INSTRUCTIONS FOR E-SERIES WATER PURIFICATION MACHINES 57,000 GPD TO 288,000 GPD 216 M3/D to 1090 M3/D OPERATION AND MAINTENANCE MANUAL

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2 INSTRUCTIONS FOR E-SERIES WATER PURIFICATION MACHINES 57,000 GPD TO 288,000 GPD 216 M3/D to 1090 M3/D OPERATION AND MAINTENANCE MANUAL TABLE OF CONTENTS 1.0 DESCRIPTION Definitions Machine Nomenclature Standard Economy (ECN) Model Features Standard Deluxe (DLX) Model Features Specifications for E-Series Machines Electrical Description Flow Description INSTALLATION Feedwater Requirements Mounting Plumbing Chemical Feed System (DLX only) Power and Electrical Requirements PREPARATION AND STARTUP Pre-treatment for Water Purification Initial Start-Up Daily Start-Up OPERATION OF LAKEWOOD INSTRUMENTS 2450 RO CONTROLLER Description Features Specifications Setup, Calibration and Customization Technician, Security, and Operator Level Menus MACHINE OPERATION AND MAINTENANCE Daily Log Sheets Pre-Filter Flushing Cleaning Draining Machine for Shipment Membrane Element Installation Membrane Element Replacement FIELD INSTALLED ACCESSORIES External Controls Permeate Purge Addition of Second Chemical Pump CIP Installation on ECN Models TROUBLESHOOTING SPARE PARTS LIST RETURN MATERIAL ORDER (RMO) PROCEDURE WARRANTY/GUARANTEE Machine Warranty/Guarantee Membrane Element Warranty/Guarantee START-UP DATA SHEET TEMPLATE DAILY LOG TEMPLATE

3 LIST OF FIGURES Figure 1.1: Normal vs. Crossflow Filtration Figure 1.2: Membrane Element with Interconnectors Figure 1.3: Cross-Sectional View of Membrane Element Figure 1.4: Principles of Operation Figure 4.1: 2450 Front Panel with Display Figure 4.2: 2450 Installation Schematic LIST OF TABLES Table 1.1: Flow Specifications for E8 Machines Table 1.2: Min/Max Primary Pressure Table 1.3: Membrane Element Specifications Table 2.1: Feedwater Requirements Table 2.2: Inlet Connections Table 2.3: Permeate Outlet Connections Table 2.4: Concentrate Outlet Connections Table 4.1: 2450 Input Specifications Table 4.2: 2450 Output Specifications Table 4.3: 2450 Monitor Specifications Table 4.4: Amplifier Settings in the Model Table 5.1: Osmonics Dry Chemical Cleaners Table 8.1: Parts Lists

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7 1.3 Standard Economy (ECN) Model Features E-Series ECN model water purification machines have all the features necessary for safe, continuous production of high-purity water. This assumes properly pre-treated feedwater with a TDS 2000 ppm, and regular operator maintenance, each shift or daily, to the operation of the system. 66% to 75% recovery. Can increase concentrate and reduce recycle flow to obtain any recovery between 66% and 75%. Epoxy-coated carbon steel frame 400 square foot membrane elements with stainless steel membrane element housings and stainless steel end caps Multi-stage centrifugal pump, SS construction (stainless steel end castings and other wetted parts, Noryl* internals) on 57K to 216K and AS (all stainless steel components) on 288K. Economy model electrical package includes PLC control, NEMA-12 enclosure with a 110 VAC, 60 Hz or 220 VAC, 50 Hz single-phase control circuit, and Lakewood 2450 monitor. Automatic inlet shutoff valve 30-inch or 40-inch stainless steel pre-filter housing including 5-micron cartridge filters, GX05-30-XK or GX05-40-XK Pre-filter, post-filter, primary and final pressure gauges Digital concentrate and permeate flow meters Digital conductivity monitor, panel-mounted, for permeate quality monitoring Autoflush system: automated high-velocity membrane flushing for the longest membrane life set at the factory Gauges, valves and rigid plumbing of stainless steel or plastic Stainless steel concentrate and recycle valves External control capabilities (level control, pre-treatment lockout, remote on/off, etc.) ALARMS included: low inlet pressure, starter overload trip, and high temperature *Noryl is a trademark of General Electric Company. 4

8 1.4 Standard Deluxe (DLX) Model Features The E8 DLX package contains all of the above ECN standard features along with the following additional features. Clean-In-Place (CIP) system. The CIP pump is plumbed, wired and mounted onto the RO frame. Adjoining plumbing for the remote CIP tank is plumbed into the RO system (some connection assembly required). Digital ph controller system Permeate purge High permeate pressure shutdown Remote data interface capabilities via modem or RS232 direct connection Additional ALARMS: high/low ph, high permeate pressure 1.5 Specifications for E-Series Machines The machine flow specifications listed in Table 1.1 below are based on 77 F (25 C) and 2,000 ppm NaCl. Table 1.1: Flow Specifications for E8 Machines Model E8-57K E8-72K E8-86K E8-108K E8-144K E8-180K E8-216K E8-288K Recovery 66-75% 66-75% 66-75% 66-75% 66-75% 66-75% 66-75% 66-75% Units gpm (m 3 /h) gpm (m 3 /h) gpm (m 3 /h) gpm (m 3 /h) gpm (m 3 /h) gpm (m 3 /h) gpm (m 3 /h) gpm (m 3 /h) Permeate Rate Concentrate Rate Recycle Rate Feed Rate 40 (9) (5-3) 9-17 (2-4) (14-12) 50 (11) (6-4) (3-5) (17-15) 60 (14) (7-5) 0-10 (0-2) (20-18) Feedwater Specifications 75 (17) (9-6) (5-8) (26-23) The feedwater requirements stated in Table 2.1 must be met to ensure quality permeate and extended membrane element life Permeate Flow Rate 100 (23) (12-8) 8-27 (2-6) (35-30) 125 (28) (15-10) 0-23 (0-5) (43-38) 150 (34) (17-11) 0-27 (0-6) (52-45) 200 (45) (23-15) 0-36 (0-8) (69-61) Stated in Table 1.1 above and on the machine serial number label (assumes no permeate backpressure, 2000mg/L TDS maximum feed concentration, and rated temperature). To estimate permeate output with backpressure, use the formula below: Maximum permeate backpressure is 80 psig (5.5 bar). (Permeate Flow on Label) x (Operating pressure) - (Permeate backpressure) (Operating Pressure) Concentrate Flow Rate Stated in Table 1.1 and factory set as stated on serial number label The pressure ranges stated in Table 1.2 below are primary pressures excluding line pressure. 5

9 E8 Model Table 1.2: Min/Max Primary Pressure Pump Model Primary Pressure Range psi (bar) Pmin-Pmax 57K-60Hz 8516KB ( ) 57K-50Hz 8510KA ( ) 72K-60Hz, 86K-60Hz 72K-50Hz, 86K-50Hz, 108K-50Hz 8512KB ( ) 12512KC ( ) 108K-60Hz 12508KC ( ) 144K-60Hz 12512KE ( ) 144K-50Hz 24009KE ( ) 180K-60Hz 24007KE ( ) 180K-50Hz 24011KE ( ) 216K-60Hz 24008KE ( ) 216K-50Hz 24013KE ( ) 288K-60Hz 39408KE ( ) 288K-50Hz 39412KE ( ) RO Membrane Rejection E8 reverse osmosis machines use Osmonics Fiberglass Reinforced Plastic (FRP) covered 823-HR(PA) membrane elements with AG membrane. For ordering information refer to Spare Parts List in section 8. See Table 1.3 below for details. Outer Cover Material Table 1.3: Membrane Element Specifications Typical Ionic Rejection (TDS) (based on 24 hours of operation at 225 psi (15.5 bar), 77 F (25 C), 7-8 ph, 2000 ppm NaCl solution) Nominal Permeate Flow Rate at 225 psi (15.5 bar) Typical Feedwater Temperature Range Maximum Temperature Range Short-Term Cleaning Temperature 823-HR(PA) *The molecular weight cutoff is based on the pore size of the membranes and the nature (size/shape) of the organic molecule. FRP % 10,500 gpd (39.75 m 3 /d) F (10-29 C) F (0-40 C) <110 F (43 C) PH Range Chlorine Tolerance Active Membrane Area Average Molecular Weight Cutoff* <0.1 ppm 400 ft 2 (37.16 m 2 ) 1500 MW* 6

10 1.6 Electrical Description This machine is equipped with a Programmable Logic Controller (PLC) to provide start/stop, sequential, and alarm control. The Lakewood Instruments 2450 RO controller monitors four parameters including: permeate flow rate, concentrate flow rate, feed ph, and permeate conductivity. Five conditions will cause the RO to alarm and subsequently shut down the machine: high permeate pressure (DLX); low inlet pressure (<12 psi), low feed ph (<2.0); high feed ph (>8.0); high temperature [>105 F (41 C)]; and starter overload trip. Configurable external control and permeate purge on DLX models is also available via the PLC. Osmonics utilizes level control as the typical purge trigger, but permeate purge cycle can be controlled via any other external control contacts where purge is required on shutdown. External control can include Remote On/Off, Permeate Storage Tank Level Control, and/or Pre-treatment Lockout (i.e., softener regeneration). Refer to the E8 ECN and DLX Electrical Diagrams in the Power and Electrical Requirements section (2.5) for more details. 1.7 Flow Description The feedwater passes through a replaceable 5-micron cartridge filter which removes bulk- suspended solids. Filtered water then flows to the inlet control valve. This solenoid-controlled diaphragm valve opens when the machine is turned on allowing water to flow to the pump inlet. When the machine is turned off, the valve closes, preventing non-turbulent flow through the membrane elements which would lead to shortened membrane life. The pump feeds water to the membrane element housings arranged in parallel and series combinations. The direction of water flow is indicated by an arrow on each membrane element housing. Water is separated by the membrane within the membrane elements and leaves the membrane element housings in two streams, permeate and concentrate. Permeate from each membrane element housing is collected in a common manifold. Check valves are installed on the permeate manifold to provide safety against backpressure. The permeate then flows through a flow meter and to the outlet point of the machine. Concentrate leaves the last membrane element housing and flows to the flow control center (recycle/concentrate manifold located behind the instrument panel). At this point, the recycle valve channels a predetermined amount of concentrate into the pump inlet. Recycle increases recovery while maintaining adequate crossflow through the membrane elements. The other two ports of the flow control center lead to the concentrate valve and final pressure gauge. The concentrate valve has three functions. It controls the amount of concentrate flowing to drain, the pressure within the machine, and helps control the system recovery. The autoflush solenoid is also included in the flow control center. The concentrate then flows through a flow meter and to the outlet point of the machine. 7

11 2.0 INSTALLATION The E8 RO machine was created like an appliance to make installation easy for you. The following installation guidelines will help you install your new E8 RO machine. 2.1 Feedwater Requirements The following feedwater requirements must be met before installing your new E8 machine to ensure quality permeate and extended membrane element life. Temperature Inlet Pressure Chlorine (continuous feed) Operating ph Silt Density Index (SDI) Table 2.1: Feedwater Requirements Typical: F (10-29 C) Maximum: F (0-40 C) Minimum 30 psig (2.1 bar) Maximum 60 psig (4.1 bar) 0 ppm For soft water [less than 1 grain per gallon (gpg) or 17 mg/l hardness], acceptable ph is For unsoftened water (contact factory with water analysis), acceptable ph is For short term (cleaning) a ph range of 2-12 is acceptable. Less than or equal to 5 to minimize membrane fouling and extend cleaning intervals. Refer to ASTM standard D Mounting E8-Series machines are equipped with a stand-alone frame, which supports the machine. At least 45 inches (114 cm) of space should be allowed on each end of the membrane element housings for removal and loading of membrane elements. If 45 inches (114 cm) are not available, the entire membrane element housing may need to be removed for membrane element replacement. 2.3 Plumbing The E8 comes with socket connections installed in all isolation valves. However, FPT connections are shipped with the machine for easy switch to threaded connections. Feedwater Inlet Connections Table 2.2: Inlet Connections 2.0-inch PVC SOC (57K-108K models) 3.0-inch PVC SOC (144K-288K models) Permeate Outlet Connections Table 2.3: Permeate Outlet Connections 1.5-inch PVC SOC (57K model) 2.0-inch PVC SOC (72K-144K models) 3.0-inch PVC SOC (180K-288K models) Concentrate Outlet Connections Table 2.4: Concentrate Outlet Connections 1.5-inch PVC SOC (57K-144K models) 2.0-inch PVC SOC (180K-288K models) 8

12 2.3.2 Clean-In-Place (CIP) Plumbing A clean-in-place assembly is designed into the Deluxe Model E8. The CIP tank attaches directly to the CIP pump via victaulic connection. Run hose or pipe from concentrate and permeate CIP outlet to CIP tank return fittings. 2.4 Chemical Feed System (DLX only) The chemical pump must be mounted to the top of the chemical tank. Plug the pump into the outlet cord hanging from the back of the RO electrical enclosure to achieve chemical feed for ph control. The Lakewood Instruments 2450 controls the ph to the chemical pump (on/off). To add a second chemical injection pump to the E8, see section 6.0, Field Installed Accessories. 2.5 Power and Electrical Requirements WARNING: IMPORTANT NOTE: Before obtaining access to terminals, all supply circuits must be disconnected. Motors are dual rated. Factory installed starters and wiring for 380 or 460 only. Must replace motor starter and motor wiring prior to converting to lower voltage. The DLX and ECN E8 machines are supplied with a single-phase, 110 VAC, 60 Hz or 220 VAC, 50 Hz control circuit and 8-foot cord which plugs into a three-prong grounded receptacle. A 20 amp dedicated service circuit is required for proper operation. For 220 VAC, 50 Hz units, plug must be customer supplied. For each model, the motor is wired at the factory to an overload protection motor starter, which is controlled by a panel-mounted manual switch. The electrical system control circuit is separate from the motor voltage. Therefore, electrical wiring required in the field needs two supply voltages, the control circuit voltage and a separate 3-phase motor voltage. All field wiring must comply with applicable local and national electric codes ECN Electrical System Installation 1. Connect the control circuit power cord to 115 VAC, 60 Hz, or 220 VAC, 50 Hz, single-phase power. 2. Connect the motor starter to 230/460 VAC or 220/380 VAC, 3-phase power to match the motor voltage and phase. Check the tag (located on the motor starter) that indicates the factory wiring. A separate, fused disconnect for the motor wiring should be used DLX Electrical System Installation 1. Connect the control circuit power cord to 115 VAC, 60 Hz, or 230 VAC, 50 Hz, single-phase power. 2. Connect the motor starter 230/460 VAC or 220/380 VAC, 3-phase power to match the motor voltage and phase. Check the tag (located on the motor starter) that indicates the factory wiring. A separate, fused disconnect for the motor wiring should be used Permeate Purge See section 6.0, Field Installed Accessories External Control See section 6.0, Field Installed Accessories. 9

13 3.0 PREPARATION AND START-UP 3.1 Pre-treatment for Water Purification All systems will operate most efficiently on filtered water with a ph of less than 6.5 and a Silt Density Index (SDI) of 5 or below. If the machine is operated on higher ph water, other forms of pre-treatment may be necessary. A water analysis prior to start-up of the machine is required. To minimize the chances of calcium carbonate, calcium sulfate, or other salt precipitation on the membrane, Osmonics evaluates each application and water condition and makes specific recommendations to assure continuity of the membrane element warranty. Data from the water analysis is processed with a computer program analysis to determine if potential problems may exist. If the machine is to be run at a different location than was originally intended, a new water analysis is required for warranty consideration and should be sent to Osmonics for review and recommendations for operation of the machine. Before installing the machine, the feedwater must be filtered to 5 microns. TLC membrane feedwater must not contain the following chemicals or permanent loss of rejection and/or permeate flow may result: free chlorine formalin (until after a membrane element has been run for 24 hours, thereafter, 0.5% formaldehyde may be used as a biocide) iodine compounds quaternary germicides cationic surfactants detergents containing non-ionic surfactants cleaners not approved by Osmonics CAUTION: A water softener should not regenerate while the machine is running unless safeguards are used to be sure the machine is operated on softened water during regeneration. NOTE: To control the RO operation based on water softener regeneration cycle, wire the softener to the External Control circuit, as described in the External Controls section. 3.2 Initial Start-Up NOTE: If your machine has the membrane elements installed in the housings, proceed to section below. If your machine is provided with the membrane elements in shipping boxes, you must load the membrane elements in the housings prior to starting the machine. For membrane element loading instructions, skip to section 5.6, Membrane Element Installation. Upon completion of membrane element installation, return to section to continue your start-up procedure. 1. Recheck the function and integrity of your pre-treatment equipment. Ensure that your water softener, activated carbon filters and iron filters (where applicable) have been leak checked, backwashed, and thoroughly rinsed for service before starting up your RO unit. 2. Attach the feedwater pipe to the inlet of the machine. The standard connection fitting is a PVC socket stub-end on the inlet ball valve. To accommodate the need for a threaded connection, an FPT stub-end was shipped with the machine. 3. Check for leaks at all connection points. 4. Turn the feedwater supply on gradually and check for leaks in the inlet plumbing. No flow should go through the machine while the power is off and the inlet solenoid is in the closed position. NOTE: When the machine is off, there should never be flow through the machine. Flow through the machine when it is off can ruin the membrane elements. 10

14 5. Attach discharge plumbing to permeate and concentrate outlet points and run the tubing to drain. The standard connection fitting is a PVC socket (SOC) stub-end on the outlet ball valves. To accommodate the need for a threaded connection, an FPT stub-end was shipped with the machine. 6. Ensure that you have made provisions for both voltages required to operate your machine. The machine requires two power sources, (1) the high voltage for the motor operation and (2) the control circuit power supply. The factory provides the 110 VAC (or 220 VAC, 50 Hz) power cord needed for the control circuit. The motor electrical service must be field wired directly into the motor starter on the machine. Bring your motor service to terminals labeled T on the motor starter. Check the voltage label to ensure that you have brought the correct voltage to the starter. IMPORTANT NOTE: Motors are dual rated. Factory installed starters and wiring for 380 or 460 only. Must replace motor starter and motor wiring prior to converting to lower voltage. 7. Be sure the power to the motor starter is de-energized. 8. With the machine On/Off switch in the Off position, plug in the factory supplied 110 VAC (or 220 VAC, 50 Hz) power cord. 9. Open your concentrate and recycle flow control valves (behind the control panel) two complete turns. Proper adjustment of these valves is critical to the operation of the RO machine. The concentrate valve determines the amount of rejected water leaving the machine and creates the operating pressure shown on the pressure gauge. The recycle valve returns unused reject flow back into the inlet stream to the RO pump. It is important to balance the operating pressure and the respective flows of these valves to ensure that your machine is operating correctly. It is also important to understand the relationship of these two valves, the pressure gauge, and your RO pump. The pump has a fixed amount of flow produced, and the valves are the control devices to distribute this fixed flow amount. The pressure gauge is an indicator of applied membrane pressure at the flows set by the valves. 10. With the power source to the motor starter de-energized, turn the On/Off switch to the On position. Water will begin to flow through the machine at this point but the pump will not start. Allow the machine to fill for ten minutes to evacuate all air. 11. As your machine is filling check for leaks and repair as needed. 12. Turn the On/Off switch to the Off position. 13. Energize the power source to the motor starter. The pump should not operate at this point. 14. Check the rotation of the high-pressure pump by, first, turning the On/Off switch to the On position. After the minimum inlet pressure of 12 psi (0.8 bar) is established and maintained for six seconds, the high-pressure pump will start. Immediately turn the On/Off switch to the Off position. Watch, or have an assistant watch the motor, or coupling shaft, for direction of rotation. The motor should rotate clockwise while looking at the motor end of the highpressure pump. If the motor is not rotating clockwise, change any two of the three leads (for 3-phase) in the motor starter and recheck rotation. Always turn the power off to change any wiring. CAUTION: Operation of the pump backwards for even a short time can cause damage to the pump. 11

15 15. Turn the On/Off switch to the On position. The high-pressure pump will operate and the machine will begin to build pressure. 16. As you are operating, be sure to watch the primary and final pressure gauges on the instrument panel. The machine is designed to operate at approximately 190 psi (13.1 bar) average operating pressure. NOTE: Do not allow the pressure to exceed the maximum pressure (Pmax) specified for your machine model (refer to the Min/Max Machine Pressure Table 1.2 for Pmax). If the pressure exceeds Pmax, open the concentrate flow control valve until the pressure gauge shows Pmax or less. 17. As the machine purges the air and fills with water, the pressure will gradually increase. You should see water flow through the permeate and concentrate piping, viewed on the operation screen of your Lakewood If you do not see flow, turn the machine off and return to section Gradually adjust the concentrate flow control valve. As you adjust the valve, watch the average pressure (Pavg) and your concentrate flow meter. Adjust the valve until your concentrate flow meter displays your design flow and you do not exceed Pmax. If you exceed Pmax before the valve is completely closed, open the recycle flow control valve one full turn, then continue to adjust the concentrate flow control valve. 19. With the concentrate flow control valve set to obtain the design concentrate flow and the pressure below Pmax, gradually adjust the recycle flow control valve until Pavg reaches 190 psi (13.1 bar). Readjust the concentrate and then the recycle valves, if necessary. 20. Your machine is now operating at the design pressure and flow rates in a 75% recovery configuration. Your specific needs or conditions may dictate the need to operate the machine at a lower recovery. If you wish to operate in a recovery configuration lower than 75%, explains the necessary steps. 21. Your machine is equipped with flow meters and a pressure gauge that will assist you in setting alternate flow rates for variable recoveries. If you wish to operate at a recovery lower than 75%, you must ensure that the flow rates for the permeate and concentrate are at desired levels. Some minor adjustments in the concentrate and recycle flow control valves may be necessary. 22. When you have selected your desired flow rate, gradually adjust the concentrate flow control valve to achieve desired flow and use the recycle valve to bring the operating pressure up to 190 psi (13.1 bar). 23. Once the desired flow rate is achieved, at 190 psi (13.1 bar) operating pressure, no further valve adjustment is needed. NOTE: Permeate flow rates are dependent upon temperature and conditions at your site. Contact your dealer if you have any questions. 24. The system is now operational. 25. Before putting the machine into final operation, continue to run the permeate and concentrate streams to drain for at least 30 minutes. This is done to ensure that all of the preservative has been removed from the membrane elements. 26. Connect the permeate line to the point-of-use of the permeate. Check for leaks and ensure that you have no kinks in hoses or blockage of any plumbing on the permeate and concentrate outlet lines. 27. Make any final adjustments to flows and pressure according to , if need be. NOTE: The membrane element(s) in your machine are rated for certain flow rates at 77 F (25 C). Maximum flow rates are achieved when the membrane elements have been completely rinsed and on-line for at least 24 hours. 12

16 28. Create copies of the start-up log sheet, Figure 11.1, and fill one out. A daily log sheet including general operating conditions (pressures, flows, concentrations, ph, and pre-treatment conditions), and routine or special maintenance (flushing or cleaning as needed) must be kept. Osmonics will require this log sheet if a warranty question arises. 3.3 Daily Start-Up Check the machine to insure isolation valves are in the proper positions for operation. To turn the RO on, depress the On/Off switch. If the alarm light is lit, push the alarm reset switch. If the alarm light stays lit, check the RO for an alarm condition. Otherwise, the main inlet valve will open, and the high-pressure pump will turn on. The high-pressure pump will not start if there is insufficient inlet pressure [<12 psi (0.83 bar)]. Daily performance data must be recorded on the daily log form as explained in Operation and Maintenance section of this manual. 13

17 4.0 OPERATION OF LAKEWOOD INSTRUMENTS 2450 RO CONTROLLER CAUTION: All electromechanical devices are subject to failure from a variety of causes. These include mechanical stress, component degradation, electromechanical fields, mishandling, improper set up, physical abuse, chemical abuse, improper installation, improper power feeds and exposure. While every precaution is taken to insure proper functioning, extra precautions should be taken to limit the ability of overfeeding by limiting chemical quantities available, secondary shutdowns, alarms and redundancy or other available methods. CAUTION: 4.1 Description Low voltage wiring and high voltage (110 plus) should not be run in the same conduit. Always run separately. Even shielded low voltage is not a guarantee of isolation. Every precaution should be taken to insure proper grounding and elimination of shorting or electromagnetic field (EMF) interference. The Model 2450 is a monitoring instrument for reverse osmosis machines and can be used for ph control. The unit provides for tracking of ph and conductivity as well as flow monitoring. The system allows for alarm set points and can do a system shutdown when safety set points are exceeded. The system can also be set up to communicate with a computer by either a direct RS232 connection or remotely by modem. System operating information such as alarms and measurement readings can be saved to a data log and downloaded to a computer. Security features allow you to select full access to programming features or to restrict limited or no access. The Lakewood Instruments 2450 controller is equipped with four relays. This machine uses relay 1 for a high/low ph, conductivity, and high temperature alarm. Relay 3 is used for ph chemical pump control. Relays 2 and 4 are available for your use. Relay 1 can be configured to accept additional timer or alarm parameters, available on the 2450 for machine shutdown LONWORKS* Technology The Model 2450 uses LONWORKS Technology which is the latest in microprocessor capability, giving the use the highest level of application flexibility. The Model 2450 is user-friendly with a large illuminated graphics screen and numeric keypad, and accesses multiple inputs and easy set up. This monitor can also be quickly upgraded in the field. It s a combination of reliability, accuracy, security and simplicity. Water meters and sensors are purchased separately. COMMUNICATION Setting and reading the monitor can be done remotely with the RS2L computer option. This data link can connect directly to a personal computer (PC) or through a modem and phone line to any modem-equipped PC. SECURITY A password system can be established which requires a user password to be able to make changes or do anything more than just read the monitor readout. An operator password can help insure that the system will be operated only by authorized personnel. *LONWORKS is a registered trademark of Echelon Corporation. 14

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20 Table 4.2: 2450 Output Specifications Relays 3 Amps, 120 VAC each 4-20 ma Two, isolated with 35L RS232 Requires Windows-based PC with RTC-RS2L Table 4.3: 2450 Monitor Specifications Conductivity Range or (with proper sensor) Conductivity Accuracy ±1 or ±10µS Conductivity Resolution 1 0r 10µS ph Range 0-14 ph ph Accuracy ±0.05 ph ph Resolution 0.01 ph Deadband Adjustable Setpoints Direct or Reverse (configurable in the field) Keypad Numeric Display Illuminated 128x64 pixel LCD Ambient Temperature F (0-70 C) Enclosure ABS Plastic 4.4 Setup, Calibration and Customization Check the Operation Make sure the monitor has power and is operating. You will notice the monitor will display SERIES 2000 REVERSE OSMOSIS MONITOR PRESS ANY KEY. This indicates that power has been applied to the monitor and no one has touched the keypad. This will also happen anytime there is a power outage and power has been returned to the monitor. 1. Press any key on the keypad and you will see the Display Process Screen 2. Press CLR on the keypad and you will see the Main Menu Screen 3. Use the and arrow keys to move through the menu Reinitialization It is suggested that you reinitialize the monitor before programming in your own numbers. This will wipe out any random settings which may be in the monitor. To reinitialize, follow these instructions. 1. After you have practiced moving up and down in the Main Menu, press 6 or highlight SYSTEM SETUP and press ENT. 2. Press 2 or highlight INITIALIZATION and press ENT. 3. Press 2 or highlight WHOLE MONITOR and press ENT. A warning will appear on the screen advising you that this option requires recalibration and reprogramming! Press 1 to proceed, 2 to cancel Set up Conductivity Preamp Settings and Temperature Compensation Prior to testing your monitor, set up the internal conductivity preamp for the sensor you are using. If you purchased a sensor with your monitor, the preamp is set up by the factory and you can proceed directly to testing. If you change the sensor used and do not verify the preamp setup for your attached sensor, the conductivity readings may be erroneous. Set up the preamp by using the following steps. 17

21 1. From the SYSTEM SETUP menu, press 1 or highlight PROCESS PARAMETERS and press ENT. The WHICH PROCESS? menu will be displayed. 2. Press 2 or highlight COND and press ENT. The CONDUCTIVITY menu will be displayed. 3. Press 2 or highlight PREAMP SETUP and press ENT. The COND PREAMP SETUP menu will be displayed, showing the current voltage gain, sample resistor, and drive frequency values. Use the and arrow keys to change each displayed value to the one appropriate for your sensor (see table below). Press ENT when each correct value has been entered and displayed. 4. You will automatically be returned to the CONDUCTIVITY menu. Press 3 or highlight CELL CONSTANT and press ENT. 5. Use the numeric keypad to enter the appropriate cell constant for your sensor (see table below). Press ENT when the correct value is displayed. 6. After pressing ENT, you will be returned to the CONDUCTIVITY menu. Press CLR to return to the WHICH PROCESS? menu. 7. Press 3 or highlight TEMP and press ENT. The TEMPERATURE menu will be displayed. 8. Press 2 or highlight TEMP COMPENSATION and press ENT. The TEMP COMPENSATION menu will be displayed. 9. Press the option number or highlight the correct value for your sensor and press ENT. The new stored value will be displayed, along with the message PRESS ANY KEY. Press any key to confirm this value. 10. Finally, press CLR three times to return to the MAIN MENU. Your preamp is now set up for your attached conductivity sensor. Table 4.4: Amplifier Settings in the Model 2450 Sensor Range (ms) Gain Sample Resistor Drive Freq (Hz) Temp Comp (NTC) Cell Const 540K.01 2 Elec K.1 2 Elec K.1 2 Elec L 4 Elec K L 4 Elec K M 4 Elec K M 4 Elec K Testing Continue to test the monitor s accessories by following these instructions. 1. Return to the MAIN MENU. 2. Press 1 or highlight OPERATION and press ENT. There may be a dark flashing line separating the two sections; this indicates which alarms are active at the moment. As shown at the bottom of the screen, press ENT to access the relays. 3. The four relays line up vertically with boxes that are blank when the relay is not in operation. Select a relay by pressing its number. The box will change (it will probably become shaded), indicating that the relay has reversed its status. 4. NOTE that relays retain manual mode even after powering down. 5. Finally, press CLR twice to return to the MAIN MENU. 18

22 4.4.5 Calibration Methodology 1. You must have an accurate reading of the system water to properly calibrate the monitor. A properly calibrated handheld temperature, conductivity, or ph meter may be acceptable for completing calibrations NOTE: If at any time you believe that the ph, conductivity, or temperature calibrations have been improperly performed, you may reinitialize the calibrations and restore them to their default values. 2. Calibrate the temperature first. Measure the temperature of the system water Press PRO on the keypad, select ZERO Use the number keys to enter the value, then press ENT Do not choose SPAN when calibrating temperature 3. To calibrate ph Measure the ph of the system water with a handheld meter Press PRO on the keypad, select zero Use the number keys to enter the value, then press ENT Do not choose SPAN when calibrating ph 4. To calibrate conductivity Take a system water sample reading with your handheld meter Press PRO on the keypad Use the number keys to enter the value, then press ENT When the number is accepted, you will see the SPAN COMPLETE screen before the LCD display switches back to the original OPERATION screen 5. Take a second sample and confirm that the readings on the monitor display are correct Setpoints (ph, Conductivity, Temperature, Permeate and Concentrate Flow) Typically, ph is the only process that will be controlled. Follow these instructions to establish the monitor s setpoint. 1. From the MAIN MENU, press 2 or highlight RELAYS and press ENT. 2. Press the number of the relay governing the operation you wish to control. 3. Press 2 or highlight SETPOINT CONTROL and press ENT. 4. Select process to control (ph, conductivity, etc.) by pressing its number. 5. Press 1 to enter SETPOINT values for that relay. Simply use the keypad numbers to enter the proper value and press ENT. When finished, you will automatically be moved down to the next value. Enter SETPOINT value Enter DEADBAND value Deadband refers to a range above and below the setpoint within which the monitor will not react. Using a deadband range reduces the chance of erroneous or nuisance relay activity due to temporary fluctuations in monitored levels. It should be a small percentage of the setpoint. Half the deadband amount will 19

23 automatically be put above the setpoint, and the other half below. For example, a ph setpoint of 7.00 ph units in DIRECT mode, with a deadband of 0.10 ph units would result in a system that turns the relay ON at 7.05 and OFF at 6.95 ph. The same setpoint in REVERSE mode would turn the relay ON at 6.95 and OFF at 7.05 ph units. Enter TIMEOUT value (maximum 17 hours 59 minutes) 6. Press 2 to enter SETPOINT directions. a. Press 1 to enable DIRECT control. (The relay opens below setpoint, e.g., relay controlling acid injection for ph control. That is, when ph rises above the setpoint, the relay closes and allows injection of more acid.) b. Press 2 to enable REVERSE control. (The relay opens above setpoint, e.g., relay controlling caustic injection for ph control. That is, when ph falls below the setpoint, the relay closes and allows injection of more caustic.) 7. When finished with all setpoint entries, you can press CLR three times to select another relay. Or, press CLR four times to return to the MAIN MENU. 4.5 Technician, Security, and Operator Level Menus The model 2450 monitor is menu-driven for easy use. Once you become familiar with the menu options, it will be easy to perform set up and calibration procedures. This section of the manual provides a comprehensive overview of the entire menu as shown from each security level. In order to lead off with a complete look at the menu, the levels are shown in the following order: 3) TECHNICIAN, 2) OPERATOR, 1) VIEW ONLY. Once you review the instructions in this section and learn the menu options, you will be able to perform your own set up and calibration using these examples to guide you through the process. The model 2450 offers three optional security levels: 1) VIEW ONLY, 2) OPERATOR and 3) TECHNICIAN. A password is required to change from one security level to another. Each level has its own factory-preset password (2222 for TECHNICIAN, 1111 for OPERATOR), but your water treatment engineer can also designate personalized passwords from the TECHNICIAN Level menu. The following pages illustrate the menu screens available in each security level. NOTE: If you personalize passwords, make sure they are recorded in a safe and secure place. 20

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39 5.0 MACHINE OPERATION AND MAINTENANCE The operation and maintenance of your Osmonics E8 Machine is relatively simple but requires regular data recording and routine preventative maintenance. We cannot emphasize too strongly the importance of filling out the daily log sheet during each operating shift. A data sheet was filled out upon start-up containing pertinent facts on the operation of your machine. These two records are invaluable in diagnosing the performance of the equipment, or warranty issues, and must be kept for reference. If you have questions concerning the operation of your machine or the method of data recording, contact the Osmonics Application Engineering Department. The three preventative maintenance procedures which must be done on a regular basis are as follows: Change the pre-filter cartridge. Flush the machine daily. Clean the machine with approved Osmonics cleaners. See the following sections for specific maintenance procedures. 5.1 Daily Log Sheets A Daily Log Sheet, which includes general operating conditions (pressures, flows and concentrations) and routine or special maintenance (pre-filter changes, flushing, cleaning, etc.), must be kept. Copies of the log can be made from the template. Acopy of this log sheet will be required by Osmonics if a warranty question arises. 5.2 Pre-Filter 5.3 Flushing A 5-micron pre-filter is factory installed to protect the membrane elements and valves from particles which may be in the feedwater. To order replacements, see the Spare Parts List The filter cartridges must be replaced, at a minimum, once per week or after every 100 hours of operation, whichever comes first. A pressure drop across the filter of 8 psig (0.6 bar) or more during operation indicates the cartridge(s) need changing. Use only Osmonics approved filters rated for 5 microns or less. Do not attempt to clean used filters. Install new replacements. IMPORTANT NOTE: Failure to change the filter according to these requirements will void machine warranty. The Autoflush system, provided on all models, automatically flushes the machine and eliminates the need for frequent manual flushing. However, if the Autoflush system becomes inoperable, the machine should be flushed manually at least daily to remove sediment from membrane surfaces. To flush the unit: 1. Open the concentrate valve until the pressure gauge indicates the minimum pressure designated on the nameplate. This increases the flushing action on the membrane. NOTE: If pressure will not decrease to designated pressure, or if the concentrate rate does not increase when the valve is opened, the valve may be plugged. 2. Operate the machine at the designated minimum pressure for 10 to 20 minutes. 36

40 CAUTION: Do not operate the machine below the designated pressure without approval from Osmonics. Operation below the stated pressure may be detrimental to the pump. 3. Close the concentrate valve and ensure that the proper concentrate flow rate is going to the drain (see the nameplate on the panel). 5.4 Cleaning Cleaning the E8 machine on a regular basis is vital. Over time, contaminants build up to form a layer on membrane surfaces, reducing the permeate flow and quality. If this build-up is not removed from the membrane, it may cause permanent chemical damage and reduce membrane element life. A decrease in permeate flow and/or rejection of salts, or an increased pressure drop across the machine will indicate when cleaning is required. Cleaning may be required as often as once every week or as infrequently as every two months, depending upon the local water supply conditions. Osmonics recommends cleaning at least every month to assure good membrane element performance and long membrane element life. Osmonics offers a full line of chemical cleaners for specific cleaning needs. See Table 5.1 below. TABLE 5.1: Osmonics Dry Chemical Cleaners Cleaner Description Part No. Quantity OSMO AD20 OSMO AK110 OSMO ET70 Dry acid detergent for cleaning PA and CA membrane elements. High ph alkaline detergent for PA membranes. Recommended for situations in which organic fouling is a problem. Cleaner intended to deal with sulfate or iron precipitation fouling. Recommended for CA and PA membrane elements lb pail 100-lb keg 300-lb drum 45-lb pail 100-lb keg 300-lb drum 45-lb pail 100-lb keg 300-lb drum 37

41 5.4.1 Cleaning Procedure 1. With the RO machine running, open the CIP permeate valve. After this valve has been opened, close the permeate service valve. Permeate water will flow into the CIP tank. Allow the water to run through the CIP tank and the CIP tank drain valve for a few minutes to assure the tank is rinsed thoroughly. After a minute or so, close the CIP tank drain valve. The CIP tank should begin to fill with RO permeate. When the CIP tank has filled to the indicated full line, turn the ON/OFF switch (on the RO machine) to the OFF position. 2. While the machine is OFF, close the manual inlet valve and open the CIP inlet valve. Divert the permeate and concentrate streams to the cleaning container for recirculation. Ensure that the pre-filter is clean. A CIP pump (supplied with DLX models only) is recommended to supply feed pressure into the machine. 3. Turn the CIP ON/OFF switch and the main ON/OFF switch to the ON position and recirculate the cleaning solution through the machine. The cleaning solution should be recirculated for approximately 15 minutes or until the solution temperature reaches 100 F (38 C), however, do not exceed 110 F (43 C). The membrane elements can only handle temperatures in excess of 85 F (29 C) for short periods of time. If heat rise occurs too quickly, larger volumes of cleaning solution or the use of a heat exchanger will slow the temperature rise. Turn the CIP off and allow it to soak for 10 minutes. CAUTION: Do not leave a cleaning strength solution in the machine for a period longer than one hour. The cleaning solution may damage the membrane elements and/or the machine during an extended period of contact. 4. To flush the detergent from the machine, close the CIP inlet valve and divert the permeate and concentrate to drain by opening the CIP drain valve. Operate the machine as described in the flushing section for at least one hour. The detergent is sufficiently flushed when the permeate conductivity is restored to nearly its previous level. 5. To return the RO to service, open the permeate and concentrate valves so that flow is routed as intended in the service mode. Close the CIP permeate and CIP concentrate valves. The RO is now ready for operation. 38

42 5.5 Draining Machine for Shipment Prior to shipping or outside storage of an Osmonics E8 machine, the system should be cleaned with the appropriate cleaner, flushed with water, and protected from biological attack with the appropriate solution. The membrane element housings and plumbing lines of the machine must be completely drained. Any water remaining in the plumbing of a machine may freeze, causing damage to the plumbing, pump, membrane elements, etc. The party shipping or storing the machine is responsible for any damage resulting from freezing. 1. Disconnect the inlet, concentrate and permeate outlets. 2. Drain all water from the cartridge filter housing. 3. Remove the tubing connections on the outlets of the membrane element housings. 4. Open the concentrate valve. 5. Open sample/drain valves in all PVC manifolds. 6. Remove drain plug from pump discharge plumbing. 7. Allow the machine to drain for a minimum of eight hours or until the opened ports quit dripping. 8. After draining is complete, reconnect all of the plumbing. 5.6 Membrane Element Installation 1. For machines with membrane elements not loaded at the factory, the following steps are to be used for installation. CAUTION: The membrane element is packaged in a small amount of bactericide solution to prevent biological growth; provide adequate ventilation when handling. The membrane element must be kept moist at all times in order to prevent possible damage to the membrane material. 2. Remove the membrane element bag containing the membrane element from the shipping tube. 3. Cut the bag open as close as possible to the seal at the end of the bag, so that the bag may be reused if necessary. 4. Remove the membrane element from the bag and remove the foam protectors from each end of the membrane element. 5. Remove the parts from the parts container (if included) and inspect. Make sure that all parts are clean and free from dirt. Examine the O-rings, brine seal, and permeate tube for nicks or cuts. Replace the O-rings or brine seal if damaged. Set the membrane element aside in a clean space, and continue on to the step below. 6. Remove the end caps from both ends of all membrane element housings on your machine. This is done by removing the screws and retaining ring on each end cap closure assembly. 7. Determine the direction of fluid flow in the membrane element housing. (Be certain to look at the Direction of Flow arrow for each membrane element housing; they may be different within a given machine.) 8. Inspect the membrane element housing and clean as necessary to remove any contaminants, obstructions, etc. 9. Apply a small amount of O-ring lubricant to all O-rings on the end caps and the brine seal on the membrane element. 39

43 10. Insert the downstream end of the membrane element in the upstream end of the membrane element housing (i.e., load in the direction of flow; the brine seal is on the end of the membrane element that goes in last). 11. Insert the membrane element in the membrane element housing with a smooth and constant motion. When you reach the point where the brine seal is about to enter the housing, gently turn the membrane element to ensure the brine seal enters the housing without coming out of the brine seal groove. 12. When all of your membrane elements are installed, you must close the membrane element housing package by reinstalling the end caps and clamps. It is preferred to install the bottom end cap first and tighten the clamp completely before installing the top end cap. 13. Reinstall the end caps by gently twisting the end cap while pushing it on to the permeate tube. Insure that you do not pinch or fatigue any O-rings while pushing the end cap on. Push the end cap on until the outer diameter of the cap passes the retaining ring groove. Install the retaining ring screws. 14. Reconnect any fittings that were removed when disassembling the membrane element housings. 15. Return to the Initial Start-Up Procedure, section Membrane Element Replacement As time progresses, the efficiency of the membrane element will be reduced. In general, the salt rejection does not change much until two to three years after installation, when operated on properly pre-treated feedwater and routine maintenance performed. The permeate flow rate will begin to decline slightly after one year of operation, but can be extended with diligent flushing and cleaning of the machine. High ph feedwater and/or precipitation of hardness can cause premature loss in rejection and even flow rate. The following procedure is to be followed to replace existing membrane elements in the machine. 1. Remove the end caps and clamps from all of the membrane element housings. 2. Remove all of the membrane elements from the membrane element housings in the direction of flow (where possible). If necessary, a membrane element can be removed against the direction of flow. A heavy-duty pliers or channel lock pliers may be necessary to pull the old membrane element out of the membrane element housing. 3. To reinstall replacement membrane elements, follow Membrane Element Replacement procedure above. NOTE: Follow Membrane Element Specifications stated in Table 1.3. NOTE: Do not allow the machine to freeze unless it is totally drained. It must thaw a minimum of 24 hours before starting. 40

44 6.0 FIELD INSTALLED ACCESSORIES 6.1 External Controls Your E8 RO machine is equipped with External Control capability. External Control is the on/off control of the RO via a signal from a remote device. Use External Control when Permeate Purge is not desired prior to RO shutdown (Permeate Purge is described in Section 6.2). The External Control could be remote on/off, level control, pre-treatment lockout, and/or post-treatment lockout, etc. Utilization of this feature requires a customer-wired control loop, wired to factory-supplied terminals. This procedure is as follows. WARNING: Before obtaining access to terminals, all supply circuits must be disconnected. 1. Establish that the remote device(s) has dry contacts available to provide the shutdown signal to the RO. Ensure that the normal mode of the contact is such that it opens when shutdown is desired. 2. With the power supply removed from the control circuit, open the control enclosure (enclosure containing on/off switch). 3. Remove jumper wire #17 from between terminals #22 and # Wire from the 24VDC source terminal #22 to the first remote device. Wire all additional devices in series with the first. 5. Wire from the last remote device to terminal #17. With multiple remote devices wired in series, as described above, an open contact from any of the configured devices will activate the External Control shutdown. 6.2 Permeate Purge Permeate Purge was designed into the E8 RO machine to provide an integral means of reducing the fouling potential of the stagnant concentrate in the RO during extended periods after automatic shutdown. The deluxe E8 machine is equipped with the necessary plumbing and electrical controls to provide a 10-minute pure water (permeate) purge. Activation of the purge cycle requires a customer-wired control loop to factory-supplied terminals. This procedure is provided later in this section. NOTE: The purge control valves can take up to one minumte to switch into purge position. This delay will not adversely affect the purge cycle. The purge cycle is activated by a shutdown signal received from an external device wired to the RO. Upon activation of the purge cycle, the machine remains in run mode and the permeate stream is redirected to the inlet of the machine. The feedwater is diluted by an amount proportional to the operating recovery of the machine. The net result after concentration of the diluted feed stream, at the operating recovery, is that the water in the machine at shutdown will have TDS concentrations approximately equal to the machine feed TDS level. The low TDS environment created reduces the potential for sepralator fouling during the down period, extending membrane life. The purge operates for a 10-minute period. During this period, no permeate is discharged from the machine, and concentrate flows from the machine at the normal operating rate. When the cycle is complete, the RO pump will shut down. When the request to restart is received, the RO will restart and operate as normal. If the restart signal is received during the purge cycle, the cycle will terminate and the RO will return to normal operating mode. If the RO is shut down by the on/off switch during the cycle, the purge cycle will reset. If the on/off switch is then set to on, and the external device is still requesting a purge-activated shutdown, the purge cycle will operate for the complete 10-minute cycle and shut down the RO. 41

45 Since this feature is designed to provide a low TDS environment during extended shutdown periods, the purge sequence will not activate for any factory configured shutdown event (i.e., on/off switch, alarm shutdown, etc.). These shutdown events are assumed to typically be short down periods. Also, activation of the purge cycle for these events may be undesirable if immediate shutdown is required. The purge cycle will activate when a shutdown request is made by an external component that is configured for purge-activated RO shutdown. If purge is desired for a manual shutdown using the on/off switch, and a long downtime is anticipated, a manual switch can be wired into the purge activated shutdown loop to perform the purge activated shutdown. The RO on/off switch can then be turned off. Level control of a permeate storage tank is Osmonics standard external control device which activates purge shutdown. Any other remote device(s) can be used where permeate purge is desired prior to RO shutdown. Examples are remote on/off, and/or post-treatment lockout, etc. WARNING: Do not configure pre-treatment devices for purge-activated shutdown. The purge cycle requires the feedwater supplied by these devices. To establish the control loop for purge-activated shutdown, perform the following steps. WARNING: Before obtaining access to terminals, all supply circuits must be disconnected. 1. Establish that the remote device(s) has dry contacts available to provide the shutdown signal to the RO. Ensure that the normal mode of the contact is such that it opens when shutdown is desired. 2. With the power supply removed from the control circuit, open the control enclosure (enclosure containing on/off switch). 3. Remove jumper #18 from between terminals #22 and # Wire from the 24VDC source terminal #22 to the first remote device. Wire all additional devices in series with the first. 5. Wire from the last remote device to terminal #18. With multiple remote devices wired in series, as described above, an open contact from any of the configured devices will activate the permeate purge cycle. 6.3 Addition of Second Chemical Pump On the Deluxe E8 RO machine, Osmonics has supplied a single chemical injection system with controls factory configured for ph control. See section 2.4 for installation of this system. To install an additional chemical injection system, use relay #2 or #4 in the Lakewood Instruments 2450 Controller. The relay can be configured to operate for ph control, or continuous, any time the RO is running (i.e., based on permeate flow). WARNING: Do not plug in chemical pumps that are larger than 1/6 horsepower. The control relays are intended for electronic or small motor-driven chemical pumps. 6.4 CIP Installation on ECN Models Osmonics has installed a plugged pipe tee in the inlet line of the E8 series units. This plug, when removed, will facilitate cleaning of the unit. Valved CIP connections are provided on the permeate and concentrate outlets to allow flow back to the cleaning tank. 42

46 7.0 TROUBLESHOOTING TROUBLESHOOTING GUIDE Symptom Possible Causes Remedies Low operating pressure Insufficient feedwater pressure or flow Clogged pre-filter High flow rates Dirty or fouled membrane elements Solenoid valve not opening Pump rotating backwards (3-phase power only) Insufficient electrical power Pump not operating correctly Open the feed pressure, open the feedwater valve, check for restrictions. Replace the cartridge. Close the concentrate valve, check the permeate and concentrate flow rates and adjust if necessary. Excessive permeate flow may indicate a damaged O-ring. Flush and clean the membrane elements. Clean or replace the solenoid valve. Switch any two 3-phase leads to the motor starter. Check the fuses or circuit breakers; measure the voltage. See the pump instructions. Low permeate flow rate Low operating pressure See the possible causes for low pressure. Low concentrate flow rate, normal or higher than normal pressure Pressure does not drop when concentrate valve is opened High operating pressure Excessive pressure drop [exceeding max P] (high primary pressure - low final pressure) Dirty or fouled membrane elements Operating on cold water less than 55 o F (13 o C) Membrane elements installed backwards or damaged concentrate seal Flow meter inaccurate Concentrate valve plugged Concentrate outlet line restricted Flow meter inaccurate Dirty concentrate valve Recycle or concentrate valve plugged Inaccurate pressure gauge Restricted or reduced permeate flow rate Restricted flow after pump outlet Telescoped membrane element covering membrane element housing outlet port Severely fouled or dirty membrane elements Flush and clean the membrane elements. Install a hot/cold feedwater tempering valve if more permeate flow is needed. Operate with a feedwater temperature of 72 to 77 o F (22 to 25 o C). Install membrane elements in the direction of fluid flow. Flush and clean the machine immediately. Membrane elements with damaged concentrate seals should be cleaned and may be returned for repair. Check the flow rate manually with a stopwatch and calibrated container. Remove the concentrate valve and/or disassemble the plumbing. Clean the valve. Examine the concentrate line for obstructions or kinks, repair or replace the tubing. Check the flow rate manually with a stopwatch and calibrated container. Disassemble and clean the plumbing to the valve. Disassemble the plumbing to the recycle valve and remove foreign particles. Check the concentrate valve stem. Replace or calibrate the gauge as required. See the possible causes for low permeate rate. Check for blockage of the concentrate flow at the inlets and outlets of the membrane element housings. Ensure that the anti-telescoping device (ATD) is located properly on the membrane element. Flush the machine, then clean it with detergent. 43

47 Symptom Possible Causes Remedies Water flowing when machine is turned off Declining rejection (high permeate conductivity) Switch on, unit not operating Electrical machine shutdown Conductivity Calibration Error message: Sensor Reading Higher Than Expected. Conductivity Calibration Error message: Sensor Reading Lower Than Expected. Conductivity drifts or changes after calibration. Inlet solenoid valve not closing or seating properly Dirty or fouled membrane elements O-ring seal broken or damaged Change in incoming water quality Inaccurate conductivity monitor or fouled probe Pressurized storage switch or float switch has cut power to machine. External control or permeate purge control contacts have shut machine down. Thermal overload in motor has tripped. No power to machine Motor and/or pump not operating properly Alarm condition has turned off machine. Alarm condition has turned off machine External control or permeate purge control contacts have shut machine down. Motor starter overloaded, heater tripped The monitor is being told the conductivity is 50% more than it thinks it is by default. The monitor is being told the conductivity is 50% less than it thinks it is by default. Calibration may have been done before the reading stabilized. The staple line may contain electrical noise. Clean or replace the valve. Clean the membrane elements with detergent immediately. Water must not pass through the inlet when the machine is off. Flush and clean the membrane elements. Replace the O-ring, check the sealing surfaces on the O-ring groove, interconnectors and end caps. Replace damaged parts. Open the concentrate valve and flush. Test the water for ph, hardness, TDS and iron content. A water analysis should be sent to Osmonics for review. Calibrate the monitor with a DS standard solution or check the readings with another conductivity meter. Replace or clean the probe. Check the connections between the probe and monitor. Check the permeate backpressure or position of float in the storage tank. Check for proper operation of control contacts. Restart machine manually or wait for automatic start-up. Allow the machine to cool; check the feedwater supply and/or amp draw of the motor. Check the fuses or circuit breakers, measure the voltage. See the pump instructions. Contact Osmonics for possible repair or replacement. Check for minimum inlet pressure and push alarm reset switch. Restart the machine by pushing the alarm bypass. Check all possible alarm conditions: inlet pressure or motor starter overload. Check for proper operation of control contacts. Restart machine manually or wait for automatic start-up. Turn the switch off; let the heater(s) cool. Is the monitor being calibrated to TDS when configured for conductivity? Verify that the sensor tip has no accumulated solids and has not bridged the piping (creating a short). Clean tip. Is the sensor fouled? Are all valves open? Clean or replace sensor. When calibrating, wait at least 15 seconds to 1½ minutes for reading to stabilize. To reduce electrical noise, use grounded metal fittings on the inlet and outlet of the monitor plumbing. 44

48 Symptom Possible Causes Remedies Water meters are not accumulating. Node Not Responding error message. Display is blank. ph reading is off by more than 1 ph unit. Relays don t turn ON/OFF during normal operation. Chemical pump will not feed chemical. Chemical pump feed reverse of what you expected. {ALARM FLASHING} Rly1: Time Exceeded Rly2: Time Exceeded Rly3: Time Exceeded Rly4: Time Exceeded {ALARM FLASHING} ph: High Alarm {ALARM FLASHING} ph: Low Alarm {ALARM FLASHING} Cond: High Alarm {ALARM FLASHING} Temp: High Alarm {ALARM FLASHING} Perm: High Alarm {ALARM FLASHING} Perm: High Alarm {ALARM FLASHING} Feed: High Alarm {ALARM FLASHING} Feed: High Alarm {ALARM FLASHING} % Rec: High Alarm May be a wiring problem. The K factor is improperly configured. Turbine meter not spinning. This message occurs when one circuit board in the monitor cannot communicate with another board. Monitor not powered. Probe calibrated using span or the ph probe is bad. Relays may be affected by other software variables. Pumping may be affected by other software variables. Relay setpoint not properly configured. The relay was not able to control the ph setpoint within the programmed over-feed time. The relay is locked out until the alarm goes away. The ph has exceeded the factory programmed high alarm value. The ph has exceeded the factory programmed low alarm value. The conductivity has exceeded the factory programmed high alarm value. The temperature has exceeded the factory programmed high alarm value. The permeate flow has exceeded the user-programmed high alarm value. The permeate flow has exceeded the user-programmed low alarm value. The feed flow has exceeded the user-programmed high alarm value. The feed flow has exceeded the user-programmed low alarm value. The % recovery has exceeded the user-programmed high alarm value. Check wiring. Reconfigure K factor. Check meter for spin. Check that all boards are mounted correctly and that all connectors are fully mated. The monitor may not have the option board that is trying to be accessed. The board that is trying to be accessed may not be working. Open the front panel. Look at the yellow LEDs on the rear power board. Are they on? If yes, check ribbon cable. Is it properly seated? If no, does the unit have power? Reinitialize calibration. Recalibrate ph using zero only. Replace ph sensor. Is the relay manually turned on or off? Is the CIP input activated? You must have permeate or concentrate flow for a relay configured as setpoint to function. Is the relay manually turned on or off? Is the CIP input activated? You must have permeate or concentrate flow for a relay configured as setpoint to function and trigger pump operation. Determine whether you need the relay configured for direct or reverse setpoint feed. Reprogram the over-feed time via RELAYS/ SETPOINT. Determine why the chemical feed is failing to control the solution ph. To reset the alarm, temporarily stop permeate and concentrate flow. See ALARMS in main menu. See ALARMS in main menu. See ALARMS in main menu. See ALARMS in main menu. See ALARMS in main menu. See ALARMS in main menu. See ALARMS in main menu. See ALARMS in main menu. See ALARMS in main menu. 45

49 Symptom Possible Causes Remedies {ALARM FLASHING} Lubrication Interval {ALARM FLASHING} Check CIP {ALARM FLASHING} Check Filters {ALARM FLASHING} Check Sepralators {ALARM FLASHING} Check Sensor {ALARM FLASHING} Cond: Fouled Sensor {ALARM FLASHING} Shorted TC {ALARM FLASHING} Opened TC {ALARM FLASHING} ph: Hi Ref Impedance {ALARM FLASHING} ph: Broken Glass {ALARM FLASHING} ph: High Ref Voltage {ALARM FLASHING} ph: Low Ref Voltage {ALARM FLASHING} CIP Switch Closed The lubrication interval timer has timed out. The Check CIP interval timer has expired. The Check Filters interval timer has expired. The Check Sepralators interval timer has expired. The Check Sensor interval timer has expired. The conductivity sensor has become fouled. The temperature compensation input is shorted. The temperature compensation input is opened. A high reference impedance exists in the ph sensor. A wire may be broken in the sensor. KCI solution in the sensor may be leaking The ph sensor glass may be broken. High reference voltage exists in the ph sensor. Low reference voltage exists in the ph sensor. The CIP switch input condition has become asserted. Relays are locked out. See System setup/timers to reset the timer. See System setup/timers to reset the timer. See System setup/timers to reset the timer. See System setup/timers to reset the timer. See System setup/timers to reset the timer. Check cable, sensor, and wiring. Check cable, sensor, and wiring. Check cable, sensor, and wiring. Replace ph sensor. Sensor must be grounded. Check sensor for leaks and repair or replace sensor. Check glass bulb on the ph sensor. Replace sensor if necessary. Check sensor wiring. Check sensor wiring. None, unless the input is wired incorrectly. 46

50 8.0 SPARE PARTS LIST For copies of this spare parts list, contact your dealer or Osmonics and ask for part number Table 8.1: Spare Parts List Pre-Filters/Membrane Elements Part Number Where Used Pre-filter cartridge, PPL, (self seal) 30-inch, 5-micron, GX05-30XK (20/ctn) Pre-filter cartridge, PPL, (self seal) 40-inch, 5-micron, GX05-40XK (20/ctn) K,72K,144K K,108K,180K,216K,288K Membrane element ALL MODELS Instruments Part Number Where Used Pressure gauge, SS, psi ( bar), 2.5-inch dia with 1/4-inch lower back mount Pressure gauge, SS, psi (0-6.9 bar), 2.5-inch dia with 1/4-inch lower back mount ALL ALL Flow sensor, turbine-type, 2.0-inch NPT ALL Flow sensor, turbine-type, 1.0-inch NPT K,72K,86K Flow sensor, Hall-effect pickup ALL Conductivity sensor for Lakewood Instruments ALL ph sensor for Lakewood Instruments DLX MODELS Valves Part Number Where Used PVC sample valve, 1/4-inch ALL PVC sample valve, 3/8-inch ALL PVC sample/drain valve, 1/2-inch K,72K,86K,108K 2-inch water/air-operated inlet diaphragm valve ALL except ECN-180,216,288 3-inch water/air-operated inlet diaphragm valve K180K,216K,288K 1.5-inch water/air-operated inlet diaphragm valve K 1.25-inch globe valve (recycle/concentrate) ALL 1.5-inch manual ball valve K,72K,86K,108K,144K 2-inch manual ball valve ALL 3-inch manual ball valve K,180K,216K,288K 1-inch permeate check valve, PVC ALL Autoflush solenoid valve, 1/2-inch, 110 VAC ALL 60HZ Autoflush solenoid valve, 1/2-inch, 220 VAC ALL 50HZ Inlet and purge (DLX) control solenoid valve, SS 3-way, 1/4-inch, 110 VAC Inlet and purge (DLX) control solenoid valve, SS 3-way, 1/4-inch, 220 VAC ALL 60HZ ALL 50HZ RO Pumps/Motors Part Number Where Used Pump mechanical seal kit, 1-inch Type 21 for all standard pumps with "E" or "K" bearing frames ALL MODELS Bearing frame grease, #2 Lithium (14.5 oz.) ALL MODELS Oil, Tonkaflo, Heavy duty (1 qt. Bottle) ALL MODELS Pump discharge screeen, 3-inch victaulic ALL except 288K Pump discharge screeen, 4-inch victaulic K 47

51 Table 8.1: Spare Parts List RO Pumps/Motors Cont. Part Number Where Used PUMP,TF,SS8510KA,15HP,TEFC, 60Hz K PUMP,TF,SS8512KB,20HP,TEFC, 60Hz K,86K PUMP,TF,SS12508KC,25HP,TEFC, 60Hz K PUMP,TF,SS12512KE,40HP,TEFC, 60Hz K PUMP,TF,SS24007KE,50HP,TEFC, 60Hz K PUMP,TF,SS24008KE,50HP,TEFC, 60Hz K PUMP,TF,AS39408KE,60HP,TEFC, 60Hz K PUMP,TF,SS8516KB-50,15HP,TEFC, 50Hz K PUMP,TF,SS12512KC-50,25HP,TEFC, 50Hz K,86K,108K PUMP,TF,SS24009KE-50,40HP,TEFC, 50Hz K PUMP,TF,SS24011KE-50,50HP,TEFC, 50Hz K PUMP,TF,SS24013KE-50,50HP,TEFC, 50Hz K PUMP,TF,AS39412KE-50,50HP,TEFC, 50Hz K CIP Pumps/Motors Part Number Where Used CIP pump mechanical seal kit, 5/8-inch Type 21 for 5500, 8500, 12500, and series pumps with "G" or "D" bearing frames ALL DLX MODELS PUMP,TF,SS5504G,5HP,TEFC,3P, 60Hz K,72K,86K PUMP,TF,SS8504G,7.5HP,TEFC,3P, 60Hz K,144K PUMP,TF,SS12503D,10HP,TEFC,3P, 60Hz K,216K,288K PUMP,TF,SS5504G-50,3HP,TEFC,3P, 50Hz K PUMP,TF,SS8504G-50,5HP,TEFC,3P, 50Hz K,86K,108K PUMP,TF,SS12504D-50,7.5HP,TEFC, 50Hz K,180K,216K PUMP,TF,SS24004D-50,15HP,TEFC, 50Hz K Chemical Feed Pumps/Motors Part Number Where Used PUMP-DIAPH,24GPD,110VAC,PVC, 110 VAC HZ DLX MODELS PUMP-DIAPH,24GPD,220VAC,PVC, 220 VAC HZ DLX MODELS Injector Valve DLX MODELS 8-inch Housing Parts Part Number Where Used O-ring, 815-series end cap, Buna-N ALL Retaining ring, 815-series end cap ALL Retainer screw, for 815-series end cap ALL Closure kit, 815 housing - Contains two end caps, two O-rings, two retaining rings, four retainer screws, and end plug ALL Interconnector, for 8-inch membrane elements ALL O-rings for interconnector ALL Blank pemeate tube, 800 series Noryl* ALL Concentrate seal, U-cup for 800 series membrane elemets ALL Electrical Part Number Where Used Pressure switch, inlet ALL MODELS Pressure switch, permeate DLX MODELS Switch, push-button, momentary (Alarm reset button) ALL MODELS Switch, push-button, maintained (on/off button) ALL MODELS *Noryl is a trademark of General Electric Company 48

52 Table 8.1: Spare Parts List Clamps Part Number Where Used Victaulic coupling, complete w/gasket 1 1/4 inch K,72K,86K 1 1/2 inch ALL 2 inch ALL 3 inch ALL 49

53 9.0 RETURN MATERIAL ORDER (RMO) PROCEDURE If materials are to be returned to Osmonics for repair, evaluation, or warranty consideration, an RMO number and form must be obtained from Osmonics. Contact the Customer Service Department. The form must be completed and returned with the material. Be sure to include a complete, detailed written reason for the return. Also include Serial Number(s), installation and removal dates, copies of operating logs, and any other pertinent information. Indicate the proposed disposition of the material. Reference the RMO number on all packages or cartons. Membrane elements must be cleaned and sanitized prior to return. Membrane elements must be kept moist at all times, so package membrane elements accordingly. All equipment must be shipped to Osmonics with the freight prepaid by the customer. IMPORTANT NOTE: Machines must never be shipped with water in them; this will void the warranty. Drain the machine completely before shipping and avoid freezing before draining. The machine should be sanitized prior to draining. Refer to the draining and cleaning instructions in this manual for details. 50

54 10.0 WARRANTY/GUARANTEE 10.1 Machine Warranty/Guarantee Seller warrants its products to be free from defects in material or workmanship for a period of 15 months from receipt or 12 months from start-up/first use of the product, whichever occurs first, but only when said products are operated at all times in accordance with Seller s written instructions. This warranty does not apply to replaceable parts or components normally subject to wear and replacement. Unless stated specifically on a formal, official Performance Warranty Document signed by an officer or director level employee of the Seller and an employee of the Buyer who is authorized to make such representations, there is no performance warranty on products or warranty on process results. Seller expressly disclaims liability for incidental and/or consequential damages including, without limitations, lost profits. This warranty is made expressly in lieu of all other warranties, express or implied, including all implied warranties of merchantability or fitness for any particular purpose. Buyer assumes all liabilities for use and misuse by buyer, its agents or assignees. Buyer shall give immediate notice in writing to Seller if products or components thereof or performance (where applicable) appear defective, and shall provide Seller with reasonable opportunity to make inspections, tests and repairs using the most efficient and cost-effective methods available for such products or components. If Seller is not responsible under the terms of this document and/or any formal performance warranty, Buyer shall pay Seller the costs and expenses of such inspections, tests and repairs. Seller s obligation under this warranty is limited to the repair or replacement at its factory, for the original user, of any product or component part thereof which shall prove to have been defective. No allowance will be made for repairs or alterations made by the Buyer without the Seller s written consent or approval. In no event shall Seller be liable to Buyer for any amount, including costs incurred or expended by Seller in attempting to correct any product deficiency, relating to any claim by Buyer against Seller in excess of the aggregate total purchase price under this contract. No changes or expenses incident to any claim will be allowed. The remedies provided herein are exclusive, and Seller shall incur no liability other than that stated herein. Goods may not be returned to Seller without Seller s written permission. Seller will provide Buyer with an RMO number to use for returned goods. All returns shall have freight and related costs prepaid by Buyer from point of origin. Seller is not responsible for meeting state and local codes or ordinances, or other special codes not specifically stated in writing on the purchase document or contract. TECHNICAL ADVICE Seller may, at Buyer s request, furnish technical assistance, advice and information with respect to the products supplied under this contract, if and to the extent that such advice, assistance and information is conveniently available. Seller has no obligation to provide such information, which is provided without charge at the Buyer s risk, and which is provided subject to the limited warranty above. 51

55 10.2 Membrane Element Warranty/Guarantee Osmonics, Inc. guarantees the proposed product to be free from defects in material or workmanship when operated in accordance with written instructions for a period of one year from start-up or 15 months from receipt, whichever is shorter. Parts not manufactured by Osmonics are covered by their manufacturers warranties which are normally for one year. Osmonics spiral-wound membrane elements are guaranteed to operate within specifications when used for general water treatment for a period of 24 months from receipt providing the membrane elements have not been abused by operating at high temperatures, high or low ph, on undisinfected water, or on solutions which tend to precipitate. For applications or water conditions other than those specified in the original purchase order for the reverse osmosis or ultrafiltration machine, the User should consult Osmonics Engineering Department as to the suitability of the solution to be run in the membrane elements. Limitations on ph and temperature can vary with membrane type and the application of the equipment. For general water treatment, ph should be kept between 3.0 and 7.0 with a temperature below 85 F (29 C) unless specifically designed for higher temperatures. For special applications or for ph or temperature ranges outside the stated limits, Osmonics may reduce the warranty period. A membrane element which fails to perform satisfactorily within the first 90 days after receipt, has not been mishandled, and is returned to the factory, will be replaced free of charge except for freight and local labor. If a membrane element fails to perform satisfactorily during the balance of the warranty period and with the return of the membrane element to the factory, Osmonics will replace the membrane element with a new membrane element and will charge the User for the portion of the 24 months that the membrane element was used plus incoming freight and local labor. Such pro rata charges will be based on the list price prevailing at the time of warranty consideration. A new membrane element supplied under warranty terms will carry the standard 24 month new membrane element warranty. If a membrane element is to be returned for warranty inspection, the User must obtain a Return Materials Order (RMO) number from Osmonics before returning the membrane elements. Membrane elements are to be returned freight prepaid to Osmonics, and Osmonics will return any warranty replacement membrane elements to the customer prepaid. Membrane elements must be kept damp at all times and must be clean and bagged in a watertight bag before returning. Only Osmonics approved cleaners, biocides, dispersants or other chemicals may be used with the membrane elements. Use of other chemicals may void the warranty. The User is responsible for knowing the membrane element membrane material and for ensuring that chemicals harmful to the membrane are never in contact with the membrane elements. It is the obligation of the User to maintain frequent operating data records. Osmonics may request these records in the warranty evaluation. User must notify Osmonics at the very first sign of changes in operation of the Osmo machine or membrane elements. Such notification should be in writing and should include all data requested on the operating log sheets. 52

56 11.0 START-UP DATA Customer Date Model No. Osmonics Tested By Serial No. Units (Circle One) Data Data Remarks Permeate Rate F C Concentrate Rate gpm gph Lpm Lph / / Total Flow Rate gpm gph Lpm Lph / / Recovery gpm gph Lpm Lph / / Pre-Filter Pressure psi bar Post-Filter Pressure psi bar Primary Pressure psi bar Final Pressure psi bar Feed TDS µs Concentrate TDS µs Avg TDS µs Permeate TDS (manual) µs Permeate TDS (meter µs) µs % Passage (Perm TDS/Avg TDS) Chlorine in Concentrate ppm Pump Model No. Pump Serial No. Low Pressure Switch Setting psi bar 53

57 54

58 For more information call toll free in the USA (800) Manufactured in the USA TM 5951 Clearwater Drive, Minnetonka, MN USA Phone: (612) , Fax: (612) Copyright 1999 Osmonics, Inc. Printed in USA, P/N Rev.A