WaterBackpack PAUL User manual

The WaterBackpack Company GmbH
PAUL Station Manual 2019-05-25
PAUL®Station
Manual
– assembly, start-up, operation and maintenance –
last modified 25.05.2019

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Content
1Principle of the PAUL®Station..................................................................1
2What can be delivered for the PAUL®Station ..........................................3
2.1 Overview..................................................................................................................3
2.2 Upgrading an existing PAUL®standard unit ........................................................4
3Before the assembly..................................................................................5
3.1 Considerations on the raw water source..............................................................5
3.2 Water supply for the Raw Water Tank...................................................................5
3.3 Overview over available accessories for the PAUL®station...............................6
3.4 Necessary tools.......................................................................................................6
3.5 Scope of delivery ....................................................................................................6
3.6 Height of the tanks relative to the PAUL®unit......................................................7
4Assembly....................................................................................................8
4.1 Set 1 to connect the Raw Water Tank with PAUL®...............................................8
4.1.1 Overview ......................................................................................................8
4.1.2 Mounting the tank connector on the Raw Water Tank..................................8
4.1.3 Connecting the Raw Water Tank with PAUL®............................................10
4.1.4 Remarks on the OPV or OPV-S.................................................................11
4.2 Set 2 to connect PAUL®with the Filtered Water Tank.......................................12
4.2.1 Overview ....................................................................................................12
4.2.2 How to install..............................................................................................12
4.3 Set 3 outlet FWT....................................................................................................14
4.4 Set 4 side outlet with hose...................................................................................15
4.5 Overfill Protection Switch (OPS) for the Raw Water Tank.................................16
4.6 Run-Dry Protection Switch (RPS)........................................................................16
5Start-up and operation.............................................................................17
5.1 OPV adjustment ....................................................................................................17
5.2 Start-up of the PAUL®station ..............................................................................18
5.3 Temporary stop of operation ...............................................................................19
6Maintenance ............................................................................................. 20
6.1 Daily .......................................................................................................................20
6.1.1 Water level inside PAUL®...........................................................................20
6.1.2 Sieve between RWT and PAUL®................................................................20
6.2 Weekly....................................................................................................................20
6.2.1 Removing slurry from the PAUL®unit.........................................................20
6.2.2 Measurement of maximum filtration capacity.............................................21

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6.3 Monthly ..................................................................................................................22
6.3.1 Cleaning of the FWT ..................................................................................22
6.4 Undefined frequency ............................................................................................22
6.4.1 Cleaning the RWT......................................................................................22
6.4.2 Cleaning the membrane module ................................................................22
7Troubleshooting....................................................................................... 23
7.1 Waterlevel in PAUL®is too low............................................................................23
7.2 How to disassemble and re-assemble PAUL®....................................................23
8Additional information.............................................................................27
8.1 Chlorine dosing.....................................................................................................27
8.2 Taking PAUL®out of operation for a long period of time..................................29
9Detailed list of parts that come with set 1 to set 4................................. 30
List of figures
Figure 1: Scheme of the PAUL®station................................................................................1
Figure 2: requirements concerning height of tanks and PAUL®unit......................................7
Figure 3: All parts that come with set 1 and how to connect..................................................8
Figure 4: RWT connector parts of set1 (top: ¾" version, down: 1“ version) pre-
assembled...............................................................................................................9
Figure 5: RWT connector parts of set1 (top: ¾" version, down: 1“ version) ready for
mounting in the RWT..............................................................................................9
Figure 6: RWT connector parts of set1 (top: ¾" version, down: 1“ version) ready for
mounting in the RWT............................................................................................10
Figure 7: LWS box ...............................................................................................................11
Figure 8: All parts that come with set 2 including water meter (left) and single valve for
the FWT (right) and how to connect......................................................................12
Figure 9: Connection between PAUL®and the Filtered Water Tank – installation scheme.13
Figure 10:Connection between PAUL®and the Filtered Water Tank (set 2) – what comes
with PAUL®and how to mount the water meter....................................................13
Figure 11:Set 3 consisting of trank connector and ball tap....................................................14
Figure 12:Side outlet with hose.............................................................................................15
Figure 13:OPV for PAUL®.....................................................................................................17
Figure 14:OPV with rotated float arm (transport position).....................................................18
Figure 15:OPV correct adjusted............................................................................................18

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Figure 16: meter reading........................................................................................................21
Figure 17: sample protocol for maximum filtration test ..........................................................21
Figure 18: membrane module – look through the slits between the plates............................26
List of tables
Table 1: List of parts included in set 1: connection between RWT and PAUL®(RWT
connection with ¾" diameter)................................................................................30
Table 2: List of parts included in set 1: connection between RWT and PAUL®(RWT
connection with 1" diameter).................................................................................31
Table 3: List of parts included in set 2: connection between PAUL®and FWT...................31
Table 4: List of parts included in set 3: outlet FWT.............................................................32
Table 5: List of parts included in set 4: side outlet with hose..............................................32

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1 Principle of the PAUL®Station
The waterbackpack PAUL®is the core of the PAUL®station. The basic idea behind it is
that it is essential to be able to tap large amounts of water in a short time. As the filtration
process in PAUL®is steady but slow, two additional tank are necessary:
a Raw Water Tank (RWT) that stores the raw water so PAUL®can filter continuously
a Filtered Water Tank (FWT) to store the filtered water during times where no water is
tapped
Figure 1 shows a scheme of the PAUL®Station arrangement.
Figure 1: Scheme of the PAUL®station
Water is pumped into the RWT (as an example, in the scheme above realized with a solar
powered solution) and flows into the PAUL®unit. The filtered water from the PAUL®unit then
flows into the FWT.
OPV: w/o LWS (box+sensor)
OPV-S: incl. LWS (box+sensor)
Single Valve
(included in set 2)
bottom outlet water taps

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As a consequence, all three units have to be equipped with installations that prevent over-
filling in order to allow fully unattended use.
This automatic overfilling prevention for the whole PAUL®station is realized by the fol-
lowing tools (see also Figure 1):
in the RWT: the OPS, i.e. Overfill Protection Switch, an electrical switch in a float is
used that switches off the electrical raw water pump if the waterlevel exceeds an ad-
justable level
in the PAUL®unit: the OPV, i.e. Overfill Protection Valve (also called "auto-stop valve")
is used that closes the inlet if the waterlevel in PAUL®exceeds a certain height
in the FWT: the SV, i.e. Single Valve (also called "auto-stop valve") is used that closes
the inlet to the FWT if the water level in the FWT exceeds an adjustable level
Another thing that is necessary in most situations is the RPS, i.e. the Run-dry Protection
Switch for the electric pump. The device itself is identical with the OPS.

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2 What can be delivered for the PAUL®Station
2.1 Overview
The minimum scope of delivery for a permanent water supply solution by the PAUL®station
consists of
PAUL®unit equipped with
OPV (Overfill Protection Valve) which replaces the standard sieve of PAUL®
This is the minimum requirement for a permanent water supply with the PAUL®station,
as it enables the connection between the RWT (or any other water supply connection)
with PAUL®and a self-closing cover which can be opened in order to fill PAUL®with a
bucket alternatively. Here a sieve is provided identical to the standard sieve.
In addition to this minimum scope of delivery, the following items are available and recom-
mended, depending upon the local circumstances:
set 1: connecting the RWT to PAUL
set 2: connecting PAUL®to the FWT
set 3: outlet of the FWT
set 4: side outlet with hose
OPS
RPS
With the side outlet with hose, you can observe the water level inside PAUL®, as the hose is
transparent. This is sufficient in most cases.
For those, however, who want/need an automated warning once the water level inside
PAUL®is low, we offer a PAUL®control unit which consists of
OPV-S (Overfill Protection Valve with Sensor) which replaces the standard sieve of
PAUL®, including the nozzle to connect the RWT with PAUL®and a self-closing cover
which can be opened in order to fill PAUL®with a bucket alternatively. Here a sieve is
provided identical to the standard sieve.
It is identical with the OPV but also has the water level sensor mounted.
LWS (Low waterlevel Warning System) box: this separate box is connected to the wa-
ter level sensor mounted on the OPV-S via a 2-wire electric connection. The LWS box
can be mounted close to PAUL®or even far remote by simply adding more wiring (re-
gardless of polarity), e.g. in the house of the caretaker.

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Although we recommend to solve the issue of water supply locally, see chapter 3.2, on spe-
cial request we can also provide
12 V DC pump and
the matching solar panel
Please note: If you ordered PAUL®together with the parts needed for the PAUL®station
configuration, some items are already mounted on your PAUL®unit.
2.2 Upgrading an existing PAUL®standard unit
If you upgrade an existing PAUL®standard unit, simply exchange the sieve and mount the
OPV (or the OPV-S) instead by removing the two screws that hold the sieve, and then mount
the OPV/OPV-S in this place by using the same screws.

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3 Before the assembly
3.1 Considerations on the raw water source
In general, it is recommended to use the best available water source. PAUL®is not able to
desalinate or detox salty or toxic waters, as is also mentioned on the device.
Thus, which water can be used?
Usually, stored rainwater, e.g. in cisterns or reservoirs is the best raw water source, as
there is little or no contamination from industry, farming or geogenic origin.
Also, rivers can be a good source, provided there is no influence of industry or farming
upstream
If – usually due to lack of water in sufficient quantity – wells have to be drilkled, this wa-
ter may also be of very good quality. However, it is a minimum requirement to check
concerning heavy metals, arsenic and fluoride, at least as a grab sample. Also the con-
centration on iron and manganese should be analyzed.
Advice can be given upon request.
3.2 Water supply for the Raw Water Tank
It has to be considered how the RWT can be fed with raw water. This will usually be done by
an electric pump. Energy might be supplied by local grid or by solar power. Of course, the
pump must fit to the type of energy supply.
Whatever solution is appropriate and feasible under the local circumstances, it should be as-
sured that filling the RWT can operate fully unattended without overfilling the RWT.
In case of electric pumps, a float switch that breaks the electric circuit for the pump when ex-
ceeding a set water level in the RWT can also be provided, the so called OPS, see chapter 2.
When selecting the pump, important criteria include
Suction or submerged pump
Energy requirement, depending upon length and diameter of hoses and height to be
sucked/pumped
Ability of permanent operation
Ability of running dry – if not, a Run-dry Protection Switch (RPS) is necessary, see
chapter 2

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3.3 Overview over available accessories for the PAUL®station
In this manual, the assembly of a PAUL®station is described, basing on all accessories
mentioned in chapter 2. Also, important hints are given. Of course, except PAUL®and the
OPV, everything can also be purchased locally, provided it has the same functionality. How-
ever, we assess as follows:
Set 1: essential
Set 2: essential
Set 3: recommended
Set 4: essential
OPS: recommended (if an electric/solar pump is involved)
RPS: dependent upon your chosen pumping solution
3.4 Necessary tools
Screw-wrench AF 17, 22, 25, 30 and 32
Hose cutter, alternatively stable scissor or cutter or knife
Crimping tool, alternatively gripper
Centre bit ¾“ or 1" and ½“
Standard set of screwdrivers and phillips screwdrivers
Drilling machine is recommended
3.5 Scope of delivery
This varies of course depending upon order.
However, in chapter 9 all single parts are listed an specified, so it is a good idea to first check
the delivery for completeness. If any doubts, please contact us via Mail. Please include pho-
tos to explain your issue.

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3.6 Height of the tanks relative to the PAUL®unit
Before assembling the PAUL®station, it is essential to determine the exact three-
dimensional position of all three tanks, i.e. the RWT, PAUL®and the FWT, to assure that all
connections between the tanks fit and fulfil specific restrictions and the hoses are long
enough.
The only requirement concerning positioning is that we recommend minimum distances in
height, as can be seen from Figure 2.
Figure 2: requirements concerning height of tanks and PAUL®unit
Please note that increasing the height difference between the bottom of PAUL®and the inlet
into the FWT will increase the transmembrane pressure TMP. This results in higher flow, but
it also might speed up pore blocking in the membrane, so please do not use this simple pos-
sibility to increase water production to a large extent.
> 0.50 m*1
> 0.50 m*3
*1: This can best be more than 0.50 m, as
this will assure that influent flow into PAUL
will always be sufficient high.
Note: if the height difference is very high,
(> 10 m estimated), then the OPV (part of
the PCU) must be the „high pressure“
version –please indicate when ordering!
*2: The bottom of the PAUL unit should at
least be 15 to 20 cm higher than the inlet
into the FWT (in no case lower than the inlet
into the FWT).
*3: water cans must fit under the taps.
Note: delivery flow can be increased by
adding a local pipe/hose system and placing
the taps as low as possible beneath the FWT
bottom.
*2

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4 Assembly
4.1 Set 1 to connect the Raw Water Tank with PAUL®
4.1.1 Overview
Figure 3 shows how to connect all parts that come with set 1.
Figure 3: All parts that come with set 1 and how to connect
On the left hand side the RWT connector can be seen. This connector comes pre-assembled
as can be seen in Figure 3.
Determine where to mount the filter. As this filter must be checked and – if necessary –
cleaned, see chapter 6.1.2, choose a location where the filter is easily accessible, see also
chapter 4.1.3. The valve is necessary to stop the water flow during filter cleaning, so the
valve should be mounted close to the filter.
Connect the RWT connector with the valve and then with the filter using the blue hose.
Finally, connect the filter with the OPV or OPV-S mounted in PAUL®using the blue hose.
4.1.2 Mounting the tank connector on the Raw Water Tank
It might be a good idea to execute this step before you put the RWT in place.
Figure 4 shows the two versions of RWT connector. Due to the different diameter, each com-
plete connector consists of different parts as can be seen from the figures and the list of parts
in chapter 9.
The wall of the RWT must be between the two seals.
As the connector comes pre-assembled, it has to be divided according to Figure 5.
Then, drill a hole in the RWT using the centre bit ¾“ or 1", depending upon your tank connec-
tion diameter.

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Figure 4: RWT connector parts of set1 (top: ¾" version, down: 1“ version) pre-assembled
Note: In raw water, even if filterd at the pump inlet, there will be settleable solids. They will
accumulate at the bottom of the RWT. Thus, it is recommended to place the RWT
connector a little higher above the bottom of the RWT, as is shown qualitative in Fig-
ure 2, depending upon solids content in the raw water etc.
Also, the RWT should have a bottom outlet at the very lowest point of the tank to en-
able flushing out solids from time to time.
Although you are free to chose your most convenient way of mounting, we recommend the
following steps depending upon the diameter of the connector:
¾" version:
Divide the pre-assembled connector as can be seen in Figure 5:
Figure 5: RWT connector parts of set1 (top: ¾" version, down: 1“ version) ready for
mounting in the RWT
Make sure the threaded pipe with external thread is firmly screwed into the threaded pipe
with internal thread which also holds the filter cage on the other side. Then place one of the
seal on the threaded pipe with external thread, as can be seen from the left side of Figure 5

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From inside the tank, push this left part of the connector together with the seal on the
threaded pipe with external thread to the outer as far as possible.
Add the second seal on the threaded pipe with external thread.
Then tighten the connector with the counter nut on the threaded pipe, holding tight the inner
part of the connector.
Finally, screw the hose nozzle with cap nut on the threaded pipe.
1" version:
Divide the pre-assembled connector as can be seen in Figure 6.
Figure 6: RWT connector parts of set1 (top: ¾" version, down: 1“ version) ready for
mounting in the RWT
From outside the tank, push the right part of the connector as can be seen from Figure 6 to-
gether with one seal and the counter nut into the drilled hole.
Then, from inside the tank, screw the left part of the connector, i.e. the filter cage with the
pipe coupling (internal thread) on the threaded pipe. Do not forget the second seal. To do so,
use the pipe coupling to tighten the whole connection. The counter nut must be loos in this
situation.
Finally, whilst still holding up the inner part of the connector, firmly tighten the connector to
the wall of the RWT with the counter nut .
Be careful when putting the RWT in place and do not damage the connector.
4.1.3 Connecting the Raw Water Tank with PAUL®
Now you can connect the RWT with the PAUL®unit, and thus carefully decide where to cut
the hose, regarding the following issues:
the water filter has to be placed horizontal with the sieve facing downward, see Figure
3
please regard the direction of flow through the water filter
1
2

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we recommend to place the valve close to the water filter
we recommend to place both valve and water filter close to the PAUL®unit as this will
ease maintenance (i.e. cleaning the filter from time to time, see chapter 6)
The hose clamps have to be fixed with a crimping tool or a gripper. They cannot be used mul-
tiple.
Please clean the RWT before you use it for the first time.
4.1.4 Remarks on the OPV or OPV-S
Usually the OPV/OPV-S is already mounted on PAUL®so you can directly start assembly
and use the hose nozzle of the OPV/OPV-S.
But if you upgrade an existing PAUL®, then you will first have to remove the standard sieve
on top of PAUL®.
Instead, mount the OPV or OPV-S in the place the standard sieve has been; it might be a
good idea to store the sieve in a safe place.
Fixing the OPV or OPV-S with the two screws is very important as otherwise the OPV or
OPV-S in total will float when the water level is rising, and thus will not prevent PAUL®from
overfilling.
The OPV-S is equipped with a water level sensor that indicates if the water level falls below a
certain limit. This water level assures that a long term standstill is possible. The sensor in the
OPV-S must be connected by a very simple two line wire. At delivery, the connector is at-
tached to the sensor cable, and this connector has to be plugged into the LWS box that can
be seen in Figure 7.
Figure 7: LWS box

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If desired (which might be the case in many situations), the wire can easily be extended to
the desired length,. e.g. by placing the LWS box in a nearby flat etc.
The LWS operates with 4 AA batteries. If no warning is issued, there is no current, which
means that the batteries last as long as their official lifetime is. Of course you can also use
AA rechargeable batteries. In order to save battery power due to unwanted conditions dur-
ing transportation, the test knob is covered with a plastic cap. If you need to replace the bat-
teries, open the LWS (4 screws) and remove this plastic, insert new batteries/recharged bat-
teries and close the box again and tighten the 4 screws properly.
Then check functionality of the LWS box itself by pressing the blue knob (see Figure 7, right
hand side) – a LED light should appear and a sound should be heard. Please check from
time to time and replace/recharge batteries if needed, see below.
To check the functionality of the whole LWS system, connect the LWS box to the OPV-S at a
low water level inside PAUL®– LED and beep should indicate low water condition. After
reaching a certain height in PAUL®, the alarm will go off. Of course it can also be switched off
by unplugging the sensor cable from the LWS box, but do not forget to reconnect it after
PAUL®is filled up again.
4.2 Set 2 to connect PAUL®with the Filtered Water Tank
4.2.1 Overview
Figure 8 shows how to connect all parts that come with set 2.
Figure 8: All parts that come with set 2 including water meter (left) and single valve for
the FWT (right) and how to connect
It is recommended to first put PAUL®and the FWT in place before cutting the hose that con-
nects PAUL®into the necessary pieces. Also, the requirements explained hereafter have to
be considered.
4.2.2 How to install
The standard PAUL®unit comes with a white-blue drinking water hose that ends with a
valve.

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From this valve, a hose connection to the water meter must be made using the white-blue
hose, see Figure 9 and Figure 10.
Figure 9: Connection between PAUL®and the Filtered Water Tank – installation scheme
Figure 10: Connection between PAUL®and the Filtered Water Tank (set 2) – what comes
with PAUL®and how to mount the water meter
PAUL Standard unit comes
with hose & valve
water meter must
be horizontal
Set 2 (PAUL to FWT)
starts after valve

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From the water meter a hose connection must be made to the single valve that has to be
mounted in the Filtered Water Tank to prevent from overfilling.
Drill a hole in the FWT close to the top of the FWT using the centre bit ½“. Remove the outer
nut and seal from the single valve and push the single valve together with the other seal and
nut from inside the tank to the outer. Fasten the valve with the seal and the nut you just had
removed.
Note: The water meter must be fixed in a horizontal position., see Figure 10.
Note: The hose that connects PAUL®with the FWT is white-blue and has an inner diameter
of 10 mm. This is essential. Do not use a hose with a bigger inner diameter, because
this could affect the flow of water through PAUL®!
Note: Observe the height arrangements according to chapter 0.
4.3 Set 3 outlet FWT
In many cases, the outlets of the FWT will be provided locally. Nevertheless, set 3 can be ob-
tained (also multiple, see note), consisting of a tank connector and a ball tap, both ¾", see
Figure 11 and also Figure 9Figure 10.
Figure 11: Set 3 consisting of trank connector and ball tap
Drill a hole in the FWT close to the bottom using the centre bit ¾“. Then, push the tank con-
nector (1) together with the white seal from inside the tank to the outer. Fasten the tank con-
nector with the connecting nut using the screw wrench AF 32 – please do not use any type
of gripper, as the nut is made of plastic.
Be sure to mount the tap on the tank connector with the inside thread!
Note: As there is no pressure in the FWT, it is highly recommended to use
multiple taps and/or taps with a large diameter.

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4.4 Set 4 side outlet with hose
The side outlet near the bottom of PAUL®(and/or optional also the bottom outlet in the bot-
tom of PAUL®) is used to flush the slurry that PAUL®retains and stores inside PAUL®. This
has to be done from time to time, depending upon the solids content of the raw water. We
recommend to flush out PAUL®every week so it will probably not been forgotten, see chap-
ter 6.2.1.
In order to facilitate this, and also in order to be able to see the waterlevel inside PAUL®, we
provide set 4, the side outlet with hose. Figure 12 shows how it works.
Figure 12: Side outlet with hose
Remove the black or red cap and install the brass screw with hose connector. Then mount
the hose on the hose connector and fix it with a hose clamp.

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In standard operation, fix the end of the hose higher than PAUL®is, so no water will flow out
of the hose. As the hose is transparent, you can exactly see and observe the water level in-
side PAUL®. This is the "simple and no energy" version which in most cases makes the op-
tional LWS unnecessary.
If flushing must be performed, lower the outlet of the hose so water and slurry can flush out of
PAUL®.
Of course any other solution offering the same functionality is also possible.
4.5 Overfill Protection Switch (OPS) for the Raw Water Tank
The Overfill Protection Switch (OPS) is to be installed in the RWT. This switch determines the
maximum water level at which the feed pump must be switched off. By this, overfilling of the
RWT will be prevented.
Concerning the necessary connections, please refer to the instructions provided with the
OPS. The black wire is the zero connector. We recommend to test whether the blue or the
brown wire is to be used besides the black wire.
4.6 Run-Dry Protection Switch (RPS)
It is highly recommended to prevent the feed pump that is used for raw water pumping from
running dry. This can be done by using a Run-dry Protection Switch (RPS) and realize the
wiring according to this task, which means that the black wire is used and the second wire to
be used is the opposite one compared with the wiring needed for overfill prevention at the
OPS. We recommend to test whether the blue or the brown wire is to be used besides the
black wire.