Carel Large ROL 160-1K2 User Manual Download

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Water Treatment System

Large ROL 160 - 1K2

Reverse osmosis plants

USER MANUAL

WTS - Large ROL

+03000131EN - ENG

Up to date version available on

www.carel.com

ENG

Summary of Contents for Large ROL 160-1K2

Page 1: ...R SIGNAL CABLES TOGETHER READ CAREFULLY IN THE TEXT Water Treatment System Large ROL 160 1K2 Reverse osmosis plants USER MANUAL WTS Large ROL 03000131EN ENG Up to date version available on www carel c...

Page 2: ......

Page 3: ...dards 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 building...

Page 4: ...o 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...

Page 5: ...nection 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 mem...

Page 6: ......

Page 7: ...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...

Page 8: ...or 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...

Page 9: ...ce 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 Rel...

Page 10: ...ected 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...

Page 11: ...rost 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 del...

Page 12: ...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 ma...

Page 13: ...feed water raw water is pumped through the pre filter which guarantees the dechlorination and a final filter capacity of 5 m This ensures the necessary clarity of the water at the membrane inlet It is...

Page 14: ...membrane inlet PI 3 Pressure container membranes 13 Pressure gauge permeate outlet PI 4 Antiscalant tank 14 Pressure switch PS LOW 5 Pump 15 Pressure switch PS MIN 6 Check valve for antiscalant injec...

Page 15: ...embrane 12 Pressure gauge membrane inlet PI 3 Antiscalant 13 Pressure gauge permeate outlet PI 4 Centrifugal multistage motor pump 14 Pressure switch PS LOW 5 Check valve for antiscalant injection 15...

Page 16: ...ge PS Adjustable pressure switch SV Diaphragm solenoid valve P Electric rotary vane pump EC Conductivity probe FI Flow indicator CV Check valve RO E P RO system control panel LSH Float level switch RV...

Page 17: ...le pressure switch SV Diaphragm solenoid valve P Electric rotary vane pump EC Conductivity probe FI Flow indicator CV Check valve RO E P RO system control panel LSH Float level switch RV Manual contro...

Page 18: ...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 pum...

Page 19: ...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 expan...

Page 20: ...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...

Page 21: ...otective 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 ne...

Page 22: ...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...

Page 23: ...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 operation...

Page 24: ...er 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...

Page 25: ...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...

Page 26: ...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...

Page 27: ...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 remo...

Page 28: ...flow rates can be read off the flow measuring sensors FI01 permeate FI02 circulation and FI03 concentrate Using the example of ROL 1000 Circulating flow rate 450 l h Concentrate flow rate 470 l h Thi...

Page 29: ...rvice 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 see...

Page 30: ...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 co...

Page 31: ...t 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...

Page 32: ...m of the sy stem Increase of the membrane feed pressure 9 2 Safety instructions for maintenance Caution Risk of electrical shock Hazardous electrical voltage Any work on the electrical system to be pe...

Page 33: ...osis 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...

Page 34: ...he pump Replace the pump in the unit and tighten the two screws to the frame Fig 9 b 9 5 Maintenance scheme 9 5 1 Daily maintenance Check if the system is working cor rectly Check that there are no le...

Page 35: ...intenance 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 t...

Page 36: ...rmed 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 D...

Page 37: ...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...

Page 38: ...hing 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 1...

Page 39: ...rts automati cally PERFORM MAINTENANCE The service hour counter has been counted down Please make a maintenance and reset the counter 10 2 1 Alarm messages If one of the following alarm messages appea...

Page 40: ...a function Button LEFT In the menu For jumping back to the previous digit within the input field Button RIGHT In menu For jumping to the next digit within the input field Button ESC In menu level To...

Page 41: ...selection with The program jumps to submenu 11H 11H WASH CYCLE 00 min 15 sec 24 h By pressing the arrow keys you specify the time period between the periodic mod ule flushes e g change 24h to 48h usag...

Page 42: ...owing 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...

Page 43: ...43 ENG Control WTS LARGE 0300131IT rel 1 0 05 09 2022...

Page 44: ...e 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 calibr...

Page 45: ...ope 2A ZERO CALIB 2B SLOPE CALIB READING 12 5 S BUFFER 15 0 S 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 bot...

Page 46: ...ntended shutdown of the system 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...

Page 47: ...rrow keys 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 7 Upper level switch LSHIGH The pressure sw...

Page 48: ...nd of the chapter Confirm the selection with The program jumps to submenu 7D Default value 05 sec 7D MAX RETRY 0 By pressing the arrow keys you set the number of start up attempts 0 9 Confirm the sele...

Page 49: ...ogram 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 system INFIL If the upstream softening sy...

Page 50: ...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 you set whether a flush should be carried out before e...

Page 51: ...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 ma...

Page 52: ...nu Notice To avoid damage to the unit Always activate the feed water valve first before activating the pump 11 6 15 Function test alarm output relay In this submenu you can manually activate the alarm...

Page 53: ...al 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 c...

Page 54: ...h The program jumps to submenu 20B Default value DISABLED 20B STAND BY IN CONTACT N O Press the arrow keys to set the switching direction N O CONTACT The input functions as a normally open contact N C...

Page 55: ...TS HP Power supply output relay 01 02 03 Main power IN 230 VAC L E N 04 05 06 Highpressurepump IN P HP 1 phase max 2A L E N 19 20 21 Alarm OUT L E N N O C N C Digital inputs 22 High level probe IN LS...

Page 56: ...RE The PSHIGH overpressure switch for the max permissible operating pressure has switched Only for ROC 140 an ROL units The PSHIGH pressure switch is not calibrated or is not working correctly Replace...

Page 57: ...ot 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...

Page 58: ...Spare parts WTS LARGE 0300131IT rel 1 0 05 09 2022 13 SPARE PARTS 1 2b 2c 3 4 17 12 19 10 14 6 5 18 11 7 8 15 16 13 9 Fig 13 a Ref 1 A Ref 1 B Ref 1 I Ref 1 C Ref 1 D Ref 1 F Ref 1 G Ref 2 L Ref 2 K R...

Page 59: ...59 ENG Spare parts WTS LARGE 0300131IT rel 1 0 05 09 2022 20 21 22 23 24 25 26 27 28 29 30...

Page 60: ...ure gauge membrane inlet PI 02 ROKL00MA16 1 1 1 1 1 1 13 Pressure gauge permeate outlet PI 04 ROKL00MA06 1 1 ROKL00MA16 1 1 1 1 14 Pressure switch PS LOW ROKC00PSLP 1 1 1 1 1 1 15 Pressure switch PS M...

Page 61: ...nsion vessel meters Distance pressure expansion vessel consumer meters Connection to the drinking water system yes no Softening system connected yes no Hoses to the anti scalant pump and canister con...

Page 62: ...he unit UV lamp replace after 9000 hours or 1 year Control Measured parameters Values at Remarks Commis sioning Mainte nance Operating hours hours Feed water pressure bar Water pressure behind pre fil...

Page 63: ...ower 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 15 mm 3 4 AG Water connection 3 4 A...

Page 64: ...g 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...

Page 65: ...Notes...

Page 66: ...Notes...

Page 67: ......

Page 68: ...CAREL INDUSTRIES Headquarters Via dell Industria 11 35020 Brugine Padova Italy Tel 39 049 9716611 Fax 39 049 9716600 e mail carel carel com www carel com WTSLARGE 0300131ENrel 1 0 05 09 2022...

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