BWT Permaq Pro 2100 Series User manual

EN
1
Installation and Operating Manual EN
BWT PERMAQ®
PRO 2110-2140
Reverse Osmosis Plant

EN
2

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LIST OF CONTENTS
1. GENERAL 4
2. EXPLANATION OF WORDS 4
3. PLACING OF PLANT 4
4. WATER QUALITY 5
5. WATER CONNECTIONS 5
6. ELECTRICAL CONNECTIONS 6
7. COMMISSIONING OF THE PLANT 7
7.1 Adjustment of outlet amount V2 7
7.2 Adjustment of recirculation amount V1 7
8. OPERATING MANUAL FOR OPERATOR MENU 8
9. MAINTENANCE AND TROUBLE-SHOOTING 11
9.1 Maintenance: 11
9.2 Trouble-shooting: 12
9.2.1 Plant capacity has dropped 12
9.2.2 The quality of the treated water is higher than 20 µS/cm. 12
9.2.3 Plant switches off 12
9.2.4 Plant does not run 12
9.2.5 Reservoir pump (option) will not operate. 13
9.2.6 The Plant Storage Tank (option) flows over. 13
9.2.7 Plant reservoir pump (option) stops and starts 13
9.2.8 CIP pump P2 and heating element HE1 are not working (Option) 13
10. TECHNICAL DATA/SPECIFICATIONS 14
10.1 Technical data: 14
10.2 Technical specifications 15
11. FUNCTIONAL DESCRIPTION 16
12. REPLACEMENT OF MEMBRANES 16
13. CIP-CLEANING OF MEMBRANES (OPTION) 16
14. VARIOUS ENCLOSURES 18
14.1 Layout drawing 19
14.2 Diagram of Principles 20
14.3 Service and Maintenance diagram 21
14.4 Operating logbook 22
14.5 Spare part drawing 23
14.6 Spare part list RO 24
14.7 Spare parts list CIP 2100-series 25
14.8 Circuit diagram 26
14.9 Declaration of Conformity 52

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1. GENERAL
This assembly and operating
instruction applies to BWT
PERMAQ®PRO 2100 total
demineralisation plants.
This assembly and operating
instruction contains important
information about the correct
installation and operation of
the RO plant, consequently the
following is very important:
1. The attached ”commis-
sioning control” must be
filled in during start-up and
filed along with the operat-
ing log-book.
2. The log-book shall be up-
dated as described in en-
closures.
3. A floor drain must be
available in the immediate
proximity of the plant.
4. The RO plant removes 95-
98 % of all salts, conse-
quently you must consider
possible post treatment
with mixed bed or similar,
if a better water quality is
requested.
5. This instruction manual
must be read carefully pri-
or to assembly and start-up
of the plant. Correct instal-
lation and operation is the
basis of our 12-month war-
ranty.
Your BWT PERMAQ®PRO
2100 plant is constructed in a
compact design with storage
reservoir (option) and softening
plant (option) installed external-
ly in order for the plant to take
up as little space as possible
and to ensure the most appro-
priate installation.
With its compact and complete
design your BWT PERMAQ®
PRO 2100 plant is easy to in-
stall since all internal installa-
tions are pre-assembled and
tested in our factory and sub-
sequently disassembled for
transport. All you have to do is
refit these parts.
Your BWT PERMAQ®PRO
2100 plant is designed for
minimum maintenance and
long unproblematic operation.
However, this depends on cor-
rect installation and mainte-
nance.
Therefore you must read this
instruction before commission-
ing the plant.
2. EXPLANATION OF
WORDS
Permeate:
The treated, to-
tally desalinat-
ed water,
which is pro-
duced by the
RO plant and is
then supplied to
the storage ba-
sin
Concen-
trate:
The water that
is led to outlet.
This water con-
tains the salts
and minerals
which have
been removed
from the raw
water.
Raw wa-
ter:
The water that
is led to the RO
plant and
which will be
desalinated in
the RO plant
TDS:
Totally dis-
solved salts.
Conductivi-
ty:
A designation
for the conduc-
tivity of the
treated water;
the lower fig-
ure, the better
water quality
Mem-
branes:
The filters of the
plant which at
high pressure
and flow are
capable of de-
salinating the
raw water.
RO:
The abbrevia-
tion for Reverse
Osmosis.
Reservoir
pump:
The pump
which conveys
the treated wa-
ter from the
plant storage
basin to con-
sumer.
Level sen-
sor:
The device con-
trolling whether
the RO plant
should
start/stop and
which stops the
reservoir pump
in case of
drainage of the
storage basin.
Softening
plant:
A pre-treatment
plant softening
the raw water
(removing
hardness from
the raw water).
3. PLACING OF PLANT
The plant has to be placed in a
non-freezing location on a
plane surface, so that the water
in the storage reservoir (option)
does not overflow when the
tank is full.
The foundation must be able to
withstand a weight load of

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235 kg in total, which is the
approximate weight of the RO
plant in operation. However,
remember to consider the
weight of the softening plant
and the storage reservoir!
The outside measures of the RO
plant are W x D x H: 970 x
600 x 1675 mm, but on plac-
ing the plant, consider that a
softening plant (option) and
possibly a storage reservoir
(option) have to be installed as
well.
An additional height of 1000
mm must be anticipated to be
able to take out the membranes
of the plant.
Furthermore, you have to make
room at both sides of the plant
for water installations especial-
ly the drainage outlet has to be
considered. No resistance
must ever occur in these!
On placing the plant you have
to ensure that the air intake at
the top of the pump is not cov-
ered up.
Furthermore, some readings
have to be performed at the
front side of the plant, e.g. flow
meter, manometer, conductivity
meter and alarms.
Consequently, the front side is
not to be covered up but must
always be visible.
In case of a possible error on
the plant, situations may arise
where the level of the storage
reservoir (option) overflows or
there may be some other sort
of leak. Therefore, there must
always be a floor drain close
by the plant, located in such a
way that the water does not
cause any damage.
4. WATER QUALITY
The raw water, which is to be
treated in the BWT PERMAQ®
PRO 2100 plant, must be of a
softened drinking water quality
and maximum 500 mg/l TDS.
The raw water should contain
no more than:
Hardness: 0,5dH (can
be obtained by means
of a softening plant
(option))
Fe: 0,05 mg/l
Mn: 0,05 mg/l
Free chloride: 0,1
mg/l (if higher a car-
bon filter must be fit-
ted (option))
Turbidity max. 1.0
NTU
Silt index: 3.0
KMnO4max.: 10 mg/l
Maximum temperature: 25C.
Note! The plant is adjusted for
operation at 10C by the facto-
ry.
If there are doubts about the
raw water composition, a wa-
ter analysis must be prepared.
The plant must be connected to
a raw-water pressure of mini-
mum 3 bar and maximum 6
bar.
The quality of the treated water
must be less than 20 µS/cm at
10C.
5. WATER CONNECTIONS
Note! All water connections of
the plant must be made in
compliance with local regula-
tions.
For connection of raw water to
the softening plant (option) see
guideline encl. the softening
plant.
Connection of soft water
to the RO plant:
Connect soft water to the outlet
on the left side of the plant (see
figure 1). We prefer connec-
tion to minimum 3/4” flexible
pressure hoses. HOH Water
Technology keeps complete
mounting kit for the BWT
PERMAQ®PRO 2100 in stock.
The best operating result is ob-
tained by connecting to mini-
mum ¾" raw-water pipes. In
this way the required pressure
and flow into the plant are ob-
tained.
In case of too small raw-water
connection, there will be a risk
of drop-outs on the plant due to
lacking water pressure/-
amount, e.g. by flush of mem-
branes when the plant is start-
ed and by bad functioning of
the softening unit.
Connection of permeate
discharge
The discharge of the RO plant
(D) must be connected to the
storage reservoir (option) (see
plan view enclosure) or to an-
other form of catch tank.

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Connection of discharge
The plant concentrate dis-
charge is ideally to be fitted
with a 20 mm PVC pipe. The
concentrate discharge shall be
led to floor drain.
Important! The drainpipe
should not be inserted into the
discharge water on the floor
drain, as it may then risk being
sucked back into the plant dur-
ing standstills.
Important! Make sure that
an obstruction never occurs
on the discharge tubing, since
this would damage the mem-
brane(s) of the plant.
Connection of outlet wa-
ter (from reservoir pump
(option))
Connect the outlet water (water
for consumption) to the water
connection on the reservoir
pump (option) The reservoir
pump can with advantage be
connected to ¾” flexible pres-
sure hoses (see plan view en-
closure).
Note! Totally desalinated
water might accelerate corro-
sion. Therefore you should al-
ways use corrosion-proof tub-
ing for the treated water, e.g.
stainless steel or PVC pipes.
6. ELECTRICAL CONNEC-
TIONS
Note! The electrical connec-
tions must be made in compli-
ance with local regulations.
The electrical connection to the
BWT PERMAQ®PRO 2100
plant must be as follows:
2100
Series
2110
2120
2130
2140
Voltage
3 x 400 V + N + PE
Power
supply
system
TN-S
Fre-
quency
50 Hz
Con-
sump-
tion,
control
panel
110 VA
Con-
sumption
RO plant
3.0 kW
6.25 A
4.0 kW
8.0 A
Con-
sumption
CIP
plant
6.62 kW, 10.9 A
Con-
sump-
tion,
Reser-
voir*
0.62–1.08 kW, 1.1 –
1.8 A
Maxi-
mum
con-
sumption
6.62 kW, 10.9 A
Maxi-
mum to-
tal con-
sumption
6.62 kW, 10.9 A
Maxi-
mum
start cur-
rent
50 A
72 A
Mini-
mum
fuse
excl. of
Reser-
voir
13 A
Mini-
mum
fuse incl.
reservoir
16 A
Recom-
mended
fuse
16A
Maxi-
mum
fuse
(class
gL/gI)
35 A
Short-
circuit
level
10 kA
Item
No.
Con-
nection
Height
Dimen-
sion
A
Inlet
soft
water
micron
filter
(op-
tion)
720
mm
¾” nip-
ple
B
Dis-
charge
concen
cen-
trate
outlet
1320
mm
¾”
socket
C
Dis-
charge
per-
meate
outlet
1420
mm
¾”
socket
D
Outlet
per-
meate
for
con-
sump-
tion
1520
mm
¾”
socket

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* = Consumption is dependent
on the type of reservoir chosen.
** = RO and CIP plant cannot
run simultaneously.
Please also rf. to enclosed elec-
trical diagram.
7. COMMISSIONING OF
THE PLANT
Check before commissioning
that all water and electric con-
nections have been made as
described in the previous par-
agraphs and in compliance
with local regulations.
Before commissioning the sof-
tening plant (option) must be
adjusted to current hardness in
the raw-water supply and start-
ed up. This is done by follow-
ing the instructions of the sof-
tening plant.
Provided that the softening
plant is now commissioned;
check if the plant supplies soft
water to the soft-water control
cock (V3). A sampling kit is
enclosed when purchasing a
new soft-water plant (see direc-
tions in the box).
Open the discharge valve V2
completely (figure 2).
Close the recirculation valve
V1 completely.
Now switch on the power sup-
ply of the plant.
The plant is now operating.
Check that the motor runs in
the right direction.
If the plant fails and the alarm
LED for low inlet pressure is
turned on, then the raw water
supply is insufficient (see chap-
ter dealing with water connec-
tion).
The plant must operate and
flush to drain for 20-30 minutes
to rinse out chemical residue,
and then the outlet/-
recirculation valve must be re-
adjusted.
After the flushing the outlet/-
recirculation valves must be ad-
justed.
7.1 Adjustment of out-
let amount V2
Important! read the whole
chapter ”Commissioning of
Plant” before starting the ad-
justment.
The outlet amount has to be ad-
justed and whichever outlet
amount is most suitable for
your plant depends on the raw-
water quality. Too high water
recovery will damage the
membranes. On condition that
the raw water complies with
the water quality requirements,
the plant may operate at a wa-
ter recovery of 40 %. When us-
ing softened raw water (rec-
ommended) a recovery of 70-
80 % can be obtained de-
pendent on whether it is sur-
face or ground water.
Plant type
Permeate capacity l/h
Outlet amount l/h 75 %
PRO 2110
600
200
PRO 2120
1200
400
PRO 2130
1700
567
PRO 2140
2300
767
An easy method for checking
the plant outlet amount is:
)/(
(%)cov
100
)/( hlpacitypermeateca
eryre
pacityypermeatecax
hlntOutletamou 
ex.: RO 2120 with 75 % re-
covery
hl
x
hlntOutletamou 4001200
75
1200100 
When the requested amount of
outlet water has been ob-
tained, tighten the counter nuts
on the outlet valve so that it is
locked. It is important that the
outlet amount is checked after
the counter nuts have been
tightened in order to make sure
that the valve has not moved.
Both counter nuts must be
locked/tightened.
Important! The needle valve
must be locked on the pre-
scribed outlet amounts. If the
needle valve is closed so that
the outlet amount is reduced,
the membrane(s) will be dam-
aged.
7.2 Adjustment of re-
circulation amount
V1
Adjust the recirculation amount
by loosening the counter nuts
on the recirculation valve V1.
Adjust at permeate amounts of
maximum 600, 1200, 1700
and 2300 l/h for PRO 2110,
2120, 2130 and 2140 respec-
tively at a temperature between
10-25 C.
If the temperature is below 10
C, the capacity must be ap-
prox. 3 % below normal ca-
pacity for each degree below
10C.
E.g. if the raw water tempera-
ture is 8 C, on an BWT
PERMAQ®PRO 2110 unit it
means that the permeate ca-
pacity is 6 % below the normal
600 l/h, i.e. 564 l/h.
When the requested pressure
and permeate capacity has
been obtained, check again if

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the outlet amount is adjusted
correctly.
We recommend that both coun-
ter nuts are loosened while the
valves get fine-adjusted.
When both valves have been
adjusted, lock both valves
V1/V2 with the counter nuts.
Take care not to move the
valve while tightening the coun-
ter nuts.
Important! Both counter nuts
must be locked/tightened on
the valves.
NB! After the valves have
been locked, start and stop the
plant 4-5 times and check the
flow again. Re-adjust the valves
if necessary.
Check on the high-pressure
manometer PI2, that the correct
operating pressure is indicated.
Note that the operating pres-
sure may vary at different tem-
peratures and capacities.
Now check the quality of the
treated water at the permeate
outlet. Conductivity must be be-
low set point (normally 20
µS/cm). This can be checked
on the conductivity meter.
The reservoir tank (option) will
now get filled up with treated
water < 20 µS/cm.
Make a note of the operating
data in the enclosed operating
logbook (see encl. operating
logbook).
1. Operating pressure –can be
read on the high-pressure ma-
nometer PI2
2. Permeate capacity –can be
read on the flow meter FI1
3. Concentrate capacity –can
be read on the flow meter FI2
4. Conductivity –can be read
on the conductivity meter QIS1
5. Also make a note in the
logbook of the raw-water pres-
sure PI1 and the raw-water
temperature.
8. OPERATING MANUAL
FOR OPERATOR MENU
8.1 Information in menu:
All screen displays are de-
signed with a header where
date, time and type of plant
can be monitored.
In case of alarm, the alarm text
in the operating button at the
right corner starts to flash at a
slow frequency.
Press ALARM
On the alarm screen all active
alarms are displayed.
Press MENU
And you return to the directory.
Press yy/mm/dd
For adjustment of date and
clock.
8.2 Functions in menu:
Press Operation : on the oper-
ating screen you can start and
stop operation, flush and pos-
sible CIP-cleaning.
Press Operation setting : In op-
eration setting you can choose
settings for start-up of RO plant
and automatic flush of plant.
(This screen display is protect-
ed with a password (see chap-
ter 14.0))
Press Mimic : on the mimic
screen status of operation and
valves/pumps is displayed.
(Option)
Press Counters : on the Counter
screen is displayed the total
flow of permeat and concen-
trate of the RO plant.
Press Alarm setting : in alarm
setting you can select settings
for set point and delays of
alarms.
(This screen display is protect-
ed by a password (see chapter
14.0))
Press Language : in Language
setting you can choose be-
tween different languages on
the screens.
Press RO model : On the model
screen you can select RO mod-
el and options.
(This screen display is protect-
ed by password (see chapter
14.0))
8.3 Operation
8.4 Information in opera-
tion:
Buttons for start, stop of plant
and start, stop manual flush. If
the CIP-option is installed, it is
operated from this point.

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When the button is activated, it
changes position between
off/on.
8.5 Functions in Opera-
tion:
Press OFF-ON RO:
For start/stop of plant.
Press OFF-ON Start flush:
For start/stop flush of plant.
Press OFF-ON Start CIP:
For start/stop CIP-cleaning of
the plant.
8.6 Operation. Setting 1
8.7 Information in Opera-
tion setting 1:
Times for delay of start-up,
valves and pump operations.
8.8 Functions in Opera-
tion setting 1:
Here you can change times of
delays of start and stop of the
plant by means of the level
switches.
You can insert delays for start
of pump and opening/closing
of valves.
Data change:
To change a setting, pres one
of the fields. A pop-up key-
board appears on the screen,
and the new value can be en-
tered and confirmed on ENT.
8.9 Operation Setting 2
8.10 Information in Op-
eration setting 2:
Time for duration of automatic
flush of RO plant.
8.11 Functions in Opera-
tion setting 2:
Here you can change times for
flush of the RO.
Data change:
In order to change a setting,
press one of the fields. A pop-
up keyboard appears on the
screen, and the new value can
be entered and confirmed by
pressing ENT.
8.12 Mimic
8.13 Information in Mim-
ic:
Operating status of the plant
Operating status of valves and
pumps.
Permeat and concentration
flow
Pumps change colour (black =
stopped, white = operation)
Valves change colour (black =
closed, white = open.)
8.14 Functions in Mimic:
By pressing on valve or pump,
the option for manual opera-
tion of components is given.
This option is protected by a
password.
You must change to manual to
make operation active. The
plant must be in stop mode to
operate the buttons.
When shifting back to Operat-
ing mode all components
change back to Auto mode.
The plant must be in stop mode
to perform manual operation.
8.15 Total counters

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8.16 Alarm setting
8.17 Information in
Alarm Setting:
Delays of alarms and set point
for conductivity.
8.18 Functions in Alarm
Setting:
Setting of times by delay of
alarms and set point for con-
ductivity in operation.
Data change:
in order to change a setting,
press on a field. A pop-up key-
board appears on the screen
and the new value is entered
and confirmed by pressing
ENT.
8.19 Type of Plant
8.20 Information in Type
of Plant:
RO type and selection of op-
tion.
8.21 Functions i type of
Plant:
Press the button of the desired
plant. The selected RO plant is
shown in the field on the left.
8.22 Alarm log:
8.23 Information in
Alarm log:
This screen display with alarm
log will appear when pressing
the Alarm button in the top
right corner. if an alarm occurs
n the plant, the alarm button
will start a flashing frequency.
The alarm will be presented
with date and time for the oc-
currence of the alarm. When
the alarm is reset on the alarm
button, the alarm text disap-
pears and the alarm button re-
turns to fixed text.
8.24 Functions in Alarm
log:
At the left side of the screen
there are two buttons which
are used for scrolling the alarm
display.
In the centre of the screen dis-
play there is a button which
shifts to the display containing
explanations of the individual
alarms.
At the right side of the screen
display there is a button for
shifting to alarm history.
8.25 Alarm History
8.26 Information in
Alarm History:
In this screen display you can
see the latest 128 alarms with
date and time of the alarm’s
occurrence. When more than
128 alarms have occurred, the
oldest occurrences will be de-
leted.
8.27 Functions in Alarm
log:
At the left side of the screen
display there are two buttons
used for scrolling up and down
in the alarm display.
8.28 Date/time
8.29 Information in
Date/Time:
Date and hour in operator
panel.
8.30 Functions in
Date/Time:
Date and hour have to be set
by pressing on the individual
buttons and entering the new
values. Confirm by pressing
ENT.
8.31 Password