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Condair AT2+ Assembly And Operating Instructions Manual

Reverse osmosis unit
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CONDAIR AT2+
Reverse osmosis unit
ASSEMBLY AND OPERATING
INSTRUCTIONS
Condair AT2+ reverse osmosis unit
03.01.2025
Air humidification, dehumidification
and evaporative cooling

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Summary of Contents for Condair AT2+

  • Page 1 CONDAIR AT2+ Reverse osmosis unit ASSEMBLY AND OPERATING INSTRUCTIONS Condair AT2+ reverse osmosis unit 03.01.2025 Air humidification, dehumidification and evaporative cooling...

  • Page 2: Property Rights

    Violations are punishable and result in an obligation to compensate for damages. Liability Condair GmbH shall not be liable for any damage caused by faulty installation, improper operation, or by the use of components or equipment which are not approved by Condair AG. Copyright notice...

  • Page 3: Table Of Contents

    Table of Contents General Safety Instructions Explanation of symbols and instructions Operator obligations Personnel obligations Training of personnel Intended use Hazards when handling the equipment Protective devices and safety measures to avert hazards 1.7.1 Protective devices 1.7.2 Informational safety measures Safety instructions for maintenance work Disposal of system components and operating materials 1.10...
  • Page 4 Commissioning and Decommissioning 56.1 Commissioning 6.1.1 Qualification of commissioning personnel 6.1.2 Rinsing out the preservative 6.1.3 Setting up automatic mode 6.1.4 Configuring permeate output and yield 6.1.5 Configuring permeate outlet pressure Decommissioning Main display, Main menu 7.1.1 Main display 7.1.2 Main menu Configurable parameters Faults and Fault Elimination...

  • Page 5: General Safety Instructions

    General Safety Instructions Explanation of symbols and instructions These operating instructions contain important specifications on the safe operation of the sys- tem. These operating instructions, particularly the chapter on safety instructions, must be observed by all those who carry out work on the system. This applies to the installation company as well as the system operator.

  • Page 6: Personnel Obligations

    Personnel obligations Prior to commencing work, all individuals who are commissioned to work on the system or carry out such work independently undertake to: read the chapter on safety and the warnings in these operating instructions and confirm by  their signature that they have understood them.

  • Page 7: Protective Devices And Safety Measures To Avert Hazards

    Electric shock Work on the electrical supply may only be carried out by a qualified electrician.  Check the system’s electrical equipment on a regular basis. Any loose connections or scorched  cables must be removed immediately. The control cabinet must be kept locked at all times. Access is only allowed to authorised person- ...

  • Page 8: Safety Instructions For Maintenance Work

    Safety instructions for maintenance work The operator must ensure that all maintenance, inspection and installation work is carried out by  authorised and qualified specialist personnel who have acquired the necessary information by studying the operating instructions. Prior to all repair and maintenance work, the system must be switched off and secured against ...

  • Page 9: Safety Instructions For Storage

    1.12 Safety instructions for storage CAUTION! The reverse osmosis unit is protected by a preservative against microbial contamination and against risk of frost down to -10°C. At room temperature (< 25°C), this preservative must be purged and replaced within 6 months at the latest. At higher temperatures, the protection period is correspondingly shorter (3 months at 30°C).

  • Page 10: Principles Of Reverse Osmosis Units

    Principles of Reverse Osmosis Units Principle of reverse osmosis Osmosis is a process on which almost all natural metabolic processes are based. If you separate two solutions of different concentrations in a system through a semi-permeable membrane, the more concentrated solution always tends to dilute. This process (osmosis) continues until osmotic equilibrium is reached.

  • Page 11: Calculation Equations

    Calculation equations The permeate output, the reject output and the permeate conductivity are determined by reading the corresponding measuring equipment on the system. If no indicating instruments (e.g. variable area flow meter) are present, the permeate output and the reject output are determined by manual volumetric measurement.

  • Page 12: Correction Factor

    Temperature T in °C Information Correction factor 1.30 1.28 1.25 1.21 If the actual permeate output exceeds the 1.18 maximum permissible permeate output, it must be reduced by lowering the working 1.15 pressure! 1.12 1.09 1.06 1.03 1.00 Design temperature Nominal output=100% 0.96 0.92...

  • Page 13: Transport And Storage

    Transport and Storage Transport to the customer CAUTION! All units must be secured against slipping and falling over during transport. Allowing the unit to tip out of its fixed position is not permitted. If system parts are protruding from the base area of the pallet, such protruding parts must be protected against damage while other parts/units are being loaded.

  • Page 14: Technical Data / Product Description

    Technical Data / Product Description Technical data Type AT2+ Quality of the feed water Soft water 0˚dH Permeate output at 7 bar Permeate volume/day 12.7 at 7 bar Yield, max. Raw water pressure min./max. Water temperature min./max. °C 5/30 Desalination rate 98/99 Working pressure 14–18...
  • Page 15 Type AT2+ 1000 1250 1500 1700 Quality of the feed water Soft water 0˚dH Permeate output 1000 1250 1500 1700 at 7 bar Permeate volume/day 16.8 24.0 30.0 36.0 40.8 at 7 bar Yield, max. Raw water pressure min./max. Water temperature min./max. °C 5/30 Desalination rate...

  • Page 16: Application Limits

    Application limits The membranes are wear parts in the longer term. Their service life depends on the feed water qual- ity and the operating conditions. In order to achieve a projected membrane service life of 3 years, the reverse osmosis units should be operated with softened water or with hard water depending on the unit type, in each case in the same quality as drinking water according to the German Drinking Water Ordinance and according to the following additional specifications: Parameter...

  • Page 17: Product Description

    Product description 4.3.1 Function The RO feed water reaches the frequency-controlled HP pump via a residual hardness monitor (op- tional accessory, only when using softened water) and a protective cartridge filter (grade of filtration 5 µm). This pump conveys the water at high pressure (level depends on the permeate flow being drawn and the desired permeate pressure) through the semi-permeable membranes.
  • Page 18 Liefergrenze Liefergrenze V-01 SPEISE WASSER PERMEA T P-01 M-01 F-01 CCR-01 MSR point list Actuators Residual hardness monitor Sampling valve for feed water (Testomat, Limitron or similar) Local display of inlet pressure PI 01 Shut-off valve for feed water before protective filter Local display of inlet pressure after PI 02 Solenoid valve for feed water...
  • Page 19 Size 350 — front view Alarm Display P-01 “ON/OFF” Main switch PI 01 PI 02 Signal QS 01 F-01 PS 01 FT 02 V-01 PT 01 Reject outlet Feed water inlet Technical Data / Product Description...
  • Page 20 Size 350 — side view FT 01 FT 03 after CCR-01 17, 18 PI 03 CCR-01 PT 02 Signal QS 01 FT 02 QS 01 P-01 Feed water inlet Technical Data / Product Description...

  • Page 21: Installation And Assembly

    Installation and Assembly Installation 5.1.1 Installation site requirements  The space required for the unit is specified in the dimensions provided in the technical data. In addition, there should be 0.8 m of space in front of the unit to allow access for operation and 1.0 m of space to the side for maintenance.

  • Page 22: Water Connections

    Water connections 5.2.1 Required qualification of assembly personnel NOTE The water connection must be carried out by trained specialist personnel only. General directives (DIN, DVGW, SVGW, ÖKGW) and local installation regulations must be observed when installing the unit. 5.2.2 Establishing the water connections Feed water ...

  • Page 23: Establishing The Electrical Connections

    5.3.3 Establishing the electrical connections DANGER! Prior to working on the electrical equipment and before starting retrofitting, maintenance, servicing or similar work, switch off the main switch of the higher-level system and secure it against being switched on again (e.g. lock it). Clearly display a sign prohibiting switching with the following information: “Do not switch! Work in progress!”...
  • Page 24 DANGER! We recommend routing the fault indication at the DO8 alarm output to the central building manage- ment system (BMS) either via X6/1-2 (NC) or via X6/1-3 (NO). If the fault is ignored or not acknowl- edged for a long period of time, this can lead to serious damage to the unit, or even a complete production stop.

  • Page 25: Commissioning And Decommissioning

    Commissioning and Decommissioning Commissioning 6.1.1 Qualification of commissioning personnel CAUTION! The unit must be commissioned by qualified specialist personnel. NOTE Before commissioning the unit, all screw connections must be tightened. 6.1.2 Rinsing out the preservative WARNING! The preservative solution contains 1.5% sodium bisulfite and 20% glycerine. The rinsed-out preservative solution must be discharged into the sewage system in accordance with the locally applicable discharge regulations.

  • Page 26: Rinsing Out The Preservative

     Switch on the PLC at the red main switch.  Inlet valve opens immediately via PLC (Main menu – “Manual operation” – Inlet valve) and rinse the system for at least 30 minutes without switching on the HP pump, using only feed water pres- sure.

  • Page 27: Decommissioning

    Decommissioning NOTE If an interval rinse of “Min. 1x daily” is set in the PLC, the unit does not need to be preserved. If decommissioning with expected downtimes of > 30 days and without interval rinse is planned, the system must be treated with preservative, which must be rinsed out again during recommissioning as described in section 1.2.

  • Page 28: Plc

    Main display, Main menu 7.1.1 Main display In this part of the display the following is displayed and controlled; items 1 to 4 are present in all displays: 1. Navigation button to access sub-menus 2. Alarm indication Green: No alarm Red: Alarm active 3.
  • Page 29 6. Actual status of the inlet valve White: The valve is closed Green: The valve is open 7. Actual status of the inlet pressure (pressure switch DI 1) White: The inlet pressure is below minimum, no alarm Green: The pressure is above minimum. Yellow: There is a low-pressure alarm (1 or 2) but the unit is not stopped Red: There is a low-pressure alarm (1 or 2) and the unit is stopped...
  • Page 30 15. Actual status of the permeate outlet valve White: The valve is closed Green: The valve is open 16. Actual permeate pressure in bar and status When there is a dynamic pressure setpoint, the calculated setpoint is displayed above the actual pressure.

  • Page 31: Main Menu

    7.1.2 Main menu 7.1.2.1 Operating principles A ball-point pen with its tip retracted is recommended for operating the touch screen of the PLC. Tap the button at the top left of the screen for at least 2 seconds to open the main menu. To select sub-menus, briefly tap on one of the following options: Main display, with status bar at the top Current alarms...
  • Page 32 7.1.2.2 Settings (ranges, min./max. alarm values) Explanation of the Settings sub-menu: Please note: If an option is not selected, the corresponding settings are not shown on the screen. Press and hold button for 2 seconds to permanently apply all the settings made. The button turns green for a few seconds.

  • Page 33: Configurable Parameters

    7.2 Configurable parameters In order to ensure a meaningful control sequence, the control parameters must be correctly configured at the time of delivery from the factory. During commissioning, the technician checks all settings to ensure they are correct or adjusts them to the situation on site. Occasionally, the user has to configure individual settings.
  • Page 34 7.1.2.1 Operating principles Please note: A tick in the green check box activates the function. Press and hold the button for 2 seconds to perma- nently apply all the settings made. The button turns green for a few seconds. Otherwise, any changes to the settings will be lost after a power failure.
  • Page 35 Type AT2+ 1000 1250 1500 1700 Set Settings Low permeate flow l/h 1) High permeate flow l/h 2) 1200 1500 1800 2040 Low permeate pressure (bar) High permeate pressure (bar) Setpoint permeate pressure (bar) Low conductivity (μS/cm) High conductivity (μS/cm) Warning conductivity (μS/cm) Timers Alarm delays...

  • Page 36: Faults And Fault Elimination

    Faults and Fault Elimination General instructions The use of high-quality individual components and the built-in safety and monitoring devices ensure a very high level of operational readiness. Should a malfunction nevertheless occur, the fault can be easily identified and the cause eliminated using the fault table listed below.

  • Page 37: Alarms

    8.2.1 Alarms The PLC indicates a problem with the system by issuing an alarm. Depending on the alarm settings in the “Inputs” and “Timers” sub-menus, the unit can be stopped (tick the Stop box) and/or the alarm relay can be activated (tick the Stop box). By calling up the main menu and selecting the “Alarm”...

  • Page 38: Alarm Causes

    8.2.3 Alarm causes 8.2.3.1 Power failure The power supply has been switched off or interrupted. Possible cause Action Power failure or unit switched off. Restore the power supply and reset the alarm. 8.2.3.2 System stop The unit is stopped by an open external contact at input DI 8. Possible cause Action External contact has switched.
  • Page 39 8.2.3.5 Low reject flow The reject flow is below the minimum setpoint for longer than the set delay time. Falling below the low reject flow can damage the membranes. Possible cause Action Wrong setting in the controls. Check and/or adjust setting. Wrong setting of the flow.
  • Page 40 8.2.3.9 Yield The yield is above the maximum setpoint. (Ratio between the permeate flow and reject flow is above the maximum value for longer than the set delay time). Too high a yield can lead to fouling of the mem- branes after some time.
  • Page 41 8.2.3.13 Low inlet pressure 1 The pressure before the RO pump is too low. The RO pump is running dry and is switched off. After a programmed delay time the pump automatically starts up again. Possible cause Action Wrong setting in the controls. Check and/or adjust setting.
  • Page 42 8.2.3.16 High pump pressure The pressure of the RO pump is above the maximum setpoint. Possible cause Action Wrong setting in the controls. Check and/or Adjust setting. Membranes fouled or damaged. Clear blockage. Pump outlet blocked. Replace O-rings of the pressure vessel which cause the leakage.
  • Page 43 8.2.3.20 UV unit The alarm contact of the UV unit is open. Please refer to the manual of the UV unit. Possible cause Action Malfunction of the UV unit. Check and/or repair the UV unit. Broken wiring to the alarm contact of the UV Check and/or repair wiring.

  • Page 44: Reject Rinse

    Reject rinse During a reject rinse, the increase in the reject flow rate causes the reject side of the membrane(s) to be flushed at a higher velocity and, due to the associated increase in shear forces, easily detachable deposits are removed and rinsed out. A reject rinse should last at least 60 minutes and should be carried out as follows: ...

  • Page 45: Inspection And Maintenance

    Inspection and Maintenance Inspection and maintenance work 9.1.1 Safety instructions CAUTION! The operator must ensure that all inspection, maintenance, and assembly work is carried out by authorised, qualified specialist personnel. Prior to all repair and maintenance work, the unit must be shut down and secured against uninten- tional start-up.

  • Page 46: Logging The Operating Parameters

    Logging the operating parameters 9.2.1 List of parameters to be logged The following parameters must be checked weekly and entered in the operations log for reverse osmosis units: Parameter Measuring point / remarks Operating hours of the RO unit Main display of PLC, No. 9, next to pump icon, in h Residual hardness in feed water Check with hardness test kit in feed water Conductivity of feed water...

  • Page 47: Operations Log For Reverse Osmosis Units

    9.2.2 Operations log for reverse osmosis units Customer: _______________________________________________________________________ Unit type: _______________________________________________________________________ Order No.: ______________________________________________________________________ Commissioned on: ________________________________________________________________ At com- Date Date Date Date Date Measured variable Unit mission- Operating hours of the RO system Residual hardness in feed °d water Conductivity of feed water µS/cm...

  • Page 48: Maintenance

    Maintenance NOTE Maintenance work for the system must be carried out periodically after 4000 operating hours (a warn- ing maintenance message is sent) and for each system part separately as required, no later than the specified maintenance intervals or described situations (column “No later than as per operating hours or described situation.”)! In the user menu you can query the operating time remaining until the next maintenance (see chapter 7 - PLC).
  • Page 49 Filter exchange log Date of filter Unit type Serial Company Location Signature exchange number (block capitals) Inspection and Maintenance...

  • Page 50: Preservation

    Preservation 10.1 General Instructions NOTE If the system is out of operation for more than 30 days, it must be preserved. In case of a prolonged decommissioning period: After 3 months at the latest, the preservative must be rinsed out and re- placed, if necessary.

  • Page 51: Preparing The Preservative Solution

    10.2.3.1 Units without dedicated rinse connectors Place the preservation tank at a higher level than the unit to ensure that the preservative solution  flows freely into the RO unit. Close the drain valve on the preservation tank  Disconnect the permeate and reject lines at the RO unit ...

  • Page 52: Preservation Steps

    Composition of the preservative solution Permeate output Soft water Sodium bisulfite Sodium Glycerine of the unit supply powder bicarbonate (l/h) (kg) (kg) Conc. chemical only 86.5% Concentration of chemical in preserva- 1.5% w/w 2.5% w/w 20% v/v tive solution 20–80 0.20 0.32 100–500 0.39...

  • Page 53: System Diagram For Preservation

    WARNING! The unit runs without any safety devices. Avoid dry running of the HP pump. Let the preservative solution circulate for 10 min  Switch off the PLC  Close the drain valve on the preservation tank  Set the 3-way ball valves to the “Service” position*. ...

  • Page 54: Wiring Diagram

    Wiring Diagram Digital output 1-W, 2-NC, 3-NO Alarm Start Testomat or start dosing pump or maintenance message RS 485 interface 1+, 2- Analogue inputs for sensors Conductivity sensor, temperature AI 6 Conductivity sensor, conductivity 5+,6- Permeate flow (alternative to DI 1) AI 1 7+,8- Feed water flow...

  • Page 55: Appendix

    Inlet water pressure 2–4 bar, provide pressure reducer if necessary Limitron residual hardness monitor Shut-off valve to humidifier Test cock and drain valve Appendix NAME: NAME: Condair AT2+ 75 Condair AT2+ 75 KUNDE: PROJEKT: KUNDE: Quick-Change PROJECTION ZEICHNER: 31-5-2018 STATUS: PROJECTION AUFTRAG: FORM.:...
  • Page 56 12.2 Dimensions Condair AT2+ 75 to 1700 Connections: A = Supply (PVC Ø25mm) B = Permeate (PVC Ø25mm) C = Waste water (PVC Ø40mm) Electrical connection: 3x400V / 50Hz TOP VIEW Connections: A = Inlet (PVC Ø25m B = Permeate (PVC C = Drain (PVC Ø40...
  • Page 57 Notes...
  • Page 58 Notes...
  • Page 59 Notes...
  • Page 60 D-10115 Berlin Phone +49 (0) 30 / 921 03 44-0 Condair Austria Perfektastrasse 45 A-1230 Vienna Phone +43 (0) 1 / 60 33 111-0 Condair GmbH Branch office Garching Parkring 3, 85748 Garching Phone +49 (0) 89 20 70 08-0, www.condair.de...

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