BWT PERMAQ PRO 2500 Series User manual

Installation and Operating Manual EN
BWT PERMAQ®
PRO 2510-2540
Reverse Osmosis Plant

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LIST OF CONTENTS
1. GENERAL 5
2. EXPLANATION OF WORDS 5
3. PLACING OF PLANT 5
4. WATER QUALITY 6
5. WATER CONNECTIONS 6
6. ELECTRICAL CONNECTIONS 7
7. START-UP OF PLANT 7
7.1 Adjustment of outlet amount 7
7.2 Adjustment of the Recirculation Amount 7
8. OPERATING MANUAL FOR OPERATOR MENU 8
8.1.1 Information in menu: 8
8.1.2 Functions in menu: 8
8.2 Operation 8
8.2.1 Information in Operation: 8
8.2.2 Functions in Operation: 9
8.3 Opr. Setting 1 9
8.3.1 Information in Operation setting 1: 9
8.3.2 Funktions in Opr. setting 1: 9
8.4 Opr. Setting 2 9
8.4.1 Information in Opr. setting 2: 9
8.4.2 Functions Opr. Setting 2: 9
8.5 Mimic 9
8.5.1 Information in Mimic: 9
8.5.2 Functions in Mimic: 9
8.6 Alarm Setting 10
8.6.1 Information in Alarm setting: 10
8.6.2 Functions in Alarm setting: 10
8.7 Plant type 10
8.7.1 Information in Plant type: 10
8.7.2 Functions in Plant type: 10
8.8 Alarm log: 10
8.8.1 Information in Alarm log: 10
8.8.2 Functions in Alarm log: 10
8.9 Date/time 10
8.9.1 Information in Date/time: 10
8.9.2 Functions in Date/time: 10
8.10 Password 10

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8.10.1 Information in Password: 10
8.10.2 Functions in Password: 10
8.10.3 Password: 10
9. MAINTENANCE AND TROUBLE-SHOOTING 10
9.1 Maintenance: 10
9.2 Trouble-shooting 11
9.2.1 The plant capacity has decreased 11
9.2.2 The quality of the treated water is higher than 20µS/cm. 11
9.2.3 Alarms 12
9.2.4 The plant does not run 12
9.2.5 Hard water is measured from the test valve: 12
10. REPLACEMENT OF MEMBRANES 12
11. PRE- TREATMENT (OPTION) 12
11.1 Dosing of Antiscalant 12
12. CIP-CLEANING OF MEMBRANES (OPTION) 13
13. VARIOUS ENCLOSURES 15
13.1 P & I Diagram 16
13.2 Layout Drawing 17
13.3 Operating journal 18
13.4 List of components and Spare parts for the BWT PERMAQ® PRO 2500 series 19
13.5 Spare parts drawing 21
13.6 Declaration of Conformity 22
13.7 Circuit diagram 23

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1. GENERAL
This user guide applies to the
BWT PERMAQ® PRO 2500
series of total desalination plants.
The guide contains important
information about the correct
installation and operation of the
RO plant, consequently below
instructions are very important:
1. Enclosed “Start-up control”
shall be completed during
start-up and filed together
with the operating journal.
2. Operating journal shall be
updated as described under
”Enclosures”.
3. There must be a floor drain
close to the plant.
4. The RO plant removes 95-
98 % of all salts so you have
to consider possible post-
treatment with mixed bed, if
a better water quality is
requested.
5. This manual must be read
carefully before assembly
and start-up of the plant.
Correct installation and
operation will form the basis
of our 12-month warranty.
Your BWT PERMAQ® PRO 2500
plant is a compact design with
reservoir (option) and softening
unit/antiscalant (option) installed
externally so that the plant takes
up least possible space and can
be installed in the most
appropriate way.
The BWT PERMAQ® PRO 2500
plant with its compact and
finished design, is very easy to
install since all internal
installations have been pre-
assembled and tested in our
factory and afterward
disassembled for transport
purposes. These installations just
have to be refitted.
The BWT PERMAQ® PRO 2500
plant is designed for minimum
service and for long and
unproblematic operation.
This, however, is determined by
correct installation and
maintenance.
You should always read this
guide prior to taking the plant
into use.
2. EXPLANATION
OF WORDS
Permeate:
Is the treated
total-desalinated
water which the
RO produces and
supplies to the
reservoir.
Concentrate
:
Is the water
which is led to
drain. This water
contaisn the salts
and minerals
which have been
removed from the
raw water.
Raw water:
Is the water
which is led to
the RO plant and
which must be
desalinated in the
RO plant.
TDS:
The amount of
totally dissolved
salts is measured
in mg/l.
Conductivit
y
Is a designation
for the salt
concentration of
the water and is
measured in
µS/cm. The lower
the figure, the
better is the water
quality.
Membranes
:
Is the plant filter
which by high
pressure and flow
is capable of
desalinating the
raw water.
RO:
Abbreviation for
reverse osmosis.
Reservoir
pump:
The pump which
transports the
treated water
from the reservoir
to the consumer.
Level sensor
A sensor which
gives signal to
the RO plant to
start and stop
and to stop the
reservoir pump in
case the reservoir
is drained.
Softening
unit:
Is a pre-filter
which softens the
water, i.e. it
removes hardness
from the water.
3. PLACING OF
PLANT
The plant must be placed in a
frost-free location on a level
foundation, so that the water in
the reservoir (option) does not
overflow when the tank is full.
The foundation must be able to
stand a weight load of 400 kg in
total which is the approximate
weight of the RO plant in
operation. Also take into
consideration the weight of the
softening unit and the reservoir!
When placing the plant you must
remember that there shall also be

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room for installing softening
unit/antiscalant (option) and
possibly a reservoir tank (option).
You must expect 1000 mm extra
height in order to be able to take
out the plant membranes. Also
there shall be room at both sides
of the plant for water
installations, especially you must
consider the outlet drain from the
plant. A resistance must
never occur in those!
Furthermore, there are readings
which have to be made at the
front of the plant, e.g. the flow
meter, manometer, conductivity
meter and alarms.
The front of the plant shall never
be covered up, but must always
be visible.
In case of an error, situations
may arise where either the level
in the reservoir (Option) may
overflow or another form of leak
may occur. There shall always be
a floor drain close to the plant,
so that this water cannot cause
damage.
4. WATER QUALITY
The raw water, which is to be
treated in the BWT PERMAQ®
PRO 2500 plant, must be of
drinking water quality and
contain maximum 500 mg/l TDS.
The raw water may maximum
contain:
Hardness 0.5 dH (can
be obtained by means
of a softening
unit(option))
Fe: 0.05 mg/l
Mn: 0.05 mg/l
Free chlorine 0.1 mg/l
(if higher, install a
carbon filter (option))
Turbidity max. 1.0 NTU
Silt index: 3.0
KMnO4max.: 10 mg/l
Maximum temperature:25 C.
Note! The plant has been
adjusted in our factory to operate
at 10 C .
If you have doubts about the
composition of the raw water,
you should always make a water
analysis.
The plant must be connected to a
raw-water pressure of minimum 3
bar and maximum 6 bar. The
quality of the treated water will
normally be under 20 µS/cm at
10 C.
5. WATER
CONNECTIONS
Note! All water connections
must be in compliance with local
regulations.
For connection of raw water to
the softening unit (option), see the
guide which is enclosed the
softening unit.
Connection of softening to
the RO plant:
Connect soft water to the
connection at the left side of the
plant. The best operating result is
obtained by connecting to
minimum 1 ½" raw water pipe.
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 the risk of outages
on the plant due to lacking water
pressure/amount, e.g. when
flushing membranes, when
starting up the plant and a poor
functionality of the softening unit.
Connection of permeate
outflow
The outflow of the RO plant (D)
shall be connected to hold-up
tanks or BWT reservoir (option).
You will benefit by connecting
with 1" flexible pressure hoses.
BWT sell complete assembly kits
for the BWT PERMAQ® PRO
2500- series.
Item
No.
Designation
Dimension
A
Intake soft
water
Micron filter
(option)
1 ½”
nipple
B
Outflow
concentrate
discharge
1¼”
coupler
C
Outlet
permeate to
consumption
1¼”
coupler
Connection of drain
(permeate (C)/concentrate
(B))
The permeate and concentrate
outlet can with advantage be
installed with two 25 mm PVC
pipes. Keep in mind that the
permeate drain must be made of
corrosion-proof material.
Permeate and concentrate
outflows are led to the floor drain
in two pipes. These two pipes
may never be united into one
pipe (see figure 1).
Important! The outlet pipe may
not be led all the way down into
the outlet water of the floor drain,
as you will then risk that the
water is sucked back into the
plant by standstill.
Important! A resistance may
never occur in the outlet pipe,
as this will damage the
membrane(s).
Connection of outlet water
from the reservoir pump
(option)
Connect the outlet water with 1"
flexible pressure hose to the

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reservoir pump (see encl. layout
drawing).
Note! Totally desalinated water
can accelerate corrosion,
therefore you should always use
corrosion-proof piping for the
treated water, e.g. stainless steel
or PVC-pipe.
6. ELECTRICAL
CONNECTIONS
Note! The electrical connections
must be made in compliance with
local regulations.
The electrical connection to the
BWT PERMAQ® PRO 2500
plant must be as follows:
2500
Series
2510
2520
2530
2540
Voltage [V]
3 x 400 V + 0 + PE
Net
TN-S
Frequency
[Hz]
50 Hz
Consumptio
n, control
panel [VA]
110 VA
Consumptio
n RO plant
(kW), [A]
5,5 kW
11 A
7.5
kW
11,5 A
Minimum
fuse excl.
of Res. [A]
(Class
gL/gI)
16 A
25 A
See also encl. electrical diagram
7. START-UP OF
PLANT
Check before stating up that all
water and electrical connections
are made as described in the
previous paragraphs and carried
out in compliance with the local
regulations.
Before start-up, adjust the
softening unit (option) at the
actual hardnesses of the raw
water supply and start it up.
Follow the instruction manual on
the softening unit.
On assumption that the softening
unit is now running, check if the
plant supplies soft water at the
sample valve (V5). A test kit is
included in all deliveries of new
softening units.
Completely open the outlet valve
V4. (See diagram of principle).
Completely close the recirculation
valve V3. (See diagram of
principle).
Now switch on the power supply
to the plant.
The plant is operating.
Check that the motor is running in
the right direction.
If the plant shuts down and the
alarm for low inlet pressure
shines, then the raw-water supply
is inadequate (see paragraph
“Water connection”).
The plant shall operate and flush
to drain for 20-30 minutes. Then
the valve must be readjusted.
After final flushing, adjust the
outlet/recirculation valves
V3/V4.
7.1 Adjustment of
outlet amount
Important! Read the entire
paragraph “Start-up of
Plant” before adjustment is
commenced.
The outlet amount must be
adjusted. The raw-water quality is
decisive for which outlet amount
suits your plant best. Too high
water recovery will damage the
membranes. With softened raw
water (recommended) a recovery
of 70- 80 % can be obtained,
dependent on whether the water
is surface or ground water.
Permeate adjustment valve V1
If the plant has a larger capacity
than prescribed, V1 must be
adjusted at the prescribed
capacities.
Plant
type
Permeate
capacity
l/h
Drainage
amount l/h
75 %
2510
3100
1033
2520
4300
1433
2530
5100
1700
2540
6200
2067
7.2 Adjustment of
the Recirculation
Amount
If it is not possible to reduce the
permeate amount at the
prescribed amount or maximum
10 % more, the pressure shall be
adjusted on valve V1.
Following must be checked
regularly:
If the operating conditions of the
plant are changed compared to
the adjustment on the start-up
day, then the plant must be
checked to see if it is necessary
to replace the membranes. (The
plant capacity changes, if the
temperature of the water is not
10 °C. For each degree Celsius
the capacity changes. If the
water is 12 °C, the capacity will
increase by approx. 6 %).

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Note! Warranties are given on
condition that the operating and
maintenance instructions are
complied with, and that the
operating journal is completed at
the stated intervals In case of
deviations you may contact
BWT’s service department.
if the capacity has
dropped more than 10
%
if the pressure after the
high-pressure pump has
increased
if the conductivity has
increased.
When the requested pressure
and permeate capacity has been
reached, check that the outlet
amount is adjusted correctly.
When both valves have been
adjusted, lock the valves V3/V4.
Important! Both lock nuts must be
locked/tightened on the valves.
Check the current operational
pressure on the high-pressure
manometer PI2.
Operational pressure can vary by
different temperatures and
capacities.
Now check the quality at the
permeate outlet to make sure the
conductivity is below set point
(normally 20 µS/cm). this can be
read on the conductivity meter.
The plant reservoir (option) will
now fill with permeate.
Write the operating data in the
enclosed operating journal (see
encl. “operating journal”).
8. OPERATING
MANUAL FOR
OPERATOR
MENU
8.1.1 Information in menu:
All screen displays are
constructed with a header where
date, time and plant type can be
monitored.
When an alarm occurs, the alarm
text in the operator button to the
right will start to flash at a slow
frequency.
Press ALARM
On the alarm screen all active
alarms will be indicated.
Press MENU
to return to this directory.
Press yy/mm/dd
to adjust date and time.
8.1.2 Functions in menu:
Press Operation
On the operation screen you are
able to start and stop flushing
and possible CIP-cleaning.
Press Opr. Settings
In operation setting you choose
settings for start-up of RO plant
and automatic flush of plant.
(This display is protected by a
Password (see paragraph 14.0))
Press Mimic
On the mimic screen you can see
operation and valve/pump
status.
Press Alarm setting
In alarm setting you can make
selections for set point and delay
of alarms.
(This display is protected by a
password (see paragraph 8.10))
Press Language
On the language screen you can
choose between various
languages to be displayed on the
screens.
Press RO Model
On the plant type screen you can
select plant type and options.
(This display screen is protected
by a password (see paragraph
8.10))
8.2 Operation
8.2.1 Information in
Operation:
Buttons for start, stop of plant and
start, stop manual flush. When
the CIP-option is installed it is
operated from here.
When the button is activated, it
changes position from off to on.
Operating status for the RO plant
is indicated in the fields beside
the text line.

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8.2.2 Functions in
Operation:
Press OFF-ON RO:
For start/stop of plant.
Press OFF-ON FLUSH:
For start/stop flush of plant.
Press OFF-ON CIP:
For start/stop CIP cleaning of
plant.
8.3 Opr. Setting 1
8.3.1 Information in
Operation setting 1:
Times of delays of start-up, valves
and pump operations.
8.3.2 Funktions in Opr.
setting 1:
Here you can change times of
delays of start and stop of plants
on level switches.
You may insert delays for start of
pump and opening/closing of
valves.
Data change:
To change a setting, press one of
the fields. A pop-up keyboard
will appear on the screen, and
the new value can be entered.
Confirm by pressing ENT.
8.4 Opr. Setting 2
8.4.1 Information in Opr.
setting 2:
Time for delays of automatic flush
of the RO plant.
The time for duration of
automatic flush of RO plant.
Delays of levels in the reservoir
8.4.2 Functions Opr.
Setting 2:
Here you can change times for
flush of the RO plant and times
for delays of levels
In the reservoir (option) these
times are used for controlling the
reservoir pump P3 (option).
Data change:
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
confimed on ENT.
8.5 Mimic
8.5.1 Information in
Mimic:
Operating status of the plant
Operating status of valves and
pumps.
Pumps change colour (black =
stopped, white = operating)
Valves change colour (black =
closed, white = open.)
8.5.2 Functions in Mimic:
When pressing a valve or a
pump you gain access to manual
operation of the components.
This option is protected by a
password.
You must change to manual to
make operation active. The plant
must be in stop position before
you can operate the buttons.
When you change back to
operating postion, all
components change back to
Auto. The plant must be in stop
position to enable manual
operation.

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8.6 Alarm Setting
8.6.1 Information in Alarm
setting:
Delays of alarms and set point for
conductivity.
8.6.2 Functions in Alarm
setting:
Setting of times by delay of
alarms and set point for
conductivity in operation.
Data change:
To change a setting, press a
field. A pop-p keyboard appears
on the screen and the new value
can be entered. Confirm on ENT.
8.7 Plant type
8.7.1 Information in Plant
type:
RO Type and selection of option.
8.7.2 Functions in Plant
type:
Press on the button for the
desired plant.
8.8 Alarm log:
8.8.1 Information in Alarm
log:
This display with alarm log
appears when pressing the Alarm
button to the right.
If an alarm occurs on the plant,
the alarm button will start a flash
frequency. The alarm will be
presented with date and time of
its occurrence. When the alarm is
reset on the alarm button, the
alarm text disappears and the
alarm button returns to fixed text.
8.8.2 Functions in Alarm
log:
At the left side of the screen there
are two buttons which are used
for scrolling up and down in the
alarm display.
8.9 Date/time
8.9.1 Information in
Date/time:
Date and time in operator panel.
8.9.2 Functions in
Date/time:
Date and time is set by pressing
on the individual button and
entering the new value. Store by
pressing ENT.
8.10 Password
8.10.1 Information in
Password:
The Password screen will appear
automatically if you select a
password-protected screen.
If you enter correct password, the
requested screen will appear.
If the correct password has not
been entered within 10 seconds,
the screen will automatically shift
back to Menu.
8.10.2 Functions in
Password:
Data Entering:
Enter the correct password and
press ENT.
8.10.3 Password:
Password will be informed if you
contact
BWT A/S
Tel.: [phone]
Service Department
9. MAINTENANCE
AND TROUBLE-
SHOOTING
9.1 Maintenance:
The RO plant is produced and
designed for a minimum of
servicing and maintenance. There
are, however, some functions that
should be checked regularly (the
interval is described below).