HygroMatik WL-ROL 160-1200 Series User manual

FlexLine
Reverse osmosis plants
MANUAL
WLROL.EN
E-8881184
ÁWLROL.ENjÈ
WL-ROL 160-1200

Page 2
Risk of electrical shock!
Hazardous electrical voltage!
All electrical work to be performed by certified expert staff (electricians or expert personnel with
equivalent training) only.
Certain computer programs contained in this product [or device] were developed by HygroMatik
GmbH ("the Work(s)").
Copyright © HygroMatik GmbH [18.05.2021]
WL-ROL160, WL-ROL320, WL-ROL460, WL-ROL600, WL-ROL1000, WL-ROL1200, EN
WL-ROL160AS, WL-ROL320AS, WL-ROL460AS, WL-ROL600AS, WL-ROL1000AS,
WL-ROL1200AS, EN
All Rights reserved.
Current version of this manual to be found on: www.hygromatik.com
HygroMatik GmbH grants the legal user of this product [or device] the right to use the Work(s)
solely within the scope of the legitimate operation of the product [or device]. No other right is
granted under this licence. In particular and without prejudice to the generality of the foregoing,
the Work(s) may not be used, sold, licensed, transferred, copied or reproduced in whole or in
part or in any manner or form other than as expressly granted here without the prior written con-
sent of HygroMatik GmbH.
Information in this manual is subject to change or alteration without prior notice.

Page 3
1. Introduction ....................................................................................................................... 6
1.1 Typographic Distinctions ...................................................................................................6
1.2 Documentation .................................................................................................................. 6
1.3 Symbols in Use ................................................................................................................. 6
1.3.1 General Symbols ............................................................................................................ 6
1.4 Intended Use ..................................................................................................................... 7
1.5 Unit sizes ........................................................................................................................... 7
2. Safety Instructions ............................................................................................................ 8
2.1 Guidelines for Safe Operation ........................................................................................... 8
2.1.1 Scope ............................................................................................................................. 8
2.1.2 Unit control ..................................................................................................................... 8
2.1.3 Unit operation ................................................................................................................. 8
2.1.4 Mounting, dismantling, maintenance and repair of the unit ............................................ 9
2.1.5 Electrical ......................................................................................................................... 9
3. Transport ............................................................................................................................ 10
3.1 Overview ........................................................................................................................... 10
3.2 Interim Storage .................................................................................................................. 10
3.3 Check for complete and correct delivery of goods ............................................................ 10
3.4 Scope of delivery ............................................................................................................... 10
4. Function and structure ..................................................................................................... 11
4.1 Mode of operation ............................................................................................................. 11
4.2 Influencing factors ............................................................................................................. 11
4.3 Operating conditions of the unit ......................................................................................... 12
4.3.1 Recovery value ............................................................................................................... 12
4.4 Operating sequence .......................................................................................................... 13
4.5 Mechanical construction ....................................................................................................14
4.6 Flowshart ........................................................................................................................... 16
5. Mechanical installation .....................................................................................................18
5.1 Environment Parameters to be met and mounting recommendations .............................. 18
5.2 Installation steps ................................................................................................................ 19
5.2.1 Feed water connection ................................................................................................... 19
5.2.2 Permeate pipe connection .............................................................................................. 19
5.2.3 Connection of the expansion vessel ............................................................................... 19
5.2.4 Connection of the concentrate line ................................................................................. 20
5.2.5 Inserting the prefilter cartridge(s) ................................................................................... 20
5.2.6 Inserting the membrane(s) ............................................................................................. 21
5.2.7 Installation of the uv quartz lamp ................................................................................... 22
6. Water connection .............................................................................................................. 23
6.1 Water connections final check ........................................................................................... 24
7. Electrical connection ........................................................................................................ 25
7.1 Procedure for electrical installation ................................................................................... 25
7.2 Remote ON/OFF and alarm relay connect ion .................................................................. 25
7.3 Electrical installation check list .......................................................................................... 25

Page 4
7.4 Connection of the level sensor of the permeate collection tank ........................................ 26
7.5 Inputs and outputs of the main board ................................................................................ 26
8. Initial start-up ..................................................................................................................... 27
8.1 Flushing of the membrane(s) ............................................................................................ 28
8.2 Adjustment of the permeate quality ................................................................................... 29
8.2.1 Increase of the working pressure before the membranes .............................................. 30
8.3 Continuation of initial start-up after successful adjustment of the recovery rate ............... 31
8.4 Filling the antiscalant tank ................................................................................................. 31
8.5 Adjusting the metering pump ............................................................................................. 31
8.6 Complete the initial start-up ............................................................................................... 32
8.7 Break of use ...................................................................................................................... 32
9. Maintenance ....................................................................................................................... 33
9.1 General .............................................................................................................................. 33
9.2 Safety instruction for maintenance .................................................................................... 33
9.3 Routine maintenance ........................................................................................................34
9.3.1 Change prefilter .............................................................................................................. 34
9.3.2 Filling of the antiscalant canister .................................................................................... 34
9.3.3 Replacing the UV lamp ................................................................................................... 34
9.3.4 Reset maintenance counter ........................................................................................... 34
9.4 Special maintenance and repairs ...................................................................................... 35
9.4.1 Membrane exchange ...................................................................................................... 35
9.4.2 Replacing the metering pump fuse ................................................................................. 35
9.5 Maintenance scheme ........................................................................................................ 36
9.5.1 Daily maintenance .......................................................................................................... 36
9.5.2 Weekly maintenance ...................................................................................................... 36
9.5.3 Maintenance every two months ...................................................................................... 36
9.5.4 Maintenance by qualified personnel ............................................................................... 36
10. Decomissioning ............................................................................................................... 37
10.1 Dismantling ...................................................................................................................... 37
10.2 Disposal after dismantling .............................................................................................. 37
11. Control .............................................................................................................................. 38
11.1 The control panel ............................................................................................................. 38
11.2 Operating states .............................................................................................................. 40
11.2.1 Alarm messages ........................................................................................................... 41
11.3 Menu navigation .............................................................................................................. 42
11.4 Setting options at operator level ...................................................................................... 43
11.5 Menu Structure ................................................................................................................ 44
11.6 Setting options at service level ........................................................................................ 46
11.6.1 Conductivity sensors ...................................................................................................46
11.6.2 Calibration of the probe zero point ............................................................................... 47
11.6.3 Calibration of the probe slope ...................................................................................... 48
11.6.4 Permeate set point calibration ...................................................................................... 48
11.6.5 RAW/MIX set point calibration ...................................................................................... 49

Page 5
11.6.6 Lower level switch LSLOW ........................................................................................... 50
11.6.7 Upper level switch LSHIGH .......................................................................................... 51
11.6.8 Calibration low pressure switch PSLOW ...................................................................... 52
11.6.9 Calibration high pressure monitor (only WL-ROL/ WL-ROC140) PSHIGH .................. 53
11.6.10 Upstream softening system INFIL .............................................................................. 54
11.6.11 Module flushing .......................................................................................................... 55
11.6.12 Configuration of the alarm - output relay .................................................................... 56
11.6.13 Operating and service hour counter ........................................................................... 56
11.6.14 Function test relay outputs ......................................................................................... 57
11.6.15 Function test alarm output relay ................................................................................. 57
11.6.16 Select language .......................................................................................................... 58
11.6.17 Change password ...................................................................................................... 58
11.6.18 Reset password .......................................................................................................... 58
11.6.19 Setting the maintenance interval ................................................................................ 59
11.6.20 Dosing pump antiscalant INPASC .............................................................................. 59
11.6.21 Stand-by-Input INSB .................................................................................................. 60
11.6.22 Set start delay ............................................................................................................ 60
11.7 Wiring diagram ............................................................................................................... 61
12. Error description ............................................................................................................. 63
13. Declaration of Conformity .............................................................................................. 65
14. Spare parts ....................................................................................................................... 67
15. Commissioning report .................................................................................................... 70
15.1 Maintenance documentation ........................................................................................... 71
16. Technical data ................................................................................................................. 74
16.1 Antiscalant ...................................................................................................................... 75

Page 6
1. Introduction
Dear Customer,
Thank you for choosing a HygroMatik
reverse osmosis unit. HygroMatik reverse
osmoses units are state of the art.
In order to operate your HygroMatik reverse
osmosis unit safely, properly and efficiently,
please read these operating instructions.
Only use the HygroMatik R.O. unit in faultless
condition and for its intended use, being
aware of safety and hazards, and observing
all instructions in this manual.
If you have additional questions, please con-
tact your expert dealer.
For all technical questions or spare parts
orders, please be prepared to provide unit
type and serial number (see name plate on
the unit).
1.1 Typographic Distinctions
•preceded by a bullet: general speci-
fications
» preceded by an arrow: Procedures
for servicing or maintenance which
should or must be performed in the
indicated order
Installation step which must be
checked off.
italics Terms used with graphics or
drawings
1.2 Documentation
Retention
Please retain these operating instructions in
a secure, always accessible location. If the
product is resold, turn the documentation
over to the new operator. If the documenta-
tion is lost, please contact HygroMatik.
Versions in Other Languages
These operating instructions are available in
several languages. If interested, please con-
tact HygroMatik or your HygroMatik dealer.
1.3 Symbols in Use
Specific Symbols related to Safety
Instructions
According to ANSI Z535.6 the following sig-
nal words are used within this document:
DANGER indicates a hazardous situation
which, if not avoided, will result in death or
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 or
moderate injury.
NOTICE is used to address practices not
related to physical injury.
1.3.1 General Symbols
This symbol is used whenever a situation
requires special attention beyond the scope
of safety instructions.

Page 7
1.4 Intended Use
HygroMatik reverse osmosis unit used to pro-
duce fully demineralized water. It may only be
used in accordance with its intended pur-
pose.
• Intended use also includes compliance
with the assembly, disassembly and
reassembly, commissioning, operating
and maintenance conditions and dis-
posal measures prescribed by us.
• Only qualified and authorized person-
nel may work on and with the system.
Persons who carry out transport or
work on and with the system must have
read the relevant parts of the operating
instructions and in particular the chap-
ter "Safety instructions". In addition, the
personnel must be informed by the
operator of any hazards that may exist.
Leave a copy of the operating manual
at the place of use of the unit.
• The installation of additional equipment
is only permitted with the written
approval of the manufacturer.
Use of the system
• The system is intended for operation
(with use of feed water in the drinking
water sector) of humidification systems.
• The limit and guide values of the Ger-
man Drinking Water Ordinance must be
taken into account.
• Frost protection and protection against
excessive moisture must be ensured
• The permitted surrounding temperature
is between 5° C and 40° C
• The use of a system separator accord-
ing to DIN 1988, part 4 is obligatory.
• Avoid water temperatures above 20°C
to prevent possible germ growth.
• Due to their construction, HygroMatik
reverse osmosis systems are not
intended for outdoor installation.
1.5 Unit sizes
The following reverse osmosis units belong
to the WL-ROC (Reverse-Osmosis-Compact)
series:
WL-ROC-25: max. permeate production rate
of 25 l/h
WL-ROC-40: max. permeate production rate
of
40 l/h
WL-ROC-80: max.
permeate production rate
of
80 l/h
WL-ROC-140: max. permeate production rate
of
140 l/h
The following reverse osmosis plants belong
to the WL-ROL (Reverse-Osmosis-Large)
series
WL-ROL-160: max. permeate production rate
of
160 l/h
WL-ROL-320: max.
permeate production rate
of
320 l/h
WL-ROL-460: max.
permeate production rate
of
460 l/h
WL-ROL-600: max. permeate production rate
of
600 l/h
WL-ROL-1000: max. permeate production rate
of
1000 l/h
WL-ROL-1200: max.
permeate production rate
of
1200 l/h

Page 8
2. Safety Instructions
These safety instructions are required by law.
They promote workplace safety and accident
prevention.
2.1 Guidelines for Safe Opera-
tion
2.1.1 Scope
Comply with the accident prevention regula-
tion „DGUV Regulation 3“ to prevent injury to
yourself and others. Beyond that, national
regulations apply without restrictions. This
way you can protect yourself and others from
harm.
2.1.2 Unit control
Do not perform any work which compromises
the safety of the unit. Obey all safety instruc-
tions and warnings present on the unit.
In case of a malfunction or electrical power
disruption, switch off the unit immediately and
prevent a restart. Repair malfunctions
promptly.
Restricted use.
IEC 60335-1 stipulates as follows:
This device may be used by children of eight
years of age and above as well as by persons
with reduced physical, sensory or mental ca-
pabilities or lack of experience and knowledge
so long as they are supervised or have been
instructed regarding the safe use of the de-
vice and understand the hazards that may re-
sult from it. Cleaning and maintenance of the
unit must not be undertaken by children with-
out supervision.
The installation room must be adequately
ventilated and be equipped with a floor drain.
A water stop mechanism (e.g. leakage detec-
tor) can be used as an alternative.
2.1.3 Unit operation
Danger of scalding!
Hot surfaces can cause injuries. Protect
yourself with suitable protective equipment.
Water leaks possible due to defective con-
nections 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.
Release pressure before starting work.
• The reverse osmosis (RO) systems
continuously produce permeate (prod-
uct water) and concentrate (waste
water). Connections and water-carrying
components must be checked regularly
for correct functionality.
Risk of material damage!
• The unit may be damaged if switched
on repeatedly following a malfunction
without prior repair. Rectify defects
immediately!
• Regularly check that all safety and
monito-ring devices are functioning
normally. Do not remove or disable
safety devices.
It is essential to leave the RO system con-
nected to the power supply permanently.
Only then the automatic rinsing can be car-
ried out (protection against germs).
WARNING
!
NOTICE
NOTICE
NOTICE
NOTICE

Page 9
Switch device ON/OFF
The system can be switched on/off in differ-
ent ways:
» Interrupt the power supply (pull the
plug) or
» operate the main fuse switch (only
WL-ROL units) or
» press the ESC key (for about 2 sec-
onds).
2.1.4 Mounting, dismantling, mainte-
nance and repair of the unit
The HygroMatik reverse osmosis units are
IP20 protected. Make sure that the unit is not
object to dripping water in the mounting loca-
tion.
Do not install HygroMatik reverse osmosis
systems above electrical equipment such as
fuse boxes, electrical appliances, etc. In the
event of a leakage, leaking water can dam-
age the underlying electrical systems.
• Use genuine spare parts only
• After any repair work, have qualified
personnel check the safe operation of
the unit
• Attaching or installing of additional
components is permitted only with the
written consent of the manufacturer
2.1.5 Electrical
Risk of electrical shock!
Hazardous electrical voltage!
Any work on the electrical system to be per-
formed by certified expert staff (electricians
or expert personnel with comparable training)
only.
During maintenance or installation work, the
device must be disconnected 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 (such as grounding
resistance).
Use only original fuses with the appropriate
amperage rating.
Regularly check the unit‘s electrical equip-
ment. Promptly repair any damage such as
loose connections or burned wiring.
Responsibility for intrinsically safe installation
of the HygroMatik reverse osmosis unit is
incumbent on the installing specialist com-
pany.
NOTICE
NOTICE
NOTICE
WARNING
!
NOTICE

Page 10
3. Transport
3.1 Overview
Proceed carefully when transporting the
reverse osmosis unit in order to prevent dam-
age due to stress or careless loading and
unloading.
Protect the device from moisture during
transport; the storage and shipping tempera-
ture is 5° to 40°C.
3.2 Interim Storage
Store the unit in a dry place and protect from
frost and strong sunlight.
3.3 Check for complete and cor-
rect 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 delivery documents
•the equipment is complete and all
parts are in perfect condition
In case of damage from shipment and/or
missing parts, immediately notify the carrier
or supplier in writing.
Time limits for filing freight claims with ship-
ping companies are*:
* Time limits for some services subject to
change.
3.4 Scope of delivery
WL-ROC
• reverse osmosis unit incl. control
• 2 membranes (WL-ROC-25: only 1
membrane)
• 1 prefilter (WL-ROC-140: 2 prefilters)
• connection material
• manual
WL-ROL
• Reverse osmosis unit incl. control
• 4 membranes (WL-ROL-160 and 320:
only 2 membranes)
• 2 prefilters (5/10 µm)
• connection material
• manual
• Antiscalant canister (for device versi-
ons with integrated antiscalant pump)
Options:
• Retrofit antiscalant WL-ROC-140
• Retrofit kit blending WL-ROC-140
• Retrofit kit blending WL-ROC-25/-40/-80
•UV-lamp
• expansion vessel
Please note
Please note
Shipping company After receipt of
goods
Carriers no later than 4 days
Parcel service immediately

Page 11
4. Function and structure
4.1 Mode of operation
General principle of reverse osmosis
Osmosis is a natural process, it is understood
as the one-sided diffusion of a liquid (here the
feed water) through a semi-permeable mem-
brane. A semi-permeable membrane is only
permeable for certain substances..
As the liquid moves through a semi-permea-
ble membrane, the pressure on the side with
the lower concentration decreases and at the
same time the pressure of the more concen-
trated solution increases until a balance is
reached, stopping the water flow. Pressure
difference between the two liquids is called
"osmotic pressure".
Reverse osmosis, on the other hand, is a
technical process in which the natural pro-
cess is reversed. It involves applying a pres-
sure higher than the osmotic pressure to the
concentrated liquid so that the water flows in
the opposite direction through the semi-per-
meable membrane and thus separates the
salts solved in the water.
Using this principle, water can be demineral-
ized for drinking water as well as for process
and industrial applications.
4.2 Influencing factors
The performance of the reverse osmosis
membrane depends strongly on the following
parameters:
Water inlet pressure at the membrane:
By lowering the working pressure, a reduc-
tion in permeate production can be achieved.
By increasing the working pressure, an
increase in permeate production is also
achieved.
The pump pressure can be changed by turn-
ing the screw on the pump (see chapter 8.4).
Be careful not to exceed the maximum pump
pressure!
Salt content of the feed water:
The higher the salt content, the faster the
membrane wear.
Temperature of the feed water:
The WL-ROL unit is set up for a feed water
temperature of 15°C. Any difference from this
temperature will affect the production quan-
tity and the quality of the permeate.
The following table shows the variation of the
permeate production quantity by 3% per dif-
fering 1°C.
The colder the feed water, the lower the per-
meate production and the better/lower the
conductivity.
The warmer the feed water, the higher the
production quantity, but the lower the perme-
ate quality.
Temperature 15 °C + 1 + 2 + 3 + 4 + 5 + 6 + 7 + 8
Correction factor 1 1,03 1,06 1,09 1,12 1,15 1,18 1,21 1,25
Temperature 15°C-1-2-3-4-5-6-7-8
Correction factor 1 0,96 0,92 0,88 0,84 0,8 0,77 0,74 0,7

Page 12
4.3 Operating conditions of the
unit
In order to ensure the high production capa-
city, the WL-ROL unit should only be fed with
drinking water that has previously been pre-
treated by a softening plant or an anti-cal-
cant.
In order to avoid a reduction of the operating
capacity, the water to be treated must comply
with certain parameters:
turbidity < 1 NTU
Iron < 0,15 ppm
SDI (Silt Density Index) < 3
Water temperature 5 to 25 °C
Free chlorine < 0,2 ppm
Hardness < 28 °dH(30 °F)
COD < 10 mg/l
TOC < 3 mg/l
TDS < 750 ppm
SiO2 < 15 ppm
conductivity < 1000 ppm
Ensure that the water is pre-treated by using
a softener or an antiscalant.
4.3.1 Recovery value
You can optimise the permeate production by
adjusting the flow rates (Ref. 1). The basis for
this is the respective recovery value of the
plant (see technical data). If the recovery
value is 68%, this means a permeate produc-
tion quantity of 68% of the feed water used
for this purpose. The difference to 100%
shows the concentrate share.
You can optimise permeate output by adju-
sting the flow rates (Ref. 1). The basis for this
is the relevant recovery value of the system
(see technical data). For example, the
recovery value for the ROL320 is 68% at a
raw water temperature of 18 °C and a TDS
value of 500 ppm.
The recovery value is calculated as follows:
RECOVERY (%) = Permeat* 100
Regulate the flow rate of the concentrate
through the BV03* valve and read it off the
FI03* flow meter. The circulation is controlled
by the BV02* valve and read off at the FI02*
flow meter. The pressure regulated in this
way on the membranes guarantees the spe-
cified production output.
The feed water temperature clearly influen-
ces both productivity and the quality of the
permeate. If the temperature rises (even by
only a few degrees), productivity increases
(which results in a better recovery value);
however, conductivity increases at the same
time.
* see chapter: Commissioning
Ref.1
A Permeat flow meter
B Recirculation flow meter
C Manual recirculation control valve
D Permeat conductavity probe
E Attachement for sampling permeat
F Flushing solenoid valve
G Manual flushing control valve
H Manual drain control valve
I Drain flow meter
(Permeat + Concentrate

Page 13
4.4 Operating sequence
The feed water (raw water) is pumped
through the pre-filter, which guarantees the
de-chlorination and a final filter capacity of 5
µm. This ensures the necessary clarity of the
water at the membrane inlet. It is next softe-
ned by the addition of an antiscalant (if used).
The feed water pressure must be at least 2 to
5 bar during normal operation to ensure a
correct supply pressure at the pump inlet.
The water then flows through the water inlet
solenoid valve SV1 and is then directed by
the pressure pump at high pressure to the
membrane(s).
The pressure switch PS HIGH provides a
signal when the pressure exceeds 12 bar at
the membrane inlet.
Pure water (permeate) passes through the
membrane; the salts solved in the water are
retained by the membrane and drained off
(concentrate).
The permeate now flows via the pure water
line (scope of delivery) to the expansion ves-
sel or directly to the consumer.
The quality of the permeate leaving the
system is controlled by the conductivity
sensor (EC PROBOUT).
The production process stops automatically
when the water outlet pressure has reached
approx. 4 bar at the pressure switch PS
MAX. The pressure in the following circuit is
kept constant by the expansion vessel.
If the pressure in the following circuit at the
pressure switch PS MIN falls below 2 bar
(when the expansion vesel is empty), the unit
starts permeate production again.
If the inlet pressure falls below 0.8 bar, the
pressure switch PS LOW gives the corre-
sponding alarm and interrupts operation.
The permeate production quantity achieved
can be read off from the permeate flow rate
display (Ref1). If this does not correspond to
the the specifications in the technical data,
please note the measures mentioned in
chapter 4.2 ff..
The reverse osmosis (R.O.) units of the WL -
ROC series cannot operate without an
expansion vessel or permeate collecting
tank.
NOTICE

Page 14
4.5 Mechanical construction
1 Control
2 UV-lamp (optional)
3 Pressure container (membranes)
4 Antiscalant - tank
5 Pump
6 Check valve for antiscalant injection
7 System feedwater solenoid valve
8 Drain water outlet
9 Permeat outlet
10 Antiscalant pump
WL- ROL- 160 - 460
Ref.2
J Prefilter CPC 20“ 5 µm
K Carbon filter CB-EC 10“ sx 10 µm
L Water inlet
J
L
K
10
9
8
6
Ref. 2
7
1
2
3
Ref.1
4
5

Page 15
WL-ROL- 600 - 1200
1 Control
2 UV-lamp
3 Pressure container (membranes)
4 Antiscalant - tank
5 Pump
6 Check valve for antiscalant injection
7 System feedwater solenoid valve
8 Drain water outlet
9 Permeat outlet
10 Antiscalant pump
1
2
3
6
7
Ref. 1
Ref. 2
9
10
8
5
4

Page 16
4.6 Flowshart WL-ROL with 2 membranes
1
SV
MIN MAX
CV CV
CVCV
HIGH
2
3
SV
FRFR
BV
BV
RO Membrane F Prefilter CV Non-return valve PS Pressure switch BV Manual ball valve C.P. Control FR Flow limiter SV Solenoid valve PI Pressure gauge EV Expansion vessel RV Manual control valve EC Conductivity sensor AS Antiscalant tank P High pressure pump DP Dosing pump 1Feedwater 2Permeat 3Concentrate

Page 17
WL-ROL with 4 membranes and antiscalant
option
1
2
4
CV
CV
SV
CV
DP
BV
BV BV
BV
BV
HIGHLOW MIN MAX
CV
BV
SV
10 μ CPP
RO Membrane F Prefilter CV Non-return valve PS Pressure switch BV Manual ball valve C.P. Control FR Flow limiter SV Solenoid valve PI Pressure gauge
EV Expansion vessel RV Manual control valve EC Conductivity sensor AS Antiscalant tank P High pressure pump DP Dosing pump 1 Feed water 2Permeat 3 Concentrate

Page 18
5. Mechanical installation
Risk of foot injuries!
Prevent unit from dropping during installation!
Helping hand of a second person is advisa-
ble.
Risk of electrical shock!
Hazardous electrical voltage.
During installation, the unit must be discon-
nected from power supply and secured
against being switched on again. The
absence of voltage must be ensured by a
measurement.
5.1 Environment Parameters to
be met and mounting recom-
mendations
When selecting the installation site for the
reverse osmosis unit, take the following into
account:
• The minimum clearances indicated in
the fitting measures section must be
observed in order to ensure adequate
unit ventilation and allow for unob-
structed access in case of maintenance
• Protection class IP20
• By design, HygroMatik reverse osmosis
units are not qualified for outdoor installa-
tion (electronic components and water-
bearing 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
pump, as well as make hoses burst
• Avoid environments with excessive
humidity, as it could have negative
effects on the electronics.
• Installation in closed rooms requires
aeration and, if necessary, temperature
conditioning in order to meet the envi-
ronmental conditions.
• Make use of existing water connections
for supply and draining.
• For proper functioning of the level con-
trol, plumb and level installation of the
unit is required.
• The optimal feed water pressure for the
reverse osmosis units is in the range of
2 bar to 5 bar. If these values are not
reached, the installation of a pressure
reducer or a booster pump is neces-
sary.
• The on-site waste water connection
must be a free outflow according to DIN
EN 1717.
• The installation room must be well ven-
tilated and equipped with a floor drain.
Alternatively, a water stop device (e.g.
leakage detector) can be used.
• Ensure that the system stands firmly.
WARNING
!
WARNING
!

Page 19
5.2 Installation steps
5.2.1 Feed water connection
» Install a shut-off valve
» Connect the feed water inlet to the
system. The diameter of the raw
water pipe must be at least equal to
the diameter of the connection
piece.
» Observe the information in the tech-
nical data.
WL- ROL-160/-320 WL-ROL-460 - 1200
5.2.2 Permeate pipe connection
» The diameter of the permeat 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 expansion tank
or return pump tank.
» Note the information in the technical
data.
WL-ROL-160/-320 WL-ROL-460 - 1200
Do never operate the unit with the permeate
line closed!
5.2.3 Connection of the expansion
vessel
» Mount the holder* of the expansion
tank on a stable wall or ensure a
secure stand on the floor.
» If necessary, connect the connection
set to the expansion vessel
» Connect the permeate line.
• Install the reverse osmosis unit as
close as possible to the consumer /
humidifier.
The maximum distance (4) is
15 metres (up to WL-ROL600)
25 metres (WL-ROL1000/1200)
• The reverse osmosis unit (1) must be
installed at the same height of the
humidifier (3) and the expansion tank.
• The number of fittings in the pipe should
be kept to a minimum. The use of angle
joints, T-pieces and reducers increases
the pressure losses in the pipe. The
diameters shown in the tables provide
for a few fittings; if the number of fittings
is doubled, the pipe with the next larger
diameter must be used.
Fig. shows
PVC connection
set

Page 20
5.2.4 Connection of the concentrate
line
» Connect the concentrate pipe to the
corresponding connector and con-
nect the pipe (not included in the
delivery) to the drain.
» The diameter of the concentrate
pipe must be at least equal to the
diameter of the connection piece.
WL-ROL-160 - 320 WL-ROL-460 - 1200
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) of
26 mm to prevent microbial contamination.
5.2.5 Inserting the prefilter cartridge(s)
Before installing the filter set in the mem-
brane container, it must be ensured that the
feed water line is closed and thus no pres-
sure is applied.
» Make sure the water inlet valve is
closed.
» Select menu item 14 SystemTest in
the control system menu, control the
water outlet valve manually and
release any possible rest pressure.
» Switch off the system ( press ESC
for 2 seconds), then disconnect the
system from the power supply
(remove the plug).
» Remove the filter housing using the
installation key supplied.
» For maintenance: remove the old fil-
ters and clean the filter housing.
» Install the new filter inserts in the
correct position.
» Replace the filter housing and screw
it tight with the mounting bowl.
» Open the water supply and vent the
filters using the screw in the upper
part of the membrane housing.
The activated carbon filter CB-EC (K)
removes the chlorine content from the feed
water.
The fine filter CPP (J) works mechanically.
When the feed water flows through the filter
strainer unit and retains contaminants larger
than 5 µm.
Replacement as part of maintenance:
see chapter Maintenance.
5 m 10 m 15 m 20 m
Unit
WL-ROL-160
WL-ROL-320 10 mm / 0,39 Inch
WL-ROL-460
WL-ROL-600
WL-ROL-1000
WL-ROL-1200
Length of premeate pipe
min. innerØ premeate pipe
10 mm / 0,39 Inch
16,6 mm / 0,65 Inch
16,6 mm / 0,65 Inch
16,6 mm / 0,65 Inch
16,6 mm / 0,65 Inch 25,4 mm
16,6 mm / 0,65 Inch 16,6 mm / 0,65 Inch
J
L
K