PR07)	> 2.0 bar	—	3.2
6.12.1 Operating pressure (PR08)	max 16 bar	—	10.4
6.12.2 Operating pressure (PR08) at HR	< 3 bar	—	—
6.13 Concentrate pressure (PR09)	max 16 bar	—	9.0
6.14 Permeate back pressure (PR10)	4 bar	±10%	4.1
6.15 Concentrate flow (FL05) normal/emergency	180 / 330	±10%	190
6.16 Permeate flow (FL01) normal/emergency	1000 l/h	±10%	995
6.17 Permeate conductivity (Q03)	1.5% of 6.4	—	11.5 µS/cm
6.18 Permeate temperature (T03)	10–35 °C	—	25.2

7. General Checks

Check	Status
7.1 Process engineering check per R+1 scheme	✓ OK
7.2 Flow sensors checked for correct nominal size	✓ OK
7.3 Labeling per P&ID + plate replacement + positions	✓ OK
7.4 Correctness of labeling language	✓ OK
7.5 Copy of test protocol, parameter list, wiring diagram in cabinet	✓ OK
7.6 Cable labeling present	✓ OK
7.7 Parameter backup and test protocol saved	✓ OK
7.8 Distance between inductive sensor G02/G03 and ball valve < 1mm	✓ OK
7.9 Analog output check per wiring diagram	—
7.7 (dup) Pump rotation direction	✓ OK
7.8 (dup) Component tightness	✓ OK
7.11 "Caution Hot" sticker on ring inlet, after cover installation	✓ OK
7.12 Extra undrilled blank loose on inlet with plastic bag	✓ OK
7.13 Thermal image of heater contactors taken (during HR)	✓ OK
7.14 Ferrites installed on controller	✓ OK
7.15 Measuring cell Q01 serial number	02822 89 70102 03 800 49

Parameter Settings (Excerpt)

Temperature / Conductivity Limits

Parameter	Description	Setpoint
P055	T02 fault °C	35
P062	Q02 < range µS/cm	1
P063	Q02 warning µS/cm	35
P064	Q02 fault µS/cm	40
P072	T03 < range °C	2
P073	T03 V09 to drain °C	25
P074	T03 warning °C	30
P075	T03 fault °C	35
P082	Q03 < range µS/cm	1
P083	Q03 warning µS/cm	25
P084	Q03 fault µS/cm	30
P092	T04 < range °C	2
P093	T04 end heat up °C	85 (80)
P094	T04 limit max °C	95
P095	T04 > range °C	99.9
P100–P104	W2/T05 limits	range 0–100, off 90, hyst. 2
P110–P114	W3/T06 limits	range 0–100, off 90, hyst. 2
P120–P124	W4/T07 limits	range 0–100, off 90, hyst. 2
P130–P134	W5/T08 limits	range 0–100, off 90, hyst. 2
P140–P144	W6/T09 limits	range 0–100, off 90, hyst. 2
P150–P154	W1/T11 limits	range 0–100, off 90, hyst. 2
P160–P163	W12/T12 limits	range 0–100, off 90

Timers / Disinfection

Parameter	Description	Setpoint
HS116	Standby after HS	30 min
D010	t-recirculation	30 min
D011	t-residence	2 h
D012	t-rinse	2 h
D013	t-impulse RO valves	20 s
D014	t-interval RO valves	3 min
D015	t-impulse subloop valves	60 s

Terminal Assignments (I/O Mapping)

Terminal	Signal	Type	Function
X3108-110	PR04	AI11	Pressure return ring line
X3111-113	PR05	AI12	Operating pressure
X3114-116	PR06	AI13	Concentrate pressure
X3117-119	PR10	AI14	Permeate back pressure
X3120-122	PR07	AI15	Supply pressure
X3123-125	PR08	AI16	Operating pressure 2
X3126-128	PR09	AI17	Concentrate pressure 2
X3129-131	T05	AI18	Temperature 5
X3132-134	AE	AI19	Analog input (reserved)
X3135-137	AE	AI20	Analog input (reserved)
X251-53	Uni-AAA001	DI	Universal digital input
X386-88	A002	DI	Digital input
X389-91	P2	AI	Analog input
X392-94	AO	AO	Analog output
X51-53	DI30–DI31	DI	Digital inputs (disabled)

📌 Note: X2 = Mainboard, X3 = Expansion board, 0X.. = VBS (Valve Bus System). Some inputs marked "disabled" are not used.

Created by: Lei RO

Date: 01.03.21

Checked / Approved: (signature)

Date: 18.03.21

2K2.1A ✓ 2K2.1B ✓

Temp: 21.8 °C

Humidity: 8:0.95

This protocol is a translation of the original German document (AF20-008099_0A465916).
All measurements and checkmarks correspond to the original test record.