1K2 Water Treatment System Large ROL 160

Product Information: Water Treatment System Large ROL 160 – 1K2

Reverse Osmosis Plants

Specifications:

• Model: Large ROL 160 – 1K2

• Power Supply: Mains power supply

• Earth Connection: Schuko plug

• Warranty on Materials: 2 years (from production date, excluding
  consumables)

• Approval: ISO 9001 certified design and production system

Product Usage Instructions:

1. Safety Instructions:

Before operating the Water Treatment System, please read and
follow these safety instructions:

• Do not install or use the system near gas appliances.

• If you smell gas, do not attempt to switch on any appliance,
  touch electrical switches, or use telephones. Call the gas supplier
  immediately or the fire brigade if unable to reach the gas
  supplier.

• Disconnect the mains power supply before accessing inside parts
  or during maintenance and installation to avoid electric shock
  hazards.

• Be cautious of water leaks as malfunctions in connections or
  the humidifier may cause leaks.

2. Installation:

The installation of the Water Treatment System must include an
earth connection using the provided Schuko plug.

3. Disposal:

Please follow the instructions below for proper disposal of the
Water Treatment System:

• The system should not be disposed of as municipal waste but
  collected separately for recycling, treatment, or disposal as
  required by law.

• At the end-of-life, return the system with all essential
  components to the WEEE collection centers identified by local
  authorities. Alternatively, return the equipment to the distributor
  or retailer if purchasing equivalent new equipment.

• Improper disposal of the system may have negative effects on
  human health and the environment.

• Follow the instructions provided in the user manual to remove
  any batteries before disposing of the equipment. Used batteries
  should be taken to appropriate waste collection centers as per
  local regulations.

• Penalties may apply for incorrect disposal according to local
  waste disposal legislation.

Frequently Asked Questions:

Q: What is the warranty period for the Water Treatment

System?

A: The warranty on materials for the Water Treatment System is 2
years from the production date, excluding consumables.

Q: How is the quality and safety of CAREL products

guaranteed?

A: The quality and safety of CAREL products are guaranteed by
the ISO 9001 certified design and production system, as well as the
appropriate marks.

ENG
Water Treatment System Large ROL 160 – 1K2 Reverse osmosis plants
USER MANUAL
NO POWER & SIGNAL CABLES TOGETHER
READ CAREFULLY IN THE TEXT!
WTS – Large ROL +03000131EN – ENG Up to date version available on www.carel.com

GENERAL WARNINGS
FAILURE TO CAREFULLY HEED THE WARNINGS SHOWN IN THIS MANUAL COULD LEAD TO FIRE OR EXPLOSION AND CONSEQUENT DAMAGE TO PROPERTY, INJURY OR DEATH. · Do not store or use petrol or other flammable vapours and liquids
in the vicinity of this or other appliances.
IF YOU SMELL GAS: 1. Do not attempt to switch on any appliance; 2. Do not touch any electrical switches; do not use telephones in the
building; 3. Callthegassupplierimmediatelyfromaneighbour’sphone.Follow
the instructions given by the gas supplier; 4. If you cannot contact the gas supplier, call the fire brigade;
· Installation and maintenance must be performed by a qualified installer, service centre or gas supplier.
CAREL Industries reverse osmosis (RO) systems are advanced products, whose operation is specified in the technical documentation supplied with the product or can be downloaded, even prior to purchase, from the website www.carel.com. Each CAREL product, in relation to its advanced level of technology, requires setup/configuration/programming to be able to operate in the best possible way for the specific application. Failure to complete such operations, which are required/indicated in the user manual, may cause the final product to malfunction; CAREL accepts no liability in such cases. The customer (manufacturer, developer or installer of the final equipment) accepts all liability and risk relating to the configuration of the product in order to reach the expected results in relation to the specific final installation and/or equipment. CAREL may, based on specific agreements, act as a consultant for the installation/commissioning/use of the unit, however in no case does it accept liability for the correct operation of the RO system and the final installation if the warnings or suggestions provided in this manual or in other product technical documents are not heeded. In particular, as well as observing the above warnings and suggestions, the following warnings must be observed for correct use of the product:
ELECTRIC SHOCK HAZARD: the RO system contains live electrical com-
ponents. Disconnect the mains power supply before accessing inside
parts or during maintenance and installation. WATER LEAK HAZARD: the RO system automatically and constantly fills/ drains certain quantities of water. Malfunctions in the connections or in the humidifier may cause leaks.
Environmental conditions, fuel and power supply voltage must all comply with the specified values. All other uses and modifications made to the appliance that are not authorised by the manufacturer are considered incorrect. Liability for injury or damage caused by the incorrect use of the appliance lies exclusively with the user. Please note that the appliance contains live electrical devices. All service and/or maintenance operations must be performed by specialist and qualified personnel who are aware of the necessary precautions and are capable of performing the operations correctly and in accordance with the safety standards and legislation in force, with specific reference to:
1. Italian law no. 46/90: “Safety standards relating to systems in buildings”; 2. Italian Presidential Decree no. 447 of 6 December 1991: “Regulations for
the enforcement of law no. 46, dated March 5, 1990, on safety relating to systems in buildings”; 3. Italianlawno.10/91:”Regulationsfortheenforcementofthenationalplan for energy savings and the development of renewable sources of energy”

ENG
CAUTION
The installation of the product must include an earth connection, using the Schuko plug available in the RO system.
Caution: · Disconnect the appliance from the mains power supply before access-
ing any internal parts. · Environmental and power supply conditions must conform to the val-
ues specified on the product rating labels. · The product is designed exclusively to demineralize drinkable water. · Only qualified personnel who are aware of the necessary precautions
and able to perform the required operations correctly may install, operate or carry out technical service on the product. · Only water with the characteristics indicated in this manual must be used. · All operations on the product must be carried out according to the instructions provided in this manual and on the labels applied to the product. Any uses or modifications that are not authorised by the manufacturer are considered improper. CAREL declines all liability for any such unauthorised use. · Do not attempt to open the appliance in any way other than described in the manual. · Observe the standards in force in the place where the RO system is installed. · The appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. · Do not install and use the product near objects that may be damaged when in contact with water (or condensate). CAREL declines all liability for direct or indirect damage following water leaks from the humidifier. · Do not use corrosive chemicals, solvents or aggressive detergents to clean the inside and outside parts of the RO system, unless specifically indicated in the user manual. · Do not drop, hit or shake the RO system, as the inside parts and the linings may be irreparably damaged,
CAREL adopts a policy of continual development. Consequently, CAREL reserves the right to make changes and improvements to any product described in this document without prior warning. The technical specifications shown in the manual may be changed without prior warning. The liability of CAREL in relation to its products is specified in the CAREL general contract conditions, published on the website www.carel.com and/or by specific agreements with customers; specifically, to the extent where allowed by applicable legislation, in no case will CAREL, its employees or subsidiaries/affiliates be liable for any lost earnings or sales, losses of data and information, costs of replacement goods or services, damage to things or people, downtime or any direct, indirect, incidental, actual, punitive, exemplary, special or consequential damage of any kind whatsoever, whether contractual, extra-contractual or due to negligence, or any other liabilities deriving from the installation or use of the product, even if CAREL or its subsidiaries/affiliates are warned of the possibility of such damage.

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Warnings 3

ENG

DISPOSAL

Fig. 1

Fig. 2

PLEASE READ AND KEEP.

WITH REFERENCE TO EUROPEAN UNION DIRECTIVE 2012/19/EU

ISSUED ON 4 JULY 2012 AND RELATED NATIONAL LEGISLATION,

PLEASE NOTE THAT:

· Waste Electrical and Electronic Equipment (WEEE) cannot be disposed

of as municipal waste but must be collected separately so as to allow

subsequent recycling, treatment or disposal, as required by law;

· users are required to take Electrical and Electronic Equipment (EEE) at

end-of-life, complete with all essential components, to the WEEE collec-

tion centres identified by local authorities. The directive also provides

for the possibility to return the equipment to the distributor or retailer

at end-of-life if purchasing equivalent new equipment, on a one-to-one

basis, or one-to-zero for equipment less than 25 cm on their longest

side;

· the equipment may contain hazardous substances: the improper use or

incorrect disposal of such may have negative effects on human health

and on the environment;

· the symbol (crossed-out wheeled bin, see Figure 1), if shown on the

product or on the packaging, indicates that the equipment must be dis-

posed of separately at end-of-life;

· if at end-of-life the EEE contains a battery (Figure 2), this must be re-

moved following the instructions provided in the user manual before

disposing of the equipment. Used batteries must be taken to appropri-

ate waste collection centres as required by local regulations;

· in the event of illegal disposal of electrical and electronic waste, the

penalties are specified by local waste disposal legislation.

Warranty on materials: 2 years (from production date, excluding

consumables).

Approval: the quality and safety of CAREL products are guaranteed by

the ISO 9001 certified design and production system, as well as the ,

e

marks.

4 Warnings

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ENG

Index
1. Introduction……………………………………………………… 7
1.1 Typographic Distinctions …………………………………………………………….7 1.2 Documentation ………………………………………………………………………………7 1.3 Symbols in Use ………………………………………………………………………………..7 1.4 Intended Use ……………………………………………………………………………………7 1.5 Unit sizes…………………………………………………………………………………………….8
2. Safety Instructions……………………………………………. 9
2.1 Guidelines for Safe Operation…………………………………………………..9
3. Transport ………………………………………………………… 11
3.1 Overview…………………………………………………………………………………………11 3.2 Interim Storage …………………………………………………………………………….11 3.3 Check for complete and correct delivery of goods………..11 3.4 Scope of delivery………………………………………………………………………….11
4. Function and structure …………………………………… 12
4.1 Mode of operation………………………………………………………………………12 4.2 Influencing factors ………………………………………………………………………12 4.3 Operating conditions of the unit…………………………………………..12 4.4 Operating sequence…………………………………………………………………..13 4.5 Mechanical construction ………………………………………………………….14 4.6 Flowchart ………………………………………………………………………………………..16
5. Mechanical installation…………………………………… 18
5.1 Environment Parameters to be met and Mounting Recommendations ……………………………………………………………………..18
5.2 Installation steps…………………………………………………………………………..19
6. Water connection……………………………………………. 24
7. Electrical connection………………………………………. 25
7.1 Procedure for electrical installation………………………………………25 7.2 Remote ON/OFF and alarm relay connection ………………….25 7.3 Electrical installation check list……………………………………………….25 7.4 Connection of the level sensor of the permeate
collection tank ………………………………………………………………………………25 7.5 Inputs and outputs of the main board………………………………..26 7.6 Technical sheet: Booster pump (RTM300M2000) ……………26
8. Initial start-up…………………………………………………. 27
8.1 Flushing of the membrane(s)………………………………………………….27 8.2 Adjustment of the permeate quality……………………………………28 8.3 Continuation of initial start-up after successful
adjustment of the recovery rate…………………………………………….30 8.4 Filling the antiscalant tank ………………………………………………………30 8.5 Adjusting the metering pump ……………………………………………….30 8.6 Complete the initial start-up……………………………………………………31 8.7 Break of use…………………………………………………………………………………….31
9. Maintenance …………………………………………………… 32
9.1 General …………………………………………………………………………………………….32 9.2 Safety instructions for maintenance…………………………………….32 9.3 Routine maintenance…………………………………………………………………32 9.4 Special maintenance and repairs…………………………………………..33 9.5 Maintenance scheme…………………………………………………………………34
10. Decomissioning………………………………………………. 36
10.1 Dismantling……………………………………………………………………………………36 10.2 Disposal after dismantling………………………………………………………..36
11. Control ……………………………………………………………. 37
11.1 The control panel…………………………………………………………………………37 11.2 Operating states …………………………………………………………………………..38 11.3 Menu navigation………………………………………………………………………….40 11.4 Setting options at operator level …………………………………………..41 11.5 Menu Structure …………………………………………………………………………….42 11.6 Setting options at service level………………………………………………44 11.7 Wiring diagram……………………………………………………………………………..55

12. Error description …………………………………………….. 56 13. Spare parts ……………………………………………………… 58 14. Commissioning report / maintenance
documentation……………………………………………….. 61 15. Technical specifications ………………………………….. 63 16. Antiscalant ……………………………………………………… 64

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Index 5

ENG

1. INTRODUCTION

Dear Customer, Thank you for choosing a CAREL reverse osmosis unit. CAREL reverse osmosis units are state of the art. In order to operate your CAREL reverse osmosis unit safely, properly and efficiently, please read these operating instructions. Only use the CAREL R.O. unit in faultless condition and for its intended use, being aware of safety and hazards, and observing all instructions in this manual.
If you have additional questions, please contact your expert dealer.
For all technical questions or spare parts orders, please be prepared to provide unit type and serial number (see name plate on the unit).

1.1
·
»
þ
italics

Typographic Distinctions
preceded by a bullet: general specifications preceded by an arrow: Procedures for servicing or maintenance which should or must be performed in the indicated order installation step which must be checked off.
Terms used with graphics or drawings

1.2 Documentation
Retention Please retain these operating instructions in a secure, always accessible location. If the product is resold, turn the documentation over to the new operator. If the documentation is lost, please contact CAREL.
Versions in Other Languages These operating instructions are available in several languages. If interested, please contact CAREL or your CAREL dealer.

1.3 Symbols in Use
Specific Symbols related to Safety Instructions According to ANSI Z535.6 the following signal words are used within this document:
DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE is used to address practices not related to physical injury.
1.3.1 General Symbols
Notice: This symbol is used whenever a situation requires special attention beyond the scope of safety instructions.

1.4 Intended Use
CAREL reverse osmosis unit used to produce fully demineralized water. It may only be used in accordance with its intended purpose.
Notice: · Intended use also includes compliance with the assembly, disassembly and reassembly, commissioning, operating and main-
tenance conditions and disposal measures prescribed by us. · Only qualified and authorized personnel may work on and with the system. Persons who carry out transport or work on
and with the system must have read the relevant parts of the operating instructions and in particular the chapter “Safety instructions”. In addition, the personnel must be informed by the operator of any hazards that may exist. Leave a copy of the operating manual at the place of use of the unit. · The installation of additional equipment is only permitted with the written approval of the manufacturer.
Use of the system · The system is intended for operation (with use of feed water in the drinking water sector) of humidification systems. · The limit and guide values as per the regulations enforced in the installation country must be taken into account. · Frost protection and protection against excessive moisture must be ensured · The permitted surrounding temperature is between 5° C and 40° C · The use of a system separator according to DIN 1988, part 4 and DIN EN 1717 is obligatory.

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Introduction 7

ENG
Notice: · Avoid water temperatures above 20°C to prevent possible germ growth. · Due to their construction, CAREL reverse osmosis systems are not intended for outdoor installation.
1.5 Unit sizes
The following reverse osmosis plants belong to the ROL (Reverse-Osmosis-Large) series · ROL160: max. permeate production rate of 160 l/h · ROL320: max. permeate production rate of 320 l/h · ROL460: max. permeate production rate of 460 l/h · ROL600: max. permeate production rate of 600 l/h · ROL1000: max. permeate production rate of 1000 l/h · ROL1K2: max. permeate production rate of 1200 l/h

8 Introduction

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ENG

2. SAFETY INSTRUCTIONS

These safety instructions are required by law. They promote workplace safety and accident prevention.

2.1 Guidelines for Safe Operation

2.1.1 Scope Comply with the accident prevention regulation,,DGUV Regulation 3″ to prevent injury to yourself and others. Beyond that, national regulations apply without restrictions. This way you can protect yourself and others from harm.

2.1.2 Unit control Do not perform any work which compromises the safety of the unit. Obey all safety instructions and warnings present on the unit. In case of a malfunction or electrical power disruption, switch off the unit immediately and prevent a restart. Repair malfunctions promptly.

Caution: Restricted use. IEC 60335-1 stipulates as follows: This device may be used by children of eight years of age and above as well as by persons with reduced physical, sensory or mental capabilities or lack of experience and knowledge so long as they are supervised or have been instructed regarding the safe use of the device and understand the hazards that may result from it. Cleaning and maintenance of the unit must not be undertaken by children without supervision.

Notice: The installation room must be adequately ventilated and be equipped with a floor drain. A water stop mechanism (e.g. leakage detector) can be used as an alternative.

2.1.3 Unit operation Caution: Danger of scalding!
Hot surfaces can cause injuries. Protect yourself with suitable protective equipment.

Notice: Water leaks possible due to defective connections or malfunctions. · Before starting work, the water supply to the reverse osmosis system (RO system) must be shut off. · The system may be under pressure. Release pressure before starting work. · The reverse osmosis (RO) systems continuously produce permeate (product water) and concentrate (waste water).
Connections and water-carrying components must be checked regularly for correct functionality.

Notice: Risk of material damage! · The unit may be damaged if switched on repeatedly following a malfunction without prior repair. Rectify defects immediately! · Regularly check that all safety and monitoring devices are functioning normally. Do not remove or disable safety devices.

Notice: It is essential to leave the RO system connected to the power supply permanently. Only then the automatic rinsing can be carried out (protection against germs).

Switch device ON/OFF

The system can be switched on/off in different ways:

»

Interrupt the power supply (pull the plug) or

»

operate the main fuse switch (only ROL units) or

»

press the ESC key (for about 2 seconds).

2.1.4 Mounting, dismantling, maintenance and repair of the unit Notice: the CAREL reverse osmosis units are IP20 protected. Make sure that the unit is not object to dripping water
in the mounting location. Notice: Do not install CAREL reverse osmosis systems above electrical equipment such as fuse boxes, electrical
appliances, etc. In the event of a leakage, leaking water can damage the underlying electrical systems. Notice:
· Use genuine spare parts only · After any repair work, have qualified personnel check the safe operation of the unit · Attaching or installing of additional components is permitted only with the written consent of the manufacturer

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Safety Instructions 9

ENG
2.1.5 Electrical Caution: Risk of electrical shock!
Hazardous electrical voltage!
Any work on the electrical system to be performed by certified expert staff (electricians or expert personnel with comparable training) only.
During maintenance or installation work, the device must be disconnected from the power supply and secured against being switched on again. The absence of voltage must be ensured by a measurement.
After electrical installation or repair work, test all safety mechanisms (such as grounding resistance).
Notice Use only original fuses with the appropriate amperage rating. Regularly check the unit`s electrical equipment. Promptly repair any damage such as loose connections or burned wiring. Responsibility for intrinsically safe installation of the CAREL reverse osmosis unit is incumbent on the installing specialist company.

10 Safety Instructions

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ENG
3. TRANSPORT
3.1 Overview
Notice: Proceed carefully when transporting the reverse osmosis unit in order to prevent damage due to stress or careless loading and unloading. Protect the device from moisture during transport; the storage and shipping temperature is 5° to 40°C.
3.2 Interim Storage
Store the unit in a dry place and protect from frost and strong sunlight.
3.3 Check for complete and correct delivery of goods
Upon receipt of the unit, confirm that: · model and serial number on the name plate match those specified in the order and delivery documents · the equipment is complete and all parts are in perfect condition
Notice: In case of damage from shipment and/or missing parts, immediately notify the carrier or supplier in writing.
3.4 Scope of delivery
ROL · Reverse osmosis unit incl. control · 2 membranes (ROL160, ROL460, ROL600) or 4 membranes (ROL320, ROL1K0, ROL1K2) · 2 prefilters (5/10 m) · manual · connection material · Antiscalant canister

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Transport 11

ENG

4. FUNCTION AND STRUCTURE

3.1 Mode of operation
General principle of reverse osmosis Osmosis is a natural process, it is understood as the one-sided diffusion of a liquid (here the feed water) through a semipermeable membrane. A semi-permeable membrane is only permeable for certain substances.
As the liquid moves through a semi-permeable membrane, the pressure on the side with the lower concentration decreases and at the same time the pressure of the more concentrated solution increases until a balance is reached, stopping the water flow. Pressure difference between the two liquids is called “osmotic pressure”.
Reverse osmosis, on the other hand, is a technical process in which the natural process is reversed. It involves applying a pressure higher than the osmotic pressure to the concentrated liquid so that the water flows in the opposite direction through the semi-permeable membrane and thus separates the salts solved in the water.
Using this principle, water can be demineralized for drinking water as well as for process and industrial applications.

3.2 Influencing factors
The performance of the reverse osmosis membrane depends strongly on the following parameters:
Water inlet pressure at the membrane: ­ By lowering the working pressure, a reduction in permeate production can be achieved. ­ By increasing the working pressure, an increase in permeate production is also achieved. ­ The pump pressure can be changed by turning the screw on the pump (see chapter 8.4). ­ Be careful not to exceed the maximum pump pressure!
Salt content of the feed water: The higher the salt content, the faster the membrane wear.
Temperature of the feed water: The ROL unit is set up for a feed water temperature of 15°C. Any difference from this temperature will affect the production quantity and the quality of the permeate.

The following table shows the variation of the permeate production quantity by 3% per differing 1°C.

Temperature

15 °C + 1

Correction factor 1

1,03

+ 2

+ 3

+ 4

+ 5

+ 6

1,06 1,09 1,12 1,15 1,18

+7 + 8 1,21 1,25

Temperature

15 °C – 1

– 2

– 3

– 4

– 5

– 6

– 7

– 8

Correction factor 1

0,96

0,92 0,88 0,84 0,8

0,77

0,74 0,7

The colder the feed water, the lower the permeate production and the better/lower the conductivity. The warmer the feed water, the higher the production quantity, but the lower the permeate quality.

3.3 Operating conditions of the unit

The ROL system can be fed with water from the normal water supply if the water has a maximum hardness up to 50°fH. In order to avoid a reduction of the operating capacity, the water to be treated must comply with certain parameters:

turbidity Iron Manganese Aluminium SDI (Silt Density Index) Water temperature Free chlorine Hardness COD TOC TDS SiO2 conductivity

< 1 NTU < 0,15 ppm < 0,05 ppm < 0,05 ppm < 3 5 to 25 °C < 0.25 ppm < 50 °fH < 10 mg/l < 3 mg/l < 1000S/cm < 15 ppm < 1000 ppm

Notice: Ensure that the water is pre-treated by using a softener or an antiscalant.

12 Function and structure

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ENG

3.3.1 Recovery value
You can optimise the permeate production by adjusting the flow rates (Ref. 1). The basis for this is the respective recovery value of the plant (see technical data). If the recovery value is 68%, this means a permeate production quantity of 68% of the feed water used for this purpose. The difference to 100% shows the concentrate share.

You can optimise permeate output by adjusting the flow rates (Ref. 1). The basis for this is the relevant recovery value of the system (see technical data). For example, the recovery value for the ROL320 is 68% at a raw water temperature of 18 °C and a TDS value of 500 ppm.

The recovery value is calculated as follows:

RECOVERY (%) = Permeate 100 (Permeate + Concentrate)

Regulate the flow rate of the concentrate through the BV03 valve and read it off the FI03 flow meter. The circulation is controlled by the BV02 valve and read off at the FI02 flow meter. The pressure regulated in this way on the membranes guarantees the spe- cified production output.

The feed water temperature clearly influen- ces both productivity and the quality of the permeate. If the temperature rises (even by only a few degrees), productivity increases (which results in a better recovery value); however, conductivity increases at the same time.

• see chapter: Commissioning

Ref.1 A Permeate flow meter B Recirculation flow meter C Manual recirculation control valve D Permeat conductivity probe E Attachment for sampling permeat F Flushing solenoid valve G Manual flushing control valve H Manual drain control valve I Drain flow meter

3.4 Operating sequence
The feed water (raw water) is pumped through the pre-filter, which guarantees the dechlorination and a final filter capacity of 5 µm. This ensures the necessary clarity of the water at the membrane inlet. It is next softened by the addition of an antiscalant. The feed water pressure must be at least 2 to 5 bar during normal operation to ensure a correct supply pressure at the pump inlet.
The water then flows through the water inlet solenoid valve SV1 and is then directed by the pressure pump at high pressure to the membrane(s).
The pressure switch PS HIGH provides a signal when the pressure exceeds 12 bar at the membrane inlet.
Pure water (permeate) passes through the membrane; the salts solved in the water are retained by the membrane and drained off (concentrate).
The permeate now flows via the pure water line (scope of delivery) to the expansion ves- sel or directly to the consumer.
The quality of the permeate leaving the system is controlled by the conductivity sensor (EC PROBOUT).
The production process stops automatically when the water outlet pressure has reached approx. 4 bar at the pressure switch PS MAX. The pressure in the following circuit is kept constant by the expansion vessel.
If the pressure in the following circuit at the pressure switch PS MIN falls below 2 bar (when the expansion vesel is empty), the unit starts permeate production again.
If the inlet pressure falls below 0.8 bar, the pressure switch PS LOW gives the corre- sponding alarm and interrupts operation.
The permeate production quantity achieved can be read off from the permeate flow rate display (Ref1). If this does not correspond to the the specifications in the technical data, please note the measures mentioned in chapter 4.2.

Notice: The reverse osmosis (R.O.) units of the ROL series cannot operate without an expansion vessel or permeate collecting tank.

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Function and structure 13

ENG
3.5 Mechanical construction
L
K J

Ref. 2 J Prefilter CPC 20″ 5 µm K Carbon filter CB-EC 10″ sx 10 µm L Water inlet

ROL 160-320

1 23
Reiff.. 1

43
152 157 45

1

Control

2

UV-lamp (optional)

3

Pressure container (membranes)

4

Antiscalant – tank

5

Pump

6

Check valve for antiscalant injection

7

System feedwater solenoid valve

8

Drain water outlet 9 Permeat outlet

9

Permeat outlet

10 Antiscalant pump

14 Function and structure

190
193 196 195 89 78 171
Reiff.. 2
168 56 67 194 199
190
Fig. 3.a 11 Pressure gauge feed water / PI 12 Pressure gauge membrane inlet / PI 13 Pressure gauge permeate outlet / PI 14 Pressure switch PS LOW 15 Pressure switch / PS MIN 16 Pressure switch / PS MAX 17 Pressure switch / PS HIGH 18 Feed water conductivity sensor
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ROL460 – 1K2

ENG

1 32
43

190
193 196 195 89 78
Reiff.. 1
190 R1if.12
Reiff.. 2
76 192
65
194

1 Control 2 Membrane 3 Antiscalant 4 Centrifugal multistage motor pump 5 Check valve for antiscalant injection 6 System feedwater solenoid valve 7 Drain water outlet 8 Permeate outlet 9 Antiscalant pump 10 Motor
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54

Fig. 4.b

11 Pressure gauge feed water / PI 12 Pressure gauge membrane inlet / PI 13 Pressure gauge permeate outlet / PI 14 Pressure switch PS LOW 15 Pressure switch / PS MIN 16 Pressure switch / PS MAX 17 Pressure switch / PS HIGH 18 Feed water conductivity sensor

Function and structure 15

ENG

4.6 Flowchart

ROL with 2 membranes

BV PI PS SV P EC FI CV RO E.P. LSH RV DP AS P DP 1 2
3

Manual ball valve Pressure gauge Adjustable pressure switch Diaphragm solenoid valve Electric rotary vane pump Conductivity probe Flow indicator Check valve RO system control panel Float level switch Manual control valve Metering pump Antiscalant tank High pressure pump Dosing pump Feed water Permeat
Concentrate

2
3/4 gas AG

3/4″ 2 bar
3/4 gas AG

16 Function and structure

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WL-ROL with 4 membranes and antiscalant option

BV PI
PS SV P EC FI CV RO E.P. LSH RV DP
AS P DP 1 2 3

Manual ball valve Pressure gauge
Adjustable pressure switch Diaphragm solenoid valve Electric rotary vane pump Conductivity probe Flow indicator Check valve RO system control panel Float level switch Manual control valve Metering pump
Antiscalant tank High pressure pump Dosing pump Feed water Permeat Concentrate

2 bar 3/4 gas AG

ENG

3/4 gas AG

3/4 gas AG 2 bar

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Function and structure 17

ENG
5. MECHANICAL INSTALLATION
Caution: Risk of foot injuries!
Prevent unit from dropping during installation! Helping hand of a second person is advisable.
Caution: Risk of electrical shock!
Hazardous electrical voltage. During installation, the unit must be disconnected from power supply and secured against being switched on again. The absence of voltage must be ensured by a measurement.
5.1 Environment Parameters to be met and Mounting Recommendations
When selecting the installation site for the reverse osmosis unit, take the following into account: · The minimum clearances indicated in the fitting measures section must be observed in order to ensure adequate unit venti-
lation and allow for unob- structed access in case of maintenance · Protection class IP20 · By design, HygroMatik reverse osmosis units are not qualified for outdoor installa- tion (electronic components and water-
bearing parts may be damaged) · Ambient temperature must lie between · +5 and +40 °C (+41 and +104 °F) in order to protect the unit electronics against damage; frost may damage the steam cylinder,
the solenoid valve and pump, as well as make hoses burst · Avoid environments with excessive humidity, as it could have negative effects on the electronics. · Installation in closed rooms requires aeration and, if necessary, temperature conditioning in order to meet the envi- ronmental
conditions. · Make use of existing water connections for supply and draining. · For proper functioning of the level con- trol, plumb and level installation of the unit is required. · The optimal feed water pressure for the reverse osmosis units is in the range of 2 bar to 5 bar. If these values are not reached,
the installation of a pressure reducer or a booster pump is neces- sary. · The on-site waste water connection must be a free outflow according to DIN EN 1717. · The installation room must be well ven- tilated and equipped with a floor drain. Alternatively, a water stop device (e.g. leakage
detector) can be used. · Ensure that the system stands firmly.
Permeate
Drain
Siphon for prevent odors

18 Mechanical installation

Fig. 5.a

Water inlet WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

ENG

5.2 Installation steps

5.2.1
» »
»

Feed water connection
Install a shut-off valve Connect the feed water inlet to the system. The diameter of the raw water pipe must be at least equal to the diameter of the connection piece. Observe the information in the technical data.

ROL-160/-320

ROL-460 – 1200

5.2.2
» »
»

Permeate pipe connection
The diameter of the permeate pipe must be at least equal to the diame- ter of the connection piece. Connect the permeate pipe to the corresponding connection piece and then connect the pipe (not included in the delivery) to the expansion tank or return pump tank. Note the information in the technical data.

ROL-160/-320

ROL-460 – 1200

Notice: Do never operate the unit with the permeate line closed!

5.2.3 Connection of the expansion vessel

»

Mount the holder* of the expansion tank on a stable wall or ensure a secure stand on the floor.

»

If necessary, connect the connection set to the expansion vessel.

»

Install shut-off valves as shown in the following figure

4 WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

Mechanical installation 19

ENG

Notice · Install the reverse osmosis unit as close as possible to the consumer / humidifier. The maximum distance (4) is 15 metres (up to ROL600) 25 metres ( ROL1000/1200) · The reverse osmosis unit (1) must be installed at the same height of the humidifier (3) and the expansion tank. · The number of fittings in the pipe should be kept to a minimum. The use of angle joints, T-pieces and reducers increases the pressure losses in the pipe. The diameters shown in the tables provide for a few fittings; if the number of fittings is doubled, the pipe with the next larger diameter must be used.

Unit ROL-160 ROL-320 ROL-460 ROL-600 ROL-1000 ROL-1200

Length of premeate pipe

5 m

10 m

15 m

20 m

min. innerØ premeate pipe

10 mm / 0,39 Inch

10 mm / 0,39 Inch

16,6 mm / 0,65 Inch

16,6 mm / 0,65 Inch

16,6 mm / 0,65 Inch

16,6 mm / 0,65 Inch

25,4 mm

16,6 mm / 0,65 Inch

16,6 mm / 0,65 Inch

5.2.4
»
»

Connection of the concentrate line
Connect the concentrate pipe to the corresponding connector and con- nect the pipe (not included in the delivery) to the drain. The diameter of the concentrate pipe must be at least equal to the diameter of the connection piece.

ROL-160/-320

ROL-460 – 1200

Notice: Ensure a free outlet and discharge according to DIN EN 1717. Pay attention to the mini- mum requirement for the free flow distance (between the drain hose and the siphon) of 26 mm to prevent microbial contamination.

5.2.5 Inserting the prefilter cartridge(s)
Before installing the filter set in the mem- brane container, it must be ensured that the feed water line is closed and thus no pres- sure is applied.

»

Make sure the water inlet valve is closed.

»

Select menu item 14 SystemTest in the control system menu, control the water outlet valve manually and

release any possible rest pressure.

»

Switch off the system ( press ESC for 2 seconds), then disconnect the system from the power supply (remove

the plug).

»

Remove the filter housing using the installation key supplied.

»

For maintenance: remove the old fil- ters and clean the filter housing.

»

Install the new filter inserts in the correct position.

»

Replace the filter housing and screw it tight with the mounting bowl.

»

Open the water supply and vent the filters using the screw in the upper part of the membrane housing.

L

K J

The activated carbon filter CB-EC (K) removes the chlorine content from the feed water (L).
The fine filter CPP (J) works mechanically. When the feed water flows through the filter strainer unit and retains contaminants larger than 5 µm.
Replacement as part of maintenance: see chapter Maintenance.

20 Mechanical installation

WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

ENG

5.2.6 Inserting the membrane(s)

Before installing the membranes in the membrane container, it must be ensured that the feed water line is closed and

thus no pressure is applied.

»

Dismantle the crescent-shaped metal plates.

»

Remove the cap of the membrane pressure vessels (by pulling it out upwards) with the enclosed disassembly

tool.

Disassembly tool

»

Remove the protective cover of the osmosis membrane (with sterile gloves) without damaging the

membrane. Do not remove the protective plastic film adhering to the osmosis membrane!

This can be recognised by the printed flow direction arrows.

»

Wet the seal of the osmosis membrane and the pegs at the ends with silicone fat if necessary.

»

Insert the membranes into the container as shown; pay attention to the position/direction of the seal.

Make sure that the lip seal is not damaged.

»

Reassemble the top caps of the containers in the correct position and secure them with the metal plates.

Check that the screw connection.

»

Re-attach the connectors to the lower part of the containers.

»

Make sure that there are no abnor- mal tensions on the lines or connections.

Notice: Use disposable gloves when installing the pre-filter(s) and membrane(s) to protect them from contamination.

WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

Mechanical installation 21

H2O H2O
H2O H2O

ENG
Units with 4 membranes and 2 membranes The ROL assembly inlet is from the left-hand side membrane, from the bottom

ONLY ROL VERSION

Joint en surbrillance

Joint en surbrillance

Section d’entrée de l’osmose inverse
Partie supérieure de la membrane

Section d’entrée de l’osmose inverse
Partie supérieure de la membrane

Fig. 5.b
Notice: Maximum permitted storage time of the membranes: · 6 months: if the membranes are supplied already impregnated with a chemical solution and/or glycol · 1 year: if the membranes are delivered dry or vacuum packed.
Store the membranes at temperatures between 0 and 35 °C.
Notice: Before connecting the system to the power supply, it is mandatory to follow the steps described in the chapter Initial start-up.
Notice: When replacing the membranes with flow in an upwards direction, to avoid damaging the gasket, proceed as follows:

Direction of flow, as indicated on the membrane

22 Mechanical installation

Groove on the pressure cap
WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

Before inserting the membrane, wrap the membrane with a layer of film measuring approximately 10×25 cm (the film can be recovered from the packaging if needed) and then place it inside the vessel.
Fig. 5.c As soon as it passes the groove on the pressure cap, remove the film and proceed until the membrane is fully inserted.

ENG

5.2.7 Installation of the uv quartz lamp (optional)

Caution: Danger from uv radiation UV radiation is harmful to the skin and eyes: disconnect power to the UV lamp before performing any operations.

Notice: The UV lamp and the quartz are very fragile. Pay extra care when performing the following operations to fit and/or remove the lamp and the quartz:

»

Open the rubber cap (A) and unscrew the

plug (B).

»

Slide the lamp (D) approximately five

centimetres out of the chamber (G)

»

Securely holding the end of the lamp (D),

»

carefully remove the fourpin lamp connector

(C) from the open end of the lamp.

»

Carefully remove the lamp (D) from the

chamber (F).

»

Then unscrew the other end of the UV lamp to

access to O-ring on the quartz tube.

»

Carefully remove the O-rings (E) from both

ends of the quartz tube (F).

Fig. 5.d

Fig. 5.e

WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

Mechanical installation 23

ENG

6. WATER CONNECTION

Have all plumbing work done only by qualified personnel (plumber or specialist with equivalent training) to minimize risks.

Caution: Risk of electrical shock! Hazardous electrical voltage! Before starting installation work ensure that the unit is not yet connected to the power supply.

General Rules · Obey local water utility regulations · Verify that necessary safety measures have been taken ­ in compliance with either German Technical and Scientific Associa-
tion for Gas and Water (DVGW) guidelines (DIN EN1717) or local regulations ­ that eliminate backflow of polluted water into drinking water treatment facilities. This may require the installation of a system separator, allowable only when free discharge into the drainage system is given. · Ensure that there is a free outflow and drain according to DIN EN 1717. Pay attention to the minimum requirement for the free flow distance (between the drain hose and the siphon) of 26 mm to prevent microbial contamination. · Supply water must not exceed 25°C (77°F) · Allowable range of water pressure: 1,5 to 4 bar / 22 to 58 psi (150.000 to 400.000 Pa). If the pressure is below 1.5 bar, install a pressure booster, if it is above 4 bar, install a pressure reducer after the reverse osmosis system. · Install a drain tap shortly before the system to flush the pipe. Flushing the pipe prevents foreign particles such as swarf or sealing material from entering the system from the pipes.

Connection of the system supply

»

Make sure that the flow rate and pressure correspond to the values given in the technical data.

»

Ensure that the water supply stays closed. This system may only be supplied with water during commissioning

(see chapter 8) !

Connection of the concentrate discharge pipe. · The diameter of the concentrate pipe must be at least equal to the diameter of the connection piece (see technical data).

Notice: In any case, a particle filter (min. 100 µm) according to DIN 13443-1 should be installed before the reverse osmosis system. Without a water filter there is a risk of damage to the system.

Notice: The following applies to ROL units: · For safety reasons the water connections are not screwed during transport. They must be screwed during installation. · Remove the transport locks from the flow pipes.
Notice: for the Australian market and to comply with Watermark requirements, a watermarked approved dual check valve shall be installed in the supply line to the humidifier when connected to potable water. Should on the other hand the humidifier be fed with treated water from a Carel reverse osmosis system connected to potable water, the dual check valve shall be installed in the supply line to the reverse osmosis system.

Water connections final check Go down the following water installation checklist: – ALL screw connections and hoses firmly connected? – Water supply line flushed before making connections? – Water connection properly installed? – Water discharge properly installed? – Does blow-down water drain freely? – Water supply line and water discharge leakage-free?

24 Water connection

WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

ENG

7. ELECTRICAL CONNECTION
Caution: Risk of electrical shock! Hazardous electrical voltage. All work related to electrical installation to be performed by expert staff (electricians or expert personnel with equivalent training) only. Do not connect the reverse osmosis unit to the live power supply before all installation work has been completed.
The customer is responsible for checking expert staff qualification.
General installation rules · All local rules concerning the implementation of electrical installations must be obeyed. · Electric connector cables to be laid professional.
Notice: Possible electronical components destruction through electrostatical discharge! Prior to commencing electrical installation work, steps must be taken to guard the sensitive electronical components of the unit control against damage from electrostatical discharge.

7.1 Procedure for electrical installation
Insert the plug into a suitable socket. The performance values are given in the technical data.

7.2 Remote ON/OFF and alarm relay connection

For connection of the remote ON/OFF signal cable and/or the alarm relay signal cables

»

open the front of the electronic control unit to access the terminal strip.

»

Lead the two-wire cable (not included in the scope of delivery) from the corresponding clamp through the

cable screw connection in the control panel to the consumers.

Fuses CAREL recommends the use of main fuses with slow – to medium – load characteristic.
The reverse osmosis system should be operated by its own residual current circuit breaker.

7.3 Electrical installation check list

Check electrical installation with respect to customer-site requirements and local power supply regulations.

þ

Supply voltage in accordance with name plate voltage rating?

þ

Have all electrical cable and plug connections been properly tightened?

7.4 Connection of the level sensor of the permeate collection tank

If using the ROL unit with a storage tank + booster pump,

»

connect the high level signal to terminals 22 – 23, and the low level signal to terminals 33 – 34.

The high level signal can be enabled in the menu “5 HIGH LEVEL”. The low level signal can be enabled in the menu “4 LOW LEVEL”. The permeate pressure switch already sup- plied does not need to be disconnected, as this does not interfere with the operating logic of the float.

NO C NC

3

4

WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

1 2
Fig. 7.a

1 level switch high 2 level switch low 3 alarm exits 4 contact ON / OFF
Electrical connection 25

ENG

7.5 Inputs and outputs of the main board

Clamp 1[L] – 2[earth] – 3[N]

Describtion 230-V 50/60 Hz-Input for system power supply

4[L] – 5[earth] – 6[N] 230-V-Output for pump supply

7[L] – 8[earth] – 9[N] 230-V-Output for dosing pump

10[L] – 11[earth] – 12[N] 230-V-Output for inlet valve

13[L] – 14[earth] – 15[N] 230-V-Output for flush valve

19[NO] – 20[C] – 21[NC] alarm aoutput optional

22[C] – 23[IN]

input pressure switch Feed water connection / Max pressure

24[C] – 25[IN]

input high pressure switch pump pressure

26[C] – 27[IN] 28[C] – 29[IN]

input pump motor protection input alarm dosing pump

30[schielded] – 31 – 32 conductivity sensor feed water

33[C] – 34[IN]

input pressure switch Feed water connection / Min pressure

35[C] – 36[IN]

input low pressure switch

37[C] – 38[IN]

input Remote-On/Off optional

39[C] – 40[IN]

input softening filter

41[shielded] – 42 – 43 conductivity sensor row water

WL-ROL
ü ü ü ü ü ü ü ü
X
ü ü ü ü ü ü ü

7.6 Technical sheet: Booster pump (RTM300M2000)

Description Tank material Volume Diameter Height Width Depth Voltage Frequency Power Inlet (from osmosi) Overfill Outlet (from pump) Drain tank

DATA PE 300 l 630mm 1300mm 880mm 760mm 220V 50Hz 0.91kW G ¾” Male G 1” Male G 1” Male G ¾” Male

Overfill: connect to a free drain, G 1″ M
Tank drain: connect to a free drain, G 3/4″ F

Water inlet: connect to the WTS, G 3/4″ M
Floating connector: connect to the WTS controller
Water outlet: connect to the users, G1″ F
Power connect to single-phase 220 V – 50 hz

Fig. 7.b

26 WEleactetricaolncnoencntieocntion

Fig. 7.c

WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

ENG

8. INITIAL START-UP

Caution Danger due to incorrect operation! Commissioning may only be carried out by qualified personnel (electricians or specialists with equivalent training).
Caution Risk of electrical shock! Hazardous electrical voltage! Follow safety instructions for work on live components.
Notice: Remove the elongated transport locks from the flow tubes (Fl01-Fl03).
Notice: Do not connect the permeate line to the expansion vessel until all other commission- ing steps (especially flushing of the mem- branes) have been carried out.
Notice: At the beginning of each commissioning with the use of new membrane(s), the ROL unit produces a higher permeate quantity in the first 2-4 hours, which is combined with a higher conductivity.
Notice: The pump may only be operated with the water inlet valve open, otherwise it could be damaged. Exception: initial start-up.
Operation steps in the short overview: Step 1: Check mechanical integrity, water connection and cabling Step 2: Removal of the transport lock from the flow tubes (Fl01-Fl03) Step 3: Flushing the membranes Step 4: Adjustment of recovery value Step 5: Connect the permeate pipe to the extension vessel and thus also to the con- sumer (It is important that this step is only done at the very end of the commission- ing process) Step 6: Filling the anti-calcant canister and adjusting the dosing pump. Step 7: Observe device and check for leaks, eliminate leaks if necessary.

8.1 Flushing of the membrane(s)
When the system is started for the first time and each time it is put into operation after a period of non-use, you must remove the chemical maintenance solutions and/or standing water. If the system is not used for a longer period of time, the membrane(s) must be replaced!
Ensure no water pressure is applied!
In addition, the membranes must be gradu- ally moistened without being submitted to the working pressure (5-6 bar). The water must flow through the filters and membranes at line pressure for several minutes before the pump can be activated.

Notice: Do not use the water produced during this phase.

»

Lead the hose for the concentrate and the permeate into the drain. Note hygiene guidelines (see chapter

water connection).

»

Make sure that the water supply is interrupted.

»

Don`t connect the permeate pipe to the consumer!

»

Connect the unit to the power supply and switch the red main switch in the switch box to “ON”.

Unit switches off after the self-test with error message “MIN PRESSURE”.

»

Press “ENTER” for two seconds, the display shows: “PASSWORD 0000”.

»

Enter service password

»

Confirm with “Enter”

»

Select menu item 14 (system test)

»

Press é

(Open the water inlet valve SV01*)

»

Press ç

(Open the flush valve SV02*)

»

Open the feed water supply

»

Vent the filter containers via the screw in the upper part of the blue filter con- tainers.

»

Open the hand control valve BV04* (flushing) completely

»

Let the system flush for 10 minutes

»

Regulate the pressure at the control valve BV04* to 1 bar, read on the pressure gauge immediatetely

downstream of the pump (PI02*).

»

Let the system flush for 10 minutes

WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

Initial start-up 27

ENG

»

Press è

(switch on the pump)

»

Adjust the pressure at flush valve BV04 to 2 -2.5 bar, read on the pres- sure gauge immediately dowstream of

the pump (PI02*)

»

Let the system run for 5 minutes

»

Press ç

(close the flush valve SV02)

The permeate produced in this phase has not yet reached its final quality. However, a part of it can be used to thin the antiscalant in the canister.

»

Let the unit run for 10 minutes in this mode and continue with the adjust- ment of the recovery rate.

»

Press è

(switch off the pump)

»

Press é

(close the water inlet valve SV01)

»

Press 2x “ESC” (leaving the service level).

The system starts the permeate production.

8.2 Adjustment of the permeate quality
Adjust the circulation volume (BV02) and the concentrate volume (BV03) to achieve the optimum recovery and permeate value (see technical data). The flow rates can be read off the flow measuring sensors FI01 (permeate) / FI02 (circulation) and FI03 (concentrate). Using the example of ROL-1000:

Fl01 Fl02
BV02 D E

Fl03
BV03 BV04 SV02

Fl01 permeate flow meter Fl02 recirculation flow meter Fl03 drain flow meter BV02 manual recirculation control valve BV03 manual drain control valve BV04 manual flushing control valve SV02 flushing solenoid valve D permeate conductivity probe E attachment for sampling permeate

Circulating flow rate: 450 l/h Concentrate flow rate: 470 l/h This results in a recovery value of 68 percent.

In general, this is calculated as follows:

RECOVER (%) = permeate*

x 100

permeate + concentrate

• quantity

Notice: · When using an upstream softening system you can reduce the amount of concentrate (lower water consumption) until a
recovery value of 75% is achieved. · Please also note the information on the correction value (chapter 4.2). · Use the red markings to document the required flow rates

Notice: If the permeate quantity (Fl01) is within the specified range (see technical data), continue with chapter 8.3

28 Initial start-up

WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

ENG

8.2.1 Increase of the working pres- sure before the membranes
If the maximum permeate quantity (Fl01*) is not reached although the recovery value cor- responds to the specifications in the technical data, you can increase the permeate quantity by increasing the pressure before the membranes.

Notice: Do not exceed the permitted pump pressure!

This can lead to pump damage.

Select a low working pressure!

Although the diaphragms can be operated at a pressure of 5 to 12 bar, we recommend the lowest possible working pressure (5 to 6 bar), both during commissioning and during nor- mal system operation. This allows for a lon- ger service life of the diaphragm(s).

To increase the pump pressure, proceed as follows:

Rotary vane pump (in models from 100 l/h to 320 l/h):

»

Open or close the by-pass valve (bypass) with a slotted screwdriver

Fig. 8.a

Multi-step pump (in the models from 460 l/h to 1.000 l/h):

»

Adjust the ball valve downstream of the pump manually

Fig. 8.b

»

Watch the pressure change on the manometer downstream of the pump and the flow rate change on the

pure water flow meter.

»

Adjust until the desired flow rate is reached.

»

Let the system run for 30 minutes.

»

During this time, periodically check that the rated parameters (flow rates, pressures and conductivity) stabilise

within the limit values.

»

Take a permeate sample (at the extraction point (E*)) and, if neces- sary, carry out a chemical-physical and

possibly bacteriological analysis to check the suitability of the water for the intended purpose.

• see figure previous page
  WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

Initial start-up 29

ENG

8.3 Continuation of initial start-up after successful adjustment

of the recovery rate

»

Connect the permeate pipe to the following consumer.

»

Open the shut-off cocks of the expansion vessel

»

Check whether the system switches off after reaching the operating pressure (approx. 4 bar).

When the pres- sure expansion vessel is completely filled, the pressure rises automatically (read the value on

the pressure gauge of the expansion vessel).

If the system does not switch off when the operating pressure exceeds approx 4 bar, consult HygroMatik.

»

Check the system for leaks.

»

If leaks appear, switch off the unit immediately. Locate and eliminate leaks

»

Repeat the tightness test

8.4 Filling the antiscalant tank
The antiscalant liquid is used to prevent cal- cium and magnesium residues present in the feed water from depositing on the membrane, causing a decline in performance and reducing operating life. The dosing pump feeds the desired antiscalant dose into the feed water circuit.
Filling the canister
Before filling the antiscalant canister, take the required amount of antiscalant (depending on the water hardness) from the table in the chapter Technical Data.

»

Using a measuring cup, thin the anti- scale in the canister with permeate (use the permeate produced during

the commissioning phase for this step).

»

Make sure not to damage the float when closing the cap on the tank.

8.5 Adjusting the metering pump

When using the recommended antiscalant Permaclean 309

»

Position the fl ow control knob at 30%

ON / OFF RESET
LED

KNOB

Fig. 8.c When the activity LED is green, the metering pump supplies an amount 10 times higher than the nominal value. Only use this setting after consultation with the specialist dealer or HygroMatik.

In standard operation, you use the dosing pump with the divider switched on (orange LED lights up constantly).

To supply the dosing pump with the antiscalant mixture from the canister, pro- ceed as follows:

»

Switch off the divider, the colour of the LED changes to green.

The DIVIDER is switched on and off as fol- lows:

»

Short press on the ON/OFF button (pump goes into standby mode).

»

Long press on the ON/OFF button, after 4 short flashes the LED chan- ges colour.

Only then release the pressure on the button

»

Set the rotary knob to 100% (fast pulse frequency).

»

Open the vent screw (A)

A

Fig. 8.d

»

Close the vent screw (A) when the transparent tube is completely filled with the antiscalant mixture.

30 Initial start-up

WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

ENG

When the antiscalant mixture reaches the pump, the “knocking noises” of the dosing pump become quieter.

»

Set the rotary knob to 30%.

When the antiscalant mixture is transported bubble-free in the tube:

»

Switch on the divider, the orange LED lights up continuously.

Notice: During operation, you can directly change the frequency of the dosing pump via the control knob.

ED flashing states
status LED (flashes per sec.) 3x RED 2x RED 2x ORANGE leuchtet ORANGE, schaltet bei jedem Klopfen aus always on (RED)

status pump operation Pump powered but voltage too low Pump powered but voltage too high Pump OFF and powered Pump ON Level alarm

Notice: When using the recommended antiscalant Pragmaclean 309, dose it according to the feed water quality (see technical data).

Only use diluted antiscalant!

8.6 Complete the initial start-up

Check mechanical intactness, water connection and cabling

»

Check functionality of water and electrical installations

»

Check functionality of the pre-treat- ment system (if available)

Checking the feed water

»

Check if the feed water parameters are within the limits given in chapter 4.3.

Notice: To ensure the functionality of the seals, the system must be put into operation within one year of the delivery date.

8.7 Break of use
The functionality of the reverse osmosis plant is connected to the continuous production of permeate.
For a break in use of up to 10 days, the plant should remain supplied with electricity and water, because the plant periodically rinses the membranes (a periodic rinse of 30 sec- onds every 24 hours of break in use is fac- tory- set). For breaks in use of more than 10 days up to a maximum period of 1-2 months, the rinsing parameters should be set to 15 minutes every 48 hours.
Notice: During breaks in use, the extension vessel or the return pump vessel (if present) must also be emptied.

WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

Initial start-up 31

ENG
9. MAINTENANCE
8.1 General
Regular maintenance is essential to ensure that the CAREL units can achieve a long service life. The necessary maintenance work refers to components that are either subject to mechanical or electrical wear, or whose function is reduced by deposits. The optimum function and required maintenance intervals of a reverse osmosis unit depend mainly on the existing water quality and the permeate quantity produced. Different water qualities can extend or shorten the maintenance intervals.
The following factors in specific could lead to an early blocking of the membranes: · Blockage as a result of the deposit of iron or calcium sulphate and calcium carbonate · Blockage with organic material
In general, a replacement of the membranes becomes necessary if a change in the following basic system parameters (at the same temperature and salinity) is noticed: · Reduction of the permeate production to a value which is insufficient for the application downstream of the reverse osmosis
system. · Too much increase in the conductivity of the water produced to a value too high for the application downstream of the sy-
stem. · Increase of the membrane feed pressure.
8.2 Safety instructions for maintenance
Caution: Risk of electrical shock! Hazardous electrical voltage! Any work on the electrical system to be performed by certified expert staff (electricians or expert personnel with comparable training) only.
Notice: Take care of ESD protection! The electronic components of the control are very sensitive to electrostatic discharges. In order to protect these components during maintenance, steps must be taken to guard against damage from electrostatic discharge.
Notice: Removal and replacement of components If necessary, the parts of the UO unit may only be replaced by qualified personnel. Replacement work must always be carried out with the system at a standstill; contact the supplier or the manufacturer directly for this purpose.
Notice: Use disposable gloves when installing the pre-filter(s) and membrane(s) to protect them from contamination.
8.3 Routine maintenance
8.3.1 Change prefilter
The HygroMatik ROL units are equipped with two different pre-filters.
L

K J

Fig. 8.a
The CB-EC carbon filter (K) is used to reduce the chlorine content in the feed water (L). The presence of chlorine in the water may irreversibly damage the membrane. The car- bon filter works by chemical reaction, combin- ing and absorbing the chlorine molecules. Consequently, its performance will decline over time.

32 Maintenance

WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

ENG

The CB-EC cartridge needs to be replaced:

·

every four months if the chlorine content in the feed water is less than 0.1 ppm.

·

every two months if the chlorine content in the feed water is between 0.1 ppm and 0.2 ppm.

The CPP micron filter (J) traps impurities around 5 µm in size. The filter works mechanically, letting the feed water fl ow through a filtering mesh. It is normal for the filter to become blocked over time, letting less water through and increasing the pressure drop.

The CPP cartridge needs to be replaced when the system feed water pressure (after having passed through the inlet filter car- tridges) is less than 1 bar during normal oper- ation (pressure read on pressure gauge PI01).

Before replacing the prefilter, check · that the ROL system is switched off · the inlet valve is closed and there is no pressure on the water line.

»

Remove the pre-filter with suitable tools.

»

Remove the old filter cartridge and clean the inlet.

»

Replace the O-ring if necessary.

»

Moisten the new O-ring and insert it.

»

Insert a new filter cartridge.

»

Mount the pre-filter with suitable tools.

»

Open the water supply and vent the filters via the screw in the upper part of the membrane container.

8.3.2 Filling of the antiscalant canister
The appropriately dosed antiscalant prevents lime deposits on the membranes. The filling level of the antiscalant canister must be con- stantly monitored. The consumption of the antiscalant mixture depends on the permeate production and the settings of the dosing pump.The reverse osmosis plant cannot work without antiscalant or softening, because oth- erwise the membranes would be irreversibly damaged. For this reason, the electronic con- trol stops operation and activates an alarm as soon as it recognizes a low level in the anti- scalant canister. To prevent this alarm and the following production stop, check the filling level of the canister regularly and refill it in time.

8.3.3 Replacing the UV lamp
The UV lamp has a limited operating life. The following intervals are recommended for replacement (whichever comes first): · 9000 operating hours · one year

8.3.4 Reset maintenance counter
Reset the maintenance hour counter in menu item 13 as described in the chapter device control.

8.4 Special maintenance and repairs

8.4.1 Membrane exchange

The membranes undergo a natural decline in performance over time, specifically:

·

annual reduction in water produced of 7%

·

annual increase in outlet water conduc- tivity of 10%

After a certain period of operation, in relation to the characteristics and volume of water treated, the membranes tend

to become blocked, with a decline in efficiency. This decline in membrane efficiency may depend on two main factors:

·

blockage due to precipitation of iron or calcium sulphate and carbonate

·

biological blockage

·

infrequent replacement of the CBC (carbon block fi lter)

Replacement becomes necessary when the system shows variations in the following fun- damental parameters (for the

same initial feed water temperature):

·

decrease in water produced to a level that is insufficient for the application connected downstream of the

reverse osmosis system.

·

excessive increase in the conductivity of the water produced to a level that is excessive for the application

connected downstream of the reverse osmosis system.

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Maintenance 33

ENG

Before replacing the membrane(s), check the following:

·

The ROL unit is switched off

·

The inlet valve is closed, there is no pressure on the water line.

The steps for membrane replacement are described in detail in the chapter mechanical installation.

8.4.2 Replacing the metering pump fuse

The fuse on the metering pump shows only be replaced by specialist personnel. The replacement procedure is as

follows:

»

Loosen the 2 screws in the upper part of thepart of the pump

»

Holding the pump, remove the 6 screws at the rear

»

Slide out the rear part of the pump until it is completely detached from the front part, so as to access the

circuit at the front of the pump.

»

Be careful with the spring on the injection element shaft

»

Locate the fuse and replace it with an identical one

»

Reposition the rear part of the pump until it is completely coupled with the front part

»

Tighten the 6 screws on the pump

»

Replace the pump in the unit and tighten the two screws to the frame.

Fig. 8.b

8.5 Maintenance scheme

8.5.1
» » »

Daily maintenance
Check if the system is working cor- rectly. Check that there are no leaks in the water-carrying components. Check the water inlet pressure.

Notice: The system supply pressure (after the pre-fil- ters) must be at least 2 bar during normal operation. Replace the filter cartridges if the pressure loss is too high.

8.5.2
» » »

Weekly maintenance
Check the max. membran pressure (max.10 bar!). Check the water conductivity of the permeate with the control unit. Note down the data for the listed tests

Notice:

·

Note that the production quantity of the permeate increases with rising water temperature, while the quality

of Permeate is decreasing. Conversely, the production quantity decreases with decreasing temperature, while

the quality of the permeate improves.

·

The indication of the measured perme- ate conductivity value on the display of the control unit settles down

to the actual value within the first minutes.

8.5.3 Maintenance every two months

»

Check that there is not too much free chlorine at the outlet (less than 0.25ppm).

34 Maintenance

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ENG

Replace the pre-filter cartridge:

»

Every 2 months if the free chlorine content is between 0.1 ppm and 0.2 ppm.

»

Every 4 months if the free chlorine content is less than 0.1 ppm.

Notice: The lifetime of the pre-filter and membrane(s) depends on feed water quality and permeate production rate.

Notice: Maximum permitted storage times of the membranes: · 6 months: if the membranes are already supplied with a chemical solution and/or impregnated with glycol; · 1 year: if the membranes are supplied dry or vacuum packed.

8.5.4 Maintenance by qualified per- sonnel

Every 6 months: Check the pre-filling pressure of the expan- sion vessel. This value must be 1.5 to 1.8 bar. To check the pressure, the outlet line of the vessel must be temporarily interrupted.

Generally:

»

Check the parameters of the water entering the system.

»

Check the conductivity of the input water and permeate with a conductivity meter.

»

Record the data for the listed tests

Maintenance schedule

Unit / spare part ROL160 ROL320 ROL460 ROL600 ROL1000 ROL1200

Min. Every 2/4 months Sediment filter Carbon filter

ROKC00FLT3

ROKC00FLT2

ROKL00FLT4

ROKL00FLT5

Every 12 months Uv lamp
ROKL00UVL1 / ROKC00UVOR
ROKL00UVL2 / ROKC00UVOR

Membrane (s)
ROKL00ME10
ROKL00ME20 ROKL00ME30 ROKL00ME20 ROKL00ME30

As needed O-ring
ROKL00OR25
ROKL00ME40

Number 2 4 2
4

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Maintenance 35

ENG
10. DECOMISSIONING
The regular operation of the reverse osmosis unit is dependent on the continuous production of desalinated water. Even during longer periods of non- use, the system must be connected to the power supply, as hygiene regeneration is regularly carried out in standby. Keep the power and water supply of the system connected. If the system does not produce any permeate for more than 10 days, the membrane(s) must be replaced and rinsed before restarting (see chapter Initial start-up and rinsing the membrane).
10.1 Dismantling
Once the RO unit will no longer be used, dismantle (demolish or scrap) it by following the installation procedures in reverse order.
Caution: Dismantling of the unit may only be performed by qualified personnel. Electrical dismantling may only be performed by trained electricians.
Obey the safety guidelines in section “Safety Instructions,” especially the guidelines for disposal.
10.2 Disposal after dismantling
The reverse osmosis unit is made up of metal parts and plastic parts. In reference to European Union directive 2012/19/ EU issued on 4 July 2012 and the related national legislation, please note that:
The components of the electrical and electronic devices must not be disposed of as municipal waste, and therefore the method of waste separation must be applied. The public or private waste collection systems defined by local legislation must be used.
Notice: The operator is responsible for the disposal of unit components as required by law. It must be stressed that if demineralised water (manual mode) or 1-50S/cm (automatic mode) are selected, the unit will signal maintenance and cleaning via the warning only, without ever shutting down the humidifier.

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11. CONTROL
The whole operation of the reverse osmosis unit ROL is controlled by a microprocessor. The control-system enables the production process and the control of the RO-unit. The measured values are shown on a LC-display. The control has the protection class IP65.
10.1 The control panel

ENG

The control panel is separated into three zones:
· the 2 operating keys ESC,
· the 4 arrow keys
· LC-display

Fig. 10.a

The operating keys are used to navigate through the menus and submenus. The function of the keys is:

ESC: Cancel or return to the previous level

éêArrow keys: Move within a menu, a submenu or a selection list
: Acceptance and storage of a selected setting

By pressing the arrow keys éê you can call up the read values:
· Permeate conductivity · Operating hours · Remaining time (hours) until the next service
Access to the main menu:
» press or about 2 sec, the display shows “PASSWORD 0000”
» enter the password using the arrow keys (0077) » confirm with
The control system regulates the automatic sequence for start-up, production, process shut-down, as well as for periodic rinses by controlling the following actuators: · Feed water valve (VFEED) · Permeate flush valve (VPER) · High pressure pump (PHP) · Dosing pump Antiscalant (PASC) · Fault signal/alarm (potential-free changeover relay)
The controller is equipped with the following digital inputs for monitoring the process: · Overpressure switch (PSHIGH) · Low pressure switch (PSLOW) · Level of permeate vessel low (PSMin) · Filling level permeate vessel full ( PSMAX) · External stand-by signal (INSB) · Error dosing pump antiscalant (INPASC) · Malfunction feed water pre-filter (INFIL)
Furthermore, the controller has a conductivity measurement (not temperature compensated) for monitoring the permeate quality, with a freely adjustable limit value.
This means that the unit is switched off and a fault message is output if the limit value of the permeate conductivity is exceeded during operation.

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Control 37

ENG

The different operating states
Permeate production: Production of product water. The VFEED, PHP and PASC relays are energized. STAND-BY: Unit is waiting on request. The unit is ready for operation, all relays are off. Flushing (to prevent deposits on the membrane surface): Factory activated in the main menu, flushing (when the unit is switched on), before/after water production and/or cyclically after a certain number of hours. The cyclic flushing can also be done in STANDBY mode.

Notice: Never deactivate the flushing function! (Avoidance of microbial contamination)

The production is controlled by the two level switches in the permeate tank: · PSHIGH starts the production · PSLOW stops production
In the MinPressure condition, the unit starts the water production: it opens the input solenoid valve and starts the pressure pump.
To avoid damage, a delay of 3 seconds is given after the input solenoid valve has opened.
When the MaxPressure condition is reached, the control unit goes into stand-by mode: the input solenoid valve closes and the pressure pump stops.
In the menu it is possible to deactivate one or both level switches and to operate the system with only one or no level switch at all. If both level switches are deactivated, the system goes into continuous production after switching on the power supply.
When the controller is switched on, a module flush is first carried out (if activated in menu 11).
After switching on the control system and module flushing (if activated in menu 10), the control system goes into production mode if the Min. pressure condition is underrun.
If programmed in menu 11 CLEANING the control unit starts an interval rinse during production as well as in standby (against standstill contamination) as soon as the countdown for the rinse interval has ended. The countdown for the rinse interval is reset at each rinse.

10.2 Operating states
After switching on the power supply, the version number of the control software appears for a few seconds. Then the controller returns to the last operating state before switching off.

CLEANING: TIME LEFT xxM xxS

WAITING START PUMP
The unit starts after the preset start delay has ended.
CLEANING: TIME LEFT xxM xxS
PSLOW= 0 und PSHIGH= 0 The permeate tank is empty. First, a module rinse is carried out when production is started (if it is programmed). Then the RO plant goes into production.
SYSTEM WAITING! HIGH LEVEL
PSLOW= 1 und PSHIGH= 0 The filling level in the permeate tank is between empty and full. The unit goes into stand-by mode.

SYSTEM WAITING! HIGH LEVEL
PSLOW= 1 und PSHIGH= 1 The pressure switch PSHIGH switches. The permeate tank is full. The unit performs a module rinse (if programmed) and then goes into stand-by mode.
COND. PERMEATE xxx µS
Shows the permeate conductivity
SERVICE IN xxxxx Hr
Shows the remaining time (in hours) until the next service.

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WORKING TIME xxxxx Hr
Shows the system operating hours.
SYSTEM WAITING! IN FILTER
The INFIL input for the feed water pre-filter or for the hardness sensor has switched (exam-ple: potentialfree contact of an upstream sof-tening unit). The unit stops. If the input is free again, the plant restarts automatically.
SYSTEM STOPPED! FAILED DOSAGE
The INPASC input for the Anstiscalant dosing pump (optionally available for WL-ROC 140) has switched. The system stops. If the input is free again, the system restarts automati-cally.
SYSTEM WAITING! IN STAND BY
The INSB input (external stand-by signal) has switched. The system stops. When the input is free again, the system restarts automati-cally.
PERFORM MAINTENANCE
The service hour counter has been counted down. Please make a maintenance and reset the counter.

ENG
10.2.1 Alarm messages
If one of the following alarm messages appears, the system stops and the alarm relay switches on. This message cannot be confirmed!
» Disconnect the system from the power supply and eliminate the cause of the alarm.
Further information can be found in the chapter Troubleshooting.
SYSTEM STOPPED! HIGH PRESSURE
The overpressure switch PSHIGH for the max. permitted operating pressure has switched. The system stops.
SYSTEM STOPPED! LOW PRESSURE
The low-pressure monitor PSLOW for the min-imum acceptable feed water inlet pressure has switched. The system stops.
SYSTEM STOPPED! HIGH COND. OUT
The max. limit value for the permeate con-ductivity has been reached. The unit stops.
You can return from the operating display level to the main menu by pressing the ENTER key.

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Decomissioning 39

ENG
10.3 Menu navigation
» use the arrow keys to move through the main menu to the relevant parameter
» press , to go to the selected submenu
» press “ESC” for about 2 seconds to return to the main menu
é Button < UP >: At the operation display level: To scroll up the operation displays. At the menu level: Scrolls up at the menu level. In the relevant parameter: To count up the input-values, and to activate (ENABLE) or deacti- vate (LOCKED) a function.
ê Button < DOWN >: At the operation display level: To scroll down the operation displays. At the menu level: To scroll down the menu level. In the relevant parameter: To count down the input value, and to enable (ENABLE) or disa-ble (LOCKED) a function.
ç Button < LEFT >: In the menu: For jumping back to the previous digit within the input field.
è Button < RIGHT >: In menu: For jumping to the next digit within the input field.
Button < ESC >: In menu level: To leave the menu level and return to the operating display level. In the parameter: To return to the previous iA longer press (2 sec) switches the system off and on.nput field/display or to leave the menu. Pressing the button for a longer time (2 sec) switches the system off and on.
Button < >:
In the operating display level: To open the menu level. At menu level: To open a menu. In the parameter: To save the entry and jump to the next entry field or return to the menu level.
Notice: By “jumping back with ESC” the earlier entries in this menu item are not saved!
Always end the menu items with “Skip to next” by pressing the ENTER key until the menu item starts again. This is the only way to save the settings you have made.

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10.4 Setting options at operator level
The following factory-set parameters can be changed at the operator level (password 0077).
Setting the required conductivity:
3B LIMIT OUT xx,x µS
By pressing the arrow keys éê you can set the max. set point
» Confirm the selection with
Setting the required flushing time / flush-ing cycle:
11G TIME 00 min 00 sec
By pressing the arrow keys éê you enter the duration of the flushing time for the peri-odic module flush..
» Confirm the selection with . The program
jumps to submenu “11H”.
11H WASH CYCLE 00 min 15 sec 24 h
By pressing the arrow keys éê you specify the time period between the periodic mod-ule flushes. e.g. change 24h to 48h (usage pause)
» Confirm the selection with .
The program jumps back to the main menu.
Notice: In the factory settings, parameter 11 CLEANING is preset to ON. If this setting has been changed to OFF in the service level, no entries can be made here in the operator level.

ENG
Setting the required language: In this submenu you can select the language shown on the display.
16 LANGUAGE 17 SET PASSWORTD

LANGUAGE ENGLISH
» Press the arrow keys éê to select your language
» Confirm the selection with .
The program jumps back to the main menu.

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Decomissioning 41

ENG
11.5 Menu Structure
The following menu list gives an overview of all parameters of the unit control. At the operator level (password 0077) only the parameters shown here in dashed lines can be changed. The other parameters are only visible at the operator level. Changing them is only possible at the service level.

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ENG

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Decomissioning 43

ENG

11.6 Setting options at service level
The following chapter is only intended for certified service staff. The password for reaching the service level can be found in the additional information provided with the unit.
CAREL is not liable for damages caused by incorrect parameter settings at this level.
Notice: The parameters have already been configured ex works and may only be changed with the appropriate expertise.
The contact configuration is preset in all submenus. Do not change this carelessly! Otherwise there is a risk of damage to the system.

11.6.1 Conductivity sensors
The CAREL RO units ROC 25-80 are equipped with one conductivity sensor (permeate).
The ROL units are equipped with two conductivity sensors. One sensor measures the conductivity of the feed water (ROH/ MIX), the other sensor that of the permeate. Both conductivity sensors are pre-calibrated ex works.
1 CAL. ROH- / MIX 2 CAL. PERMEATE
In the case of recalibration during maintenance, the calibration can be carried out either with the a help of a buffer solution with known conductivity, or with a conductivity tester according to the principle of comparative measurement.
Notice: When selecting the calibration liquid (not included in the scope of delivery), please note the selected measuring range: · Note that this conductivity measurement is not tempera-
ture-compensated. · To achieve a high measuring precision it is therefore re-
commended that the calibration liquid (or the water sample for the comparison measurement) has approximately the same conductivity and temperature as the permeate to be measured.

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Display shows three lines:

– – –

After a few minutes of running time, measure the conductivity of the permeate and/or raw/ mixed water with an external conductivity meter and enter the measured value in the corresponding parameter:

3 LIMIT OUT

»

Press ê + è at the same time

»

Press to calibrate

»

Press ESC to exit without calibrating

4 LIMIT ROH-/MIX

»

Press ê + è at the same time

»

Press to calibrate

»

Press ESC to exit without calibrating

11.6.2 Calibration of the probe zero point

»

Remove the conductivity probe from the flow

assembly and dry it.

»

Select 2A CAL ZERO in the main menu

2 CAL PERMEATE 3 LIMIT OUT

2A ZERO CALIB 2B SLOPE CALIB

READING 3.12 µS ZERO OK

A conductivity value is now displayed in the upper line.

»

Confirm the selection with

The display value may be > 0 µS, but should remain < 50 µS, otherwise the controller would not accept the calibration. In this case the conductivity probe may be faulty and must be replaced. The display shows the message “ZERO ERROR cal.

» repeat the calibration or quit the parameter without saving with ESC

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11.6.3 Calibration of the probe slope
2A ZERO CALIB 2B SLOPE CALIB

READING 12,5 µS BUFFER 15,0 µS

ENG

»

In the main menu, select 2B SLOPE CALIB

»

Enter the conductivity of the buffer solution in

the “BUFFER” field according to the table on

the bottle label.

»

Hold the sensor in the buffer solution and wait

until the “READ” value has stabilized.

»

press , to confirm the displayed slope value

and exit the parameter

and press ê, to return to the main menu

or

»

press ESC to exit the parameter without

saving

The buffer value must not be 0, otherwise the calibration is not saved.

11.6.4 Permeate set point calibration
With the assistance of the permeate conductivity measurement and a freely adjustable limit value for the permeate conductivity, the unit can be stopped and an alarm message issued if the permeate quality is reduced.

»

Select 3 LIMIT OUT in the main menu

3 LIMIT OUT 4 LIMIT RAW/MIX

Press the arrow keys éê to select whether the set point function should be active or inactive.

3A LIMIT OUT ENABLED

»

Confirm the selection with

If the set point function has been activated, the program jumps to submenu “3B”..
3B LIMIT OUT 50,00 µS

By pressing the arrow keys éê you can set the max. set point

»

Confirm the selection with

The program jumps to the submenu “3C”.

If the permeate conductivity exceeds the limit value set here during production, the system stops, the alarm
Decomissioning 45

ENG

message “ALARM CONDUCTIVITY” appears on the display and the alarm output relay picks up.

3C END WASH ENABLED
By pressing the arrow keys éê you can select in the submenu “3C FLUSH TIME END” the reaction of the control system when the set point is reached at the end of a module flush.

SWITCHED ON: At the end of module rinsing before the transition to the standby state, the permeate conductivity exceeds the limit value. The alarm message “ALARM CONDUCTIVITY” appears on the display and the alarm output relay picks up.

The unit stops.

OFF: The conductivity control during and after module rinsing is deactivated.

»

Confirm the selection with .

The program jumps to the submenu 3D”.

3D DELAY 0M 00Sec
Enter a delay time by pressing the éê arrow keys. The delay is intended to prevent the system from being switched off abruptly due to temporary measurement value peaks.

0 Sec = no delay (Causes an immediate switch-off when the set max. conductivity value is reached. See note at the end of the chapter)

»

Confirm the selection with .

The program jumps back to the main menu.

If a module flush is followed by a longer standstill period, an increased conductivity value may temporarily occur. If the parameter 3C is set to ON, this will lead to an unintended shutdown of the system

46 Decomissioning

11.6.5 RAW/MIX set point calibration
With the assistance of the feed water conductivity measurement and a freely adjustable limit value for the conductivity, the unit can be stopped and an alarm message issued if the feed water quality is reduced.

»

Select 4 LIMIT RAW/MIX in the main menu

4 LIMIT RAW/MIX 5 LOW LEVEL

Press the arrow keys éê to select whether the set point function should be active or inactive.

4A LIMIT RAW/MIX ENABLED

»

Confirm the selection with

If the set point function has been activated, the

program jumps to submenu “4B”..

4B LIMIT RAW/MIX xx,xx µS

By pressing the arrow keys éê you can set the max. set

point

»

Confirm the selection with .

The program jumps to the submenu “4C”.

If the feed water conductivity exceeds the limit value set here during production, the system stops, the alarm message “ALARM CONDUCTIVITY” appears on the display and the alarm output relay picks up.

4C DELAY ENABLED

Enter a delay time by pressing the éê arrow keys. The delay is intended to prevent the system from being switched off abruptly due to temporary measurement value peaks.

0 Sec = no delay

(see note at the end of the chapter)

»

Confirm the selection with .

The program jumps to the submenu 4D”.

4D INSTR. ON HOLD YES

Press the arrow keys éê to select whether the set point function (monitoring of the conductivity limit value during production) should be active or inactive.

YES= active

NO = inactive

Confirm the selection with . The program jumps back

to the main menu.

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11.6.6 Lower level switch LSLOW
With the aid of the level switch, the minimum fill level in the permeate vessel can be monitored and the system can be started automatically if the pressure falls below the required level.

»

Select 5 LOW LEVEL

5 LOW LEVEL 6 HIGH LEVEL

»

Press the arrow keys éê to select if pressure

switch should be active or inactive.

5A LOW LEVEL ENABLED

ENABLED= active DISABLED = inactive ( not recommended)

»

Confirm the selection with

If the set point function has been activated, the program jumps to submenu “5B”.

5B LOW LEVEL CONTACT N.O.

Press the arrow keys éê to set the switching direction.

N.O. CONTACT = The input functions as a normally open contact.

N.C. CONTACT = The input works as a normally closed contact

»

Confirm the selection with .

The program jumps to submenu “5C”

»

Default value: NC

5C INPUT DELAY 00Sec

»

Press the arrow keys éêto set the time of

delay

0 Sec = no delay (see note at the end of the chapter)

»

Confirm the selection with .

The program jumps back to the main menu.

11.6.7 Upper level switch LSHIGH
The pressure switch can be used to control the maximum level in the permeate vessel and stop production when this level is reached.

»

Select 6 HIGH LEVEL in the main menu

ENG

6 HI LEVEL 7 MIN PRESSURE

6A HI LEVEL ENABLED

»

Press the arrow keys éê to select if relay

input should be active or inactive.

ENABLED= active (ex works) DISABLED = inactive

»

Confirm the selection with .

If the set point function has been activated, the program jumps to submenu “6B”.

6B HI LEVEL CONTACT N.O.

Press the arrow keys éê to set the switching direction.

N.O. CONTACT = The input functions as a normally open contact.

N.C. CONTACT = The input works as a normally closed contact (not recommended)

»

Confirm the selection with .

The program jumps to submenu “6C”.

6C INPUT DELAY 00Sec

»

Press the arrow keys éê to set the time of

delay

0 Sec = no delay (see note at the end of the chapter)

»

Confirm the selection with .

The program jumps back to the main menu

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Decomissioning 47

ENG
11.6.8 Calibration low pressure switch PSLOW
With the help of a pressure switch between the feed water pre-filter and the high pressure pump the system inlet pressure can be monitored. If the pressure falls below a mini-mum pressure set on the pressure switch during production (e.g. due to a clogged pre-filter), production can be shut down and the system stopped.
7 MIN. PRESSURE 8 MAX. PRESSURE

7A LOW PRESSURE ENABLED

»

Press the arrow keys éê to select if pressure

switch should be active or inactive.

»

Confirm the selection with .

The program jumps to submenu “7B”.

»

Default value: ENABLED

7B LOW PRESSURE CONTACT N.C.

By pressing the arrow éê keys you set switching direction.

N.O. CONTACT = The input functions as a normally open contact.
N.C. CONTACT = The input works as a nor-mally closed contact

»

Confirm the selection with .

The program jumps to submenu “7C”

»

Default value: NC

Notice: N.C. contact is set ex works here. Do not change this! Otherwise there is a risk of damage to the system.

7C INPUT DELAY 00Sec

»

Press the arrow keys éê to set the time of

delay

0 Sec = no delay (see note at the end of the chapter)

»

Confirm the selection with .

The program jumps to submenu “7D”.

»

Default value: 05 sec

48 Decomissioning

7D MAX RETRY 0

By pressing the arrow keys éê you set the number of

start-up attempts (0-9).

»

Confirm the selection with .

The program jumps to submenu “7E”.

»

Default value: 4

7E ALARM WASHING YES
The menu item is not assigned.
Function of the startup repeats: If the number of start-up repeats is set to “0”, the unit stops as soon as the low-pressure monitor switches (and any delay time set has ended). All output relays are switched off! The display shows

SYSTEM STOPPED! LOW PRESSURE

If the number of start-up repeats is set to e.g. “5”, the unit stops as soon as the low-pres-sure monitor switches (and any delay time set has ended). The feed water valve SV1 stays activated. The display shows
LOW PRESSURE! ALARM 1/4

If the minimum inlet pressure returns, the system starts up again automatically. If the system produces constantly for the next 10 minutes without any further disturbance, the repeat counter is reset to “0”. If the pressure drops again, the system stops again and the counter is raised.
If the minimum inlet pressure does not return, the system will continue to start up within the next 20 minutes until the number of repeti-tions is reached. All output relays are now finally switched off! The display shows
SYSTEM STOPPED! NO PRESSURE

WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

11.6.9 CalibrationhighpressuremonitorPSHIGH
The system operating pressure can be controlled by means of a pressure switch between the high pressure pump and the RO modules. If a maximum pressure set on the pressure switch is reached during production (e.g. due to an overly restricted concentrate valve), the system can be stopped.
8 MAX PRESSURE 9 PUMP TEMP IN

8A HIGH PRESSURE ENABLED

»

Press the arrow keys éê to select if pressure

switch should be active or inactive.

»

Confirm the selection with .

The program jumps to submenu “8B”.

8B HIGH PRESSURE CONTACT N.C.

»

Press the arrow keys éê to set the switching

direction.

N.O. CONTACT = The input functions as a normally open contact.

N.C. CONTACT = The input works as a normally closed

contact

»

Confirm the selection with .

The program jumps to submenu “8C”.

Notice: N.C. contact is set ex works. Do not change this! Otherwise there is a risk of damage to the system.

8C INPUT DELAY 00Sec

»

Press the arrow keys éê to set the time of

delay

0 Sec = no delay

(see note at the end of the chapter)

»

Confirm the selection with .

The program jumps back to the main menu.

»

Default value: 00 sec

Menu item 9: “High pressure pump TSHP ” is not active.

9 PUMP TEMP IN 10 SOFTENER

11.6.10

Upstream softening

WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

ENG

system INFIL
If the upstream softening system is e.g. equipped with an automatic backwashing device and has a potentialfree switching con-tact to show the backwashing, then the control system can shut down the WL-ROC system for the duration of the filter backwashing and put it on hold. It is also possible to connect an upstream 1-col-umn softening system to the control so that the RO unit goes into standby mode for the duration of the regeneration.

10 SOFTENER 11 CLEANING

10A SOFTENER ENABLED

»

Press the arrow keys éê to select if relay

input should be active or inactive.

»

Confirm the selection with .

The program jumps to submenu “10B”.

»

Default value: Disabled

10B SOFTENER CONTACT N.O.

»

Press the arrow keys éê to set the switching

direction.

N.O. CONTACT = The input functions as a normally open contact.
N.C. CONTACT = The input works as a normally closed contact

»

Confirm the selection with .

The program jumps to submenu “10C”.

»

Default value: NC

10C INPUT DELAY 00Sec

»

Press the arrow keys éê to set the time of

delay.

0 Sec = no delay (see note at the end of the chapter)

»

Confirm the selection with .

The program jumps back to the main menu

»

Default value: 00 sec

11.6.11

Module flushing

Decomissioning 49

ENG
In this submenu you configure the module flush(es). Four flushing procedures can be programmed:
· At start-up of production · During shutdown of the production · During production at a programmed time interval · In standby mode against standstill germination (same
time interval as during production)
10 SOFTENER 11 CLEANING

11A WASHING ENABLED

»

Press the arrow keys éê to select if relay

input should be active or inactive.

»

Confirm the selection with .

The program jumps to submenu “11B”.

11B PUMP YES

By pressing the arrow keys éê you set whether the high pressure pump should run during flushing.

Yes = Pump ON NO = Pump OFF

»

Confirm the selection with .

The program jumps to submenu “11C”

»

Default value: PUMP NO

11C EVIN YES

Press the arrow keys éê to select, if a flush should be done when production is started up.

YES = active

NO = inactive

»

Confirm the selection with .

The program jumps to submenu “11D”.

»

Default value: EVIN YES

11D START PROD. ENABLED

By pressing the arrow keys éê you set whether a flush

should be carried out before each start.

»

Confirm the selection with .

The program jumps to submenu “11E”.

11E TIME 00min 00sec

By pressing the arrow keys éê you set the duration of

the flushing time.

»

Confirm the selection with .

The program jumps to submenu “11F”.

11F END PROD. ENABLED

By pressing the arrow keys éê you set whether a flush should be carried out at the end of the production.

»

Confirm the selection with .

The program jumps to submenu “11G”.

11G TIME 0min 15sec

By pressing the arrow keys éê you set the duration of

the flushing time for the periodic module flushing.

»

Confirm the selection with .

The program jumps to submenu “11H”.

»

Default value: 01 min 00 sec

11H WASHCYCLE 0min 15sec 24h

By pressing the arrow keys éê you specify the time period between the periodic module flushes.

e.g. change 24h to 48h (usage pause)

»

Confirm the selection with .

The program jumps back to the main menu.

»

Default value: 00 min 30 sec 24 h

50 Decomissioning

WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

11.6.12

Configuration of the alarm

output relay

(See 11.7 wiring diagram)

12 ALARM 13 RESET

12A ALARM ENABLED

»

Press the arrow keys éê to to turn the alarm

output on or off.

»

Confirm the selection with .

The program jumps to submenu “12B”.

12B OUTPUT ALARM CONTACT N.C.

»

Press the arrow keys éê to set the switching

direction.

»

Default value: NC

N.O. CONTACT = The input functions as a normally open contact. N.C. CONTACT = The input works as a normally closed contact.

»

Confirm the selection with éê .

The program jumps back to the main menu.

ENG

11.6.13

Operating and service

hour counter

The operating hours counter always runs when the system is in production mode. It is for general information and has no further control function.

It counts down the time. As soon as the counter has reached “0 hours”, the following message appears on the display: “EXECUTE MAINTENANCE” (do maintenance).

The counter is set in the ” 18 MAINTENANCE” submenu.

13 RESET 14 SYSTEM TEST

13A RES HR COUNT ENTER = YES

»

Press the arrow keys éê to select, if the

operation counter should be reset.

»

Confirm the selection with .

The program jumps to submenu “13B”.

13B RES SERVICE ENTER = YES

By pressing the arrow keys éê you select if the service

interval should be reseted.

»

Confirm the selection with .

The program jumps back to the main menu.

Resetting the parameters to factory settings (except password):

»

Switch off the system

»

Press and hold é and è and switch on the

system. Only then release the buttons.

RESET Password:

»

Switch off the system

»

Press and hold é and ESC and switch on the

system. Only then release the buttons.

WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

Decomissioning 51

ENG

11.6.14

Function test relay outputs

In this submenu you can check the relay outputs.

10 SOFTENER 11 CLEANING

11A WASHING ENABLED

Display changes automatically

11D START PROD. ENABLED

» UP é DNê Lç R è E

Press the keys described below to switch the relay.
Feed water valve Permeate flush valve VPER Concentrate-flush valve VCONC High pressure pump HP Dosingpump Antiscalant PASC

»

Press the key again to switch the relay back.

»

Press ESC to return to the main menu

Notice:
To avoid damage to the unit: Always activate the feed water valve é first before activating the pump è.

11.6.15

Function test alarm output

relay

In this submenu you can manually activate the alarm output. The switched-on relay is then reset to its switching status as programmed in submenu 12.

15 ALARM TEST 16 LANGUAGE

UP=ALARM ESC=TEST EXIT

»

Press “UP” é, to switch the relay.

»

Press the key again to switch the relay bac

»

Press ESC to return to the main menu

11.6.16

Select language

In this submenu you can select the language shown on the display.

16 LANGUAGE 17 SET PASSWORD

LANGUAGE ENGLISH

»

Press the arrow keys éê to select your

language

»

Confirm the selection with .

The program jumps back to the main menu

52 Decomissioning

WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

11.6.17

Change password

In this submenu you can change the password to program the main menu.

17 SET PASSWORD 18 MAINTENANCE

OLD PASSWORD 0000

»

Press the arrow keys éê to enter your latest

password

»

Confirm the selection with .

If the entry is correct, the program displays “PASSWORD ACCEPTED” and jumps to the next submenu.

NEW PASSWORD 0000

»

Press the arrow keys éê to enter your new

»

password Confirm the

selection

with

.

The program jumps to the screen:

CONFIRM 0000

Press the arrow keys éê to enter your new password

again.

»

Confirm the selection with .

The program jumps to the screen:

PASSWORD CHANGED

If the entry is incorrect, “CONFIRM ERROR” appears on the display for approx. 2 seconds before the programme jumps back to the “NEW PASSWORD” input display so that the new password can be entered again.

11.6.18

Reset password

To reset the password follow the steps below:

»

disconnect the unit from the power supply

»

press the two buttons é ESC while

reconnecting the plug (connect to power

supply).

The display will show “RESET PASSWORD” for a few seconds before the pump is started up.

WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

ENG

11.6.19

Setting the maintenance

interval

In this submenu you activate the service interval and enter the countdown of the service hour counter. In the delivery status, the service hour counter is set to 00100 hours. (100 hours). Resetting the countdown is described in submenu 13.

18 MAINTENANCE 19 DOSING PUMP

18A FAILED DO. ENABLED

»

Press the arrow keys to activate or

inactivate the service hour counter

»

Confirm the selection with .

The program jumps to submenu “18B”.

18B FAILED DO. CONTACT N.C.

Press the arrow keys to enter the Service intervall in

hours

»

Confirm the selection with .

The program jumps back to the main menu.

11.6.20

Dosing pump antiscalant

INPASC
If a dosing pump for the dosing of antiscalant is

installed instead of an upstream softening system,

then either the potential free fault signal output of the

dosing pump or the level switch (empty indicator) in

the dosing vessel can be connected to the controller.

If the INPASC input is switched, the control system can switch off the RO system for the duration of the fault and put it in the waiting mode. As soon as the fault has been eliminated, the control system automatically returns the RO system to production mode.

19 DOSING PUMP 20 STAND BY/ INPUT

19A FAILED DO. ENABLED

»

Press the arrow keys éê to select if relay

input

should be active or inactive.

»

Confirm the selection with .

The program jumps to submenu “19B”.

»

Default value: DISABLED

Decomissioning 53

ENG

19B FAILED DO. CONTACT N.C.

»

Press the arrow keys éê to set the switching

direction.

N.O. CONTACT = The input functions as a normally open contact. N.C. CONTACT = The input works as a normally closed contact

»

Confirm the selection with .

The program jumps to submenu “19C”.

19C INPUT DELAY 00Sec

»

Press the arrow keys éê to set time of delay.

»

Confirm the selection with .

The program jumps back to the main menu.

»

Default value: 00 sec

11.6.21

Stand-by-Input INSB (Release contact)

20 STAND BY / INPUT
21 PUMP DELAY

20A STAND BY IN ENABLED

»

Press the arrow keys éê to select if relay

input should be active or inactive.

»

Confirm the selection with .

The program jumps to submenu “20B”.

»

Default value: DISABLED

20B STAND BY IN CONTACT N.O.

»

Press the arrow keys éê to set the switching

direction.

N.O. CONTACT = The input functions as a normally open contact. N.C. CONTACT = The input works as a normally closed contact

»

Confirm the selection with .

The program jumps to submenu “20C”.

20C INPUT DELAY 00Sec

»

Press the arrow keys éê to set the time of

delay

0 Sec = no delay (see note at the end of the chapter)

»

Confirm the selection with .

The program jumps back to the main menu.

11.6.22

Set start delay

20 STAND BY/ INPUT 21 PUMP DELAY

21A PUMP DELAY 00 sec

»

Default value: 00 sec

Notice: Output activation / delay: In order to avoid pipeline damage due to “water hammer”, a delay of 3 seconds between pump on (or off ) and solenoid valve on (or off ) and a delay of 2 seconds between pump on (or off ) and pressure pump on (or off ) has been set at the factory.

54 Decomissioning

WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

11.7 Wiring diagram
internal power supply

ENG

Conductivity probe for osmosis output

Alarm dosing pump IN PASC

Thermoswitch IN /TS HP

Highpressure switch PS HP

High level probe IN / LS HIGH

Relay outputs, potential loaded

F1 F2
01 02 03 04 05 06

07 10 13 16

F3

08 11 14 17

09 12 15 18 19 20 21

22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

blue black red

blue black red

Low level probe IN / LS LOW Low pressure switch IN / PS FEED Stand-by IN SB Fault filter IN FIL Conductivity probe for osmosis input

Dosing pump Antiscalant P ASC SOLENOID VALVE V FEED SOLENOID VALVE V PER SOLENOID VALVE V CONC Alarm

Main power 230 VAC High pressure pump PHP 1-phase, max. 2A

Power supply, output relay

01

02

L

E

04 05

L

E

03 N

Main power IN 230 VAC

06 High pressure pump IN / P HP N 1-phase, max. 2A

19 20

L

E

N.O. C

21 N Alarm OUT N.C.

Digital inputs

22 23

High level probe IN / LS HIGH

24 25

High pressure switch IN / PS HP

26 27

Thermoswitch IN ( pressure pump motor) / TS HP

28 29

Alarm dosing pump IN PASC

Conductivity measurement option 1

30

blue

Conductivity probe for osmosis output

31

black

ECDI /01

32

red

0,0 ­ 99,9 S/cm

07

08

L

E

10 11

L

E

13 14

L

E

16 17

L

E

Output relay

09 N

Dosing pump Antiscalant OUT/ P ASC

12 N

SOLENOID VALVE (EV IN) / V FEED

15 N

SOLENOID VALVE (EV OUT) / VPER

18 N

SOLENOID VALVE (EV Conc) / V CONC

Digital inputs

33 34

Low level probe IN / LS LOW

35 36

Low pressure switch IN /PS FEED

37 38

Stand-By IN SB

39 40

Filter IN FIL

Conductivity measurement option 2

30

blue

Conductivity probe for osmosis output

31

black

ECDI /1

32

red

0,0 ­ 999,9 S/cm

WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

Decomissioning 55

ENG

12. ERROR DESCRIPTION

If an error appears, the permeate production stops. The display in the control panel switches from the current display to the display of an error code.

List of possible faults and error codes

Alarm indication on the display ALARM – CONDUCTIVITY
SYSTEM STOP – HIGH PRESSURE The PSHIGH overpressure switch for the max. permissible operating pressure has switched. Only for ROC 140 an ROL units SYSTEM STOP – NO PRESSURE The PSLOW overpressure switch for the min. permissible operating pressure has switched.
System STOP – DOS PUMP (only for systems with dosing pump)

Possible cause

Action

The conductivity measuring instrument

has lost calibration or is no longer working Recalibrate or replace the conductivity sensor.

correctly.

The feed water parameters have changed. Contact your supplier or the manufacturer.

High permeate conductivity due to blocked membrane(s).

Replace the membrane(s).

Piping blocked

Eliminate the cause of the blockage.

If the error occurs after a module flush, chan-

Delay time too short

ge the delay time in parameter 3D. If the error occurs during production, adjust parameter

4C.

Check the conductivity limit value entered.

Conductivity limit value chosen too low Adjust if it`s necessary. Note the technical data

of the consumer / humidifier.

The PSHIGH pressure switch is not calibrated or is not working correctly.

Replace the pressure switch.

Water pressure too high.

Re-adjust the pump pressure.

Membrane(s) is/are blocked.

Replace membrane.

The PSLOW pressure switch is not calibrated Check an existing pre-treatment (if any).

or is not working correctly.

Replace the pressure switch.

Decreasing flow rate. Blocking of filter cartridges..

Replace them.

Water pressure too low.

Check the function of the solenoid valve. Check the water inlet pressure.

Dosing pump does not work.

Check the fuse and replace it if necessary . Dosing pump is not working, replace it.

Dosing pump does not work, the magnet The suction filter in the anti-coating canister is

“knocks”.

blocked. Clean the filter.

Dosing pump does not work, the magnet Dirt deposits in the valve or valve is blocked.

does not “knock” or only damped.

Replace the dosing pump.

The red LED in the display of the dosing pump lights up.

Level alarm. Refill with anti-calant.

56 Error description

WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

ENG

List of possible faults and error codes (sequel)

Problem

Possible cause

Action

Reduction of the permeate rate.

Check pump P, make sure it is running correct-

Decrease of permeator inlet pressure

ly, replace it if necessary. Readjust the pressure to the sizing values and

adjust the bypass inside pump P if necessary.

Increase the pressure loss at the membrane due to blockages caused by hardness minerals

Check the process parameters and contact the supplier to arrange for replacement of the
membrane(s) if necessary.

The pressure switches have lost calibration, are worn or no longer function correctly.

Adjust or reset the flow rate and pressure to match the process values.
Check the electrical connections.

Blocked piping.

Correct the cause.

If necessary, check the water supply or adjust

Reduction of the water flow rate.

the shut-off valves in front of the system. Filter cartridges blocked. Replace the filter

elements.

The parameters of the water entering the system have changed.

Contact your supplier or the manufacturer.

Immediate stop (within one minute after start-up).

The pressure switches installed on the PVC distributor of the permeate are not working
correctly or are not calibrated.

Check the function of the pressure switches and replace them if necessary.

Inlet pressure of the expansion vessel is too low. Membrane of the expansion vessel is
damaged.

Check the inlet pressure of the expansion tank and replace it if it is damaged.

The solenoid valves do not open

Control board or the solenoid valve coil is not supplied with voltage.

Restore the power supply to the control board and/or check the connections and the
solenoid valve supply.

Solenoid valve is defective.

Replace the solenoid valve.

Incorrect pressure.

Check the water inlet pressure.

Process parameters not correct.

Check the parameter settings.

High permeate conductivity

The membrane(s) is/are blocked or contami- Replace the membrane(s). Contact your sup-

nated.

plier or the manufacturer.

Low water pressure

Low water pressure Inlet valves closed

Check the water inlet pressure. Check the function of the solenoid valve.

Decreasing flow rate

Blocked filter cartridges. Replace them.

The osmosis production does not start althou-

Check the connections and the function of

gh it is activated and no alarm has been given. The pressure switches doesn`t supply a signal. the pressure switches and replace them if

necessary.

The fuse that protects the pump is blown. Replace the fuse and test pump operation.

The system does not carry out the set sequences.

Power supply failure.

Check the power supply.

WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

Error description 57

ENG
1 2c 2b 3 12 17 4
Ref.1 – B Ref.1 – A Ref.1 – C Ref.1 – D
58 Spare parts

13. SPARE PARTS
9 13 16 15 8 7 11 18 5 6 14 19 10
Fig. 13.a

Ref.1 – I Ref.1 – G Ref.1 – F
Ref.2 – J

Ref.2 – L Ref.2 – K

WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

20 22 24 26 28 WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

ENG

21

23

25

27

29

30

Spare parts 59

ENG

Ref. number
1 2a
2b
2c
2d
2e 2f 3a
3b
4
5 6
7
8 9a 9b 10a 10b 10c 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Ref.1 A/B/I
Ref.1 C Ref.1 D Ref.1 F Ref.1 G Ref.2 K
Ref.2 J
Ref.2 K/J
Ref.2 K/J
Ref.2 K/J

Description
Controller Membrane vessel
Osmotic membrane (ROLxxxxxx0)
Nanofiltration membrane (ROLxxxxxxB)
Membrane vessel O-ring
Vessel top cap
Vessel bottom cap Caps extraction tool PVC lower connection between membranes PVC upper connection between membranes Antiscalant tank with cap Antiscalant liquid – EN 15040 compliant – 10 L drum Antiscalant liquid – EN 15040 compliant – 25 L drum Antiscalant liquid – NSF certified – 25 L drum Rotary vane pump
Centrifugal multistage motor pump 50 Hz (ROLxxx5xx0)
Centrifugal multistage motor pump 50 Hz (ROLxxx5xxB)
Centrifugal multistage motor pump 60 Hz (ROLxxx6xxx)
Centrifugal multistage motor pump 60 Hz (ROLxxx6xxB) Check valve for antiscalant injection Water inlet solenoid valve “PVC drain line (after flow meter / flushing control valve)” PVC permeate line (after flow meter) Antiscalant dosing pump Connectin tubing kit for dosing pump Motor 50 Hz w/ elastic joint and adapter (ROLxxx5xxx) Motor 60 Hz w/ elastic joint and adapter (ROLxxx6xxx) Adapter motor to pump Elastic joint motor to pump Pressure gauge (feed water) / PI 01 Pressure gauge (membrane inlet) / PI 02 Pressure gauge (permeate outlet) / PI 04 Pressure switch / PS LOW Pressure switch / PS MIN Pressure switch / PS MAX Pressure switch / PS HIGH Feed water conductivity sensor Flexible hose kit for pump suction and recirculation line PVC inlet water line between filters and solenoid valve
PVC fittings on drain/recirculation before control valves
PVC recirculation line after control valve PVC fittings at pump suction PVC fittings at pump discharge before membranes PVC permeate line before flow meter PVC check valve Glue for PVC fittings
Flow meter
Manual control valve Permeate conductivity sensor Flushing solenoid valve Manual ball valve CB-EC activated carbon filter
Sediment filter
Filter vessel
Filter vessel O-ring
Filter spanner

Spare part number
ROKL00EP00 ROKL00VS25 ROKL00VS40 ROKL00ME10 ROKL00ME20 ROKL00ME30 ROKL00ME1B ROKL00ME2B ROKL00ME3B ROKL00OR25 ROKL00OR40
ROKL00TC25 ROKL00TC40 ROKL00BC25 ROKL00BC40 ROKL00EXMB ROKL00PVCCSP ROKL00PVCFSP ROKL00PVCRSP ROKL00AT00SP ROKL00AS10 ROKL00AS25 ROKL00AS00 ROKL00PUMP ROKL00PU32SP ROKL00PUM5 ROKL00PUX5 ROKL00PBM5 ROKL00PBX5 ROKL00PUM6 ROKL00PUX6 ROKL00PBM6 ROKL00PBX6 ROKL00JV00SP ROKL00IV12 ROKL00IV34 ROKL00PVCPSP ROKL00PVCISP ROKL00PVCJSP ROKL00PVCMSP ROKL00DP00 ROKL00DPPI ROKL00MOT5 ROKL00MOT6 ROKL00AD00SP ROKL00EJ00SP ROKL00MA06 ROKL00MA16 ROKL00MA06 ROKL00MA16 ROKC00PSLP ROKL00PSLL ROKL00PSHL ROKL00PSHP ROKL00CP02SP ROKL00PVCTSP ROKL00PVCQSP ROKL00PVCKSP ROKL00PVCSSP ROKL00PVCNSP ROKL00PVCOSP ROKL00PVCDSP ROKL00PVCHSP ROKL00PVCESP ROKL00PVCGSP ROKC00CV20SP ROKL00PVCLSP ROKL00FL20 ROKL00FL25 ROKL00FL32 ROKL00VAL2 ROKL00CP01SP ROKL00IV12 ROKL00VALS ROKC00FLT2 ROKC00FLT5 ROKC00FLT3 ROKC00FLT4 ROKC00HOUS ROKL00HOU2 ROKC00OR10 ROKL00OR20 ROKC00WREN ROKL00WREN

Qty ROL160
1 2
2
2
2
2
2
x
1 x x x 1
1 1
1
1
1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1
1
1

Qty ROL320
1 4
4
4
4
4
4
x
1 x x x
1
1 1
1
1
1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1
1
1

Qty ROL460
1 2 2
2
2
2 2 1 1 1 x x x
1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1
1 1 1

Qty ROL600
1 2
2
2 2
2 2 1 1 1 x x x
1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1
1 1 1

Qty

Qty

ROL1K0 ROL1K2

1

1

4

4

4 4

4 4

4

4

4

4

4

4

1

1

2

2

1

1

x

x

x

x

x

x

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2 x 3
2 1 1 1 1
1
1
2
x

2 x 3
2 1 1 1 1
1
1
2
x

1 1 2 x
3
3 1 1 1
1
1
1
2
x

1 1 2 x
3
3 1 1 1
1
1
1
2
x

1 1 2 x
3
3 1 1 1
1
1
1
2
x

1 1 2 x
3 3 1 1 1
1
1
1
2
x

Optional kit
“UV sterilizer 680 l/h ROKL00DBK1”
“UV sterilizer 1360 l/h ROKL00DBK2″

Spare part description
UV lamp Quartz glass O-ring for quartz glass Electronic ballast UV lamp Quartz glass O-ring for quartz glass Electronic ballast

Spare part number
ROKL00UVL1 ROKL00QZL1 ROKC00UVORSP ROKL00UVT1 ROKL00UVL2 ROKL00QZL2 ROKC00UVORSP ROKL00UVT2

ROL160 ROL320 ROL460 ROL600 ROL1K0 ROL1K2

x

x

x

x

x

x

For ordering spare parts, a template can be found on the www.CAREL.com website under the,,Contact” tab.

Your spare parts order may as well be directed per e-mail to the CAREL main office using the address [email protected].

Please make sure to specify your unit model and serial number.

60 Spare parts

WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

14. COMMISSIONING REPORT / MAINTENANCE DOCUMENTATION

Commissioning report for CAREL reverse osmosis systems ROC and ROL

Unit Customer

Type Type of pressure expansion vessel Date of maintenance Company / name
Commercial / Private Street / Number Postal code / City Contact on site

Serial number Telephone number

Unit condition

Unit delivered complete? Transport locks removed? All hoses and connections checked for
damage? All detachable PVC screw connections
tightened? (ROL) All electrical cables checked for external damage?

Checked / Value yes no yes no yes no
yes no
yes no

General

Distance appliance – pressure expansion vessel Distance pressure expansion vessel – consumer Connection to the drinking water system Softening system connected? Hoses to the anti-scalant pump and canister con-
nected (if available)? Prefilter and membranes in position?

meters meters yes no yes no yes no
yes no

Feed water

Total hardness Conductivity Temperature Water inlet pressure

°fH S/cm
°C bar

Permeate / Konzentrate

Conductivity permeate Conductivity concentrate Conductivity Mixwater (only ROC with blending kit) Operation pressure Permeate quantity Concentrate quantity Demineralisation rate Switch-on pressure Switch-off pressure Antiscalant dosing (if available) activated according
to operating instructions and canister filled to mixing
ratio?

S/cm S/cm S/cm
bar l/h l/h % bar bar yes no

Note: The commissioning values are to be documented as a basis for the system assessment. A water analysis is to be attached to this protocol.

Datum / Sign

Remarks

ENG

WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

Commissioning report / maintenance documentation 61

ENG

Maintenance checklist for CAREL reverse osmosis systems ROC and ROL

Unit

Type

Type of pressure expansion vessel

Date of maintenance

Company / name

Customer

Commercial / Private Street / Number Postal code / City Contact on site

Serial number Telephone number

The following system components were tested (settings, setpoints, levels, etc.):
Activated carbon pre-filter (ROL) 5 m-prefilter membrane(s) electrical connections Dosing pump (if available) Tightness of the unit UV lamp (replace after 9000 hours or 1 year) Control

Error – free
operation
Yes / No

Replacement
Yes / No

Remarks

Measured parameters
Operating hours Feed water pressure Water pressure behind pre filter Total hardness feed water Conductivity feed water Temperature feed water Conductivity permeate Conductivity mixed water (only WL-ROC with blending option) Operation pressure switch-on pressure (max 2 bar) switch-off pressure (max 4 bar) Concentrate quantity in relation to the feed water
Concentrate quantity in relation to the feed water quantity used Reset service counter

hours bar bar °fH s/cm °C s/cm s/cm

Values at Commis- Maintesioning nance

bar

bar

bar

Remarks

Samples taken for analysis Feed water Permeate

Remarks

NOTE: The commissioning values are to be documented as a basis for the system assessment. Copy this form for multiple use.

Date / Sign

62 Commissioning report / maintenance documentation

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ENG

15. TECHNICAL SPECIFICATIONS

Technical data ROL (Reverse Osmosis Large)

ROL 160

ROL 320

ROL 460 ROL 600

ROL 1000

ROL 1200

Permeate production [l/h] *

160

320

460

600

1000

1200

Concentrate production [l/h]*

160

150

460

600

470

570

Circulation [l/h]*

160

150

460

600

450

450

Water consumption during operation [l/h]

320

470

920

1200

1470

1770

Max. Recovery rate [%]

50

68

50

68

Minimum water flow required for flushing [m3/h] ­ 2bar

0,9 – 1,2

1,8 – 2,1

Max. Working pressure [bar]

10

Feed water temperature [°C]

5 – 25

Feed water pressure [bar]

2 – 5

Feed water total dissolved salt [ppm]

< 750

Feed water conductivity [S/cm]

< 1000

Number of membranes

2

4

2

2

4

4

Size of low-energy-membranes

2,5″ x 40

4″ x 40 4″ x 40 XL 4″ x 40 4″ x 40 XL

Membrane pressure [bar]

7,9

8,8

7,4

7,9

8,1

8,8

Permeate pressure [bar]

2 – 4

Electrical connection

230V /1Ph /N /50 or 60Hz depending on product code

Electrical power [kW]

0,95

1,65

Weight (kg) during operation

75

83

100

125

Dimensions

height

1555

1550

[mm]

depth

510

700

width

940

1090

Permeate pipe connection

3/4″ AG or John Guest Ø 15 mm

3/4″ AG

Water connection

3/4″ AG

Drainage connection

3/4″ AG or John Guest Ø 15 mm

3/4″ AG

Water hardness [°fH] Drain function

up to 50 ü

Conductivity measurement

Permeate and feed water monitoring, alarm function included

• Specifications refer to the reference water quality: 15°C, TDS: 500 ppm, 26.7 °fH, permeat pressure: 1 bar

These values are theoretical because they can change with the temperature of the feed water and its chemical and physical qualities. These values were used for feed water with a TDS of 500 ppm and a water temperature of 18°C.

The temperature of the feed water has a great influence on the productivity and quality of the permeate. As the temperature increa- ses, the permeate output also increases, but with a worse conductivity value.

The recovery value is calculated as follows:

RECOVERY (%) = Permeate
Permeate + Concentrate*

• quantity

x 100

If a softening unit (e.g. the WaterLine-D) is connected upstream, the recovery value can increase up to 75%.

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Technical specifications 63

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16. ANTISCALANT

Dosage specifications:
When using the recommended antiscalant Pragmaclean 309 the correct dosage depends on the ROL size and on raw water hardness, keeping constant at 30% the stroke on the dosing pump.

Notice: Use only diluted antiscalant!

How to proceed: Fill the empty canister (20l) with the quantity of antiscalant specified in the table below (l), then fill with permeate water collected from the sample tap up to full tank.

Litres of antiscalant < 25 °fH

ROL160

0.8

ROL320

0.8

ROL460

2.1

ROL600

2.7

ROL1K0

2.5

ROL1K2

3

25 to 33 °fH 33 to 50 °fH

0.9

1

1

1.2

2.5

2.9

3.2

3.7

3.1

3.7

3.7

4.5

64 Antiscalant

WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

Notes

Notes

CAREL INDUSTRIES – Headquarters Via dell’Industria, 11 – 35020 Brugine – Padova (Italy) Tel. (+39) 049.9716611 – Fax (+39) 049.9716600 e-mail: [email protected] – www.carel.com

WTS LARGE +0300131EN rel. 1.0 – 05.09.2022

References

• CAREL

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