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

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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

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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