Reverse Osmosis System Installation Guide and Operation Manual.

Reverse Osmosis System Installation Guide and Operation Manual.

Table of Contents 1 Introduction...2 2 Installation...3 2.1 Feed water connection...3 2.2 Permeate and concentrate plumbing...3 2.3 Electrical Connections...4 3. Start up and operation....6 3.1 Start-up procedure....6 3.2 Operation: R.O.C. (Reverse Osmosis Controller)...6 3.2.1 Alarms...6 3.2.2. Front panel description...7 3.2.3 Operation Method...9 4. Warnings... 11 1

1 Introduction We thanks you for the choice on our Reverse Osmosis System, we integrate the system using quality tested components to assure a long lasting machine with a minimum maintenance. 2

2 Installation In this section you will find detailed instructions to install the reverse osmosis unit. The installation is divided in three major items. Feed water connection, permeate and concentrate water plumbing and electrical connection 2.1 Feed water connection The unit is equipped with a booster pump which needs to have 35psi of pressure in the intake port to work properly. Because of that, this machine CANNOT BE USED without a low pressure pump, which is not provided. If the low pressure pump should be installed far away from the unit, the piping used to fed the unit should be calculated so the pressure drop does not lowers the intake pressure below 35psi. The water feed should be between 68 and 115 degrees Fahrenheit for best performance and membrane durability 2.2 Permeate and concentrate plumbing To achieve the flow and the water quality advertised in the membrane datasheets (for any membrane) is very important that the permeate water can flow without any restriction. For permeate lines longer than 5 feet, the use of hard PVC pipe is recommended and the pipe diameter must be choose to minimize the pressure drop. For permeate lines longer than 25 feet or vertical longer than 10 feet the use of an intermediate tank and a pump is highly recommended. Concentrate plumbing is not as critical as permeate is but there are two considerations to keep in mind when designing the concentrate plumbing: First, the flow through the concentrate line is between 2 and 4 times higher than the permeate flow, so the drain will have to manage that flow. And second, if the drain is obstructed or closed for any reason the pressure inside the unit will rise too much causing severe damage to the membrane, the pump and the machine internal piping; for that reason the concentrate must be directed to an open drain as shown in the following figure. 3

Figure 1: Drain example The use of hard pipe in the concentrate line is recommended in case the drain is not located close to the unit. 2.3 Electrical Connections The unit must be powered with 220VAC and grounded through the main wire. The power consumption depends on the booster pump, it will be 16 Amps for the 10.000gpd. Thermal protection should be installed. There is an auxiliary connection inside the box to wire a float sensor and the low pressure pump contactor (220vca coil). Low Pressure Pump CONTACTOR 220VAC Coil Float Close Circuit => RUN Figure 2: Auxiliary connections 4

To install a float sensor, first remove the jumper between terminals 3 y 4 on the terminal block. The sensor should be installed as Normally Closed circuit so it opens the circuit when it detects water. Below, you will find the electrical circuit diagram of the machine control box. Low Pressure Pump CONTACTOR 220VAC Coil Float Close Circuit => RUN Figure 3: Electrical circuit diagram 5

3. Start up and operation. It is important to follow this start-up procedure to ensure the proper operation of the system. In this section you will find the steps the operator should follow to start the machine and how to operate the machine once it is running. 3.1 Start-up procedure. 1. Make sure the needle valve is fully open by turning it CCW. This will help to fill up the machine quicker. 2. Turn on the machine. If the Low Pressure Alarm goes off, there is either low pressure in the intake or there is still air in the system. If after restarting the machine a couple of times the alarm is still going off, check the low pressure pump and the feed piping. 3. Close the needle valve (CW) to adjust the permeate flow to the desire amount. The system pressure should never exceed 150psi since it will damage the membranes. 3.2 Operation: R.O.C. (Reverse Osmosis Controller) The Reverse Osmosis Controller was specially design for these machines. It will command the High pressure pump, the Low pressure pump, and the Solenoids and it will also read signal from a conductivity sensor and a float sensor to control the machine. 3.2.1 Alarms Low feed protection: In case of raw water supply break-off, the LOW FEED PRESS lamp will be lightened, the nixie tube will display ALA and the buzzer will give an alarm, the controller will shut down the whole RO system. After that, the controller will keep detecting the low feed switch. When the water supply is resumed, the system will be restarted. Low pressure protection: In case of low pressure, the LOW PRESS lamp will be lightened, the nixie tube will display ALA and the buzzer will give an alarm, the controller will shut down the whole RO system and try to start up for the first time after 1 minute. If the water pressure is normal, the water producing process 6

will be resumed. If the start-up fails for three times, the system will come into a dead-lock status. Press the ECS key(external control switch) or the reset key to exit and then restart. High pressure protection: In case of high pressure over limit, the HIGH PRESS lamp will be lightened, the nixie tube will display ALA and the buzzer will give an alarm, the controller will shut down the whole RO system and wait for the elimination of high pressure. When the high pressure eliminates, the controller will try to start up for the first time after 1 minute. If the water pressure is normal, the water producing process will be resumed. If the start-up fails for three times, the system will come into a dead-lock status. Press the ECS key (external control switch) or the reset key to exit and then restart. Conductivity over limit alarm: When the conductivity of the measured solution is over limit, the HIGH lamp on the panel will be lightened, the buzzer will give an alarm, and the control relay will switch on (this relay can drive to turn on the by-pass valve. When the conductivity falls below the limit, the alarm will be set off. 3.2.2. Front panel description Figure 4: Front panel III. The display board is shown in the above figure, there are three areas from up to down: I, II and 7

Part I contains 4 LED status indicator lamps and conductivity value display area. The 4 LED status indicator lamps respectively indicate: POWER indicator lamp for power supply HIGH indication for conductivity over limit alarm μs/cm conductivity value, representing that the displayed value is the conductivity value of the produced water temperature value of the fluid, representing that the displayed value is the temperature value of the current fluid Part II is the indication of RO system operation status, which contains 9 LED indicator lamps, and the lamps respectively indicate: LOW FEED PRESS indicator lamp for low feed alarm, indicating that there is no water in the raw water tank or the water is not sufficient. LOW PRESS indication for inlet water operation of high pressure pump, indicating that the inlet water operation pressure of high pressure pump is too low. HIGH PRESS indication for over pressure operation of high pressure pump, indicating that the outlet pressure of high pressure pump is too high. INLET VALVE indication for inlet magnetic valve turning on, indicating that the inlet magnetic valve is turned on. M1 indication for low pressure pump operation, indicating that the low pressure pump is switched on. M2 indication for high pressure pump operation, indicating that the high pressure pump is switched on. RO indication for water producing status, indicating that the RO system is in water producing operation. FLUSH VALVE indication for flush magnetic valve turning on, indicating that the flush magnetic valve is turned on. FULL indication for full pure water tank, indicating that the water level in the pure water tank has reached the high limit. Part III contains setting and operation keys, their meanings are: parameter setting key, select the parameter items to be modified or inquired. circularly select thousand, hundred, ten and unit digit, the selected digit flashes. adjust the number of the selected digit (circle from 0 to 9) C/T key, confirm to save the modified parameter in parameter modification or switch between the indication value of conductivity and temperature in measuring status. 8

3.2.3 Operation Method When the instrument is powered on, the POWER lamp will be lightened, and the nixie tube will display the conductivity value. Switch on ECS to start water producing, stand by in the nixie tube if it is not switched on. A Press key, the nixie tube indicates 1.000 (electrode constant). Press key again and again, the following menu items will come out: Figure 5 Electrode constant: this value is keyed in by the manufacturer at ex-factory, it should not be modified at will. In case of replacement of electrode, please enter it under the direction of the manufacturer. Conductivity limit value: the default value is 100.0 (operation limit). Flush time at start-up: A-005 005 is the default value, the unit is second, and the setting range is 0~249s. If the setting is 90, then the membrane will be flushed for 90s in each time the system start up to produce water. Flush time at water level: B-005 005 is the default value, the unit is second, and the setting range is 0~249s. If the setting is 90, then in each time that the pure water tank is full and the system stops, or the system restart after low water level is detected, the membrane will be flushed for 90s. Flush interval: C-03 03 is the default value, the unit is hour, and the setting range is 0~99h. If the setting is 03, then the membrane will be flushed once at every 3 hours of continuous water producing or standing by status. If you are not satisfied with the above mentioned parameter settings, you can modify them by, and keys. When the data modification is finished, press key to save the data and go back to measuring status (if you don t press this key, the system will automatically go back to measuring status after 3 minutes, but the data modification will not be saved.) 9

3.3 Operation: Maintenance To keep the unit performing to the maximum of its capabilities periodic maintenance routines should take place. The maintenance procedures are simple but their effect will extend the RO machine life span. Two maintenance tasks should be done periodically: 1. The sediment filter should be replaced every 150 working hours or 2 month, whatever happens first. 2. Flush the system periodically. If there is a float driving the system, the machine will flush itself every time it starts and stops working. If the machine is started manually, the operator should restart it every 5 to 10 hours to flush the membranes. 10

4. Warnings WARNING! This machine runs with 220 VAC make sure that it is powered and grounded properly. WARNING! The membranes were not made to work over 150 psi. If you go over 150 psi trying to get more permeate water you will damage the membranes affecting the machine. WARNING! The pumps supplied with ours Reverse Osmosis Systems are multi-stage centrifugal type. DO NOT run the pump dry or without sufficient feed water (35psi intake pressure). This will cause damage to the pump and will void the warranty. Make sure to feed the pump ALWAYS with filtered water. Otherwise, damage and loss of performance can be the result of sediment and debris in the feed water. The maintenance of the pre-filtration system is critical for the life of membrane, replace the cartridge periodically or if the in feed pressure drop. 11