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HygroMatik WL-ROC-25 Manual

Reverse osmosis system
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WL-ROC-25/40/80/140
FlexLine
Reverse osmosis system
MANUAL
ÁWLROC.EN=È
WLROC.EN
E-8881186

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  • Page 1 WL-ROC-25/40/80/140 FlexLine Reverse osmosis system MANUAL ÁWLROC.EN=È WLROC.EN E-8881186...
  • Page 2 Current version of this manual to be found on: www.hygromatik.com HygroMatik GmbH grants the legal user of this product [or device] the right to use the Work(s) solely within the scope of the legitimate operation of the product [or device]. No other right is granted under this licence.

  • Page 3: Table Of Contents

    1. Introduction ........................6 1.1 Typographic Distinctions ....................6 1.2 Documentation ........................6 1.3 Symbols in Use ......................... 6 1.3.1 General Symbols ......................6 1.4 Intended Use ........................7 1.5 Unit sizes ........................... 7 2. Safety Instructions ......................8 2.1 Guidelines for Safe Operation ................... 8 2.1.1 Scope ..........................
  • Page 4 9.2 Adjusting the metering pump ..................... 29 10. Maintenance ........................30 10.1 General ..........................30 10.2 Safety instructions for maintenance ................30 10.3 Change prefilter ....................... 31 10.4 Membrane exchange ....................... 31 10.5 Maintenance scheme ...................... 32 10.5.1 Daily check ........................32 10.5.2 Weekly check .......................
  • Page 5 12.7.21 Stand-by-Input INSB ....................55 12.7.22 Set start delay ......................56 12.8 Wiring diagram ....................... 57 13. Error description ......................59 14. Declaration of Conformity ....................61 15. Spare parts ........................63 16. Commissioning report / maintenance documentation ..........66 17.

  • Page 6: Introduction

    Specific Symbols related Safety Only use the HygroMatik R.O. unit in faultless Instructions condition and for its intended use, being According to ANSI Z535.6 the following sig- aware of safety and hazards, and observing nal words are used within this document: all instructions in this manual.

  • Page 7: Intended Use

    1.4 Intended Use 1.5 Unit sizes The following reverse osmosis units belong HygroMatik reverse osmosis unit used to pro- to the WL-ROC (Reverse-Osmosis-Compact) duce fully demineralized water. It may only be series: used in accordance with its intended pur- pose.

  • Page 8: Safety Instructions

    2. Safety Instructions 2.1.3 Unit operation These safety instructions are required by law. They promote workplace safety and accident Danger of scalding! prevention. Hot surfaces can cause injuries. Protect 2.1 Guidelines for Safe Opera- yourself with suitable protective equipment. tion 2.1.1 Scope Comply with the accident prevention regula- Water leaks possible due to defective con-...

  • Page 9: Mounting, Dismantling, Maintenance And Repair Of The Unit

    Responsibility for intrinsically safe installation fuse boxes, electrical appliances, etc. In the of the HygroMatik reverse osmosis unit is event of a leakage, leaking water can dam- incumbent on the installing specialist com- age the underlying electrical systems.

  • Page 10: Transport

    Please note • reverse osmosis unit incl. control Proceed carefully when transporting the • 2 membranes (WL-ROC-25: only 1 reverse osmosis unit in order to prevent dam- membrane) age due to stress or careless loading and • 1 prefilter (WL-ROC-140: 2 prefilters) unloading.

  • Page 11: Function And Structure

    4. Function and structure 4.2 Influencing factors The performance of the reverse osmosis 4.1 Mode of operation membrane depends strongly on the following parameters: General principle of reverse osmosis Water inlet pressure at the membrane: Osmosis is a natural process, it is understood as the one-sided diffusion of a liquid (here the By lowering the working pressure, a reduc- feed water) through a semi-permeable mem-...

  • Page 12: Operating Conditions Of The Unit

    4.3 Operating conditions of the 4.4 Operating sequence unit The WL-ROC system can be fed with water The feed water (raw water) is pumped from the normal water supply if the water has through the pre-filter, which guarantees the a maximum hardness up to 20°dH. de-chlorination and a final filter capacity of 5 µm.

  • Page 13: Mechanical Construction

    20 Prefilter sediment / CPP* Engine 14 Permeate pipe 21 Conductivity sensor WL-ROC-140 * activated carbon filter • WL-ROC-25 - 80: 5μ • WL-ROC-140: 10μ ** sediment filter • only WL-ROC-140 The devices of the Hygro- Matik WL-ROC series are designed for wall moun- ting.

  • Page 14: Installation Arrangement

    5. Installation arrangement A: consumer The following illustration shows an example of B: max. 15 metres (25 metres with fixed piping) total pipe the installation arrangement of the reverse length between the UO-system and the last consumer. osmosis system, a pressure expansion vessel C: concentrate P: permeate and existing consumers heatersteam humidi-...

  • Page 15: Flowchart

    Flowchart Page 15...
  • Page 16 Page 16...
  • Page 17 Page 17...

  • Page 18: Mechanical Installation

    • Protection class IP20 • By design, HygroMatik reverse osmo- sis units are not qualified for outdoor installation (electronical components and water-bearing parts may be dam- aged) •...

  • Page 19: Installation Steps

    6.2 Installation steps 6.2.3 Connection of the expansion vessel » Mount the holder* of the expansion 6.2.1 Feed water connection tank on a stable wall. » Connect the feed water inlet to the » Seal the thread of the holder* (e.g. system.

  • Page 20: Connection Of The Concentrate Line

    DIN EN 1717. Pay attention to the mini- mum requirement for the free flow distance (between the drain hose and the siphon) of Fig.WL-ROC-25 26 mm to prevent microbial contamination. 6.2.6 Inserting the membrane(s) The colour of the supplied hoses indicates...
  • Page 21 WL-ROC-140: Inserting the membrane Pay attention to the correct installation direc- tion of the membrane. Only insert the membrane from the right- Use disposable gloves when installing the hand side, otherwise the lip seal may be pre-filter(s) and membrane(s) to protect them damaged.
  • Page 22 » Pull the end cap (4) out of the mem- brane pressure tube on both sides. » Pull out the membrane (5) from the left side of the membrane pressure tube. » Install a new membrane (see Inser- ting the membrane). »...

  • Page 23: Water Connection

    7. Water connection Connection of the system supply » Make sure that the flow rate and Have all plumbing work done only by quali- pressure correspond to the values fied personnel (plumber or specialist with given in the technical data. equivalent training) to minimize risks..
  • Page 24 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? ...

  • Page 25: Electrical Connection

    Connection of a dosing pump (WL- ROC-140) Please note The customer is responsible for checking Fuses expert staff qualification. HygroMatik recommends the use of main General installation rules fuses with slow- to medium-load characteris- • All local rules concerning the imple- tic.

  • Page 26: Inputs And Outputs Of The Main Board

    8.3 Inputs and outputs of the main board clamp describtion WL-ROC-025/-040 WL-ROC-060 WL-ROC-140 1[L] - 2[earth] - 3[N] 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 16[L] - 17[earth] - 18[N] 230-V-Output for flush valve 19[NO] - 20[C] - 21[NC] alarm output optional...

  • Page 27: Initial Start-Up And Flushing Of The Membrane(S)

    9. Initial start-up and flushing » Let the system run for 10 minutes 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 »...

  • Page 28: System Start-Up After Initial Commissioning

    Step 4: Observe device and check for leaks • At the start of each commissioning with » Let it run for 15 to 30 minutes the use of new membrane(s), the WL- » If leaks occur, switch off the unit ROC unit produces a higher permeate immediately.

  • Page 29: Adjusting The Metering Pump

    Only use this setting knob. after consultation with the specialist dealer or HygroMatik. ED flashing states In standard operation, you use the dosing pump with the divider switched on (orange status LED (flashes per sec.) status pump operation...

  • Page 30: Maintenance

    10.1 General WARNING Regular maintenance is essential to ensure that the HygroMatik units can achieve a long Risk of electrical shock! service life. The necessary maintenance Hazardous electrical voltage! work refers to components that are either subject to mechanical or electrical wear, or Any work on the electrical system to be per- whose function is reduced by deposits.

  • Page 31: Change Prefilter

    10.3 Change prefilter » WL-ROC-140: Open the lids on both sides of the container and slide the Before replacing the prefilter, check membrane cartridge out through the • that the WL-ROC system is switched off left opening. • the inlet valve is closed and there is no »...

  • Page 32: Maintenance Scheme

    10.5 Maintenance scheme 10.5.3 Maintenance every months 10.5.1 Daily check • Check that there is not too much free » Check if the system is working cor- chlorine at the outlet (less than rectly. 0.25ppm). » Check that there are no leaks in the water-carrying components.

  • Page 33: Maintenance By Qualified Staff

    10.5.4 Maintenance by qualified staff Generally: » Check the parameters of the water entering the system. every 6 months: » Check the conductivity of the feed- Check the pre-filling pressure of the expan- water and permeate with a conduc- sion vessel. tivity meter.

  • Page 34: Decomissioning

    11. Decomissioning 11.2 Disposal after dismantling The reverse osmosis unit is made up of metal The regular operation of the reverse osmosis parts and plastic parts. In reference to Euro- unit is dependent on the continuous produc- pean Union directive 2012/19/EU issued on 4 tion of desalinated water.

  • Page 35: Control

    12. Control 12.2 Access to the main menu: The whole operation of the reverse osmosis » press or about 2 sec, the dis- unit WL-ROL is controlled by a microproces- play shows “PASSWORD 0000“ sor. » enter the password using the arrow The control-system enables the production keys (0077) process and the control of the RO-unit.

  • Page 36: Operating States

    The different operating states If programmed in menu 11 CLEANING the control unit starts an interval rinse during pro- Permeate production: Production of prod- duction as well as in standby (against stand- uct water. The V and P relays FEED still contamination) as soon as the countdown are energized.

  • Page 37: Alarm Messages

    SYSTEM STOPPED! CLEANING: TIME FAILED DOSAGE LEFT xxM xxS The IN input for the Anstiscalant dosing PASC SYSTEM WAITING! pump (optionally available for WL-ROC 140) HIGH LEVEL has switched. The system stops. If the input is free again, the system restarts automati- cally.

  • Page 38: Menu Navigation

    Button < LEFT >: SYSTEM STOPPED! In the menu: For jumping back to the LOW PRESSURE previous digit within the input field. The low-pressure monitor PS for the min- Button < RIGHT >: imum acceptable feed water inlet pressure has switched. The system stops. In menu: For jumping to the next digit within the input field.

  • Page 39: Setting Options At Operator Level

    12.5 Setting options at operator level In the factory settings, parameter 11 CLEAN- ING is preset to ON. If this setting has been The following factory-set parameters can be changed to OFF in the service level, no changed at the operator level (password entries can be made here in the operator 0077).

  • Page 40: Menu Structure

    12.6 Menu Structure At the operator level (password 0077) only the parameters shown here in dashed lines can be changed. The other parameters are The following menu list gives an overview of only visible at the operator level. Changing all parameters of the unit control. them is only possible at the service level.
  • Page 41 Page 41...

  • Page 42: Setting Options At Service Level

    12.7 Setting options at service 12.7.1 Conductivity sensors level The HygroMatik RO units WL-ROC 25-80 are equipped with one conductivity sensor (per- The following chapter is only intended for cer- meate). tified service staff. The password for reaching The WL-ROL units (and WL-ROC-140 with...

  • Page 43: Calibration Of The Probe Zero Point

    Display shows three lines: - - - µS 2 KAL. PERMEAT READING 3.12 ZERO OK 3 GRENZW. PERMEAT After a few minutes of running time, measure the conductivity of the permeate and/or raw/ A conductivity value is now displayed in the mixed water with an external conductivity upper line.

  • Page 44: Permeate Set Point Calibration

    » press , to confirm the displayed 3B LIMIT OUT slope value and exit the parameter µS 50,00 and press , to return to the main menu By pressing the arrow keys you can set the max. set point » press to exit the parameter with- »...

  • Page 45: Raw/Mix Set Point Calibration

    If the set point function has been activated, Enter a delay time by pressing the the program jumps to submenu "4B".. arrow keys. The delay is intended to prevent the system from being switched off abruptly 4B LIMIT RAW/MIX due to temporary measurement value peaks. µS xx,xx 0 Sec = no delay...

  • Page 46: Lower Level Switch Lslow

    12.7.6 Lower level switch LS » Press the arrow keys to set the time of delay With the aid of the level switch, the minimum 0 Sec = no delay fill level in the permeate vessel can be moni- (see note at the end of the chapter) tored and the system can be started automat- ically if the pressure falls below the required »...

  • Page 47: Calibration Low Pressure Switch Pslow

    12.7.8 Calibration pressure Press the arrow keys to set the switch PS switching direction. N.O. CONTACT = The input functions as a With the help of a pressure switch between normally open contact. the feed water pre-filter and the high pres- sure pump the system inlet pressure can be N.C.
  • Page 48 7C INPUT DELAY LOW PRESSURE! 00Sec ALARM 1/4 » Press the arrow keys to set If the minimum inlet pressure returns, the the time of delay system starts up again automatically. If the system produces constantly for the next 10 0 Sec = no delay minutes without any further disturbance, the (see note at the end of the chapter)

  • Page 49: Calibration High Pressure Monitor (Only Wl-Rol/ Wl-Roc140) Pshigh

    12.7.9 Calibration high pressure mon- itor (only WL-ROL/ WL-ROC140) 8C INPUT DELAY 00Sec HIGH The system operating pressure can be controlled by means of a pressure switch between the high » Press the arrow keys to set pressure pump and the RO modules. If a maxi- the time of delay mum pressure set on the pressure switch is 0 Sec = no delay...

  • Page 50: Module Flushing

    12.7.11 Module flushing » Press the arrow keys In this submenu you configure the module select if relay input should be active flush(es). Four flushing procedures can be or inactive. programmed: ENABLED= active • At start-up of production DISABLED = inactive •...

  • Page 51: Configuration Of The Alarm - Output Relay

    Press the arrow keys to select, if a » Confirm the selection with . The flush should be done when production is program jumps to submenu "11H". started up. YES = active NO = inactive 11H WASHCYCLE 0min 15sec » Confirm the selection with .

  • Page 52: Operating And Service Hour Counter

    13B RES SERVICE 12B OUTPUT ALARM ENTER = YES CONTACT N.C. By pressing the arrow keys you select » Press the arrow keys to set if the service interval should be reseted. the switching direction. » Confirm the selection with .

  • Page 53: Function Test Relay Outputs

    12.7.14 Function test relay outputs 12.7.15 Function test alarm output relay In this submenu you can check the relay out- In this submenu you can manually activate puts. the alarm output. The switched-on relay is then reset to its switching status as pro- grammed in submenu 12.

  • Page 54: Change Password

    12.7.17 Change password before the programme jumps back to the "NEW PASSWORD" input display so that the In this submenu you can change the pass- new password can be entered again. word to program the main menu. 17 SET PASSWORD 18 MAINTENANCE 12.7.18 Reset password To reset the password follow the steps below:...

  • Page 55: Dosing Pump Antiscalant Inpasc

    Press the arrow keys to enter the Ser- » Press the arrow keys to set viceintervall in hours the switching direction. » Confirm the selection with . The N.O. CONTACT = The input functions as a program jumps back to the main menu. normally open contact.

  • Page 56: Set Start Delay

    » Press the arrow keys to set the 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 "20C".

  • Page 57: Wiring Diagram

    12.8 Wiring diagram internal power supply Relay outputs, potential loaded 6,3AT 07 10 13 16 08 11 14 17 22 23 24 25 24 25 26 27 28 29 30 31 32 01 02 03 04 05 06 09 12 15 18 19 20 21 33 34 35 36...
  • Page 58 Page 58...

  • Page 59: Error Description

    13. 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 60 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 correctly, 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 61: Declaration Of Conformity

    14. Declaration of Conformity Page 61...
  • Page 62 Page 62...

  • Page 63: Spare Parts

    Spare Wall mouting bracket SS/painted 3/4" F-F for 18L or 40L expansion vessel ROKC00CV18 Spare Check valve push-in 1/8"-compression fitting for tube Ø1/4" x 1/8" M (WL-ROC-25/40/80) ROKC00CV10 Spare connection piece 90° incl. non return valve for membrane tube 10mm...
  • Page 64 Spare Pressure guage 16 Bar; SS case; 63 mm diameter; Brass 1/4"G Back, glycerine filled ROKC00VALN Spare Permeate check valve CV3 - diam. 6 mm (WL-ROC-25 / 40) ROKC00FLT1 Spare Carbon block cartridge filter CB-EC 10" SX 5μm (WL-ROC-25/40/80) ROKC00FLT2 Spare Carbon block cartridge filter CB-EC 10"...
  • Page 65 Flow restrictor w ith none-return valve 0,5l/h for WL-ROC-25 E-5000124 Spare Flow restrictor w ith none-return valve 0,9l/h for WL-ROC-40 E-5000126 Spare Flow restrictor w ith none-return valvel 1,1 l/h for WL-ROC-25/40 E-5000128 Spare Flow restrictor w ith none-return valve 1,4 l/h for WL-ROC-80 E-5000130 Spare...

  • Page 66: Commissioning Report / Maintenance Documentation

    16. Commissioning report / maintenance documentation Commissioning report for HygroMatik reverse osmosis systems WL-ROC-XX and WL-ROL-XX Unit Type Serial number Type of pressure expansion vessel Operating hours Date of maintenance Company / name Customer Commercial / Private Street / Number...
  • Page 67 Maintenance checklist for HygroMatik reverse osmosis systems WL-ROC-XX and WL-ROL-XX 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...
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  • Page 70: Technical Specifications

    As the temperature increa- • UV-lamp for WL-ROC-140 ses, the permeate output also increases, but with a worse conductivity value. • Retrofit kit blending WL-ROC-25 to 80 The recovery value is calculated as follows: • expansion vessel Page 70...

  • Page 71: Dosing Antiscalant

    18. Dosing Antiscalant How to proceed » Fill the empty canister (20l) with the quantity of antiscalant specified for Dosage specifications: the existing feed water quality. When using the recommended antiscalant Pragmaclean 309, dose it depending on the Example: feed water quality: For a WL-ROC-140 with soft feed water, fill 1.3 litres of Pragmaclean 309 into the cani- Soft water...
  • Page 72 Lise-Meitner-Str.3 • D-24558 Henstedt-Ulzburg Phone +49(0)4193/ 895-0 • Fax -33 eMail hy@hygromatik.de • www.hygromatik.com member of CAREL Group Ein Unternehmen der Gruppe 100%...

This manual is also suitable for:

Wl-roc-40Wl-roc-80Wl-roc-140

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