BWT PERMAQ Compact 951 Bedienungsanleitung

BW T PERM AQ®

Compact 951 – 953

Reverse Osmosis Plant

Installation and Operating Manual EN

List of contents

1General .................................................................................5

2Definitions .............................................................................5

3Functional description ............................................................6

4Placement of plant.................................................................6

5Water quality ........................................................................7

6Water connections .................................................................7

6.1 Connection of raw water/inlet water:...........................................................................7

6.2 Connection of permeate outlet.....................................................................................7

6.3 Connection of outlet hose (concentrate) ........................................................................8

6.4 Connection of overflow hose .......................................................................................8

6.5 Connection of soft-water control valve ..........................................................................8

7Electric connections ................................................................8

8Commissioning of the plant ...................................................8

8.1 Start-up of softening plant ...........................................................................................8

8.1.1 Replacement of regeneration meter disk.................................................................9

8.2 Adjustment of outlet amount ......................................................................................10

9Automatic functions .............................................................11

10 Maintenance and Troubleshooting .......................................12

10.1 Maintenance:.......................................................................................................12

11 Replacement of membranes.................................................13

12 CIP-cleaning of membranes (OPTION) ..................................13

13 Technical data .....................................................................15

14 Technical specifications ........................................................16

15 Appendix ............................................................................17

15.1 Survey of Alarm Conditions ...................................................................................18

15.2 Settings ...............................................................................................................19

15.3 Trouble-shooting ...................................................................................................20

15.3.1 Plant capacity has dropped.............................................................................20

15.3.2 Treated water quality is higher than 20 µS/cm..................................................20

15.3.3 Alarm: Transport pump ...................................................................................21

15.3.4 Indication: Level low.......................................................................................22

15.3.5 Alarm: level high OPTION ..............................................................................22

15.3.6 The plant is not operating ...............................................................................23

15.3.7 Alarm: The transport pump stops and starts .......................................................23

15.3.8 Hard water is measured at the soft-water sample valve.......................................24

15.4 P&I Diagram ........................................................................................................25

15.5 Arrangement Drawing...........................................................................................26

15.6 Wiring Diagram...................................................................................................27

15.7 Start-up test ..........................................................................................................35

15.8 Operating Journal.................................................................................................36

15.9 Spare parts..........................................................................................................37

15.9.1 Spare parts softening plant..............................................................................37

15.10 Declaration of Conformity......................................................................................45

1General

This assembly and operating instruction

applies BWT PERMAQ Compact 950 total

desalination plants.

This assembly and operating instruction

contains important information about correct

installation and operation of the BWT

PERMAQ Compact 950 plant, consequently

the following is very important:

1. Enclosed ”Start-up control” shall be

filled in during commissioning and

filed along with the operating logbook.

2. The operating logbook shall be

updated as described under

”Enclosures”.

3. There must be a floor drain in

proximity of the plant. The drain shall

be dimensioned to the max flow from

the feed water.

4. The BWT PERMAQ Compact 950

plant removes 95-98 % of all salts. It is

possible to post-treat with a mixed-bed

or similar if a better water quality is

requested.

5. The instruction should be read carefully

before assembly and start-up of the

plant. Correct installation and service

will be a condition for our 12-month

warranty.

Therefore, read this instruction before

assembling or starting up the plant.

Your BWT PERMAQ Compact 950 plant is

made in a compact design with reservoir tank,

softening plant and reverse osmosis plant

joined in one unit to take up a little space as

possible.

Your BWT PERMAQ Compact 950 plant with

its compact and good finish is easy to install

since all internal installations are pre-fitted and

tested in our workshop.

Your BWT PERMAQ Compact 950 plant is

designed for minimum service and for long

and unproblematic operation.

However, this is on condition of correct

installation and maintenance.

You should therefore read this instruction

before taking the plant into use.

2Definitions

There will be some technical words in this

instruction, which we have explained below.

Permeate:

Is the treated, totally desalinated water which

is produced by the RO plant and supplied to

the reservoir tank.

Concentrate:

The water which is led to drain. This water

contains the salts and minerals which have

been removed from the water.

Raw water:

The water which is led to the RO plant and

which shall be desalinated.

TDS:

The amount of dissolved salts measured in the

unit mg/l.

Conductivity:

A designation for the salt concentration of the

water, measured in the unit μS/cm. The lower

the number, the better is the water quality.

Membranes:

The filters of the plant, which under high

pressure and flow are capable of desalinating

the raw water.

RO:

The abbreviation for Reverse Osmosis.

Transport pump:

The pump which transports the treated water

from the plant reservoir tank to consumer.

Level sensor:

The sensor which emits a signal if the RO

plant shall start and stop the transport pump in

case of drainage of the reservoir tank.

Softening plant:

A pre-filter which softens the water, i.e.

removes hardness from the water.

3Functional description

The raw water is lead through an ion

exchange resin where the water is softened

before it is passed beside a pressure switch

which ensures the plant against dry running. A

sample valve is installed to test the hardness of

the water.

The high-pressure pump presses the softened

raw-water through the RO membrane high-

pressure pump. The desalinated

water/permeate will be led to a reservoir. The

water with the concentrated salts/concentrate

will be led to drain. The relation between

permeate/concentrate can be adjusted

manually by means of a needle valve.

When permeat is need for consumption a

transport pump delivers it to the consumer. A

pressure tank keeps two litres to ensure a

steady flow to the consumer. A pressure switch

starts/stops the transport pump as required.

There is a bypass valve installed which can be

used if power is lost. This will ensure softened

water to the equipment if required.

4Placement of plant

Important! If you move the plant by means of a

lifting truck, be careful not to damage the

supporting legs underneath the plastic tank.

The plant must be placed in non-freezing

ambiance on a level foundation so that the

water in the reservoir tank does not overflow

when the tank is full.

The foundation must be able to stand a weight

load of 900 kg in total which is the approx.

weight of the RO plant in operation. The

outside measures of the RO plant are WxDxH:

1500 x 660 x 1350 mm, but when placing

the plant, take into consideration that the

cover must be dismounted during

maintenance.

You must include 1000 mm extra height in

order to be able to extract the plant

membranes.

Also make room on the left side of the plant

for the water installation, especially the outlet

drain from the plant should be considered.

There must never be an obstruction in this

outlet!

Placing of the plant should be done in such a

way that the air intake at the top of the pump

never gets covered up.

Furthermore, there are readings which have to

be performed on the front of the plant, e.g.

flow meter, manometer, conductivity meter

and alarms.

Therefore the front should not be covered up

but always remain visible.

In case of an error on the plant, situations may

arise where either the level in the reservoir

overflows or another kind of leak may occur.

Consequently there must be a floor drain in

proximity of the plant, placed in a way that

prevents such water from causing damage.

5Water quality

The raw water to be treated in the BWT

PERMAQ Compact 950 plant must be

drinking water quality with maximum 500

mg/l TDS.

The raw water may maximum contain:

Fe: 0.05 mg/l

Mn: 0.05 mg/l

Free Chlorine: 0.1 mg/l (if higher, a

carbon filter must be installed (option))

Turbidity max. 1.0 NTU

Siltindex: 3.0

KMnO4 max.: 10 mg/l

Maximum temperature: 25°C.

Note! The plant is factory set to operate at

10°C.

If there are doubts about the raw-water

composition, a water analysis will have to be

made.

The plant must be connected a raw-water

pressure of minimum 3 bar and maximum 7

bar.

The quality of the treated water will be <20

μS/cm at 10°C.

6Water connections

Note! All water connections of the plant must

be made in compliance with local regulations.

6.1 Connection of raw water/inlet

water:

A ball valve shall be installed at the inlet side

of the plant, so that the raw water can be

turned off when performing a service check of

the plant.

Connect raw water to the top connector at the

left side of the plant labeled “raw water”. We

recommend connection with ¾" flexible

pressure hoses. BWT HOH sells complete

assembly kits for the RO 950 series.

The best operating result is obtained by

connecting to minimum ¾" raw-water pipes.

In that way you will usually obtain the

necessary pressure and flow to the plant.

If the raw-water connection is too small, there

is a risk of outages on the plant due to lacking

water pressure/amount, e.g. during flushing of

the membranes or when the plant is started

up, which may entail a poor function of the

softening plant.

6.2 Connection of permeate outlet

Connect the outlet water (water to

consumption) to the bottom water connection

at the left side of the plant labeled “for

consumption”. We recommend connection

with ¾" flexible pressure hoses.

Note! Totally desalinated water may

accelerate corrosion, which is why you must

always use corrosion-proof piping for the

treated water, e.g. stainless steel or PVC-pipe.

6.3 Connection of outlet hose

(concentrate)

The outlet water from the plant (concentrate) is

led out through the connection in the middle of

the left side of the plant labeled “concentrate”.

The water is led to floor drain.

Important! The outlet pipe may not be inserted

into the water in the floor drain as there is

then a risk that this water gets sucked back

into the plant during standstills.

Important! There must never be a resistance in

the outlet pipe, as this will damage the plant

membrane(s).

6.4 Connection of overflow hose

At the left side of the plant the overflow nozzle

shall connected to a ½” plastic hose which

shall be led to the floor drain. this overflow is

a safety overflow in case of errors occurring

on the plant level sensor and the reservoir tank

consequently gets overfilled.

6.5 Connection of soft-water control

valve

Install the test valve on the left side of the

plant. The test valve is to be fitted on the

connection closest to the front, see encl. 14.2

fig. 1 (the valve is in the salt tank).

7Electric connections

Note! The electric connections must be done in

compliance with local regulations.

The electric connection to the BWT PERMAQ

Compact 950 plant must be as follows:

Voltage: 3 x 400 Volt + 0 + Earth fuse: 16

Amp –3.5 kW

All internal connections in the plant like e.g.

pump control and level control have been

preassembled in our factory. They only have

to be connected to the main current in the

terminal box.

See also wiring diagram (enclosure).

8Commissioning of the plant

Check before start-up that all water and

electric connections are done as described in

previous chapters and in compliance with

local regulations.

8.1 Start-up of softening plant

1. Check that the number (see encl.

diagram page 6) of the standard-

mounted regeneration meter disk fits

the actual hardness on site. If not, the

meter disk (water meter) must be

exchanged, see illustrations 2.1, 2.2

and 2.3 on page 5. You can order the

correct meter disk from BWT HOH or

your supplier.

2. The brine valve has been pre-adjusted

in our factory, but it should always be

checked that the float (A-figure 1) is

halfway up the shaft as a minimum

when looking from the top of the float.

The water must be above the grid plate

in order to be in contact with the slat.

This also applies to the yellow plastic

ring (B-figur 1) under the float; it must

be pressed home.

3. The valves on the in- and outlet side

and the bypass valve (if fitted) must be

closed.

4. Open the valves at the intake side a

little so that the filter slowly fills

withwater. At the same time water will

be filled into the brine tank by means

of the brine valve.

5. Put the one and then the other tank in

backwash position ofr a while to get

any air out of the system. This is done

by pressing down the crosshead screw

in the middle of the automatism and

simultaneously turning it clockwise.

Check that this makes the water run out

the discharge hose to drain.

6. When the air is out, put the filter in

operation (at position 12 or 6 o´clock)

by turning the crosshead screw once

more.

7. Then open the valves on the outlet and

intake sides completely.

8. Check that water runs into the brine

tank. Check that the water is above the

grid plate (approx. 5 cm above).

9. Fill up the tank with BWT HOH salt

tablets.

10.Normally there shall be enough salt in

the cabinet to cover the water

completely.

11.Now the plant is ready for service and

will supply softened water instantly.

8.1.1 Replacement of regeneration meter

disk

Remove the top cover of the automatism fig.

2.1 (bolt with hexagon head SW AF ¼”).

Take out the plastic mushroom together with

the O-ring and the spring fig. 2.1

When taking out the existing meter disk take

care not to remove or move other parts in the

control element.

When installing the new meter disc, push the

top blocking device (catch) aside with a small

screwdriver. See fig. 2.2

Replace the spring and the plastic mushroom

with the O-ring fasten the cover. The pin

protruding from the underside of the cover

must be at position 5 o´clock see fig. 2.3.

Press the cover back in place –If the cover

cannot be pushed home manually –check if

all pins/parts have been placed correctly.

Wrong fitting of the meter disc will cause the

plant to get operating trouble after a short

while and it will supply hard water.

Consequently, it is very important that this is

carried out with the greatest care.

Capacity I hardness degrees dH°/litre per

regeneration

Disc number

7°dH –2280 litre

14°dH –1140 litre

21°dH –760 litre

28°dH –570 litre (standard)

35°dH –456 litre

42°dH –380 litre

48°dH –325 litre

56°dH –285 litre

Before start-up, the softening plant must be

adjusted to the actual hardness in the raw-

water supply and then started up. This is done

by replacing the water meter disk, so that it

matches the actual hardness.

Slowly open the raw-water supply and close

the “by-pass” valve (encl. 14.2 Q fig. 2).

Check that all water connections are tight.

Fill the salt tank with salt tablets. Use only salt

tablets and make sure that these are of a pure

quality, e.g. type BWT.

The soft-water plant is now ready for

operation. Check if the plant supplies soft

water on the soft-water check valve at the left

side of the cabinet. Test set is included. (see

instruction in the box).

Pull the permeat hose (encl. 14.2 A fig. 2) out

of the reservoir tank and lead it away from the

tank to a drain. Take care not to damage the

PVC fitting on the flow meter.

Open the outlet valve completely (encl. 14.2 I

fig. 2).

Now turn on the power supply.

Now the plant is operating.

Check that the motor is running in the right

direction.

The plant must operate and flush to drain for

20-30 minutes to rinse out chemical residue

before readjusting the outlet valve.

After flushing, the outlet valve shall be

adjusted (encl. 14.2 I fig. 2) again.

8.2 Adjustment of outlet amount

The outlet amount must be adjusted at 25 %,

i.e. if the plant produces 400 l/h, 133 l/h

must be led to sewer. This adjustment is very

important to avoid the plant membranes from

getting damaged.

The plant is now adjusted at a capacity of

75/25, which means 75 % permeate and 25

% concentrate to drain. An easy way to check

this is by multiplying the permeate capacity by

1/3.

The outlet amount is measured by timing the

produced outlet water. E.g. if 300 litres of

permeate is produced per hour, you must

produce 100 litres to drain per hour which

corresponds to 1.67 l/min. This can be

checked with a measuring cup.

When the requested amount of outlet water

has been obtained, tighten the counter nuts on

the outlet valve, so that it is locked. It is

important that the outlet amount be checked

after the counter nuts have been tightened to

make sure that the valve has not moved. Both

counter nuts must be locked/tightened.

Important! The needle valve must be locked at

the prescribed outlet amounts. If the needle

valve is closed, so the outlet amount becomes

reduced, the plant membrane(s) will be

damaged.

NB! After the valves have been locked in

position, the plant must be started and

stopped 4-5 times, and then the flow must be

checked again and the valves readjusted if

necessary.

Check on the high-pressure manometer (encl.

14.2 E fig. 2) that it shows the correct

operating pressure.

Approx. operating pressure:

951-S 24 bar

952-S 19 bar

953-S 19 bar

Note that an operating pressure may vary at

different temperatures and capacities.

Now check the quality of the treated water on

the permeate hose (encl. 14.2 A fig. 2) to

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