ROCHEM RO-Wasserbehandlung GMBH PDF

ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg. Page No.
1

ROCHEM RO-Wasserbehandlung GmbH
Knickberg 1a, D - 21077 Hamburg
( +49-(0)-40-7038577-0
4 +49-(0)-40-7038577-29

Operation Manual V 0.1
Date: 22.11.2008

Type of Unit: RO-1530 ST03-30S
SEA-WATER DESALINATION (S)
FSS

Project: UAE Hull106 Order No.: P08027 Serial No.: 2366

ROCHEM RO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg. Page No. 2

I NT RODUCT I ON

I. Contents

Page

I. Contents 2
II. Preface 4
III. How to Use this Manual 5
IV. Safety Remarks 6
V. Log Sheet 7
VI. Warranty 8
VII. Notes 9
VIII. Service 10
Order Form for Spare Parts
How to Contact our Service Department

1) Functional Description
1.1 Description of Process 12
1.2 Unit Arrangement 13
1.3 Controls, Displays & Measurements 18
1.4 Safety and behavior rules 19

2) Operating
2.1 Commissioning 20
2.2 Starting the Unit 21
2.3 Monitoring during Normal Operation 24
2.4 Stop with Rinse 25
2.5 Sandfilter Backwash 28
2.6 Circuit Cleaning 31
2.7 Preservation 39
2.8 Disinfection 45

3) Fault Indication & Finding
3.1 Error Codes and Implication 47
3.2 Faults without Lamp Indication 49

4) Maintenance, Cleaning & Calibration
4.1 Schedule for Checks & Maintenance Works 50
4.2 PLC 52
4.3 Contactors 56

4.4 Electric Motor 57
4.5 Pressure Switch 58
4.6 Pressure Transmitter 59
4.7 Conductivity Meter 60
4.8 Filter Pump 67
4.9 Plunger Pump 72
4.10 Sand-Filter 79
4.11 Cartridge Filter 81
4.12 Deacidification-Filter 79
4.13 PT Module 82
4.14 Motor Control Valve 110
4.15 Pulsation Damper 117

5) Specification
5.1 Layout Diagram, Installation Plans 119
5.2 Pipe & Instrument Diagram 123
5.3 Parts List 125
5.4 Tools & Resources 128
5.5 Unit Specification 129
5.6 Water Feed Analysis 131
5.7 Electric Schematics 132

Annex:

Actuator for Motor-Control-Valve


II. Preface

ROCHEM Reverse Osmosis Systems have been designed as space-saving modular plants, in
order to provide to you a flexible system, where space is restricted.

All components and materials used have been manufactured to the highest quality
requirements, guaranteeing long life on a self-controlling 24 hours operation. ROCHEM
systems are simple to operate and require a minimum of service. More than 2100 plants
supplied worldwide confirm this.

ROCHEM Reverse Osmosis Systems meet the requirements and specifications of the
following organizations:

Deutsches Institut fr Normung
Verband Deutscher Elektrotechniker e.V.
Verein Deutscher Maschinen Anstalten
Verein Deutscher Ingenieure
Germanischer Lloyd
Det Norske Veritas
Registro Italiano Navale (RINA)
Lloyd's Register of Shipping
Bureau Veritas (French)
ABS (American Bro of Shipping)
Russian Maritim Register of Shipping

They are also built to comply with military specifications and requirements.

III. How to Use this Manual

This manual should provide to you all the information required for operating and maintaining your
ROCHEM Reverse Osmosis System. When designing this system great regard has been
paid for safety. When working on this or any other system there is always an element of danger,
which the owner, operator and technician need to be aware of. Appropriate maintenance
minimizes any danger and maximizes availability.

Any work of maintenance or repair, must be carried out correctly. Appropriate technical
knowledge as well as any applicable regulations for safety and environment must be provided
by the owner, operator and/or the maintenance personnel.

THIS MANUAL DOES NOT REPLACE ANY PERSONAL TRAINING!

IV. Safety Remarks
F
The fresh water generator must not be operated within harbour area. Or in
waters polluted with oil.

F
When operating this equipment certain parts are electrified. Ignorance of operating
procedure can cause death, injury or material damage. ANY WORK AT OR ON THE
PLANT MUST ONLY BE DONE BY PERSONS TRAINED ON THE MACHINE AND
FAMILIARIZED WITH THE INFORMATION IN THIS MANUAL. REPAIR AND
MAINTENANCE MUST ONLY BE DONE BY APPROPRIATELY QUALIFIED
TECHNICAL PERSONNEL.

F
PROTECTION, SUCH AS PULLEY / BELT GUARDS, MAY BE REMOVED ONLY
FOR MAINTENANCE OR REPAIR AND MUST BE RE INSTALLED IMMEDIATELY
AFTER ANY SUCH REPAI R OR MAINTENANCE HAS BEEN COMPLETED.

The owner and user, are responsible for complying to all prevailing laws to maintain a safe
working environment.

For plant protection please note the following important items:

F
There must not be any visible movement (vibration/pulsation) of the pointer on
pressure gauge PI160. If this occurs then one of the following is causing this fault: 1-
Some nitrogen gas has leaked from the pulsation damper. 2- The diaphragm in the
pulsation damper is damaged. 3- High pressure pump valves or packing are defective.

F
The PT modules will be damaged, if there is any vacuum in the feed water
supply line or concentrate discharge line.

F
Do not allow any back pressure on the permeate outlet, when there is no
pressure on the feed supply, otherwise the membrane cushions will be
damaged. Do not allow pressure on the permeate side of the modules when the
unit is stopped. The maximum pressure in the permeate line is 3 bar. If a permanent
pressure above this value is required then an additional booster pump will be
necessary.

F
The feed pressure to the high pressure pump PP160 must not fall below 0.5 bar.
If this happens, the pump will be damaged by cavitation.

F
The membranes are not resistant against chlorine or any oxidizing agent. De-
ionized or distilled water in the unit will reverse the flow direction and destroy
the membranes.

F
Please take care of the feedwater quality conditions for the membrane module
performance. Do not allow to operate the RO unit in areas of river esturiances,
especially in regions with low draff where the water can be expected to carry a
high amount of suspended solids and silicates. This could cause unremovable
deposits on the membrane surfaces affecting the desalination process,
reducing capacity and finally requiring the membranes to be replaced.


V. Log Sheet

In order to make any troubleshooting as easy as possible, we recommend you to fill in the
following chart daily with the parameters measured on the unit.

Date
operating
hours
Feed
water
conducti-
vity
FI130 TI130 PI130 PI140 PI150 PI160 PI180 CI180 FI180


VI. Warranty

ROCHEM RO-WASSERBEHANDLUNG GMBH. Warrants that this system will produce
pure water within its designed limitations for a period of twelve (12) months from the date
of dispatch, provided that the system is operated on feed water of the minimum standard in
accordance with the submitted reference analysis and that the operator adheres exactly to
the installation, operating and maintenance instructions and recommendations.

Components of the system supplied by ROCHEM RO-WASSERBEHANDLUNG which are
found to be defective through poor workmanship or materials, will be repaired or replaced
if their performance is proven to be less than normal by industry standards.

This warranty will be considered null and void if a unit is operated with malfunctioning
components or controls which result in the system being unable to meet its designed
performance.

ROCHEM RO-WASSERBEHANDLUNG will repair or replace a unit or components found
to be defective due to bad workmanship or materials on a free of charge ex works
Hamburg basis.

A defective unit or component may be returned, freight prepaid, to
ROCHEM RO-WASSERBEHANDLUNG for repair or replacement ex factory, as
determined by ROCHEM RO-WASSERBEHANDLUNG, should the unit be found defective
under this warranty.

This warranty does not cover any system or component which fails, due to damage from
mishandling, misuse, substandard feed water, improper maintenance or neglect of
maintenance, poor or improper installation or incorrect electrical supply. This warranty may
also be voided if serial numbers and or components are found to be mutilated or missing.

This warranty does not cover or apply to consumable items such as filter elements,
lubricants, pulsation dampers, shaft seals of centrifugal pumps, valves, and seats of the HP
pumps or chemicals used in the operation or maintenance of the system.
The terms of this warranty become effective on dispatch of the equipment from our factory.

There are no warranties expressed or implied which go beyond the foregoing statement.


VII. NOTES

VIII. Service

To:

Telephone: + 49 (0) 40 7038577-0 Telefax: +49 (0) 40 7038577-29

e-mail:

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Rochem RO-Wasserbehandlung GmbH

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Telephone: + 49 (0) 40 7038577-0 Telefax: +49 (0) 40 7038577-29

e-mail:
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Rochem RO-Wasserbehandlung GmbH


1) FUNCTIONAL DESCRIPTION

1.1 Description of Process
This fresh water generator uses the principle of the Reverse Osmosis.

If two saline liquids are separated from another by a semi-permeable membrane, which does
only allow molecules over a certain size to pass through, then, these liquids will tend to equalize
their concentrations. This process is called Osmosis. Should one of these liquids be salt water
and the other pure water, water molecules would diffuse through the membrane towards the
salt water and dilute this. A certain pressure would occur in the system when this happens this
pressure is called the Osmotic Pressure.

For water desalination or dechlorination this process is artificially reversed, Reverse Osmosis.
The system is subjected to a pressure above the Osmotic Pressure, causing a molecule
movement into the reverse direction: Only the water molecules diffuse from the salt water
through the membrane to the pure water side. The ions of the salt water cannot pass through
and remain on the salt water side.

Within the ROCHEM PT modules the REVERSE OSMOSIS process takes place whilst the
feed water is in motion, flowing over the membrane surfaces. About 30% of the water in the
feed water passes through the membrane, the remaining 70% retaining the rejected salts. The
feed water is gradually increasing in salt concentration as it flows through the module. The salts
filtered out and left behind by the membrane are carried away and discharged, in case of sea
water desalination they are returned to the sea as brine (concentrate). The pure water
permeate produced flows to a fresh water storage facility.

The amount of pure water that can be produced depends on the following factors:
1- the operating pressure,
2- the salt content of the feed water,
3- the feed water temperature.
For example the oceans have a salt content of approximately 3 %. whereas the Red Sea has
a much higher salt content of approximately 4 %,
To overcome the increase in salinity the operating pressure is increased.

Each standard system has been designed for a certain production rate of pure water, assuming
a feed water temperature of 25C. For each 1C drop in feed water temperature the permeate
production drops by 3%. For example: Designed output at 25C is 100 l/h.
Then with a feed temperature of say 15C the permeate output is 100-30% = 70 l/h.
A rise in temperature above 25C increases the pure water production only slightly. 25C is the
optimum feed temperature.

Note: Some systems can be supplied to produce the required quantity with a low feed
water temperature.


1.2 Unit Arrangement
The water desalination system consists mainly of the following components:

Sandfilter safety valve control panel
(master-switch)

conductivity
display

control cabinet

flowmeters

Sample valves

Deacidification
Filter

removable pump
carrier
(PK130, PP160,
VS160)
sandfilter cartridge filters manual valves gauges

General arrangement of the RO1530 (individual deviations not allowed for)

Sketch of operating principle


BRIEF DESCRIPTION OF MAJOR COMPONENTS

The plant is controlled by a PLC unit Telemecanique TSX-Micro. The
control program is stored on a microchip called EEPROM. When
switching on the plant the processor loads the program automatically from
the EEPROM into its Random Access Memory. By means of a
programming device, connected to the serial interface of the processor
unit, changes can be made to the program.

The following valves must be set manually for the different operating functions:
VK121 VK132 VK134 VK133 VK171
normal operation

stop rinse

circuit cleaning

sandfilter
backwash
- air rinse -

sandfilter
backwash
- water rinse -

valves handle
showing
normal
functional
flow

valve closed


Pressure switch PS150 is activated by the water pressure before the
high pressure pump and switches the plant off in the event of insufficient
feed (to protect the pump against cavitation). It is de activated when the
pressure drops below a set value of 0.5 bar. High pressure pump will not
start if this pressure switch is not activated. When not activated fault will
show.
Pressure switch PS170 (if installed) monitors the pressure in the
concentrate line from the PT module. It stops the plant at a pressure of 6
bar, in order to avoid damage to the module. Most probable cause for this
to be activated is that a valve on the concentrate discharge is closed.
This pressure switch is activated when the pressure goes above the 6 bar
setting. When activated fault will show.
Pressure switch PS180 stops the plant when the pressure in the
permeate line rises to 3 bar. This is to save the PT module from damage.
This pressure switch is activated when the pressure goes above 3 bar.
When activated fault will show.

Centrifugal pump PK130 filter pump, delivers the feed water at a
pressure of up to 4 bar through the cartridge filter and from there to the
high pressure pump PP160. This centrifugal pump has its own integral
electric motor.

The sand filter retains all sediment particles over 50 m in size. As the
density of these particles increases, the pressure drop across the inlet and
outlet increases. To reduce this pressure drop and remove these particles,
the sandfilter is backwashed by air and feed water (generally when 2 to 2.5
bar are reached).

Within cartridge filter FC140 sediment particles of 10 m or more in size
are retained within the filter element. These cartridge filter elements have
to be replaced when dirty, they cannot be cleaned.

High-pressure pump PP160 is a positive displacement pump. (plunger
pump) this pump delivers feed to the PT modules at a pressure of up to
65 bar. (note: pressure is controlled by VS160). The pump is powered
through a belt drive from a three-phase motor. Minimum feed pressure to
this pump is 0.5 bar.

The pulsation damper fitted on the high-pressure pump discharge
converts the pressure fluctuations, common for a plunger pump, into a
steady pressure. It consists of a pressure vessel, internally separated by
an diaphragm into two sections. The outermost section is filled with
nitrogen at a pressure of 30 bar. The pulsations from the 3 plungers of the
HP pump are absorbed by the gas pressurized membrane. It is normal to
observe pulsations in the pointer of PI160 when pointer is rising through 25
to 32 bar, (resistance against gas pressure).

Innerhalb der ST-Module wird das Rohwasser unter dem angelegten
Druck durch die Membrankissen gepresst. Das Wasser dringt durch die
Membranen und wird als Permeat abgefhrt; Salzmolekle und andere
Verunreinigungen des Rohwassers knnen die Membran grtenteils nicht
passieren (Rckhaltung bei NaCl 98,5-99%), bleiben zurck und werden
vom nachfolgenden Rohwasser mitgenommen, so dass sich dieses von
Modul zu Modul weiter aufkonzentriert. Das Konzentrat wird (bei
Seewasserentsalzung) in das Meer zurckgeleitet.

The pressure in the PT module or modules, is automatically controlled and
adjusted by motor valve VS160, which in turn is controlled by the PLC.
The plant is designed for a maximum operating pressure of 65 bar.
The operating pressure is 65 bar with normal sea water.
This valve should never be fully closed during operation. When in operation
this valve reduces the flow area to increase the pressure between the HP
pump discharge and the outlet of the modules. If this valve closes a fault
will show.
This valve can be manually operated by a hand wheel should the power
unit fail.
The concentrate flows from the unit through the manually operated concentrate valve VK171,
which allows three positions:

(a) at normal operation, discharge (e.g. sent overboard back to sea),

(b) at circuit cleaning, returning to cleaning tank B111,

(c) at closed position.

A conductivity sensor transmits the conductivity of the permeate to the
conductivity meter, (measuring the remaining salt content). An increase in
conductivity implies a higher salt content. The value displayed in the
conductivity meter is in s/cm. As a rough guide, if the reading shown is
divided by 2 the figure obtained would be the approximate value of salts as
p.p.m.(mg/l).


The pure water solenoid valve VE1801 is automatically controlled by the conductivity of the
permeate. If the maximum pre-set value (1000 S/cm for sea-water desalination, 50 S/cm for
mains water purification) is exceeded, VE1801 sends the permeate into the cleaning tank (from
there to drain). When good permeate is produced, at a quality with a lower conductivity than the
maximum pre-set value, then VE1801 sends this water to fresh water storage.
If the plant operates more than 15 to 20 minutes at high conductivity (over the set limit), it
automatically shuts down and a fault signal is displayed.
As an option the plant can be equipped with a fresh water storage control. Starting and
stopping the unit will then be actuated by 2 level switches fitted in the storage tank. When the
low level switch is activated, the plant will start automatically. When the tank is full the high level
switch will be activated and the unit stops and will be in a stand by mode waiting to be
restarted either by remote (level switch) or manually by pressing the start button.


1.3 Controls, Displays and Measurements

The control panel is equipped with a main switch, a conductivity meter and 5 lamp buttons:

lamp button color function
1 green START
2 yellow STOP WITH RINSE
3 yellow CIRCUIT CLEANING
4 yellow SANDFILTER BACKWASH
5 red FAULT RESET / LAMP CHECK

The flow meter FI180 is installed in the permeate line from the PT
module(s). Inside the plastic body there is a floating indicator. When its top
edge aligns to the appropriate mark on the scale, indicates the rate of pure
water produced. The scale is marked in liters per hour on the front of the
transparent plastic body.
The floating indicator 1 is magnetic and actuates a eletrical siglal to the
PLC. The PLC in turn sends a signal to the motor valve VS160. VS160
controlled the pure water flow.

The conductivity meter displays the conductivity of the permeate,
measured by the conductivity sensor. Conductivity provides a measure for
the salt content remaining: The higher the conductivity, the higher the salt
content.

The pressure gauges PI140 and PI150 (PI140-PI150) indicate the
pressure loss across the cartridge filter, PI130-PI140 indicates the
pressure loss across the sandfilter. If the pressure loss reaches an
approx. value of 2 to 2.5 bar, the sandfilter must be backwashed.
PI160 shows the operating pressure of the unit, shown as the inlet
pressure to the PT Modules.
The pressure gauges are filled with a glycerin type liquid, this is to
minimize pointer vibration.

1.4 Safety and behaviour rules

Intended use

This system is use for drinking water processing.

Briefing

When operating this equipment certain parts are electrified. Ignorance of operating procedure
can cause death, injury or material damage. ANY WORK AT OR ON THE PLANT MUST
ONLY BE DONE BY PERSONS TRAINED ON THE MACHINE AND FAMILIARIZED WITH
THE INFORMATION IN THIS MANUAL. REPAIR AND MAINTENANCE MUST ONLY BE
DONE BY APPROPRIATELY QUALIFIED TECHNICAL PERSONNEL.

Electrical endangerments

During the operation of electrical devices some sections are energized dangerous. Neglect the
warning notes can occur death, bodily injury, or damages to property. The cabinets and devices
are only to be opened by qualified personnel.

Mechanical endangerments

The system was designed in the state of the art. In order to ensure safe handling of the system,
all preventive measures have to checked for effectiveness. The operator has to ensure by
regular maintenance that the function of the respective protection devices will preserved.
Detailed instructions, as far as necessary, can be found in the appropriate chapter.

Chemical endangerments

The operation of the unit and functions depending upon field of application different chemicals
(e.g. cleaner, pH stabilizers, flocculant, disinfectant). The respective safety notes can be found in
the appropriate section.


2) OPERATING

2.1 Commissioning
Before commissioning the plant, please take note of the following:

First, please read the safety remarks in the first pages of this manual!

LIMITS OF PERFORMANCE
Maximum flow rates Feed Water: 800 l/h
Permeate: Designed + 30%
Note: High feed flow will cause an unacceptable
pressure loss across the PT modules and a
higher ampere loading on the HP pump motor
Operating pressure
Maximum operating pressure
65 bar
73 bar

Before first commissioning the plant the following checks must be made:

ASSEMBLY CHECKS BEFORE FIRST COMMISSIONING
Control cabinet
- Check voltage

- Check frequency
The voltage must be checked across each two phases:
from L1 to L2
from L1 to L3
from L2 to L3
The plant must only be operated at the ratings it was designed for.
- Check control voltage Check transformer output voltage. For all PLC inputs, pressure
switches and level switches 24 V DC +/-5%. must be obtained.
PT Modules Check torque loading.
Pressure switches
PS150, PS170 and PS180
Check correct settings (for adjustment see chapter 4.5 in the
section for Maintenance, Cleaning and Calibration).
Flow meter Check setting of magnetic switch behind flow meter.


2.2 Starting the Unit

Lamp signals : l lamp on
? lamp flashing
lamp off

Lamp signals when unit is shut-down:

Step
No.
Action Effect Lamp signal
1 Open all valves to and from
the RO unit.

2 Open VK111 - Drain all water from cleaning tank.

3 Set valves to Normal
operation:

VK121 VK132 VK134 VK133 VK171
normal
operation

4 Turn master-switch to I
(On).
- Conductivity display illuminated.
5 Press lamp button 1. - Motor control valve VS160 is open.
?
- When WS161 sends signal "valve
completely open to the PLC, filter
pump PK130 starts.

- High pressure pump PP160 starts
300 seconds. after pressure switch
PS150 has given start signal.

- Motor control valve VS160 runs
towards close to bring up pressure.

- Pressure transmitter PT160 stops
pressure rise when maximum
pressure or maximum permeate flow
rate is reached. VE1801 sends
permeate into tank B111, since
conductivity limit is exceeded.

- Conductivity of permeate drops below
allowed maximum. VE1801
switches to permeate discharge, i.e.
fresh water storage.
l


1st Sequence after pressing of START button and unit running. Permeate quality has not reached the set level
and made Permeate is being Dumped.

2nd Sequence, Permeate Conductivity has fallen below the set point and Permeate is now being sent to
Storage.


2.3 Monitoring during Normal Operation

The following functions are continuously monitored:

Parameter Device Set values
Feed pressure pressure switch PS150 (min. pressure) 0,5 bar
Pressure at inlet to module pressure transmitter PT160 (max. pressure)

73 bar
Pressure of discharged
concentrate
pressure switch PS170 (max. pressure) 6 bar
Pressure of delivered permeate pressure switch PS180 (max. pressure) 3 bar
Flow rate of permeate flow meter FIS 180 (nominal capacity), shut-down
delayed
1300 l/h
Conductivity of permeate conductivity sensor/meter CIT80 (max. value) 1000 S/cm (sea
water) or 50
S/cm (town
mains water)
Amperage of electric motors motor circuit-breakers (see electric
schematics and
rating plates)

FUNCTIONS FOR MANUAL CONTROL

Lamp check: By pressing lamp button 5 all button lamps will illuminate. Replace any faulty lamp
immediately.
FAILURE OF UNIT
In the event of an operating failure the plant is automatically stopped and a fault signal is
displayed by the lamp buttons being illuminated in various sequences. Lamp button 5 flashes,
the yellow lamp buttons 2,3 and 4 are either on or off in a certain combination indicating the
cause of the failure.
A table of all fault signals is located at the front of the control cabinet. (Also refer to section
Fault Indication & Finding).
After correcting the problem the plant can be restarted after pressing lamp button 5 to clear the
fault from the PLC.


2.4 Stopping the Unit

? lamp flashing
lamp off

Lamp signal at unit shut-down:
Step
No.
Action Effect Lamp signal
1 Close valve VK111. - To stop cleaning tank emptying
l
2 Press lamp button 2
(STOP WITH RINSE)
- VE1801 changes over to fill tank
B111 with permeate.
?l
- Tank B111 full LS1113 activated

- Motor control valve opens to reduce
operating pressure.

- Unit stops.
?
3 Set valves as below: (to take suction from cleaning tank)
VK121 VK132 VK134 VK133 VK171
stop rinse

4 Press lamp button 1 - Rinse with permeate starts.
l
- Low level switch LS1111 activated
(tank empty). Unit stops.

5
To protect the unit for external
pressure fluctuations set the
valves as below

VK171

(delivery to cleaning tank)

VK121

(suction from cleaning tank)

Open valve VK111. Tank B111 is drained.

Note:
If a stand-still of more than 10 days is intended, a preservation must be carried out prior
to shut down. This is to prevent bacterial fouling on the membranes.

1st Sequence after pressing of STOP/RINSE button. Solenoid Valves VE1801/2 change over to fill tank B111
with permeate.

2nd Sequence after pressing of STOP/RINSE button. Centrifugal Pump PK130 sucking permeate from
cleaning tank to rinse the Unit.

2.5 Sandfilter Backwash

A sandfilter backwash is necessary, when the pressure loss across the sandfilter due to
sedimentation exceeds 2 or - as a maximum - 2.5 bar.
Note: Unit must be stopped to start this procedure
? lamp flashing
lamp off

How to carry out a sandfilter backwash:

Step
No.
Action Effect
Lamp
signal
Unit is stopped
1 Close VK111, if open. (to stop draining of cleaning tank B111)
(SANDFILTER BACKWASH).

?
3 Set valves for air rinse:
VK121 VK132 VK134 VK133 VK171
sandfilter
backwash
- air rinse -

4 Air treatment: Connect air supply
to connecting branch VF139.

5 Open VK136 and flush sandfilter
for 10 min. with air (max. pressure
0.5 bar)

If unsure about the low air pressure, Put your ear
against the sand filter and listen. When air is
heard Bubbling stop increasing the air pressure.

6 Disconnect air supply at
connecting branch VF139.

7 Open valve VK121:

to sea suction

8 Close valve VK136
9 Water treatment: Press lamp-
button 1 (START)
Filter pump PK130 starts. Sandfilter is rinsed
with raw water. Raw water passes the sandfilter
and flows through brine outlet back to sea.
Unit stops automatically.
l
10 After approx. 10 to 15 min. of
water rinse press STOP/RINSE.
Unit is rinsed with water and stops afterwards.

1st Sequence after pressing of SFB button.
Air-Rinse

2nd Sequence after pressing of SFB button.
Water-Rinse


2.6 Circuit Cleaning

Organic and inorganic substances within the feed water are deposited on the membrane
surfaces (described as Fouling and Scaling). This causes an increased salt content in the
permeate and a reduction in the fresh water production. By circuit cleaning these
sedimentations are flushed off and removed.
A circuit cleaning is required, when the fresh water production has dropped by 10 to 15% (equal
water temperature assumed). Generally, it should be carried out every 3 to 4 weeks.

CHOICE OF CLEANER:

The ROCHEM cleaning solutions are specially formulated and made for the membranes
used in our PT modules. Use of other chemicals can cause damage and loss in
performance. The membranes can be damaged by oxidizing agents (e.g. free chlorine, Cl
2
,
ozone O
3
). In the sea water these contents are normally neutralized by other existing organic
substances. Oxidizing agents are sometimes used in sea water pipe systems, to avoid fouling
and kill bacteriums.

Cleaner Application
Type AA For organic sedimentation and fouling
Type C To remove iron fouling.

For normal cleaning cleaner AA would be used.

It is recommended that C is used every 4 months to remove iron deposits. These would come
from the sea water and also from pipe lines, suction chest and vessels hull.

If the type of deposits / fouling is not known, all cleaners C and AA should be used consecutively.
Run the unit for a minimum of 3 hours between cleanings to check results.
Maximum concentration of cleaner: 5 liters of cleaner per 100 liters of water (which corresponds
to 5 liters of cleaner per cleaning cycle for this unit).

CAUTION:

F
NEVER MIX DIFFERENT CLEANERS!
If done, this will only neutralize the cleaning solution and the cleaning results will be
minimal. This can also damage the membrane surfaces.


F
Never pass any external water (e.g. distilled, chlorinated or de-ionized water)
into the RO unit. This would cause damage to the membranes by osmosis.

F
The feed water temperature should not exceed 30C.

F
When using 2 cleaners, to be fully effective they must be used in the following
sequence:
1st Cleaner C (acidic cleaner).
2nd Cleaner AA (alkaline cleaner).
Acidic cleaner should always be used before the alkaline cleaner. This removes
the deposits nearest the membrane surface making it easier for the alkaline
cleaner to remove the organic deposits.

F
Never disassemble the membrane modules for cleaning the membrane cushions
by hand or other soft equipment which will in any way affect the membrane layer
surface and the membrane material will lose its salt rejection ability.

STARTING THE CLEANING PROCESS

The cleaning can only be initiated from normal operating mode.

? lamp flashing
lamp off


Step
No.
Action Effect
Lamp
signal
1 Close valve VK111. - To stop cleaning tank draining
l
(CIRCUIT CLEANING).
- Magnetic valve VE1801 switches over
and allows the permeate to be delivered
into tank B111, until level switch LS1113
is actuated.

?ll
- Motor control valve VS160 runs open.

- Operating pressure drops.

- Switch WS161 is made, when VS160 has
completely opened.

- Pumps PK130 and PP160 are stopped.
?


3 Set valves for Circuit Cleaning: (for closed circuit operation)
VK121 VK132 VK134 VK133 VK171
circuit cleaning

4 Open VK111 for a moment to
get space for cleaner.
Put injector hose into the can
with 7.5 liters of cleaner and
open valve V111 to allow the
cleaner to be sucked in.
(Make sure only 7.5 liters of
cleaner are sucked in.)
- Cleaning agent
?
(START).
- Pumps PK130 and PP160 start.
l

Close V111 when container is
empty.
- Cleaner and permeate are being mixed,
pumps run intermittently (each 5 min.
operation followed by 5 min. Stop).
Cleaning cycle time: approximately 2 hrs.

6 Cleaning completed - Unit stops (approx. after 2 hours).
7 Open VK111 to draining Tank
B111

For the first start after cleaning the unit is programmed to rinse with raw
water. First the plant is flushed for 5 minutes without pressure increasing,
then for another 5 minutes under pressure. During this time the permeate
produced is not supplied to the fresh water storage, this is to avoid the
possibility of any chemicals being in the permeate.

??

CAUTION:

F
After every cleaning cycle the cartridge filter elements must be replaced.


RO CLEANER AA

a.) Safety marks for the employer

Sodium hydroxide solution, 2-5 %

Hazards for human health and the environment
Breathing in and swallowing may result in health damage. Causes burns. Can cause bronchitis.
Add to water when diluting, never the other way round. Reacts with acids under the formation of heat, risk of splashing!
Forms hazardous vapours with ammonium compounds and light metals (hydrogen Danger of Explosion!).
Hazardous to water - avoid ingress into the ground, water and sewage!

Protective measures and behaviour rules
Work with good ventilation! Open seals cautiously! Do not leave vessels open! Limit stored quantities to
one shift requirement! Avoid contact with eyes, skin and clothing!
Preventive skin protection necessary. Remove product residues from the hands immediately!
Thoroughly clean hands after completing work and before every work break! Avoid splashes!
Use skin care agent! Immediately change wetted clothing! Change clothing after completing work!
Store street clothing separately from work clothing! Observe restrictions on activity!
Eye protection: Full protection goggles! If there is a risk of being sprayed: wear a face guard as well as
eye shields.
Hand protection: Gloves made of: Natural rubber, Polychloroprene, Nitrile rubber, Butyl rubber,
Flourinated rubber It is advisable to wear cotton gloves underneath protective gloves.

Breathing protection: particulate filter. P2 (white)
Skin protection: Use skin protection ointment containing grease for all uncovered parts of the body.:

Body protection: Alkali-resistant protective clothing! When diluting or filling: plastic apron!

Behaviour in danger situations
Collect and dispose of with absorbent non-combustible material (e.g. kieselguhr, sand)! Caution! Spilt solution presents
risk of slipping (by iwater contact)!
Product is not combustible. Only fight fires with breathing apparatus independent of ambient air and Responsible
physician or clinic:
Accident phone:

First Aid
During all First Aid assistance: protect yourself and immediately inform a doctor.
After eye contact: Rinse for 10 minutes with water or with eye-wash solution.
After skin contact: Take off soiled clothing immediately. Clean with abundant amounts of water and
soap. Rinse with water for 15 minutes after burns.
After breathing in: Fresh air. Keep airways clear: remove false teeth, vomit etc.. If breathing or
heartbeat stops: immediately apply artificial respiration and heart massage.
After swallowing: No domestic agents. Do not cause vomiting. If conscious, see that plenty of water is
drunk a little at a time.
First Aid specialist:

Proper disposal
Do not pour into the sewage or a refuse bin!
For disposal, collect in:

_____________________________
Signature of the employer


RO CLEANER C

a.) Safety marks for the employee

Citric acid, 10-30 %

Breathing in, swallowing or absorption through the skin may result in health damage. Causes burns.
Temporary complaints (cough) are possible. Can cause laboured breathing, eye damage.
Add to water when diluting, never the other way round. Reacts with alkalis under the formation of heat, risk of splashing!
Ensure a fresh air supply when working! In the event of vapours, work only with exhaust ventilation!
Keep away from ignition sources! Do not smoke! No naked lights! Do not leave vessels open!
Avoid splashes! Limit stored quantities to one shift requirement! Avoid contact with eyes, skin and
clothing! Preventive skin protection necessary. Use skin care agent!
Thoroughly clean hands after completing work and before every work break! Store street clothing
separately from work clothing! Immediately change wetted clothing! Observe restrictions on activity!
Eye protection: Full protection goggles!
Hand protection: Gloves made of: Butyl rubber
It is advisable to wear cotton gloves underneath protective gloves.

Breathing protection: partikular filter P2 (withe)

Body protection: When diluting or filling: plastic apron! Spray processes: protection suits!

Remove only after applying personal safety equipment! Clean objects and flooring which have become wetted or
soiled immediately with plenty of water! Collect and dispose of with acid-binding material (e.g. limestone meal) and
rinse remainders away with water!
Product is combustible, suitable extinguishing agents: water in a jet, carbon dioxide, extinguishing powder, foam! In the
event of a fire in the environment, cool the receptacle with sprayed water! Explosive mixtures can be generated if strongly
heated!
Responsible physician or clinic:
Accident phone:

First Aid
After skin contact: Take off soiled clothing immediately. Rinse with water for 15 minutes after burns.
After breathing in: Fresh air. Keep airways clear: remove false teeth, vomit etc.. If breathing or
heartbeat stops: immediately apply artificial respiration and heart massage.
After swallowing: Do not cause vomiting. If conscious, see that plenty of water is drunk a little at a time.
No domestic agents.

Proper disposal

_____________________________


1st Sequence after pressing of CLEAN button. Solenoid Valves VE1801/2 change over to fill tank B111 with
permeate.

2nd Sequence after pressing of CLEAN button. Cleaner is sucked into cleaning tank B111.

3rd Sequence after pressing of CLEAN button. Unit is now running in Closed Circuit Cleaning Mode.


2.7 Preservation

To prevent fouling during a stand-still of more than 10 days, the unit must be preserved.
? lamp flashing
lamp off

Step
No.
Action Effect
Lamp
signal
1 Close valve VK111 To stop cleaning tank draining
l
2 Press lamp button 3 (CIRCUIT
CLEANING).
- Solenoid valves VE1801/2 switch over
and send permeate to tank B111.
?ll
- Tank full level switch LS1113 activated

- Motor control valve VS160 runs open.

- Operating pressure drops.

- Switch WS161 is made, when VS160 has
completely opened.

- Pumps PK130 and PP160 are stopped.
?
3 Set valves for Preservation: (for closed circuit operation)
VK121 VK132 VK134 VK133 VK171
circuit cleaning

get space for biocide.
with 5 liters of biocide
(ROCIDE) and open valve
V111 to allow the biocide to be
sucked in. (Make sure only 5
liters of biocide are sucked in.)
- Preserve agent
?
5 Press lamp button 1 (START). - Pumps PK130 and PP160 start.
l

empty.
- Preserve solution is mixed with permeate.

- Unit stops after approx. 2 hours.


Note: A sufficient circulation of the preserve solution has already been
reached after 30 min. , the process can now be aborted:

6 Press lamp button 2 (STOP).

7 Open VK111 to empty tank
B111.
Preserve solution passes through the
discharge line.

8 Turn off master-switch.
For the first start after Preservation the unit is programmed to rinse with raw

??

CAUTION:

F

The unit is now ready for normal operation.


RO Membrane Biocide (ROCIDE)

a.) Safety marks for the employee

Sodiumbisulfit


Breathing in and swallowing may result in health damage.
Irritating (respiratory tract, eyes, skin, organs of digestion).
Eye damage possible.


Avoid dust development! Avoid contact with eyes, skin and clothing!
Thoroughly clean hands after completing work and before every work break!
Use skin care agent! Immediately change wetted clothing!
Eye protection: Full protection goggles!
Hand protection: Gloves made of: Natural rubber, Polychloroprene, Nitrile rubber, Butyl rubber,
Flourinated rubber
It is advisable to wear cotton gloves underneath protective gloves.

Breathing protection: particulate filter. P2 (white)


Collect and dispose of, avoiding dust in the process! Product is not combustible.
In the event of a fire in the environment, cool the receptacle with sprayed water! Hazardous vapours are produced under
the influence of heat!
Responsible physician or clinic:
Accident phone:

First Aid

After skin contact: Take off soiled clothing immediately. Clean with abundant amounts of water.
After breathing in: Fresh air. Keep airways clear: remove false teeth, vomit etc..
After swallowing: Do not cause vomiting. If conscious, see that plenty of water is drunk a little at a time.
No domestic agents.

Proper disposal

_____________________________


1st Sequence after pressing of CLEAN button. Solenoid Valves VE1801/2 change over to fill tank B111 with
permeate.

2nd Sequence after pressing of CLEAN button. Biocide is filled into cleaning tank B111.

3rd Sequence after pressing of CLEAN button. Unit is now running in Closed Circuit Cleaning Mode.

2.8 Disinfection

If the permeate should be found contaminated of bacteriums, or generally after a longer stand-
still without a prior preservation), a disinfection should be carried out.
? lamp flashing
lamp off
Step
No.
Action Effect
Lamp
signal
Unit is running in normal operating mode.
l
1

(to stop draining of cleaning tank B111)
2 Press lamp button 3 (CIRCUIT
CLEANING).
Solenoid valves VE1801/2 switch over and
send permeate to tank B111.
?ll
Tank full level switch LS1113 activated
Motor control valve VS160 runs open to
reduce operating pressure.

Switch WS161 is made, when VS160 has
completely opened.

Pumps PK130 and PP160 are stopped.
?
3 Set valves for Disinfection: For closed circuit operation
VK121 VK132 VK134 VK133 VK171
circuit cleaning

get space for biocide.
with 5 liters of biocide
(ROCIDE) and open valve
V111 to allow the biocide to be
sucked in. (Make sure only 5
liters of biocide are sucked in.)
- Disinfect agent
?
5 Press lamp button 1 (START).
empty.
Pumps PK130 and PP160 start. Membrane
biocide is sucked in and mixed with
permeate.
l
Unit stops after approx. 2 hours.
6 Open VK111. (to empty tank B111)


For re-start:
8 After approx. 10 hours turn
valves back to Normal
Operation:

VK121 VK132 VK134 VK133 VK171
normal operation

9 Press lamp button 1 (START).

For the first start after disinfection the unit is programmed to rinse with raw

??
CAUTION:

F

The unit is now ready for normal operation.


3) FAULT INDICATION & FINDING
3.1 Error Codes, Implication and Faults
Fault conditions are indicated by lamp buttons 2 to 5 (lamp button 1 is off).
A plate describing all fault displays is located on the front of the machine.

? lamp flashing
lamp off

Lamp signal Device Meaning Possible causes
LAMP SIGNALS A: RED LAMP BUTTON IS ILLUMINATED PERMANENTLY
1 2 3 4 5
l l
PS150 Feed pressure before PP160 too low

- Insufficient feed supply
- pre filters / strum box blocked
- external pump required
- VK121 not in correct position
- pump PK130 defective
- pressure loss in cartridge filter too high
- pressure switch PS150 defective
- connection to processor defective
l l
PS180 Pressure in permeate line too high

- permeate line to external tank not open
- excessive back pressure on discharge
- deacidification filter blocked
- wrong flow direction in deacidification
filter (correct: from top to bottom)
- pressure switch PS180 defective
ll l
I Electric motor load too high

- Circuit-breaker not properly adjusted
- circuit-breaker defective
motor malfunctioning due to...
- damage to bearings
- short circuit
- ambient temperature too high
- insufficient cooling
- voltage or frequency wrong
- phase broken
l l
VS160 Motor control valve closed during
operation

- Pipe damaged in high-pressure section
- to high resistance in VS160, valve gland
packing too tight
- corrosion, damage spindle/seat in VS160
- limit switch WS162 defective
- high pressure pump drive belts not
correct
- damaged / worn packing in high
pressure pump.
- PT module damaged


ll l
PI160
PT160
Over pressure in PT module

- PT160 does not stop pressure rise
- VS160 does not open
- relay output to VS160 defective
- set value at PT160 wrong
- PT160 damaged
ll l
PS170

Over pressure in concentrate line

- Discharge line valves not open
- VK171 in wrong position during operation
- PS170 defective
lll l
CS180 Permeate conductivity too high

- Module dirty
(circuit cleaning required!)
- torque on module not correct
- sealing or membrane in module
damaged
- operating pressure too low
- feed water conductivity extremely high
- feed water temperature above 35C
- magnetic switch on CIT180 defective
- CIT180 not properly adjusted
LAMP SIGNALS B: RED LAMP BUTTON FLASHES
1 2 3 4 5
l ?
LS1111 Level switch LS1111: Tank empty
l ?
UP Subroutine stopped
ll ?
Reserved
ll ?
VS160 Motor control valve malfunctioning

- high resistance in VS60 valve spindle
due to gland packing
- corrosion damage in VS60
ll ?
FT180 Permeate flow rate too high

- PT Module malfunction due to internal
leakages (sealing or membrane
damaged)
- floating indicator jammed or damaged
(corrosion)
- operating pressure too high
- low salinity feed water
ll ?
RF001 (Reserved)
lll ?
LS1113 Max. filling time B111 exceeded - too long filling time B111
- drain valve VK111 open
- LS1113 defective


3.2 Faults without Lamp Indication

Lamp signal Device Meaning Possible causes
FAILURES WITHOUT FAULT INDICATION
Plant cannot be started - Check energy supply and fuses
- processor out of order
High-pressure generation failed - set value on PT160 wrong
- permeate flow rate too high
- no signal from PT160 to processor, e.g.
due to defective cable
Excessive pressure fluctuation during
operation
- pulsation damper gas pressure wrong.
Correct pressure (if possible) or replace
pulsation damper
- valves in HP pump worn or damaged
PP160 valves malfunctioning - normal wear
- particles between valve plate and valve
seat. Dismantle valve and check.
Replace, if necessary


4) MAINTENANCE, CLEANING &
CALIBRATION
In order to maximize availability the unit must be maintained regularly. Checks and maintenance
works should be carried out according to the tables below. Detailed instructions, as far as
necessary, can be found in the following chapters.
The check list at the end of this manual should be filled in daily. This assists to detect failures
sooner and easier.

4.1 Schedule for Checks & Maintenance Works

REGULAR CHECKS
Frequency Action
daily - visually inspect all sections for leakages
- check if motors or pumps make unusual noises
- check oil levels (pump motors and compressors, if installed)
- check pressure losses across cartridge filters and modules
- fill in log sheet
monthly - check calibration of conductivity meters by comparing with readings taken with
a manual measurement
- check and update stock of spares and consumables
- visually check all safety devices, such as overfill couplings
half-yearly - check contactors for lose screws or wires
biannual -. Change PLC-battery


MAINTENANCE REQUIREMENTS OF UNIT AND COMPONENTS
Device Designation on
P&I diagram
Required action Recommended
frequency
Chapter
Electric motors (for plunger pump
PP160)
replace bearings after approx. 20,000
operating hours
4.4
Cartridge filter FC140 replace filter elements as required 4.9
PT module FM160 replace membranes (only if necessary) 4.11
circuit cleaning every 500 operating
hours or earlier, if
required
2.5
check torque 150 hours after
commissioning, then
monthly
4.11
Plunger pump PP160 check plungers, pumping
section and crankshaft
section
every 3,000 operating
hours
4.8
check valves and seals,
replace as necessary
every 3,000 operating
hours
4.8
check belt tension weekly
check oil level, top up if
necessary
weekly 4.8
replace oil filling 50 hours after first
commissioning, then
every 750 operating
hours or monthly
4.8
Pulsation
damper
SP160 replace if necessary 4.13
check gas pressure annually


4.2 PLC

This component can only be serviced by a ROCHEM engineer and the following is given for
emergency use only except that the battery must be changed every 24 months. The inside door
of the control panel should have a sticker giving the date of last battery change. The battery is
Part No. 20417, it is a AA 2.6 volt Lithium battery.
Modicon TSX Micro Processor

Analogue Converter Function display Digital input card 1/2

24V Input. Battery Compartment, Digital output
Card 4

Battery Changing
The power supply must be on before removal of the battery.

Photographs are taken looking up and
under the battery compartment.

1 Press in and down to release the
Battery compartment.

2 Battery compartment open.

3 Remove old battery and fit new
Battery, ensure that the polarities are correct.
Close Battery compartment.

+
_

The instructions given on the next two pages are for basic information only.
ROCHEM MUST be consulted before any of the following replacements or
removals are made.

Analogue Converter
The analogue converter changes the 0 - 20ma inputs to 0 10VDC inputs. Should
this Converter fail and in an emergency have to be replaced by Ships Personnel the following
procedure given below must be carried out:

Power Supply MUST be switched off when carrying Out This Operation.

Removal of Analogue Converter

1 Remove Multi-pin Plug with screwdriver.
2 Plug removed.
3 With screwdriver loosen the 2 securing screws.
4 Remove the converter.

Fitting of New Analogue Converter

The new Analogue Converter MUST have all switch setting made
Before fitting. Switch sets C1, C2, C3 and C4 to be set.
All switches to be set as shown below.
C1 Switches set at 0




A After setting all switches refit as in
photo 4.
B Secure the Analogue Converter with
the 2 screws shown in photo 3.
C Fit the Multi-pin plug and secure with
the 2 screws. Photos 2 and 1.

Processor Card Replacement

The Modicon TSX Micro Processor is fitted with
2 sizes of cards.
1 1 off Large Type: TSX DEZ32D2
2 1 off Small Type: TSX DSZ08R5

The following information on card removal
and replacement is again for emergency use.

1 2
Removal is shown for Type DEZ32D2 card, the process of removing Type DSZ08R5 cards is
the same. Do not remove any wires from the Terminal Blocks.

1 Remove top screw. 2 Remove bottom screw 3 Lift off terminal block

4 Pull up lever card 5 Lift out card carefully 6 Type DEZ32D2

7 Re-fit new card block 8 Push down securing lever 9 Re-fit terminal

10 Secure bottom screw.

11 Secure top screw


Processor Function Display

BASE EXT. WRD. Diag. Diagnostic Run
LED LED LED LED Button LED

TER. LED

I/O LED

ERR.LED

BAT.LED

Input Output
Signals Signals

Descriptive Function Of Parts Shown Above
ITEM Function
Input Signals Card 1, Digital Input signals.
Output Signals Cards 2 Digital Output signals.
BASE LED Alight when power is on.
EXT. LED Not used.
WRD. LED Not used.
DIAG. LED Not used.
TER. LED Communicating signal between unit and programming PC .
I/O LED Analogue error.
ERR. LED Corrupted program.
BAT. LED Battery requires replacement.
RUN. LED Alight when unit is running
DIAG. Button Do not touch this button only for programming use.

LED Alight

LED Flickering

LED Flashing


4.3 Contactors

Maintenance requires qualified personnel
ACCESS ONLY BY ELECTRICIAN

The control cabinet contains the PLC unit and all
wiring and electrical components.

Due to thermal load upon the contactors, the
screws that tighten the wires could become
loose after some time.

Step
No.
Action
1 Turn off master-switch.
2 Check, if necessary re-tighten, screws L1, L2, L3 and T1, T2, T3 with a suitable
screwdriver.


4.4 Electric Motor Art. 11280

After about 20,000 operating hours, but no later than after 4 years, the roller-bearings should be
checked and, if necessary, replaced. The type of bearings fitted do not allow for cleaning or re-
greasing.

1 stator feet
2 rotor
3 end shield drive end
4 flanged end shield drive end
5 end-shield, non-drive end
6 V-ring drive end
7 bearing, outer cap
8 grease thrower
9 roller-bearing DIN 625

10 bearing, inner cap
11 V-ring non-drive end
12 bearing, outer cap
13 grease thrower
14 roller-bearing DIN 625

15 bearing, inner cap
16 external fan
17/18 external fan sing (sheet steel)
19 terminal board (according to DIN)
20 terminal plate with insulators
21 protective cable bushing for flameproof
motor (stud terminal)
22 terminal clamp for ex motors
23 gland cover
24 terminal box
25 terminal box, bottom part
26 terminal box lid
27 entry section (A or B)
28 single-entry sealing chamber (E)
29 double-entry sealing chamber (F)
30 compression gland

Please notice:

These parts have no part numbers. For part orders, please state

designation (pos. from above drawing) for three-phase motor [motor part number as from parts list]

Example: bearing, outer cap - (Pos. 7) for three-phase -motor 11280


4.5 Pressure Switch Art. 12218

The pressure switches are fitted for safe operation of the
unit, to avoid any unnecessary damage. They will stop the
unit when certain pre determined pressures are not
prevailing. These are fitted within the system at critical
locations.

Electrically connected as an opener or as a closer.

The switching points of the pressure switches should
regularly be checked and re-adjusted, if necessary.

Pressure switch Function Switching value Connection
PS150 protects pump PP160 from cavitation 0,5bar closer
PS170 protects concentrate pipe system from
over pressure
6 bar opener
PS180 protects permeate pipe system from over
pressure
3 bar opener

Adjusting the Switching Value:

1 stress relief device
2 adjusting screw for scale
3 red pointer for upper pressure
4 green pointer for lower pressure
5 adjusting screw for green pointer

Step
No.
Action
1 Remove cover from pressure switch.
2 By turning screw 2 the scale is moved up or down. This sets the switching value.
3 Adjust screw 5 in such a way that the green pointer is level with the red pointer.

4.6 Pressure Transmitter Art. 20480
The pressure transmitter measures the operating pressure before the
module and passes it as a 4 to 20 mA signal on to the PLC. At a
pressure of 0 bar it will give a 4 mA signal, at 100 bar a 20 mA signal.
Between these limits pressures and output signals are proportional.
If the transmitter does not function as described above, it is defective
and needs replacement.


4.7 Conductivity Meter (Part No.: 20321/20322/20686)

Meters: CIS 180

Type LF 1010-3-2R-5-00s/cm

Conductivity Meter
Part No.20321

Conductivity Probe
Part No.20322

Sensor Cable
Part No.20686

Meter Features
Protection IP65. 14.2mm LED display. Indicating range 2000(0) digit.
Measuring range programmable from 02.000S/cm up to 02000mS/cm.

This meter has been designed for the measurement of conductivity, as a degree of the purity
or concentration of a liquid. In connection with 4-electrode conductivity cells a high accuracy
and intensitivity of contaminations can be achieved..

Sensor Cable

8 pole stainless steel 1.4571socket, PVC cable, IP67, 2m long.

Conductivity Probe
4- Electrode Conductivity cell. Probe includes cap nut (G1").

Lid Opened


Connection Diagram


Controls and Indicators

Description
Operating of the device is arranged in 2 levels. The requested parameter can be called by button.
Selection within a parameter or entering data, use buttons and . Parameters are stored zero-voltage
safe in the EEPROM.
After switching on the supply voltage, the device initializes itself. The display shows the message I n i t .
After the initializing procedure the device is working in the Working level. Set points of the alarm outputs
can be pre-selected if available.
Activating the button for more than 2 seconds, the program is jumping into the Configuration level.
Now all the parameters defining the function of the device can be programmed.
After finishing the configuration or when longer than 2 minutes no button was pushed, the program jumps
back to the working level. Leaving the configuration level is possible at any time when pushing the button
for 2 seconds.
Error codes:
Display If the input signal is more than 3% outside of the programmed measurement range the
flashes A/D- converter is over driven and the display flashes with appr. 1Hz

E r r o r1 EEPROM test. Reading this message, a program error has been occurred. When pushing
the button a copy of the EEPROM will be reloaded and the device will work with the
factory settings. If this copy does not work, please ship the device to factory for repair
service.

Lo c Program lockout. See configuration page.
Start-up note:
Before the device can be used, it must be configured for the intended


Notes to representation
Parameter is only displayed when configured

Parameter is only displayed when feature is included (see order code)

Please note: All parameters can be called if they are not blocked by other programmed parameters
and if they are available. Factory settings are shown in [ ] .
Working Level
Button Display Description

Actual process value conductivity

Output indication
(only if installed and activated).

Actual process value temperature


Configuration Level
Button Display Description (displayed values are factory setting)


Button Display Description (displayed values are factory setting)


End of configuration.
The actual values and alarm outputs are displayed again

Checking the accuracy of Display
A portable hand conductivity meter similar to ROCHEM part No.12339 should be used to check
the functioning of the meter and probe.
Obtain a sample of water (not sea water), immerse both the probes of the unit and hand meter.
Recheck with another water sample with a different conductivity.

Service:
The display should be checked as described above every 6 months.
If unable to recalibrate the meter then the most likely cause of this fault would be the conductivity
probe and this should be replaced before replacing the conductivity meter.

Service:
Every 3 months remove the probe and clean with a little detergent and a soft bottle brush. Do
not use abrasives on this probe.

4.8 Filter Pump PK130 Part No. 21092

This pump is fitted with Victaulic couplings as shown.
Care must be taken when fitting the seal. Ensure that the lips of the seal are not pushed over
as they must fit over and seal on the machined spigot.

CRT4 5. Vertical Multistage Centrifugal Pump
This pump is virtually maintenance free because of the materials used in its construction. If the
mechanical seal leaks it should be replaced as soon as possible. The motor is a totally
enclosed, fan-cooled, 2-pole Grundfos standard motor with principal dimensions inaccordance
with the IEC and DIN standards.Electrical tolerances according to IEC 34/EN 60034.

This pump is used to boost the seawater through the sand and cartridge filters and to activate
pressure switch PS150.
If this pressure switch is not activated by 0,5bar pressure, the unit will not start.

When ordering spare parts. The following details must be given:
Pump Serial Number + quantity and part that may be required given in the drawings shown in
the dismantling and assembling instructions
Example CRT4-5 Serial No.85805906 1off Part No. 37.
The pump should be checked regularly for air that may be trapped in the upper chamber of the
pump. In normal operation this will not be a problem but in rough seas there could be a
considerable amount of air entrapped in the feed water.


Shaft Seal kit No. 21143
Pos. Description AUUE
37 O-Ring 137.5 x 3.3 2
105 Shaft seal 1



The pump in the photo on the 1
st
page is the pump fitted to your RO unit.
The pump shown in the service dismantling / assembly section has a different base otherwise it is
the same pump.
Dismantling Sequence
1

2

3

4

5

6


Assembly
7

8

9

10

11

12

13


Assembly
14

15

16

17

Replacement
Seal Kit.
Part Number:

Seal kit comprises of
the parts shown
alongside. (Add. 2 O-
Rings Pos. 37)

When pump is re-
installed and the RO unit
is started for the 1
st
time
after removal. The pump
must be purged of air.

Use the air release valve
To remove air from the
pump. Do not over
tighten as this could
damage the valve seat.
It is preferred that it
should only be hand
tight.


4.9 Plunger Pump Art. 12746

Type 3537

Part No.12746 is for this pump complete but without pulley and any additional fittings to the
pump manifold.

This pump is fitted with a Nickel Aluminum Bronze manifold. The other parts used in this pump
are made from quality materials. When replacing any components use only original specified
parts otherwise damage can be caused.

PUMP MUST NEVER BE RUN DRY

Any leakage from the pump and or pump connections must be attended to immediately.

LUBRICATION Crankcase
Only use SAE 15W40 oil. (engine oil).
The volume of oil required to fill the crankcase to the correct level is 4 liters.
Correct oil level can only be seen when pump is stopped. Correct oil level is when level is across
center of center dot on bubble gauge at back of pump. (Position A below).

OIL Changing
After the 1st 500 running hours drain crankcase, flush out with half liter of fresh oil and refill. Every
5,000 running hours change oil as described above.

Check oil level daily and top up if required.
Do not allow the breather hole on the oil filler
cap to be blocked. (Position B).

ROTATION
If the pump has been disconnected for any reason,
before restarting the unit check that the pump
rotation is correct before running the unit.

Correct rotation is shown here.

WARNING
The oil bath crankcase assures optimum
lubrication only when pump rotates in the correct
direction.


Type 3537 High Pressure Pump

Access to Pump
Power to the RO plant must be switched off before opening the front
panel.

Remove the 4 x 8mm
and 2 x 10mm Cap Screws (using 8 & 10mm hexagonal
keys) from the Front Panel and lift off panel,
Remove the 2 x 12mm bolts
(2 x 19mm spanners)

Pull out the Pump Unit by pulling evenly on the pump pulley and base of the safety valve.

? Pump pulled out for Service


Oil filling Cap (unscrews)
Oil drain valve
Oil level sight glass, correct oil level to be in middle of sight glass when pump is stopped

High Pressure Pump. Type 3537

Adjusting Belt Tension

Belt Deflection Force: 3.8 to 5 lbs. Belt Deflection:
Notes: 1 - The best tension for a V-belt drive is the lowest tension at which the belts will not slip.
2 - Check the tension frequently during the 1
st
day of operation after fitting new belts.
3 - Too much tension shortens belt and bearing life,
4 - Keep belts and sheaves free of any foreign material that may cause the belts to slip.

Unlock the lock nuts before attempting to adjust the belt tension. Secure these lock nuts after belts have been
tensioned and correctly aligned.
Motor adjusting screws. Lock nuts

Pulley Removal

Checking Tensions of Drive Belts
Use a belt tension device to check
the tension on the belts.
After the correct tension has been
obtained ensure that the pulleys
are aligned correctly. Both
outside faces of the pulleys have to
be 100% in line with each other.
Note: Photo here is turned 90 from

Pump Pulley: Remove the 3 Allen grub screws as shown
Insert 2 of the screws into the 2 empty holes and
screw in each screw 1 turn alternately.
The pulley will be pushed off the Taperlock bush towards the pump.
Remove the 2 screws. When the pulley is loose the Taperlock
bush will open. The Taperlock bush can now be removed by
pushing off from the shaft.

Motor Pulley: Remove the 2 Allen grub screws as shown
Insert 1 screw into the empty hole and screw home
The pulley will be pushed off the Taperlock bush towards the pump.
Remove the screw. When the pulley is loose the Taperlock bush
will open. The Taperlock bush can now be removed by pushing off
from the shaft.
Refitting of Pulleys and Belts: Refit the pulleys in reverse order ( pulley on before taper bush). Ensure
that the screw holes in the pulleys are aligned before pulling together with screws. Fit the 2 middle belts
first. Belts to be tensioned and aligned. Align pulleys by using a strait edge to check that the outer
faces of both pulleys have full surface contact with the :staight edge.
NOTE: If this pulley alignment is not carried out then the belts will wear very quickly.


Drive Assembly

1- Motor

2 Back bearing
Part of motor Item 1
3 Front bearing
Part of motor Item 1
4 Shaft Key
DIN 6885-A 10x8x100mm
5 TAPERLOCK pulley

6 TAPERLOCK bush

7 Hex. Socket grub screw
flat point (2) 7/16 x 1.875
8 V-belt (5 belts)

9 Hex. Socket grub screw
flat point (3) DIN913 M12 x 35
10 TAPERLOCK bush

11 TAPERLOCK Pulley

12 Shaft Key
DIN 6885-A. 10x8x70mm

Pump Details

1- Die cast aluminum crankcase for strength and l ight weight. 2- Oversized crankshaft bearings for extended life.
3- Chrome-moly crankshaft for strength and long life. 4- Oversized connecting rods for strength.
5-Special stainless steel plunger rods for strength. 6- Stainless steel slinger provides back up protection for
crankcase seal keeping pumped fluids out of
crankcase.
7- Abrasion resistant ceramic plungers for extended seal
life
8- Nickel aluminum bronze manifolds for continuous duty
9- 100% wet seal design increases service life by allowing
pumped fluid to cool and lubricate both sides.
10- Special stainless steel valves, seats and springs
provides corrosion resistance and long life.
11- Special V-Packings for performance and seal life. 12- Crossheads are 360 supported for alignment.


Cathodic Protection
Fitted to this pump is a sacrificial anode to protect the pump head from corrosion i.e. (electrolytic action caused
by different metals).
The anode is fitted in the hexagonal plug in the top of the pump as shown below. This anode must be checked
every 3 months and replaced when necessary. Use the socket for the DT modules to remove the plug BUT do not
use the DT module torque spanner as it may be damaged. Use PTFE tape as thread sealant when securing back
into the pump.

Ensure that all water that has escaped when removing the plug is wiped off all surfaces
before fitting front cover. Also check that none has spilled onto the lower RO unit.

1 Part No. 10947 - Anode plug. 2 Part No. 20451 - Anode
3 Part No. 13182 - Spring 5 Part No. 11862 - Protective cover
4 Part No. 13424/13244 - M8 x 60 lg. cap screw and washer


EXPLODED VIEW

Serial number of pump is stamped on side of crankcase


Pump Head

Item Part No. Description Qty Item Part No. Description Qty.
106 44113 Seal, LPS w/SS-Spring 3 158 48362 Back up ring, V Packing Spacer 3
107 44754 Lo-Pressure Seal Spacer 3 159 18697 O-ring, V Packing Spacer 3
110 45124 Inlet Manifold 1 162 48363 Back up ring, Valve Seat 6
112 11379 O-ring, Inlet Manifold 3 163 26142 O-ring, Seat 6
117 18175 Socket Screw M14x40 4 164 44612 Valve Seat, Stepped 6
126 19086 Female Adapter 3 166 44108 Valve
127 44609 V-Packing 3 167 44109 Valve Spring 6
128 45368 Male Adapter 3 170 44729 Washer, Spring Retainer 6
141 54113 Coil Springs 12 171 44644 Coil spring, Valve Plug 6
142 45382 Spacer with Coil Springs 3 172 89827 O-ring Valve Plug 6
155 701492 O-Ring, V-Packing Spacer 3 174 44643 Valve Plug M70 6
156 48362 Back-Up-Ring, Spacer 3 185 15369 Discharge Manifold 1
157 45369 Spacer, V-Packing 3

Part No. Description
00257
Seal Kit Comprising of :
3-pieces of item 97 O-ring Plunger retainer
3-pieces of item 106 Lo-Pressure Seal
3-pieces of item 112 O-ring, Inlet Manifold

3-pieces of item 127-V-Packing
6-pieces of item 155-O-ring, V-Packing Spacer
3-pieces of item 156-Back up ring, Spacer
3-pieces of item 158-Back up ring, V-Packing Spacer
3-pieces of item 159- O-ring, V-Packing Spacer
00256
Valve Set Comprising of:
3-pieces of item 162, Back up Ring, Valve Seat
3-pieces of item 163, O-ring, Valve Seat
3-pieces of item 164, Valve Seat,
3 pieces of item 166, Valve.
3 pieces of item 167, Valve Spring.
3 pieces of item 168, Retainer. Spring
3 pieces of item 170, Washer, Spring Retainer.
3 pieces of item 172, O-ring, Valve Plug.
3-pieces of item 173, Back up Ring, Valve Plug


Pump Body

ITEM Part No. Description
Qty
ITEM
Part No. Description
Qty.
2 30055 Key M10 x 6 x 32 1 48 25625 Drain Plug 1
5 11824 Screw, Hex head M10 x8x 70 8 49 23170 O-ring, Drain Plug 1
6 15847 Washer, Split lock M10 8 50 45936 Crankcase Cover 1
7 19934 Washer M10 8 51 16612 O-Ring Crankcase Cover 1
8 44542 Cover, Bearing 2 53 44559 Crankcase 1
9 44543 Shim, Split Bearing Cover 2 55 27488 Guide Pins 2
10 12398 O-ring, Bearing Cover 70D 2 56 27790 Oil Pan 1
11 13296 Oil Seal, Crankshaft 2 58 15849 Lock Washer (split M6) 2
15 29326 Bearing 2 59 89618 Screw M6 x 10 2
20 64 43864 Pin, Rist 3

46611 Rod, Connecting Assembly
(44941,43641,88155)
2
65 45116 Plunger Rod 3
21 44940 Locking Washer (M10) 4 69 29338 Washer, Oil Seal 3
22 43641 Washer, (M10) 4 70 29454 Oil Seal, Crankcase 3
23 88155 Screw HH (M10 x60F) 4 75 44752 Barrier Slinger 3
Items 21, 22 & 23 to be replaced as a set 88 45676 Keyhole Washer M16 3
25 29325 Crankshaft, Dual End 1 90 43921 Plunger 3
31 828710 Protector, Oil Cap 1 95 89778 Stud, plunger ret. M10x135 3
32 43211 Oil Filler Cap 1 96 20189 Back-up Ring, plunger ret. 3
33 14177 O-ring, Oil Filler Cap 70D 1 97 701490 O-ring, Plunger Retainer 3
34 44319 Bolt, Eye (M12 x 1.75) 1 98 44085 Gasket, Plunger Retainer 3
35 701144 Rivet 4 99 44084 Plunger Retainer M10 3
36 701147 Nameplate 1 100 814279 Retainer Seal (2 pcs.) 3
37 92241 Gauge, Oil Bubble 1 101 44112 Long Tab Wick 3
38 44428 Gasket, Flat 1 250 44516 Shaft Protector 1
40 89627 Screw, Hex Head M8 x 25 4


Fault Diagnosis.

FAULT DIAGNOSIS

PROBLEM
PROBABLE CAUSE SOLUTION
Pulsation. Faulty Pulsation Damper.

Damaged / Worn Suction Valves.
Check Gas Pressure.
Replace Diaphragm.
Check / Replace Suction Valves
Insufficient Pressure.
(Pressure Control Valve closed).
Belts Slipping.
Worn Packing.

Worn Inlet or Discharge Valves.
Leaking Hi-Pressure Seals.
Tighten Or Replace Belts.
Change Packing and inspect
plungers for Damage.
Replace Valves.
Repair with Seal Kit.
Water Leaking From Under
Manifold.
Worn or Damaged Lo-Pressure
Seals.
Worn Male and Female Adapter

Repair with Seal Kit.

Install new male and female
adapter.
Lubricate and replace O-rings in
seal area.
Oil Leak between Crankcase and
pumping Section.
Worn Crankcase Piston Rod
seals.
Replace crankcase piston rod
seals.
Oil leaking in area of Crankshaft Worn crankshaft seal or
improperly installed oil seal
retainer O-ring.
Bad bearing
Remove oil seal retainer and
replace damaged O-ring and / or
seals.
Replace bearing.
Water in Crankcase May be caused by humid air
condensing into water inside the
crankcase.
Leakage of packing seals.
Change oil every 500 running
hours.

Repair with seal kit.
Oil Leaking from under-side of
Crankcase
Worn Crankcase seals. Replace seals.
Oil leaking from drain plug. Loose drain plug or damaged O-
ring.
Tighten drain plug or replace O-
ring.
Excessive play in the area of
Crankshaft
Worn main bearing from
excessive tension on drive belts
Replace bearing, Properly
tension belt. Use only the correct
type and length.
Loud knocking noise in pump Pulley loose on crankshaft.

Broken or worn bearing
Check key on crankshaft.
Check taper bush assembly.
Replace bearing.
Frequent drive belt failure Pulleys on pump and motor are
not in correct alignment.
Align pulleys correctly, fit new
drive belts and recheck
alignment after setting belts to
correct tension.
Frequent or premature failure of the
packing.
Scored plungers.

Replace plungers.


Servicing
SERVICING of Valves.
The pump does not need to be removed for this operation and it is not necessary to disconnect
the suction or discharge connections to the pump.

Disassembly

1. Remove the six (6) M41 Hexagonal Valve Plugs. 3 on top
and 3 on front.
2. Under the Valve Plug is a coil spring and washer. Remove
these by hand.
3. Then screw a M8 bolt into the top of the Spring Retainer
and pull out the valve assembly including Retainer, Spring,
Valve Seat, O-ring and Back-up Ring) from the valve
chamber.
4. Each valve assembly should be remain together, do not mix
the components of each valve.
5. If the assembly separates, the parts will lift out without any
tools.

Re-assembly
1. Examine the O-rings on the Valve Seat,
replace if cut or worn. Lubricate the
O-rings before installing.
Examine the surface of the Valve and
Valve Seat for pitting, groves, wear or
damage and replace if necessary.
2. Next assemble Valve Retainer, Spring,
Valve and Seat by snapping together
securely. Thread the M8 bolt into the
spring retainer for installation.
3. Lubricate the O-Ring and Back-up-Ring surface and walls
of valve chamber and press Valve Assembly squarely into
chamber, Remove M8 bolt. Place the washer over the top
of the Spring Retainer and then the Coil Spring on top of
the Washer.
4. Examine the O-ring and Back-up-Ring on the valve plug
and replace if cut or worn. Lubricate new O-ring and Back-
up-Ring before installing on Valve Plug to avoid damage
as they are worked over the plug threads.
5. The Back-up-Ring must go on first, then the O-Ring.

6. Slowly thread the Valve Plug into valve chamber. Exercise caution to avoid extruding or
cutting the Back-up-Ring or O-ring.
7. Torque to specifications given in Torque chart on page 15.


Servicing
Removing The Discharge Manifold
The discharge connections must be removed for this operation.
1. Remove the 8 M12 Hexagonal socket
head screws.
2. To assure alignment use two M12
studs as guides while removing
manifold.
3. Tap the backside of the discharge
manifold with a soft mallet and
gradually work the head from pump.
4. Properly support manifold to avoid
damage to the ceramic plungers.
5. Remove the O-Rings from lower
chambers of the face of the Inlet
Manifold.

Removing the Inlet Manifold
The inlet (suction) connections must be removed
for this operation.
1. Remove the four (4) M14 hexagonal socket head bolts.
2. Rotate crankcase by hand (one to two turns) to separate the inlet
manifold from the crankcase.
3. Carefully tap the rear of the inlet manifold with a soft mallet and
gradually work off head from pump.
4. Note: Support the underside and exercise caution to keep manifold
aligned with Plungers to avoid damage to the plungers
as the manifold is being removed.
5. NOTE: 2 Screwdrivers on opposite sides of the manifold may be used to assist separation

SERVICING THE PACKING

Disassembly of the V-Packings
1. Place the crankcase side of the inlet manifold down on the
work surface.
2. First remove the V-Packing Spacer. These may stay in
either the Inlet or Discharge Manifold ports when the
Discharge Manifold is removed. If they are extremely dirty or
dry, remove the exposed O-Ring and Back-up-Ring and
insert 2 screwdrivers on opposite sides to pry out of
chamber.
3. Examine both front and rear O-Rings and Back-up-Rings on
the V-Packing Spacer for cuts or wear and replace as
needed.


Servicing

Disassembly of the V-Packings Continued

Re-assembly of the V-Packings

4. To remove the V-Packing Cylinder, insert two screwdrivers on
opposite sides of the V-Packing Cylinder
and pry out. Examine the O-Ring for wear, replace as needed.
5. Next remove Spacer with coil springs. Examine for broken or
fatigued springs or scale build up or pitting and replace as
needed.
6. Then with reverse pliers remove the Male Adapter, V-Packings
and Female Adapter. NOTE: Using the reverse pliers may
damage the V-Packings or Female Adapter.
7. Examine female Adapter for worn inside diameter and replace
if required.

1. Lubricate outer surface of V-Packi8ng Cylinder and install new
O-Ring in groove. Press V-Packing Cylinder with O-Ring
end down into the manifold chamber until completely seated.
2. Insert the Female Adapter into the Manifold Chamber with the
V groove up.
3. Next fit the new V-Packings together, lubricate the outer surface
of the packings and insert into Manifold Chamber with the V
groove up.

4. Then install the Male Adapter into the Manifold Chamber with the V groove down
(notches up).
5. Lubricate outer surface of Spacer with coil springs and insert into Manifold Chamber with
springs facing down,
6. Lubricate outer surface of V-Packing Spacer, install new O-Rings and Back-up-Rings in
both the front and rear groove and press into Manifold Chamber with
small diameter down until completely seated.


Servicing

Disassembly of the LO-Pressure Seal
1. With the Inlet Manifold on blocks and with the crankcase side down, insert screwdriver into
seal chamber and tap opposite sides of the Washer Spacer to drive out seal assembly.
(Spacer and LO-Pressure Seal).
2. Replace the LO-Pressure Seal and examine O-Ring for wear and replace as needed.

Re-assembly of the LO-Pressure Seal
1. With the crankcase side of inlet manifold up insert the Spacer into the seal chamber.
2. Install LO-Pressure Seal into seal chamber with garter spring facing down and press
squarely into position.

SERVICING THE PLUNGERS
Disassembly
1. Remove the seal retainers from the ceramic plungers.
2. Remove the inner collar from the front of the seal retainer.
3. Remove the used wick and install new wick.
4. Lubrication: Three drops per hole, twice per month.
5. Replace Inner Collar on Seal Retainer.
6. Loosen plunger retainer 4 to 5 turns.
Push plunger towards crankcase until plunger retainer
pops out.
7. Unscrew and remove plunger retainer, gasket, O-ring,
back-up ring, ceramic plunger, keyhole washer and
barrier slinger from the plunger rod.


Servicing

Re-assembly
1. With these plunger items removed, examine the Crankcase Oil Seal for wear or deterioration
and replace as needed.
2. Replace keyhole washer on plunger rod.
3. Carefully examine each plunger for scoring or cracks and
replace if worn. NOTE: Ceramic plunger can only be
installed in one direction (front to back).
Do not force onto rod.
4. Examine gasket, O-ring and back up ring on
plunger retainer and replace if cut or worn.
Lubricate O-ring for ease of installation and to avoid
damaging O-rings.
NOTE: First install gasket, then O-ring and back up ring.
5. Apply a small amount of Loctite 242 to the threads of the
Plunger Retainer and thread Plunger Retainer onto
plunger rod. Torque per specifications See Page 15.
6. Slip Seal Retainers over plungers.
Insert smaller diameter first.
NOTE: Line up wicks with the oil holes in the crankcase and tabs in the oil pan.
7. Rotate shaft and line up two outside plungers.
8. Lubricate the Plungers.
9. Carefully replace inlet manifold onto plungers and press towards crankcase. Keep manifold
aligned to avoid damaging plungers. To assure alignment use two studs as guides and
remove when manifolds are in place.
10.Replace four (4) hex socket screws and torque to specification.
11.Examine inlet port O-Rings at bottom of manifold and replace if cut or worn.
12.Lubricate the outer surface of V-Packing Spacer, O-Rings and valve chamber walls and
carefully slip Discharge Manifold over V-Packing Spacer.
13.Hand tighten the two (2) hex socket head screws. Torque per chart and in the sequence
below.

5
8
1 4
77
6
3
2



Servicing

SERVICING THE CRANKCASE SECTION
1. While manifold, plungers and seal retainers are removed, examine crankcase seals for wear.
2. Check oil level and for evidence of water in oil.
3. Rotate crankshaft by hand to feel for smooth bearing movement.
4. Examine crankshaft oil seal externally for drying, cracking or leaking.

Consult ROCHEM if crankcase service is required.

TORQUE CHART
ITEM THREAD TOOL SIZE TORQUE
Anode Plug
Plunger Retainer M14 M22 70 Nm
Inlet Manifold Bolts M16 M12 75 Nm
Discharge Manifold Screws M16 M10 75 Nm
Valve Plugs M70 M41 150 Nm
Crankcase Cover Screws M10 M17 21 Nm
Bearing Case Screws M10 M17 21 Nm
Connecting Rods M10 M17 43 Nm

Important Note: The suction hose must be checked at regular intervals to see if it is
touching / rubbing on the pump motor or frame. It must not be in contact with either the
frame or the motor. If the hose is touching any of these 2 surfaces then it must be moved
to another position. To move the hose: Loosen the 2 cap screws 1 turn in the clamp.
Slacken the union slightly to allow the hose tail fitting to be turned. Turn the hose tail
Approximately 10 from the vertical. Check by looking under the motor to see that the hose is
clear of the motor and frame as in photo below. Retighten the clamp and union.

Union Air Vent Plug Clamp

4.10 Sandfilter (Part No.: 11476) with top and bottom connections
Maintenance:
When the pressure loss across the sand filter reaches 2.5 bar, a sandfilter backwash will be
required. (Please see chapter 2.5 "Sandfilter backwash").
The sand filter is filled with 3 sizes of quartz sand. The Sand in this filter normally never requires
to be changed. However if the sand does have to be changed. Before filling the sand, fill the
bottom with water to a level of approximately 50cm. This is to prevent damage to the collection
filters during filling.

Replacing the Filter bed
Step
No.
Action
1 Stop the unit with rinse and remove power.
2 Close water inlet valve and manual valve before and behind the filter (if installed).
3 Open filter head.
4 Suck sand and water out of the filter vessel by means of an industrial vacuum cleaner.
5 Refill the filter with new sand as to the chart below.
6 Close filter head and check seals for correct seats.
7 Open water inlet valve and manual valves, respectively.
8 Start unit with a sandfilter backwash.

Sandfilter with top and bottom connections
Sandfilter - Article code Type installed
Diameter 610 mm
Total length L
1
2010 mm
Size Vessel length L
2
1980 mm
Volume 450 ltr.
Top connection 4
Bottom connection 4
Pressure vessel C-2469-F7
0,3-0,7 mm 11530
Parts Amount:
300kg
(12bags)

2,0-3,0 mm 11529
Amount
100 kg
(4 bags)

3,0-5,0 mm 11528
Amount
100 kg
(4 bags)


Sand filter with top and bottom connections
1 Pressure vessel 4 Sand 0,3-0,7 mm
2 Upper distribution system 5 Sand 2,0-3,0 mm
3 Lower distribution system 6 Sand 3,0-5,0 mm

1 Distribution tube
2 Distribution head
3 O-ring
4 Adapter
5 O-ring
6 Angle

1 Angle
2 O-ring
3 Adapter
4 O-Ring
5 Distribution
head


4.11 Cartridge Filter (Art. 11488)

The cartridge filter elements must be
replaced, when the pressure loss across
the cartridge filter has reached 2 bars
(PI140-PI150). The filter elements cannot
be cleaned.

The overall pressure loss must in no
cases get that large that the plunger
pump inlet pressure drops below 0.5
bar!

A check should be carried out daily and
after any circuit cleaning the filter
elements should be replaced.

(1) Filter Housing
(2) Filter Element (10 m)
(3) O-ring

Replacing the Filter Elements:

Step
No.
Action
1 Press lamp button 2 (Stop with rinse)
2 Close feed water inlet valve VK121 and discharge valve VK171.
3 Unscrew the filter housing bottom part from the top part using the belt spanner
(part no. 13573).
4 Replace filter elements (part no. 20216).
5 Reassemble the filter housing, check O-ring (part No. 11533) and ensure it fits correctly.
Torque only hand tight without the use of a belt spanner.
6 Open feed water inlet valve VK121 and discharge valve VK171.

The unit is now ready for restarting.

4.13 Deacidification Filter (Art. 21113)
Maintenance: The de-acidification filter is filled with dolomitic limestone. This is being
continuously consumed and must be topped up at the latest when the filling height has
dropped down to 50 %. In order to check this, the vessel must be opened. The
maintenance interval depends of the concentration of available carbon acid.
Topping up the Filter Material
Step No.
Action
1 Shut down the unit with STOP/RINSE and remove power from unit.
2 Close water inlet valve and manual valves before and behind the filter (if installed).
3 Open valve VK190
4 Open filling tube
5 Refill filter material up to a height of approx. 90% (for appropriate quantity of filter
material see chart below).
6 Close filling tube properly
7 Close valve VK190
8 Re-open water inlet valve and manual valves before and behind the filter (if installed).
For the first 10 minutes after topping up the filter material, the produced permeate should not be
used as drinking water. It is recommended, before re-commissioning the unit to by-pass the
external fresh-water facilities and drain off the water.

De-acidification filter
Filter article number 21113
Diameter D 406 mm
Overall length L
1
1449
mm

Size Vessel length L
2
1370
mm

Volume 132 ltr.
Upper connection 4
Lower connection 4
Parts Pressure vessel
Dolomitic filter material 11521
Total of filling material:
175 kg


Part. No.: 21113

Type C (with filling tube)
1 Pressure vessel
2 Upper distributor,
3 Lower distributor
4 Dolomitic filter material Part No.:15151

1 Verteilerrohr
2 Verteilerkopf
3 O-Ring
4 Adapter
5 O-Ring
6 Winkel

Lower distributor

1 Angle
2 O-ring
3 Adapter
4 O-ring
5 Distribution head

Upper distributor


4.13 ST Module Art.02102

ST-Module


4.14 Motor Control Valve Art.22813

Actuator (see original maker instructions enclosed)

General Valve Instructions

Remove or Separate

Turn (Counter clockwise)

Install or Insert

Turn (Clockwise)

Use standard wrench or tool.

Do NOT Rotate or turn

Use special tool or wrench

Examine

Lubricant

Special tool (brass)

Keep hands clear when valve is in operation.

Shut off pressure before taking valve apart.

1



2

3

4

6

5

7

8



9

10

11
12

13


Assembly

14 Best to replace with new components.

1


2

3

4

5

6

7



Testing for leakage

8

9

10
11

If packing leaks, tighten just enough to stop leakage.
Test packing by tightening gland 1/4 turn past finger tight.


4.15 Pulsation Damper Part. 22076

The function of the pulsation damper can be checked by observing the pointer motion on pressure gauge
PI160, while the unit is starting up. From approx. 30 bar on the pointer vibration must decrease
remarkably. If not, the pulsation damper needs refill or replacement of the membrane (both only possible
for Type B dampers) or even of the complete damper.

Maintenance:

The gas pressure should be checked 2
days after first commissioning, repair or
replacement, then once after 4 months
and afterwards in 1 years intervals. The
check is being performed by means of a
special charging unit. The pressure
should always be approximately 5 bar
above the half operating pressure. If not,
the nitrogen filling has to be topped up
or the membrane needs replacement.

Replacement of the whole pulsation
damper is generally needed after 8,000
to 12,000 operating hours.

Type A: Welded version
(Art. 22076)

Type B: Threaded version
(Art.)
F
The pulsation damper must only be filled with nitrogen, in no cases with oxygen!

F
If the gas pressure within the nitrogen bottle lies above 30 bar, a gas pressure reducing
valve and a safety valve will be required.

Replacing the Pulsation Damper

Step
No.
Action
1 Switch unit off.
2 Close water inlet valve and manual valves before and behind the filter (if installed).
3 Unscrew pulsation damper and install the new one.
4 Open feed water inlet valve and manual valves, respectively.
5 Restart the unit at lamp button 1 and observe the pointer vibration. It must decrease from 30 bar on
and tend to zero with rising pressure.


Check Gas Pressure and Make up Nitrogen Filling
For filling the pulsation damper a charging unit (Art. 13615) will be required.
Step
No.
Action
1 For filling up a cold damper first calculate the pressure to be set:
pressure setting = 30 bar x present temperature (K) / expected operating temperature
(K)
2 Switch off unit and remove power.
3 With a 6 mm socket spanner, loosen socket head screw at the pulsation damper gas valve slightly
by half a turn.
4 Screw union nut D of the charging unit onto the pulsation damper gas valve. Turn the charging unit in
such a way that the pressure gauge can be read easily.
5 Open valve V by turning the valve spindle A of the charging unit open by one turn. When pointer
movement occurs turn ahead by one turn. The pressure gauge now shows the present pressure
inside the pulsation damper.
If pressure is too high: Open pressure relieve valve B so nitrogen can escape.
If pressure is too low: Top up nitrogen as follows:
6 With the union nut G1, attach the flexible filling hose to the pressure reducing valve of the nitrogen
bottle. Connect the other end of the hose to the manifold C of the charging device.
7 Open the gate valve of the nitrogen bottle. While spindle A is screwed in, pass nitrogen slowly into
the pulsation damper. Close bottle gate valve and read pressure from the pressure gauge. Repeat
from step 6 on until the desired pressure has been established.
8 After 5 min. check pressure again.
9 If the desired pressure is reached and remains stable, close pulsation damper gas valve by
tightening the socket head screw P.
10 Unscrew the charging unit and finally torque socket head screw to 25 Nm.
11 With soapy water, check water tightness of pulsation damper gas chamber.

charging unit

charging hose

gas valve on pulsation
damper

A


5) SPECIFICATION
CIRCUIT DRAWINGS, PARTS LISTS AND TECHNICAL DATA

5.1 Layout Diagram

ROCHEMRO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg. Page No. 119




5.2 Pipe & Instrument Diagram

Legend to the Pipe & Instrument Diagram
The letters indicate the FUNCTION of the component:
PK Centrifugal Pump VF Safety Spring Valve
FC Cartridge Filter VK Ball Valve
PP Plunger Pump VR Non-return Valve
FM PT Module VS Motor Control Valve with Electric Motor
VD Globe Valve or Check Valve VV Valve (general)
TI Thermometer PT Pressure transmitter
PI Pressure gauge FI Flow gauge
VE Solenoid Valve CI Conductivity meter
The numbers indicate the LOCATION of the component::
110 Rinse and cleaning system 150 Behind cartridge filter but before plunger
pump
120 External components of unit 160 High-pressure Section
130 Filter Pump 170 Concentrate
140 Cartridge Filter 180 Permeate
190 Post treatment permeate

ROCHEMRO-Wasserbehandlung GmbH, Knickberg 1A, 21077 Hamburg. Page No. 123

5.3 Parts List

Grp. Art. Designation Specification Qty. Unit P+I diagram

ANB 10001 taper bush with keyway Typ: 2012/42 GG Nut DIN6885/1 1 St
ANB 10002 taper bush with keyway Typ: 3020/35 GG Nut DIN6885/1 1 St
ANK 10041 belt XPA 1332 LW 5 St
ANS 22111 pulley Typ: TB SPA 112 x 5 GG25 DIN2211 1 St
ANS 21053 pulley Typ: TB SPA 250 x 5 GG25 DIN2211 1 St
ANZ 10170 motor slides Typ: G132/10PM - 530mm (1 Sa.) 1 St
ARD 22076 pulsation damper BNr: 7210SS Typ: CAT 0,7l; NPT1" 1 St S P 1 6 0
ARE 22813 servo motor control valve Typ: RC250 G3/4 230VAC 1 St V S 1 6 0
ARH 10292 2-way ball valve BNr: 161.346.044, d32 PVC 1 St V K 1 9 0
ARH 10302 2-way ball valve
Typ: DN5; G1/4"Edelstahl 03-125.5
mit Flgelgriff 1 St
ARM 21098 2/2 way solenoid valve TYP: 5282-A 13,0 NBR MS G1/2 220V 1 St V E 1 8 0 1
ARM 21097 2/2 way solenoid valve TYP: 5282-B 13,0 NBR MS G1/2 220V 1 St V E 1 8 0 2
AR 10444 pressure maintaining valve
BNr:121.967; PN 10;Typ: DHV 716;
DN 25; PVC-U 1 St V F 1 3 5
AR 10512 non return valve BNr: 161.360.444 1 St V R 1 8 0
AR 10458 spring safety valve Typ: D012,5 G1 NPT-G1 85bar 1 St V F 1 6 0
AR 10472 non return valve
BNr: 149 B 1129 RV290P G3/8
Po/Vi/E 1 St V R 1 3 9
ARV 10508 2-way valve BNr: 5.0110.00 G1/4- DN 4 - PP 1 St V 1 3 0
AZU 23426 pipe ellbow ZNr: 613.0823426-3a 3 St
AZU 20143 stand pipe ZNr: 613.0620143-3a 1 St
BEA 10556 pipe clip BNr: RANE-325, Ro 25mm 3 St
BEA 10558 pipe clip BNr: RANE-532, Ro 32mm
1
2 St
BEA 10560 pipe clip BNr: RANE-540, Ro 40mm 1 St
BEA 10573 bow type handle BNr: GN 565-26-192 SW 3 St
DOS 10818 injector BNr: 54389 SP820.20, Typ: d 25 PVC 1 St V 1 1 1 2
DRT 19611 pressure connection MCV
ZNr: 623.19611-4a Vic1" - NPT 3/4"
1.4539 1 St
DRT 10900 pin for pump frame ZNr: 623.10900-4a d20-id8,5 2 St
DRT 19612
pressure connection HP-
pump
ZNr: 623.19612-4a VIC1" - NPT1"
1.4539 1 St
DRT 10947 sealing plug ZNr: 623.10947-4b11/2"NPT GBZ 1 St
DRT 20451 zinc anode ZNr: 623.623.20451-4a 1 St
EMD 11280 three-phase motor
Typ: B3, BG160L6, KKr, 480V/60Hz,
12,6 kW, 24,5A 1 St E M 6 0
FIG 21113 pressure vessel Typ: SP-16-043 D406xH1450 V0132 1 St F D 1 9 0
St = piece(s)
Satz = Set



FIG 11476 pressure vessel
Typ: C-2469-F7 D610xH1980-
2010/V0450, gekrzt 1 St F S 1 3 0
FIG 11488 cartridge filter housing Typ: AVPP20 3/4"NPT Gew.bu. 1 St F C 1 4 1
FIG 11488 cartridge filter housing Typ: AVPP20 3/4"NPT Gew.bu. 1 St F C 1 4 2
FIM 11521 dolomitic limestone Typ: JW 00 8 St
FIM 20216 cartridge filter element Typ: WFMB010-20; 10m 2 St F C 1 4 0
FIM 11528 sand Typ: 3 - 5 mm 4 St F S 1 3 0
FIM 11529 sand Typ: 2 - 3mm 4 St F S 1 3 0
FIM 11530 sand Typ: 0,3 - 0,7 mm 12 St F S 1 3 0
FTE 11657 bend 90 BNr: 11-223E G1 i-1 a 1 St
FTE 11671 double nipple BNr: 11-207E G1/4" DIN2999 1 St
FTE 20954 gauge connection BNr: SS- 6MTA-7-8RG G1/2 1 St
FTE 11703 socket BNr: 11 - 201, G1"x 43, 1.4571, 2 St
FTE 11704 socket BNr: 11 - 201, G11/4"x 48, 1.4571, 2 St
FTE 11723 reducing bushing BNr: 11-212e G1/2-3/8, 1.4571 1 St
FTE 11672 barrel nipple BNr: 11-210 1/2" - 60E; L= 60 mm 2 St
FTE 11772 t-piece BNr: SS-6 MO-3 6mm 1 St
FTE 11681 elbow male connector BNr: SS- 6MO-2-4RT 6MM-G1/4A 1 St
FTF 11944 quick coupling BNr: 6468 CK-3/8-PK-9-KU 7 St
FTF 12097 angle coupling BNr: 6272 GCK-3/8-PK-9-KU 3 St
FTM 20360 male hose nozzle BNr: 12-026 L.W. 6mm - MS 1 St
FTM 11800 reducing bushing BNr: 11-1541 G 1/4- 1/8 Ms 2 St
FTM 20290 quick acting coupling / hose BNr: 12-025 GA3/8-MS 1 St
FTM 11810 union elbow BNr: WE 6LLR, G1/8" Ms 2 St
FTP 11835 hose nozzle BNr: 721.960.409 Typ: d 40 PVC 1 St
FTP 11837 hose nozzle BNr: 721.960.407 Typ: d 25 PVC 2 St
FTP 11838 hose nozzle BNr: 721.960.408 d32 PVC 6 St
FTP 11838 hose nozzle BNr: d32 PVC 6 St
FTP 11896 socket BNr: d32 PVC 3 St
FTP 11903 reduction BNr: d63 - 50 PVC 4 St
FTP 11930 reduction nipple BNr: d20 - 3/8" PVC 10 St
FTP 11931 reduction nipple BNr: d25 - 1/2" PVC 1 St
FTP 11864 covering cap for zinc anode BNr: d40 1 St
FTP 11978 t-piece BNr: 721.200.107 d25 PVC 2 St
FTP 11994 thread socket BNr: d20 - 1/2" PVC 2 St
FTP 12054 union BNr: 721.510.108 d32 PVC 15 St
FTP 12056 union BNr: 721.510.107 d25 PVC 20 St
FTP 12067 elbow 45 BNr: 721.150.107 d 25 PVC 8 St
FTP 12068 elbow 45 BNr: 721.150.108 d 32 PVC 8 St
FTP 12080 elbow 90 BNr: 721.100.106 d20 PVC 1 St
FTQ 12116 pipe union
BNr: 1.0100.32-401400B1, DN 4/6 -
3/8" PP 2 St



FTQ 12147 T-hose coupling
BNr: 1.0300.10-400000B1, DN 4/6-
4/6-4/6 PP 4 St
FTQ 12166 union elbow BNr: 1.0200.41, DN 4/6 - G 3/8" PP 4 St
FTQ 12168 union elbow BNr: 1.0200.41 G1/2" DN 4 PP 4 St
FTQ 12174 union elbow
BNr: 1.0200.32-401400B1, DN 04/06 -
NPT 3/8" PP 4 St
KEN :: unit marking plates Diverse Schilder, Standard 1530-2000 1 St
KEN 21090 operator control panel ZNr: 643.0621090-3c 1 St
KEN 21070 valve position plate ZNr: 643.0621070-4b 1 St
MDA 20480 pressure transmitter BNr: 9073957, S-10, 100 bar, G1/2B 1 St P T 1 6 0
MDA 12218 pressure switch BNr: 1010084 FF4 - 8 1 St P S 1 5 0
MFM 21091 rotameter Typ: 807-50D-72114-1-73-10000 1 St F I 1 3 0
MFM 12282 rotameter Typ: 817-32D-72114-1-62-02500 1 St F I 1 8 0
MFM 12418 limit transmitter Typ: 1272/000/Z25/01, DN 25, 4-20mA 1 St FI T 1 8 0
MLF 20322 conductivity electrode
TYP: LF4213A-C 0,5 MIT 8
POL.STECKER 1 St C I S 1 8 0
MLF 20321 conductivity meter TYP: LF-1010-3-2R-5-00-S/cm, LED 1 St C I S 1 8 0
MLF 20323
cable for conductivity
electrode
TYP: SKM8E-02 2METER ,MIT
8POL.STECKER einseitig offen 1 St C I S 1 8 0
MMG 21161 pressure gauge - 100 bar BNr:RChgG 63-3,rFr 0-100 bar 1 St P I 1 6 0
MMG 21160 pressure gauge - 10 bar BNr: RChgG 63-3, rFr 0-10 bar 1 St P I 1 3 0
MNS 12428 level switch
BNr: ERPP-3/8PPS-L100/12-PP44A-
5PVC, 3/8" 1 St L S 1 1 1 1
MNS 12428 level switch
BNr: ERPP-3/8PPS-L100/12-PP44A-
5PVC, 3/8" 1 St L S 1 1 1 3
MTM 12439 thermometer Typ: 0/60-G1/2-050-1.4571 1 St T I 1 4 0
PPK 21092 centrifugal pump Typ: CRT4-5, 2,2 kW / 60Hz/440V 1 St P K 1 3 0
PPP 12746 plunger pump Typ: 3537 Al -Bz; 136 l/min, 800 1/min 1 St P P 1 6 0
ROP 12969 Pipe Typ: 32,0 x 2,4 HL=5 Mtr.PVC 20 m
ROP 12970 Pipe Typ: 25,0 x 1,9 HL=5 Mtr.PVC 6 m
SCF 20585 hp-hose Typ: DN6 x 800 bds.BEL6/PF1 1.4539 1 St
SCF 20883 hp-hose Typ: DRS1/4-0,5 BEL6 1.4539 570mm 1 St
SCF 23213 hp-hose Typ: DN25x1800 bds. 1" Vic. 1.4539 1 St
SCF 22463 hp-hose Typ: DN25x2300 bds. 1" Vic. 1.4539 1 St
SCM 13119 rubber-water hose Typ: Goldschlange 32 x 5,5mm 6 m
SCM 13133 plastic water hose Typ: 2236 PL-4 id = 4mm 5 m
SCM 13134 plastic hose BNr: 12134, PU-9-SW 5 m
SCM 13143 plastic hose Typ: DN40 Perbunan Uniflex 2 m
SCM 13146 plastic hose Typ: DN25 Perbunan Uniflex 2 m
SDA 17391 megi damper stainless steel Typ: 40x30 bds. IG M8 8 St
SMZ 13182 spring for anode 5.332.001.0 1 St
SMZ 13269 nut Typ: M28x1,5 -6mm hoch -A4 SW41 1 St
VIK 13515 victaulic coupling Typ: 77 Gre 33.7 od (1" ) 3 St
VIK 13516 victaulic coupling Typ: 77 Gre 42,4 od (1 1/4") 3 St
VIK 13515 victaulic coupling Typ: 77 Gre 33.7 od (1" ) 3 St



XMO
ST0210
2 ST-module Typ: ST Module 3 St F M 1 6 0
XSS 23632 control cabinet
Typ: 480V/60Hz, Vipa, 600 x 600 x 350
mm 1 St
YTA 19557 Cleaning tank
ZNr.: 627.0419557 -2b PE-HD V=
110l 1 St B 1 1 1
YVS 21234 damper holding device ZNr: 622.0621234-4b 1 St
YVS 21176 holder rotameter ZNr: 622.0621176-3a 1 St
YVS 16282 front sheet - pump frame ZNr: 624.0416282-2c 1 St
YVS 21116 base frame ZNr: 632.0621116-2a 1 St
YVS 19618 holder coductivity transmitter ZNr: 624.0419618-4a 1 St
YVS bracket motor control valve 1 St
YVS 19545 cartridge filter holding ZNr: 622.0419545-3a 1 St
YVS 16328 sand filter mounting ZNr: 622.16328-3a id=610 2 St
YVS 21119 sand filter mounting ZNr: 622.0621119-3b id=410 2 St
YVS 19546 gauge sheet ZNr: 624.0419546- 4a 1 St
YVS 22387 module safety bead ZNr: 626.0722387-4c 2 St
YVS 21121 module holder ZNr: 626.0621121-3b 1 St
YVS 21120 module frame ST04 ZNr: 626.0621120-2b 1 St
YVS 19558 pipe connections ZNr: 622.0419558-4b 1 St
YVS 21274 pump+motor plate ZNr: 625.0421274-2a 1 St
YVS 21123 belt guard ZNr: 625.0621123-4a 1 St
YVS 10926 suction connection ZNr: 613.0610926-3a CAT3527-3537 1 St
YVS 20878 cross-stur cartidge filter ZNr: 622.0620878-4b 1 St
YVS 19548 plate of valve ZNr: 624.0419548- 3b 1 St
YVS 21270 supply frame ZNr: 621.0621270-0a 1.4571 1 St
YYY 21302 feed connection CAT3537 ZNr: 613.0621302-2a 1 St


5.4 Tools, Resources

Part No./
Artikel-Nr.
Designation German
Bezeichnung deutsch
Designation English
Bezeichnung English
Qty./
Menge
FILTERMATERIALIEN FILTER MATERIALS
11521 Juraperle 25Kg Sack Dolomitic Limestone (25kg sacks) 25kg
20216 Filterkerzenelement (PP 10m) cartridge filter element (PP 10m) 1
SONDERWERKZEUG SPECIAL TOOLS
12339 Handmessgert Leitfhigk./Temperatur hand-meter conductivity /temp. 1
13578 Drehmomentschlssel 1/2", 150Nm torque spanner 1/2", 150Nm 1
13573 Bandschlssel klein belt spanner small 1
13672 Steckschlssel fr ST-Modul socket spanner for ST module 1
13606 Maulschlssel 50mm Open-end spanner 50mm 1
13615 Fllvorrichtung Pulsationsdmpfer Filling device for pulsation damper 1
BETRIEBSMITTEL OPERATING MATERIALS
10629 Desinfektionslsung Typ D, 5 l Membrane Biocide (Cleaner Type Rocide) 5l
10651 Reiniger A: Fouling-Reiniger, 5 l Cleaner A: Fouling Remover, 5 l 5l
10653 Reiniger A: Fouling-Reiniger, 25 l Cleaner A: Fouling Remover, 25 l 25l
10658 Reiniger C: Eisenreiniger, 5 l Cleaner C Iron Remover, 5 l 5l
10660 Reiniger C: Eisenreiniger, 25 l Cleaner C Iron Remover, 25 l 25l
VERSCHLEITEILE WEARING PARTS
10041 Keilriemen V-belt 5
21143 Gleitringdichtung PK130 Shaft seal PK130 1
15216 Dichtungssatz Plungerpumpe HP-Pump seal kit 1
19615 Ventilsatz Plungerpumpe HP-Pump valve kit 2
20451 Zinkanode Hochdruckpumpe Zinc anode for HP pump 1
11533 O-Ring Kerzenfiltergehuse O-Ring Cartridge filter housing 1

5.5 Unit Specification

Unit Type: RO 1530-ST03-30S

Raw Water Quality : Sea Water
Unit Type : RO 1530-ST03-30S
Quantity Of Modules : 3
Raw Water Feed (l/h) : 5,300
Voltage Supply 3 phase (V) : 480
Frequency (Hz) : 60
Control Semi-automatic

RAW WATER
Raw Water Input nominal (l/h) : 5,300
Raw Water Pre-Pressure min/max (bar) : 0,5 2
Operation Pressure (bar) : 60-70
Operation Pressure max. (bar) : 73
Raw Water Temperature Nominal (C) : 25
Raw Water Temperature Range (C) 5-35
Raw Water Quality : open sea water
Total Dissolved Solids (TDS) max (ppm) : 44000
pH-Value nominal : 7-8
pH-Value Range Cleaning : 2 - 12
Silt Density Index Nominal (SDI) (%/min) : 5
Turbidity Nominal (NTU) : 1
Concentration Free Cl2 (ppm) : 0
Concentration Free Cl2 Short Time (ppm) 0,1

PURE WATER
Pure Water Output nom. (l/d) : 30.000
Conductivity Designed (S/cm) : <1000
Total Dissolved Solids (TDS) max (ppm) : <500
pH-Value nominal : 6,5-9,5
Recovery Rate Calculated (%) : 24

MAIN DIMENSIONS
Unit Section
Length (mm) : 1,850 (~2,400)
Width (mm) : ~800
Height (mm) : ~1,950


WEIGHTS Approx:
Total Transport (kg) incl. Sand a. Limestone ~1400
Total Operation (kg) ~1650

Flange connections
Brine Discharge nominal diameter : 1
Permeate Outlet nominal diameter : 1
Raw Water Inlet nominal diameter : 1
Drain Outlet nominal diameter : 1

PRESSURE STAGES
Raw Water Inlet (bar) : 0,5 - 2
Brine Discharge (bar) : 0 - 6
Permeat Outlet (bar) when running : 0 - 3
Permeat Outlet (bar) when stopped : 0
Drain Outlet (bar) : 0

ELECTRICAL SPECIFICATIONS
Supply Power Voltage 3 phase (V) : 480
Frequency (Hz) : 60
Control Voltage Intern Produced (V) : 24 DC
Control Voltage Intern Produced (V) 230 AC
Total Connectet Current (480V) (A) 30
Total Connected Power (kW) 17
Spec. Energy input nominal (kWh/m) 10 to 12


5.6 Water Feed Analysis

Guideline to sea water and pure water quality at membrane filtration

Feed Water
(Sea Water)

Pure Water Results
Max. Limits
according to
WHO-
restrictions
Salt
Rejection [%]
Conductivity at 25C [S/cm] 48000-50000 700-1300 -
Dissolved Solids TDS [ppm] 35000-36000 350-750 1000 -
Silicate SiO
2
[ppm] 0.1 less than detection limit 98-99
pH Range 7.5-7.9 6.5-6.8 6.5-8.5 -
Turbidity [NTU]
(NTU=Nephelometric turbidity units)
3 (max.) 0.1-0.2 5 -
Silt Density Index SDI [%/min] 20 (max.) 0.5-1 -
Free Clorine Cl
2
[ppm] 0 0 -
CATIONS [ppm]
Sodium Na
+
10750 180 200 98.3
Potassium K
+
390 7.5 98.1
Magnesium Mg
++
1295 3.5 (hardness: max.
500 mg/l as CaCo
3
)
99.7
Calcium Ca
++
500 mg/l as CaCo
3
)
99.5
Strontium Sr
++
13 less than detection limit -
ANIONS [ppm]
Chloride Cl
-
20500 240 250 98.8
Bromine
Br
-

65 1.0 98.5
Fluorine F
-
1-2 <dl -
Sulfate SO
4
--
2700 3.4 400 99.9
Bicarbonate HCO
3
-
500 mg/l as CaCo
3
)
99.4
TRACE ELEMENTS [ppm]
Iron Fe
++
0.002-0,02 less than detection limit 0.3 -
Manganese Mn
++
Aluminum Al
3
+
Barium Ba
--
0.05 less than detection limit -
Rubidium Rb
+
Lithium Li
+
SOLUTE GAS [ppm]
Oxygen O
2
0-9 0-5 50
Nitrogen N
2
8-15 4-8 50
Carbonic Acid CO
2
35-60 15-30 50
Argon Ar 0.2-0.4 0.1-0.2 50


5.7 Electric Schematics

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