Carel Large ROL 160-1K2 User Manual
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Carel Large ROL 160-1K2 User Manual

Carel Large ROL 160-1K2 User Manual

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

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  • Page 1 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...
  • Page 3 The liability of CAREL in relation to its products is specified in the CAREL WATER LEAK HAZARD: the RO system automatically and constantly fills/ general contract conditions, published on the website www.carel.com...
  • Page 4 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 marks.
  • Page 5 Index 1. Introduction ............... 7 12. Error description ............. 56 1.1 Typographic Distinctions ..............7 13. Spare parts ............... 58 1.2 Documentation ..................7 14. Commissioning report / maintenance 1.3 Symbols in Use ....................7 documentation ............61 1.4 Intended Use ....................7 1.5 Unit sizes......................8 15.

  • Page 7: Typographic Distinctions

    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.

  • Page 8: Unit Sizes

    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. Unit sizes The following reverse osmosis plants belong to the ROL (Reverse-Osmosis-Large) series •...

  • Page 9: Safety Instructions

    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.
  • Page 10 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. Safety Instructions...

  • Page 11: Interim Storage

    3. TRANSPORT 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. Interim Storage Store the unit in a dry place and protect from frost and strong sunlight.

  • Page 12: Function And Structure

    4. FUNCTION AND STRUCTURE 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 semi- permeable 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.

  • Page 13: Operating Sequence

    4.3.1 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.

  • Page 14: Mechanical Construction

    Mechanical construction Ref. 2 J Prefilter CPC 20“ 5 µm K Carbon filter CB-EC 10“ sx 10 µm L Water inlet ROL 160-320 10 9 9 13 9 16 9 15 7 11 Rif. 1 Ref. 1 Rif. 2 Ref. 2 6 18 9 14 9 19...
  • Page 15 ROL460 - 1K2 10 9 9 13 9 16 9 15 Rif. 1 Ref. 1 9 10 Rif. 2 Rif. 2 Ref. 2 9 12 9 14 Fig. 4.b Control Pressure gauge feed water / PI Membrane Pressure gauge membrane inlet / PI Antiscalant Pressure gauge permeate outlet / PI Centrifugal multistage motor pump...
  • Page 16 Flowchart ROL with 2 membranes Manual ball valve Pressure gauge Adjustable pressure switch Diaphragm solenoid valve Electric rotary vane pump Conductivity probe Flow indicator Check valve RO E.P. RO system control panel Float level switch Manual control valve Metering pump Antiscalant tank High pressure pump Dosing pump...
  • Page 17 WL-ROL with 4 membranes and antiscalant option Manual ball valve Pressure gauge Adjustable pressure switch Diaphragm solenoid valve Electric rotary vane pump Conductivity probe Flow indicator Check valve RO E.P. RO system control panel Float level switch Manual control valve Metering pump Antiscalant tank High pressure pump...

  • Page 18: Mechanical Installation

    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.

  • Page 19: Installation Steps

    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.
  • Page 20 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. •...
  • Page 21 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.
  • Page 22 Units with 4 membranes and 2 membranes The ROL assembly inlet is from the left-hand side membrane, from the bottom ONLY ROL VERSION Gasket Gasket Highlighted Highlighted Entry Section Entry Section Reverse osmosis Reverse osmosis Upper heads of vessel Upper heads of vessel Fig.
  • Page 23 5.2.7 Installation of the uv quartz lamp Before inserting the membrane, wrap the membrane with a layer of film measuring approximately 10x25 (optional) cm (the film can be recovered from the packaging if needed) and then place it inside the vessel. Caution: Danger from uv radiation UV radiation is harmful to the skin and eyes: disconnect...

  • Page 24: Water Connection

    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.

  • Page 25: Electrical Connection

    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.
  • Page 26 Inputs and outputs of the main board Clamp Describtion WL-ROL 1[L] - 2[earth] - 3[N] 230-V 50/60 Hz-Input for system power supply ü 4[L] - 5[earth] - 6[N] 230-V-Output for pump supply ü 7[L] - 8[earth] - 9[N] 230-V-Output for dosing pump ü...

  • Page 27: Initial Start-Up

    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).
  • Page 28 » 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...
  • Page 29 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 mem- branes.
  • Page 30 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).
  • Page 31 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.

  • Page 32: Safety Instructions For Maintenance

    9. MAINTENANCE 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.

  • Page 33: Reset Maintenance Counter

    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.

  • Page 34: Maintenance Scheme

    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. 9.4.2 Replacing the metering pump fuse The fuse on the metering pump shows only be replaced by specialist personnel.

  • Page 35: Maintenance By Qualified Per- Sonnel

    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: •...

  • Page 36: Disposal After Dismantling

    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).

  • Page 37: The Control Panel

    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 Fig.
  • Page 38 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.

  • Page 39: Working Time

    10.2.1 Alarm messages WORKING TIME If one of the following alarm messages appears, the system stops and the alarm relay switches on. xxxxx Hr This message cannot be confirmed! Shows the system operating hours. » Disconnect the system from the power supply and eliminate the cause of the alarm.

  • Page 40: Menu Navigation

    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...

  • Page 41: Wash Cycle

    10.4 Setting options at operator level Setting the required language: The following factory-set parameters can be changed at In this submenu you can select the language shown on the operator level (password 0077). the display. Setting the required conductivity: 16 LANGUAGE 3B LIMIT OUT 17 SET PASSWORTD xx,x µS...

  • Page 42: Menu Structure

    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. Control WTS LARGE +0300131IT rel.
  • Page 43 WTS LARGE +0300131IT rel. 1.0 - 05.09.2022 Control...

  • Page 44: Conductivity Sensors

    11.6.1 Conductivity sensors The following chapter is only intended for certified The CAREL RO units ROC 25-80 are equipped with one service staff. The password for reaching the service level conductivity sensor (permeate). can be found in the additional information provided with the unit.
  • Page 45 11.6.3 Calibration of the probe slope Display shows three lines: 2A ZERO CALIB - - - 2B SLOPE CALIB  READING 12,5 µS After a few minutes of running time, measure the conductivity of the permeate and/or raw/ mixed water BUFFER 15,0 µS with an external conductivity meter and enter the measured value in the corresponding parameter:...
  • Page 46 11.6.5 RAW/MIX set point calibration message "ALARM CONDUCTIVITY" appears on the display and the alarm output relay picks up. With the assistance of the feed water conductivity measurement and a freely adjustable limit value for the 3C END WASH conductivity, the unit can be stopped and an alarm message issued if the feed water quality is reduced.

  • Page 47: Input Delay

    11.6.6 Lower level switch LSLOW 11.6.7 Upper level switch LS HIGH With the aid of the level switch, the minimum fill level in The pressure switch can be used to control the the permeate vessel can be monitored and the system maximum level in the permeate vessel and stop can be started automatically if the pressure falls below production when this level is reached.
  • Page 48 11.6.8 Calibration low pressure switch 7D MAX RETRY 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 By pressing the arrow keys éê...
  • Page 49 11.6.9 Calibration high pressure monitor 11.6.10 Upstream softening system IN HIGH The system operating pressure can be controlled by If the upstream softening system is e.g. equipped with means of a pressure switch between the high pressure an automatic backwashing device and has a potential- pump and the RO modules.
  • Page 50 11.6.11 Module flushing 11E TIME In this submenu you configure the module flush(es). Four flushing procedures can be programmed: 00min 00sec • At start-up of production • During shutdown of the production • During production at a programmed time interval By pressing the arrow keys éê...

  • Page 51: Alarm Enabled

    11.6.12 Configuration of the alarm 11.6.13 Operating service output relay hour counter (See 11.7 wiring diagram) The operating hours counter always runs when the system is in production mode. It is for general information and has no further control function. 12 ALARM It counts down the time.
  • Page 52 11.6.14 Function test relay outputs 11.6.15 Function test alarm output relay In this submenu you can check the relay outputs. In this submenu you can manually activate the alarm output. The switched-on relay is then reset to its 10 SOFTENER switching status as programmed in submenu 12.

  • Page 53: New Password

    11.6.17 Change password 11.6.19 Setting the maintenance interval In this submenu you can change the password to program the main menu. 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 17 SET PASSWORD 00100 hours.
  • Page 54 20C INPUT DELAY 19B FAILED DO. 00Sec CONTACT N.C. » Press the arrow keys éê to set the time of delay » Press the arrow keys éê to set the switching direction. 0 Sec = no delay (see note at the end of the chapter) N.O.

  • Page 55: Wiring Diagram

    11.7 Wiring diagram internal power supply Relay outputs, potential loaded F1 F2 Power supply, output relay Output relay Main power IN 230 VAC Dosingpump Antiscalant OUT/ P Highpressurepump IN / P SOLENOID VALVE 1-phase, max. 2A (EV IN) FEED SOLENOID VALVE (EV OUT) Alarm OUT SOLENOID VALVE...

  • Page 56: Error Description

    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 Possible cause Action ALARM - CONDUCTIVITY...
  • Page 57 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- ly, replace it if necessary. Decrease of permeator inlet pressure Readjust the pressure to the sizing values and adjust the bypass inside pump P if necessary.

  • Page 58: Spare Parts

    13. SPARE PARTS Fig. 13.a Ref.1 - B Ref.2 - L Ref.1 - I Ref.1 - A Ref.1 - G Ref.1 - C Ref.1 - F Ref.2 - K Ref.1 - D Ref.2 - J Spare parts WTS LARGE +0300131IT rel. 1.0 - 05.09.2022...
  • Page 59 WTS LARGE +0300131IT rel. 1.0 - 05.09.2022 Spare parts...
  • Page 60 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 hy@CAREL.de. Please make sure to specify your unit model and serial number.
  • Page 61 14. COMMISSIONING REPORT / MAINTENANCE DOCUMENTATION Commissioning report for CAREL reverse osmosis systems ROC and ROL Unit Type Serial number Type of pressure expansion vessel Date of maintenance Company / name Customer Commercial / Private Street / Number Postal code / City...
  • Page 62 Maintenance checklist for CAREL reverse osmosis systems ROC and ROL Unit Type Serial number Type of pressure expansion vessel Date of maintenance Company / name Customer Commercial / Private Street / Number Postal code / City Contact on site Telephone number...

  • Page 63: Technical Specifications

    15. TECHNICAL SPECIFICATIONS Technical data ROL (Reverse Osmosis Large) ROL 160 ROL 320 ROL 460 ROL 600 ROL 1200 1000 Permeate production [l/h] * 1000 1200 Concentrate production [l/h]* Circulation [l/h]* Water consumption during operation [l/h] 1200 1470 1770 Max. Recovery rate [%] Minimum water flow required for flushing [m3/h] –...
  • Page 64 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.
  • Page 65 Notes...
  • Page 66 Notes...
  • Page 68 CAREL INDUSTRIES - Headquarters Via dell’Industria, 11 - 35020 Brugine - Padova (Italy) Tel. (+39) 049.9716611 - Fax (+39) 049.9716600 WTS LARGE +0300131EN rel. 1.0 - 05.09.2022 e-mail: carel@carel.com - www.carel.com...

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