BWT PERMAQ Compact CRU User manual

BWT PERMAQ
Compact CRU
Installation and Operating Manual UK
www.bwt-group.com

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CONTENTS
1. GENERAL INFORMATION 4
2. EXPLANATION OF WORDS 4
3. FUNCTIONAL DESCRIPTION 4
4. INSTALLATION OF BWT PERMAQ COMPACT CRU 5
4.1. Positioning 5
4.2. Water connections 5
4.3. Electric installation 6
5. START AND OPERATION OF BWT PERMAQ COMPACT CRU 6
6. TECHNICAL SPECIFICATIONS AND SETTINGS 7
7. SURVEY OF ALARM CONDITIONS SETTINGS 8
8. TROUBLE SHOOTING 9
9. ANNEX 11
9.1. Technical specifications 11
9.2. P&I Diagram BWT PERMAQ Compact CRU 12
9.3. Layout 13
9.4. Electrical connections 14
9.5. PCB –circuit board 15
9.6. Start-up test 16
9.7. Spare parts list BWT PERMAQ Compact CRU 17
9.8. Spare parts overview 17
9.9. Disposal 18
9.10. Declaration of Conformity 19

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1. GENERAL INFORMATION
This operating and maintenance manual applies to BWT PERMAQ Compact CRU. CRU is the
abbreviation for Concentrate Reusable Unit.
This manual should be read carefully prior to installation and commissioning of the BWT
PERMAQ Compact CRU.
Important! Enclosed “Start-up test”(section 9.6) shall be completed.
Correct installation and operation is a condition for our 12-month warranty.
With its compact and complete design, the BWT PERMAQ Compact CRU is easy to install as
all internal installations have been pre-assembled and tested in our workshop.
The BWT PERMAQ Compact CRU is designed for minimum service and for long and unprob-
lematic operation. This, however, is determined by correct installation and maintenance.
2. EXPLANATION OF WORDS
There will be a few technical explanations in this manual, which we describe below.
CRU: Concentrate Reusable Unit
Permeate: The treated, totally desalinated water which is produced by the RO-plant and
supplied to the reservoir tank.
Concentrate: Is the water that is led to outlet or to BWT PERMAQ Compact CRU. This wa-
ter contains the salts and minerals that have been removed from the raw water.
Raw water: Is the water which is led directly to RO-plant and which must be desalinated in
the RO-plant.
Membranes: Is the filter of the plant which by high pressure and flow is capable of desali-
nating the raw water.
RO: The abbreviation for Reverse Osmosis.
Transport pump: Is the pump which transports the treated water from the tank to the con-
sumer.
Level switch: Is a switch, which gives a signal when the RO-plant must either be started or
stopped, and it stops the transport pump in case of dry-running of the tank.
3. FUNCTIONAL DESCRIPTION
The BWT PERMAQ Compact CRU is a unit that reuses concentrate for flushing water. In this
way the BWT RO Compact CRU will reduce water wastage and increase WCF (Water Con-
version Factor) of the RO plant significantly.
Note! Concentrate contains a high percentage of salts and minerals for which reason it is
not recommended to be used as drinking water.
BWT PERMAQ Compact CRU is equipped with 100l tank with built-on level measurement
and pump section. The level switch controls start and stop of the transport pump. The unit has
a built-in protection against dry-running of the transport pump. The pump section consists of a

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transport pump which is equipped with a solenoid valve at the raw water inlet and a pres-
sure switch and hydrophore at the outlet. When there is concentrate in the tank and the pres-
sure switch detects a drop in the pressure, the transport pump will start , i.e. when there is a
request for water. The pump stops when the pressure increases. The hydrophore equalizes
pressure surges at start and stop of the pump. The non-return valve protects against air get-
ting into the system. When tank is full with concentrate and there is no water consumption the
incoming concentrate will be led to the drain through the overflow branch (on the backside
of the unit). Note! The overflow branch must be connected to the drain with the drain hose
before taking BWT PERMAQ Compact CRU in use.
4. INSTALLATION OF BWT PERMAQ Compact CRU
4.1. Positioning
The BWT PERMAQ Compact CRU must be placed in frost-free surroundings on a level foun-
dation. The foundation shall be able to carry a weight load of 130 kg. The weight load of
any other plants should also be taken into account!
Important! There must be free space at either side of the unit for water installations. In case
of a stoppage, a situation may occur where the concentrate level in the unit overflows. There
must always be a floor drain nearby, located so that the water cannot cause damage. There
must be easy access to the main switch of the plant.
4.2. Water connections
Note! All water connections of the unit shall be installed in compliance with local regula-
tions.
Concentrate inlet: 10 mm hose
Raw water inlet: ½” outside thread
Outlet : ½” outside thread
Drain: 1¼” hose
Important! If the water connection for consumption is too small there is a risk of outage on
the unit due to lacking water pressure/amount. In general, pressure losses should be mini-
mized.
Important! Concentrate can accelerate corrosion. Therefore, always use corrosion-proof
piping for the concentrate, e.g. stainless steel or PVC pipe.
Important! There must be an air gap between the drain hose and drain water level, or else
drain water can be sucked back into the tank.
Important! The drain hose may never be bent or in any other way obstructed, as this can
cause water overflow in the tank.

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4.3. Electric installation
Note! The electric connections must be made in compliance with local regulations. The elec-
tric connection to the BWT PERMAQ Compact CRU must be as follows:
Voltage : 230 V/50 Hz
Fuse: 10A
Max. power consumption: 1.0 kW
Colour code of power cable:
Blue wire: N
Brown wire: L
Yellow/green wire: PE
5. START AND OPERATION OF BWT PERMAQ Compact CRU
Note! Check before start-up that all water and electrical connections are made as de-
scribed in the previous sections and that they are in compliance with local regulations.
The transport pump pressure switch and pressure tank are preset in our factory and do not
need to be adjusted.
1: Make sure that the overflow branch is connected to the drain and there is concen-
trate flow (max. 500l/h) from BWT RO plant in to the BWT PERMAQ Compact CRU
2: Power ON the BWT PERMAQ Compact CRU and check that the transport pump mo-
tor is running. Note! The transport pump cannot be started until the tank of the unit
has been filled up.
3: Wait for the tank to be completely filled. Check that level switch stops the transport
pump automatically when the tank is full. NOTE: Do not touch the level switch.
4: Create a large consumption of water for 5 min (the TP-pump needs to be bled of air)
5: Check that the transport pump starts automatically.
6: Check that the pump supplies water and pressure. If the pump does not supply water
and pressure, see Chapter 8: Trouble-shooting.
7: When the transport pump is found to be working properly, consumption of concen-
trate shall be stopped.
8: Wait for the transport pump to stop automatically.
Note! (on BWT RO reservoir and BWT CRU units): The transport pump doesn’t stop
until 10-30 sec. after the consumption has stopped due to the built-in time delay in
the control box.
9: The BWT PERMAQ Compact CRU has now been commissioned and is ready for use.

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6. TECHNICAL SPECIFICATIONS AND SETTINGS
It is possible to change the various time settings for Start, Stop and Alarm, plus delayed start-
up of pumps.
Use of DIP-switch:
No. 1 (Only available for PERMAQ COMPACT 41)
No. 2 Transport pump
No. 3 Selection of BWT PERMAQ Compact CRU model
No. 4-6 Transport pump

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7. SURVEY OF ALARM CONDITIONS SETTINGS
LED function: In normal operation the LED’s are lit corresponding to the components they rep-
resent. Fault conditions are described in Chapter 8. Trouble shooting
“Re-start ALARM” on TP-pump:
(Nothing is working –
permanent condition)
See: Fault 4
ALARM - Too high water level:
(Nothing is working –
permanent condition)
Option
Too low water level:
(no ALARM, TP-pump stopped)
See: Fault 1
External stop - TP-pump,
can be jumped at start-up
Remove the
cause for external
stop signal
CRU unit is running, everything OK
CRU unit is on Standby
POWER
TRANSPORT
PUMP
(TP-pump)
LEVEL
ALARM
Description
of alarm-
and fault
conditions
Trouble-
shooting/
comments
LED’s are lit
LED’s flashes slowly (½ Hz)
LED’s flashes rapidly (5 Hz)
The unit emits beep tone at Alarm condition (Nothing is working), which can only be neutral-
ized by rectifying the fault, then switching the plant OFF for 5 seconds and switching ON
again.

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8. TROUBLE SHOOTING
This chapter deals with problems that may occur on the plant. Follow the instructions in the
relevant flow diagrams in order to perform a troubleshooting. Warning! ALWAYS pull the
POWER PLUG before replacement of electrical components and wait 3 minutes.
Descrip-
tion of
fault
Reason for fault
Action
Fault 1:
The tank
is empty
Low water level.
Check that the RO-plant is running and there
is flow of concentrate to the BWT PERMAQ
Compact CRU. The RO-plant may produce
less concentrate than there is need of for con-
sumption.
Check if too many consumers are connected
on the BWT PERMAQ Compact CRU and
switch some off. Let the BWT PERMAQ Com-
pact CRU become completely filled up.
Check if the level switch float is stuck in top of
the reservoir. Carefully push the level switch
float up/down so that it is at concentrate wa-
ter level.
Check if the level switch and/or the level
switch cable are defective. If so, replace.
Check the TP-pump (See Fault 1, Fault 2
and Fault 3).
Fault 2:
TP pump
doesn’t run
Switch is at OFF.
Push switch to ON.
Low water level.
Let the reservoir become completely filled up
and the TP pump will start automatically.
Defective pressure switch.
Short the pressure switch by making a jumper
between the two plugs. If the pump only runs
when this jumper is connected and there is a
request for water, then the pressure switch is
defective and must be replaced.
Defective capacitor.
Locate transport pumps capacitor in the con-
trol box and replace it.
Defective fuse.
Check the PCB and replace the fuse
(F3-Circuit Board) of the TP pump.
Defective TP-pump.
Replace TP-pump.

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Defective PCB.
Replace PCB.
Float of the level switch is
stuck.
Push the level switch float carefully up/down
until it is at concentrate level.
Defective level switch.
Replace level switch.
External stop signal on the TP-
pump.
Check and rectify cause of the external stop
signal.
Fault 3:
TP-pump is
running but
no water is
getting to
the con-
sumer
Air in the TP-pump.
The TP-pump needs to be bled of air. Switch
power OFF, fill up the tank and turn switch
power back to ON. Let the pump run a while
with a large flow in order to get the remaining
air out of the pump case.
Low water level.
Disconnect the consumer. Let the tank become
completely filled and the TP-pump will start au-
tomatically.
Fault 4:
TP-pump
starts and
stops
If the piping connection is too
small there is a risk of outages
on the plant due to lacking wa-
ter pressure/amount etc.
Replace the outlet pipe (water for consump-
tion) with an outlet pipe with a larger dimen-
sion.
Non-return valve is
leaky/defective.
Replace the non-return valve.
The hydrophore is defective or
lacking air.
Replace the hydrophore and set the pre-
pressure at 2.7 bar.
The hydrophore capacity is too
small.
Contact BWT for technical advice.
Pressure switch set incorrectly.
Set the pressure switch at 4.0 bar (Stop) and
3.0 bar (Start).

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9. ANNEX
9.1. Technical specifications
BWT PERMAQ Compact CRU
Designation
Tag
number
Type/data
Tank volume
100 l
Max. concentrate flow to the CRU
500 l/h
Transport pump
P1
0.85 kW, 4.5A
Pump capacity
3 bar / 3 m3/h
Height/Width/Depth
810/580/630 mm
Concentrate inlet, diameter
10 mm
Consumption water outlet, diameter
½”
Raw water inlet, diameter
½”
Weight (empty/full)
30/130 kg
Water temperature (Min. /Max.)
5-35°C
Pressure switch
PS01
-0.2 to 8 bar
Solenoid valve, NO
V1
POM
Non-return valve
V2, V3
½”

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9.2. P&I Diagram BWT PERMAQ Compact CRU

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9.3. Layout

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9.4. Electrical connections

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9.5. PCB –circuit board

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9.6. Start-up test
Name of customer: Plant number: Work-sheet number:
Type of plant: Permeate flow [l/h]: Concentrate flow [l/h]:
In case of problems, please fill in the problem report
Can the problem be related to the manufacturing?
Can the problem be related to the plant or the installation?
The plant - we mean only the part of the whole installation which was delivered by BWT (i.e only the plant).
The installation - we mean the piping etc. leading to the plant.
Can the problem be related to the sales department?
Description, please describe the problem
Signature
Name/initials of technician: Date: Time consumption for the start-up [hours]:
Problem report
The start-up test sheet must be completed and filed together with the operating journal.
RO plant
BWT PERMAQ Compact CRU
Status on start-up
Problems on start-up
Pressure switch start/stop, transport pump is OK
Drainage protection, overflow branch is connected to the drain
Pre-pressured hydrophore is OK
YES, there were problems at start-up
Start-up by dealer, specify dealer _____________________________________
YES, the problem can be related to the manufacturing NO, the problem cannot be related to the manufacturing
NO, there were no problems at start-up
Start-up by BWT
YES, the problem only concerns the plant
YES, the problem only concerns the installation
YES, the problem concerns both the plant and the installation NO, the problem does not concerns the plant or the installation
YES, the customer was misinformed
NO, the customer had been well-informed
Max. concentrate flow from RO to the CRU is < 500 [l/h]

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9.7. Spare parts list BWT PERMAQ Compact CRU
* Contact your local BWT dealer for detailed information.
9.8. Spare parts overview
Pos. Nr.
BWT PERMAQ
Compact CRU
Recommended
spare parts
Spare part No.
Recommended
replacement
frequency
1
100 l tank
451202073
2
Transport pump
454100070
3
Hydrophore 0.5 liter
1
451404571
3-5 years
4
Pressure switch
1
451202803
5
Level switch
1
451404485
5 years
Cable for level switch
1
451404450
6
Push-in fitting, 10x½”, elbow
1
454091010
7
½” Non-return valve
1
200729004
8
Solenoid valve ½”
1
200753004
9
Control box complete
*
PCB
*
-
20 µF Capacitor (Transport
pump motor)
1
750001270
-
Cable for level switch
451404470
-
10 mm plastic hose
454001010
3 years

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9.9. Disposal
The packaging is to be taken to a local waste disposal site if no longer required. The pack-
aging comprises of environmentally-friendly materials that can be used as secondary raw
materials.
The device, including accessories and batteries, is not to be thrown into the household
waste. EU legislation in Member States requires electrical and electronic equipment to be
collected separately from unsorted municipal waste so that it may be recycled.
In Denmark and several other countries, BWT itself assumes responsibility for the return and
conformant disposal of its electronic and electrical products. These products may not be
placed with household waste or brought to collection centres run by local public disposal
operations –not even by small commercial operators.
For disposal in Denmark and in the other member nations of the European Economic Area
(EEA), please contact our local BWT service technicians or our Service Center in Greve,
Denmark:
BWT HOH A/S
Geminivej 24
DK-2670 Greve
In countries that are not members of the European Economic Area (EEA) or where no
BWT subsidiaries or dealerships are located, please contact your local authorities or a
commercial disposal operator.
Remove the batteries and hand them in to a collection point prior to disposal/scrapping of
the device.
BWT, its affiliates, subsidiaries, dealers and distributors will not take back equipment con-
taminated with hazardous materials (ABC contamination) –neither for repair nor disposal.
Please refer to our web site (www.bwt-group.com) for more detailed information regarding
addresses for repair service or disposal of your device.

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9.10. Declaration of Conformity
EC DECLARATION OF CONFORMITY FOR MACHINERY
DIRECTIVE 2006/42/EC, ANNEX II, A
LOW VOLTAGE DIRECTIVE
EMC DIRECTIVE
BWT HOH A/S
Geminivej 24 - DK-2670 Greve
tel.: [phone] - fax: [phone]
[email protected] - www.bwt.dk
herewith declares that:
BWT PERMAQ Compact CRU
- is in conformity with the provisions of the Machinery Directive
(directive 2006/42/EC)
- is in conformity with the provisions of the following other EC directives
- Low Voltage Directive (2006/95/EC)
- EMC Directive (2004/108/EC)
- Place: Greve, Denmark
- Date: 31-07-2013
_________________________________
Lars Jensen
Head of Product Management

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For further information, please contact
BWT HOH A/S
Geminivej 24
DK-2670 Greve
Tel : [phone]
Fax: [phone]
E-Mail: [email protected]
BWT Birger Christensen AS
Røykenveien 142 A
Postboks 136
N-1371 Asker
Tel : [phone]
Fax: [phone]
E-Mail: [email protected]
BWT Vattenteknik AB
Box 9226
Kantyxegatan 25
SE-213 76 Malmö
Tel : [phone]
Fax: [phone]
E-Mail: [email protected]
BWT Separtec OY
PL 19 Varppeenkatu 28
FIN-21201 Raisio
Tel : [phone]
Fax: [phone]
E-Mail: [email protected]
BWT Austria GmbH
Walter-Simmer-StraBe 4
A-5310 Mondsee
Tel : [phone]
Fax: [phone]
E-Mail: [e-mail]
BWT Wassertechnik GmbH
IndusiriestraBe 7
D-69198 Schriesheim
Tel : [phone]
Fax: [phone]
E-Mail: [e-mail]
Cillichemie ltaliana SRL
Via Plinio 59
1-20129 Milano
Te l: [phone]
Fax: [phone]
E-Mail: [e-mail]
BWT France SAS
103, Rue Charles Michels
F-93206 Saint Denis Cedex
Tel : [phone]
Fax: [phone]
E-Mail: [e-mail]
BWT Belgium NM.
Leuvensesteenweg 633
B-1930 Zaventem
Tel : [phone]
Fax: [phone]
E-Mail: [e-mail]
BWE Česká Republika s.r.o.
Lipovo 196 -Cestlice
CZ-251 01 Říčany
Tel : [phone]
Fax: [phone]
E-Mail: inf[email protected]z
BWT Polska Sp. z o.o.
ul. Polczyhska 116
PL-01-304 Warszawa
Tel : [phone]
Fax: [phone]
E-Mail: [e-mail]
BWT Hungária Kft.
Keleti út. 7.
H-2040 Budaörs
Tel : [phone]
Fax: [phone]
E-Mail: [e-mail]
BWT UK Ltd.
Coronation Road, BWT House
High Wycombe
Buckinghamshire, HP12, 3SU
Tel : [phone]
Fax: [phone]
E-Mail: [email protected]
BWT Nederland B.V.
Centraal Magazijn
Energieweg 9
NI-2382 NA Zoeterwoude
Tel : [phone]
Fax: [phone]
E-Mail: [email protected]
BWT AQUA AG
HauptstraBe 192
CH-4147 Aesch
Tel : [phone]
Fax: [phone]
E-Mail: [e-mail]
OOO Russia BWT
Ul. Kasatkina 3A
RU-129301 Moscow
Tel : [phone]
Fax: [phone]
E-Mail: [email protected]
Cilit S.A.
C/Silici, 71 -73
Poligono Industrial del Este
E-08940 Cornelia de Llobregat
Tel : [phone]
Fax: [phone]
E-Mail: [email protected]