OSMONICS E4, E4LE, EZ4 SERIES TM WATER PURIFICATION MACHINES INSTALLATION, OPERATION, AND MAINTENANCE MANUAL GE Infrastructure Water & Process Technologies
INSTALLATION, OPERATION AND MAINTENANCE MANUAL E4, E4LE, AND EZ4 SERIES WATER PURIFICATION MACHINES TABLE OF CONTENTS Page 2.0 INSTALLATION 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 Mounting the Unit Plumbing Installing Clean-In-Place Valves Concentrate Outlet Connections Feed Water Requirements Transporting Pure Water (Permeate) to Point-of-Use Pressure Correction Factors Electrical 2.8.1 Single-Phase Electrical 2.8.2 Three-Phase Electrical Machine Control 2.9.
Page 2.17 2.18 2.19 2.20 2.21 2.22 Operation and Maintenance 2.17.1 Daily Flushing for the Economy Model 2.17.2 Daily Flushing for the Deluxe Model Pre-Filter Cartridge Membrane Element Cleaning 2.19.1 Step Wise Cleaning 2.19.2 Procedure to Clean with a CIP Pump Suction Cleaning Changing Out Membrane Elements Troubleshooting 16 16 16 17 17 17 17 19 20 22 LIST OF FIGURES Figure Description 2.1 2.2 2.3 2.4 2.
2.0 INSTALLATION 2.1 Mounting the Unit When installing your new GE Infrastructure Water & Process Technologies reverse osmosis (RO) machine, allow at least 45-inches (114 cm) above the machine for membrane element removal and loading. If space is not available, the entire membrane element housing can be removed for membrane element change outs. If the membrane element housings are to be removed to change out the membrane elements, at least 6-inches (15.
2.3 Installing Clean-In-Place Valves NOTE: Clean-In-Place (CIP) valves are not included with the machine. The CIP valves must be purchased and installed by the customer. When installing the CIP valves, a three-way valve should be installed in the inlet feed stream of the machine. The tees on the permeate and concentrate lines should be installed with two-way valves.
Table 2.2 E-Series Feed Water Requirements Temperature 50° - 85°F (10° - 29°C) 33° - 104°F (0.16° - 40°C) Inlet Pressure Minimum: Maximum: Chlorine (continuous feed) 0 parts per million (ppm) Operating pH 5.5 - 8.5 Silt Density Index (SDI) Less than or equal to 5 to minimize membrane element fouling and extend cleaning intervals. Refer to ASTM* standard D4189. * 2.6 Typical: Limits: 30 psig (2.1 barg) 60 psig (4.
2.7 Pressure Correction Factors It is often necessary to operate RO machines with permeate back pressure. Permeate back pressure will decrease permeate production. See Table 2.3 (Pressure Correction Factors) to calculate loss of permeate. Table 2.3 Pressure Correction Factors BACK PRESSURE % LOSS OF PERMEATE FLOW E4/EZ4 PRESSURE CORRECTION FACTOR (PCF) E4LE E4/EZ4 E4LE 10 psig (0.7 barg) 5% 10% 0.95 0.90 20 psig (1.4 barg) 10% 20% 0.90 0.80 30 psig (2.0 barg) 15% 30% 0.80 0.
2.8 Electrical This RO machine requires two supply voltages; the control voltage and the pump motor voltage. 2.8.1 Single-Phase Electrical The control voltage can be connected to either a 115 VAC, 60 Hertz or 220 VAC, 50 Hertz single-phase power supply. The RO control circuit should always be installed on at least a 15 Amp, single-phase dedicated circuit. Reverse osmosis machines with 115 VAC, single-phase control voltage include an eight-foot (2.
Figure 2.1 Three-Phase Allen Bradley Motor Starter 2.9 Machine Control 2.9.1 Economy Model To remotely control the Economy Model (ECN) with float switches and/or pretreatment lockout, remove the jumper between terminals 4 and 5 and wire in the float switches or pretreatment components in series. After all field wiring is complete and complies with local and national electrical codes, move onto Section 2.10 (Pretreatment for Water Purification). NOTE: 2.9.
and complies with local and national electrical codes, move onto Section 2.10 (Pretreatment for Water Purification). External control contacts are normally closed, dry contacts. NOTE: 2.10 Pretreatment for Water Purification A water analysis of your feed water should have been performed, as part of the planning and engineering that went into developing your RO system.
6. Turn the ON/OFF button on the machine ON. System will open allowing water to flow through the machine to the drain through the permeate and concentrate CIP valves. Let the machine run to drain for 5 - 10 minutes. This provides a wet start-up of the pump and removes any air in the system. 7. Turn the ON/OFF button on the machine to the OFF position. 8. Re-energize the pump power and trigger the ON/OFF button on the machine to check rotation of the pump motor.
The concentrate valve is drilled, and when completely closed the machine is running at the correct concentrate flow for a 75% recovery (Table 2.4, Flow Specifications for E4-Series Machines). If the temperature of the inlet feed water is not 77°F (25°C) use the Temperature Correction Factor Table (Technote 113). The proper adjustment of the recycle and concentrate valves are critical to the correct operation of the machine. CAUTION: 2.13 Optimum recovery will vary according to water quality.
2.14 Recovery The machine flow specifications listed below are based on 25°C (77°F). Table 2.4 Flow Specifications for E4-Series Machines E4-Series 2200 4400 6600 8800 11000 13200 Recovery 50-75% 50-75% 50-75% 50-75% 50-75% 50-75% Units LPM/GPM LPM/GPM LPM/GPM LPM/GPM LPM/GPM LPM/GPM Permeate Rate 5.8/11.6 11.6/3.06 17.3/4.6 23.1/6.1 28.9/7.6 34.7/9.2 Concentrate Rate (50%) 5.8/11.6 11.6/3.06 17.3/4.6 23.1/6.1 28.9/7.6 34.7/9.2 Concentrate Rate (75%) 1.9/0.5 3.9/1.
2.15 Autoflush Timer 2.15.1 Programming the Autoflush Timer The Autoflush timer clock operates and displays in real time, but the Autoflush feature will only work when the RO machine is operating. When the machine is operating in the Autoflush Mode, the total flow through the machine is increased. This provides extra cross flow which flushes the loose foulants from the surface of the membrane elements.
STEPS 1. While holding down the Clock Key (⊗), press the h key to advance to the current minute. 2. While holding down the Clock Key (⊗), press the h key to advance to the current minute. 3. While holding down the Clock Key (⊗), press the h key to advance to the current minute. NOTE: If the h and m keys are held down for longer than 2 seconds, the numbers will advance rapidly. If the days are flashing, it indicates the day of the week was not set when setting the time.
2.15.4 Programming Twenty-Four Hour or Seven Day Schedules NOTE: It is helpful to write out the program schedules before programming the time. Example: Figure 2.3 Programming the Timer 2.15.5 Changing a Program Select the program to be changed with the Prog. Key. A new set of days may be selected with the Day Key just as in the initial programming. Hour and minute can be changed with the h and m Keys. 2.15.6 Deleting a Program To delete one or a few programs: Press the Prog.
2.15.7 Troubleshooting the Autoflush Timer PROBLEM: Days are flashing, pressing any Key does nothing except “Hand” Key turns output ON and OFF. SOLUTION: Time of Day and Day of Week have not been set. See Section 2.15.3 (Setting-Up the Autoflush Timer Clock). PROBLEM: Time of day was set while holding the Clock Key down, but days are still flashing. SOLUTION: Current day of week was not set while holding down the Clock Key. See Setting-Up the Autoflush Timer Clock (Section 2.15.2).
2.16 Calibrating the Conductivity Probe STEPS 1. Make sure the calibration meter is in Measure Mode (with the MEAS LED light ON). 2. Immerse the Conductivity Probe in a 13.00 microSiemens (mS) prepared solution. 3. Immerse and agitate Conductivity Probe, and wait for the reading to stabilize. 4. Calibrate the meter by adjusting the CAL adjustment screw until the Liquid Crystal Display (LCD) display reads 13 mS of the solution.
2.17 Operation and Maintenance The operation and maintenance of an E-Series RO machine requires regular data recording and routine preventative maintenance. It cannot be emphasized enough the importance of filling out the Daily Log Sheet (Technote 106) during each operating shift. A Start-Up Data Sheet (Technote 105) should have been completed at startup containing pertinent facts on the operation of your machine.
2.18 Pre-filter Cartridge A 5 micron pre-filter cartridge is factory installed to protect the membrane elements and valves from particles, which may be in the feed water. To order replacements, see the Spare Parts List (Technote 118, P/N 1233377). A pressure drop across the filter of 8 psi (0.55 bar) or more during operation indicates that the pre-filters cartridge(s) need changing. Use only GE approved filters rated for 5 microns or less. Do not attempt to clean used filters. IMPORTANT NOTE: 2.
When set properly, the RO machine, the CIP pump, and the CIP container should be assembled in a loop configuration to recirculate the water through the machine and back to the container during cleaning. The size of the CIP container should be a minimum of three times the permeate rate. CAUTION GE recommends the use of a CIP or booster pump to provide the proper feed water pressure and quantity to the RO machine during cleaning. Figure 2.
2.20 5. Let the CIP solution dwell in the machine for 20 minutes. 6. After the 20 minute dwell time, start the CIP recirculation process again for 10 minutes. 7. After the 10 minute recirculation time is complete, de-energize the machine. Then, open the inlet water line and route the concentrate and permeate lines to the drain. 8. Start the RO machine and flush to drain for 20 minutes. Verify the permeate quality is good before returning to normal operation. 9.
NOTE: 2.21 As previously mentioned, the manufacturer recommends use of a CIP or booster pump to circulate the cleaning solution during membrane element cleaning. 7. After suction cleaning cycle is complete, reopen inlet water and flush machine to drain for twenty minutes. 8. After permeate quality is verified as good, return machine to normal operation mode.
5. Reattach the housing clamp and tighten. 6. Next reconnect the permeate and concentrate lines. The machine is ready for start-up.
2.22 Troubleshooting This troubleshooting guide can assist you in identifying common operating problems you may experience with your machine. Many of these problems can be easily corrected by the operator, however, for those that persist or are not understood, you should contact the GE Customer Support Center. Have the following information available when calling the Customer Support Center: 1. Machine installation date 2. Model number 3. Serial number 4. Weekly log sheets 5.
TROUBLESHOOTING GUIDE PROBLEM Low Operating (continued) Low Permeate Flow Rate POSSIBLE CAUSE SOLUTION Pump rotating backwards (three-phase power only) Switch any two of the three-phase leads to the motor starter. Insufficient electrical power Check the fuses or circuit breaker, measure the voltage. Pump not operating correctly See pump instructions. Low operating pressure See possible causes for low pressure.
TROUBLESHOOTING GUIDE PROBLEM Low concentrate flow rate, normal or higher than normal pressure High operating pressure Excessive pressure drop [over 50 psig (3.0 barg)] (high primary pressure low final pressure) POSSIBLE CAUSE SOLUTION Concentrate valve plugged Remove the concentrate valve step and/or disassemble the plumbing. Clean the valve Concentrate outlet line restricted Examine the concentrate line for obstructions or kinks, repair or replace the tubing.
TROUBLESHOOTING GUIDE PROBLEM POSSIBLE CAUSE SOLUTION Excessive pressure drop Telescoped membrane element Flush and clean the membrane [over 50 psig (3.0 barg)] covering membrane element elements (high primary pressure housing outlet port low final pressure) (continued) Severely fouled or dirty Flush the machine then clean it with membrane elements detergent.
TROUBLESHOOTING GUIDE PROBLEM Switch ON, unit not operating Deluxe (DLX) electrical machine shutdown POSSIBLE CAUSE SOLUTION Pressurized storage switch or float switch has cut power to machine Check the permeate back pressure or position of float in the storage tank. Fluid temperature higher than 100F (38C) or thermal overload in motor Allow the machine to cool; check the feed water supply and/or amp draw to the motor. No power to machine Check the fuses or circuit breakers, measure the voltage.
For more information call 952-933-2277 or 800-848-1750 in the U.S., or visit www.gewater.com. GE Infrastructure Water & Process Technologies North American Sales 5951 Clearwater Drive Minnetonka, MN 55343-8995 USA (952) 933-2277 Phone (952) 933-0141 Fax Euro/Africa Sales 230 rue Robert Schurman ZA des Uselles 77350 Le Mée sur Seine FRANCE +33 1 64 10 2000 Phone +33 1 64 10 3747 Fax © 2005, General Electric Company. All rights reserved. P/N 1161875 Rev.
