installation, operation & maintenance manual for...

Installation Guide – WPS RO systems – Models 2.000, 4.000, 6.000, and 8.000 GPD

Installation, Operation & Maintenance Manual

For Commercial & Industrial

Reverse Osmosis Systems

WPS Model: 2.000, 4.000, 6.000, and 8.000 GPG


TABLE OF CONTENTS 1.0 INTRODUCTION

1.1 Manual User’s Guide 3 1.2 Disclaimer Statement 3 1.3 Equipment Support 3 1.4 General Safety Guidelines 3

2.0 EQUIPMENT DESCRIPTION

2.1 General System Description 4 2.2 Mechanical Component Description 5 2.4 Electrical Component Description 7

3.0 INSTALLATION

3.1 Pumbling connections 8 3.2 Electrical connections 8 3.3 Equipment Installation Procedures 9

4.0 OPERATION 4.1 Initial Startup 10 4.2 Normal Operation 10 4.3 Short Term Shutdown Procedure 11 4.4 Long Term Shutdown Procedure 11

5.0 MAINTENANCE

5.1 Maintenance Schedule 13 5.2 Filter Cartridge Replacement 13 5.4 Membrane Element Replacement 14 5.5 Troubleshooting 15

6.0 CONTROLLER – PLC MANUAL 1 General 19 2 Process flow selection 19 3 Functions 20 4 Main technical specifications 20 5 Front panel illustration 21 6 Operation method 23 7 Rear panel illustration 24 8- Conductivity electrode installation 25 9-Maintenance 26


1.0 INTRODUCTION 1.1 MANUAL USER’S GUIDE This manual describes the procedures necessary to install, operate, and maintain your Reverse Osmosis System. Please read this manual carefully before installing and operating your equipment. The equipment warranty may be voided if installation or operation instructions are not followed correctly. This manual has been formatted for ease of use, combining the instruction for the entire RO unit into one manual.

1.2 DISCLAIMER STATEMENT These manuals should provide complete and accurate information to meet your operating and/or service requirements based on the information available at the time of publication. The information in these manuals may not cover all operating details or variations or provide for all conditions in connection with installation, operation and maintenance. Should questions arise which are not answered specifically in this manual, contact WPS.

1.3 EQUIPMENT SUPPORT WPS continually strives to provide safe, efficient, trouble-free equipment using the optimum technology for your application. For service, sales, parts, or additional manual copies call WPS.

1.4 GENERAL SAFETY GUIDELINES This equipment operates at high voltage and high pressure, and has moving parts that may cause serious injury or fatality if not operated and maintained according to the procedures outlined in this manual. 1. No one should use or service this equipment without proper training and supervision. It is the responsibility of the owner to ensure that this equipment is used properly and safely, strictly following the instructions contained herein. 2. Always wear safety equipment (safety glasses, gloves) for protection while working on the equipment. 3. Always operate the equipment at the parameters specified. 4. Never remove any components from the unit while under pressure. 5. Proper maintenance assures the equipment will run properly and can lower the risk of injury. Be sure to follow the instructions on maintenance carefully. 6. Continuously inspect the system for leaks and damage. Correcting problems as they occur will help prolong the life of the system.


2.0 EQUIPMENT DESCRIPTION 2.1 GENERAL SYSTEM DESCRIPTION The purpose of this section is to introduce the user to the equipment. A thorough understanding of the equipment will help when installing, testing, and operating the system.

Mechanical Description The major components are supported by aluminum frame and designed in such a way to provide easy access for servicing, maintenance, and monitoring system performance. The frame is a type full frame configuration designed to offer maximum support and protection for the RO unit’s components. The pressure vessels are arranged to accommodate future expansion if necessary, without disturbing the existing components. The RO unit’s piping is neatly arranged and supported on the frame. All high pressure valves, as needle valves are 316 stainless steel. Additional pressure gauge indicates the individual pressure for final concentrate flows. The needle valve is mounted in close proximity to the respective flow rate indicators for ease of field adjustment. The feed, product, and reject piping is designed for minimal removal during RO membrane loading and unloading.

Electrical Description The RO unit’s control system is comprised of a Control Panel. The Control Panel is an enclosure housing a programmable logic controller (PLC) for the integral control of the RO unit as well as discrete inputs and outputs for communicating with the pretreatment and post treatment equipment. The PLC is fully programmed and the control system is integrity tested prior to shipment. The Control Panel also houses a contactor motor starter. The Control Panel is mounted to the RO’s aluminum frame in such a way to as allow easy access to the conductivity monitor and control devices such as lights and switches. The RO unit comes standard with a multi-function quality monitor. The monitor will display the system alarms and product conductivity. One alarm from the monitor will shut down the system on low quality. Discrete input and output ports are supplied for communication with optional pretreatment and post treatment system components. Full documentation of the PLC program is provided in this document.. Three other optional devices may be included on your unit as well, they are:

1. A beacon light that will illuminate during flushing process. 2. A beacon light that will illuminate during pump work. 3. A multiple led alarms will laminate at the PLC screen.


2.2 MECHANICAL COMPONENT DESCRIPTION The major mechanical components that make up the RO unit are described below. Automatic Feed Water Control Valve

An automatic valve is mounted in the RO unit feed piping. This valve will shut off flow to the unit when it shuts down. A solenoid valve is connected to the Control Panel to control the operation of this valve. The solenoid system requires a minimum of 30 psi water pressure, the feed water supply pressure supplies this source.

Pre-filter Housing

Single polypropylene filter housing is mounted to the RO frame. It contains 5 micron, nominal rated filter cartridges to pre-filter the RO feed water prior to the RO membranes. Filter Pressure Gauge (Optional)

The line pressure from the filter inlet is displayed directly on separate 0-100 psi pressure gauges. These are located on the inlet piping of the filter housing. The gauges have a 63mm stainless steel case, and are constructed of all stainless steel wetted parts and glycerin filled. High Pressure Pump

The RO unit has a high pressure booster pump mounted to the frame to boost the feed water to the required operating pressure for the reverse osmosis membranes. The pump is a vertical or horizontal, multi-stage type with 316 stainless steel construction of all wetted parts, with 316 stainless steel impellers. The pump is designed to provide the pressure and flow necessary to operate the system, with additional pressure available to allow for fouling or a minor decrease in feed water temperature.


Low Feed Pressure Switch

A low feed water pressure switch is mounted on the Control Panel. It is adjusted to shutdown the RO unit if the inlet feed water pressure drops below the set point.

Pump Discharge Throttling Valve (Optional) The water discharged from the high pressure pump is regulated by a stainless steel ball valve. By adjusting the position of the valve, you can regulate the flow and pressure feeding the first stage pressure vessels of the RO unit. Reverse Osmosis Pressure Vessels

The RO unit has 4" round pressure vessels mounted to the frame. The vessels are constructed of fiberglass or stainless steel and rated for 300 PSI. The connections are mounted in the tap of the vessels to allow connection. The vessels are built to ASME specifications, but are not code stamped.

Reverse Osmosis Membrane Elements The RO unit is designed for 4" x 40" reverse osmosis membrane elements housed in pressure vessels on the frame. The elements are constructed of Thin Film Composite (TFC) membrane material. The membranes are designed to reject over 98% of the dissolved solids and over 99% of the suspended solids and organic material. Use care to prevent chlorine and other oxidants from coming in contact with the membrane elements, as this will cause permanent, irreversible damage.

Concentrate Throttling Valve The concentrate flow back pressure is regulated by throttling valves. This valve is used to control the differential pressure across the membrane surface flow, which in turn regulates the overall recovery rate of the system.

Flow Indicators

There is one flow indicators on the RO unit. They display the flow rates for the product. It consist of in-line float type flow meter located on the front of the unit. The flow indicators display the flow rates directly in GPM and m3/hr.


Concentrate Pressure Gauge

The final concentrate pressure is displayed on a 0-300 PSI pressure gauge, located on the concentrate piping. The gauge has a 63mm stainless steel case, and is constructed of all SST wetted parts and is glycerin filled.

Feed, Product, and Concentrate connection The feed connection must be done with piping PVC Schedule 80 in ½‖, ¾‖, or 1‖ depending on the model. The product circuit must be connected to the 1/2‖ BLUE hose provided with the equipment. The concentrate circuit must be connected to ½‖ BLACK hose provided with the equipment.

2.3 ELECTRICAL COMPONENT DESCRIPTION Control Panel

It houses the motor starter, PLC, solenoid valves and alarm horn The Control Panel contains the electrical main switch, flow monitors, and the switches and indicator lights listed below: Switch

RO Unit (Off-On) Indicator Lights

Pump Run Running (Green) Flushing process running (Red) (Optional) Low Quality (Red) Low Feed Pressure (Red)

Alarm Horn

An alarm horn is mounted to the bottom of the Control Panel to give an audible warning during an alarm status condition.

Controller PLC screen


3.0 INSTALLATION The purpose of this section is to provide general information on installation of new equipment. All equipment must be installed according to applicable codes. Installation of the RO unit consists of the following steps: 1. Install indoors in an area protected from freezing. Space allowances for the removal of the membranes from the pressure vessels should be provided. This system requires 42" minimum clear space on each side. 2. Anchor the skid to the foundation. 3. A fused high voltage disconnect switch located within 10 feet of the unit is recommended. This disconnect is not provided with the RO system. 4. Responsibility for meeting local electrical and plumbing codes lies with the owner / operator. 5. The water supply should be sufficient to provide a minimum of 30 psig pressure at the design feed flow. 6. Proper pretreatment must be determined and installed prior to the RO system. 7. Install any pre-treatment equipment and interlock to RO unit. 8. Install any post-treatment equipment and/or storage tank and interlock to RO unit.

3.1 PLUMBING CONNECTIONS 1. Connect the pretreated feed water line to the inlet side of the pre-filter housing. A feed water shutoff valve should be located within 10 feet of the system. 2. Temporarily connect the outlet of the product water flow meter to drain. The product water line should never be restricted. Membrane and/or system damage may occur if the product line is blocked. 3. Connect the outlet of the concentrate water flow meter to a drain. The reject drain line should never be restricted. Membrane and/or system damage may occur if the reject drain line is blocked.

3.2 ELECTRICAL CONNECTIONS 1. A safety switch or fused disconnect should be installed within 10 feet of the system. 2. Verify that the disconnect switch is de-energized using a voltmeter. 3. Attach the power supply ground to the chassis ground. It will be necessary to drill a hole in the enclosure and install a water tight strain relief or conduit connector. The hole size and location must be determined by the installer. Check the pump motor nameplate for the amperage draw at various voltages to determine the wire size required. 4. Connect control device wiring.


5. Run electrical conduit for the high voltage power supply between the Control Panel and the main power supply. 6. Run electrical conduit between the Control Panel and any pre-treatment equipment lockout relays. 7. Run electrical conduit between the Control Panel and the product water storage tank level sensing device. 8. Run electrical conduit between the Control Panel and the chemical injection pumps. 9. Verify that all electrical connections are secure and wired per the electrical schematic. 10. Verify that the voltage supplied is correct and matches the Voltage Identification Tag on the pump motor and inside the Control Panel.

3.3 EQUIPMENT INSTALLATION PROCEDURES 1. Locate a level, flat, clean, hard surface, capable of supporting the weight of the RO unit. NOTE: This area should have a local floor drain to carry away water which will fall to the floor during operation, testing, and servicing this equipment.

2. Lay out the area that the RO System will occupy. 3. Move the RO unit to the location laid down in the previous step. 4. Drill holes in the pad through the frame tie down holes. 5. Level the RO unit by installing shim stock under the frame near the frame tie down holes. 6. Install the anchor bolts and secure the frame to the anchor bolts using flat washers, lock washers, and nuts. 7. Install the feed water plumbing line. The plumbing runs should never be smaller than the actual RO inlet pipe size, and may need to be larger for pipe runs over 50 feet. NOTE: The plumbing materials should be of non-corroding materials (PVC, etc.) Use of this material will reduce the tendency to foul the membranes from metal precipitation.

8. Install the product water plumbing line. 9. Install the concentrate, or reject line directly to an open drain. NOTE: As a general rule, no valves should be installed in this line.

10. Install a tank level sensing device with an adjustable dead band. We recommend a pressure switch with inches of water scale. The dead band will prevent frequent start/stop action of the system during run time. The plumbing installation should now be complete. Check the plumbing to ensure all joints are properly connected and supported.


4.0 OPERATION 4.1 INITIAL STARTUP The following procedure should be performed for the initial startup of the RO System or to restart the system if it has been idle and secured for a long term shutdown.

1. Verify that the pretreatment equipment is installed and working properly. Verify that no free chlorine is present in the feed water. 2. Verify that the on/off switch is in the off position. 3. Verify that the pump discharge valve is open. 4. Install a 20" five micron filter cartridge in the pre-filter housing. 5. Open the needle control valve completely by turning it counterclockwise. 6. Open the feed water shutoff valve installed. 7. Confirm the storage tank is ready to receive water and the drains are all clear. 8. Check to ensure there are no repairs or service in progress to the RO unit or down stream equipment. 9. If the RO membranes were not installed at the factory, the need to be installed now, before proceeding with the start up. PRE-START, LOW PRESSURE SYSTEM FLUSHING

1. Verify that the feed water pressure to the RO unit is within 30 to 50 psi. If there is no feed pressure, make sure the main supply valve is opened. (If the pressure is too low, you may need to install a feed water booster pump to avoid low pressure fault shutdowns. If the pressure is too high, you must install an automatic pressure regulating valve to protect the low pressure pump seals and PVC piping from over pressurization.) 2. Fully open the concentrate valves. 3. Turn the system on. 4. Verify flow through the unit by checking the feed inlet pressure gauge on the wet instrument panel. Check for water flow out of the concentrate drain line. 5. Allow the flushing process to run for a minimum of 1 minute. This will assure all the air will be flushed out. 6. When flushing is complete, re-connect the tubing and return the valves to the operating position.

4.2 NORMAL OPERATION Use this section for daily startup or to restart the system after a short term shutdown. 1. BEFORE starting the RO unit, verify that the following conditions exist: DEVICE CONDITION

RO system switch OFF Control Panel circuit breaker (inside Control Panel) ON Manual feed water valve OPEN Concentrate globe valve open 4 full turns Any valves in the process supply line OPEN


Pre treatment equipment ready for use Post treatment equipment ready for use Storage tank ready for use

IF ALL THE ABOVE CONDITIONS EXIST, THE SYSTEM IS READY TO START. IF ONE OF THE SETTINGS IS INCORRECT, CORRECT THE SETTING PRIOR TO PROCEEDING.

2. Turn the switch to the ON position. This will start the system. NOTE: The pump will not start for 60 seconds. When you turn the switch to ON the feed inlet valves opens to fill the unit with water under low pressure. This purges any air out of the unit. (If any leaks are noticed at this time, turn off the system and correct the leaking component before the pump starts.) After the 60 second delay, the pump will start. Be prepared to adjust the pump discharge and concentrate valves to correctly set the product and concentrate flow. If the system does not start up after the initial 60 second delay, check the storage tank. If it is full, the system will not start until the tank drops below the setup point by the tank level sensing device. If the low feed pressure light is on, the system also will not start.

3. Verify that the product and concentrate flows are correct. If not, adjust the pump concentrate valve until the correct parameters are reached. Adjustment procedure: First, adjust the unit to make the correct amount of RO product water by adjusting the system pressure. Once this flow is correct, make a note of the operating pressure. Second, adjust the unit to make the correct amount of concentrate to drain flow by adjusting the

concentrate throttling valve.

4. Once the RO unit is operating at the parameters outlined on the RO Operating Specification, record the operating parameters. It is imperative to record the operating parameters daily, since RO trouble shooting may require a trended analysis of the RO operating parameters. NOTE: If the RO will not start, or can not achieve the correct flows, go to the trouble shooting section for more information.

5. If the RO unit shuts down due to a fault condition, you must turn the switch to OFF, then back to ON to reset the Control Panel.

4.3 SHORT TERM SHUTDOWN PROCEDURE NOTE: There are two methods for shutting the RO unit down.

Short term shut down is for when the system will be down for a short period of time, as to perform brief maintenance or service. Long term shut down should be used for when the system will be down for a prolonged shutdown, as for major repairs, modifications or going out of service.

1. Turn the switch to OFF. Turn the main power supply OFF. 2. Close the manual feed water inlet valve. 3. Once the feed water inlet pressure indicator reads zero, it is safe to service the unit. The system is now isolated from the standpoint of electrical and hydraulic energy and can now be safely serviced. To restart system, simply open the manual feed water valve and turn the switch back to ON.

4.4 LONG TERM SHUTDOWN PROCEDURE


If the system is to be down for a period longer than 7 days, it is recommended that a biocide be pumped into the membrane elements to prevent biological growth. Failure to store the membranes in a biocide for long term shutdown can cause irreversible damage to the membranes due to bacterial growth.

1. Turn the RO unit switch and the disconnect switch to the OFF position. 2. Fully close the manual feed water isolation valve and install a Lock-Out device and a lock Out Tag on the valve. 3. If applicable, you may also have to fully close any process valves located in the RO unit product line down stream of the product divert to drain valve junction to prevent unwanted RO product water from passing this point, and install Lock-Out / Tag-Out equipment on the valve. The RO UNIT is now isolated from a standpoint of electrical energy and hydraulic or water pressure energy and may be safely stored for up to a year. If longer storage is required, the membranes need to be removed and stored under more controlled conditions.


5.0 MAINTENANCE

5.1 MAINTENANCE SCHEDULE

Procedure Frequency Check system for leaks and failures Daily

Collect operational data and adjust valves to achieve proper flow rates

Daily

Change pre filter cartridge elements monthly or when the pressure differential reaches 10-15 psi, which ever occurs first.

Lubricate pump motor bearings 2 times a year

Calibrate instrumentation 2 times a year

Clean RO membrane elements When normalized productivity rate drops by more than 15% of the clean membrane normalized productivity rate, when the RO feed pressure increases by 25 psig over the clean feed pressure, or when the RO rejection rate drops by more than 3%

Replace RO membrane elements When cleaning the membranes fails to restore the proper performance

5.2 FILTER CARTRIDGE REPLACEMENT Required down time: 25 minutes 1. Shut down RO unit. 2. Wait until the automatic feed water valve fully closes, as evidenced by the feed inlet pressure indicator winding down to 0 (zero). 3. Open the sample valve located downstream of the filter housing to relieve any pressure, then remove the filter housing bowl, turn counter clockwise to loosen and remove the bowl and filter cartridge. 4. Remove the old filter cartridge elements and dispose of them. 5. Rinse the filter housing bowl out with fresh water. 6. Install the new filter element by setting them in the bowl making sure to align the center of the cartridge with the hole in the bottom of the filter housing bowl. 7. Replace the filter housing bowl by tightening in a clockwise direction taking care not to pinch the o-ring seal. 8. Restart system, and check for leaks around the o-ring seal.


9. If no leaks are observed, the RO unit is back in normal service. 10. If a leak is detected, turn the RO unit off, wait for the automatic feed water valve to fully close, remove the top, and inspect the o-ring for damage. If damage is observed, replace the o-ring.

5.3 MEMBRANE ELEMENT REPLACEMENT Required down time: 2 - 6 hours You will need the following: Safety equipment (glasses, boots, etc.) Lock-Out / Tag-Out equipment Rubber mallet 24 liquid ounces of glycerine Set of new membrane elements

1. Secure the unit for a short term shutdown. 2. Remove the product pipe connection from the end of the pressure vessel by un-screwing the fittings in the product lines. Some water will inevitably drain from the broken plumbing connections so be prepared for a wet floor. NOTE: The flow arrowhead sticker located on one end of the pressure vessel indicates the direction of flow through the pressure vessel. You should unload and reload the new RO membrane elements in the direction of flow. This greatly reduces the chance of rolling or damaging the brine seals.

3. To determine the correct procedure for pressure vessel end cap disassembly, consult the pressure vessel manufacturer literature. 4. Remove the retaining rings that hold the end caps. 5. Carefully remove the end caps by applying even steady pulling force on them. NOTE: Be sure to make note of which end cap came out of which end of the pressure vessel so they may be reinstalled in the same vessels.

6. Push the old membrane elements out of the pressure vessel in the direction of the flow arrowhead sticker on the outside of the vessel. 7. Remove the membrane product tube adapters from the old membrane elements if they did not remain on the vessel end caps and keep them. Dispose of the old membrane elements. 8. Check the o-rings on the interconnectors for damage and replace any that show signs of wear or damage. (It is a good idea to replace all the o-rings at the same time you replace the RO membrane elements). Apply a liberal coating of glycerin to the o-rings and brine seals before they are inserted back into the pressure vessel. 9. Remove enough new RO membrane elements from the protective packaging to fill one pressure vessel. 10. Install the interconnectors between the RO membrane elements as you load them into the vessel.


11. Load the new membrane elements in the pressure vessel in the same direction as the flow arrowhead sticker. Make sure that the membrane brine seal is on the end to enter the pressure vessel last. NOTE: The flow arrow on the new RO membrane element should match the flow arrowhead sticker on the pressure vessel.

12. Carefully reinstall the product tube adapters on the ends of the membrane element product tubes. Apply a liberal amount of glycerin on the o-rings to make installation easier. 13. Carefully reinstall the end caps back in the ends of the pressure vessel, taking care to put them in the same ends that they came out of. Use a small amount of glycerin on the orings to make installation easier. 14. Carefully tap the end caps into place, using the rubber mallet. Re-assemble the end cap assembly per manufactures instructions. 15. Carefully reinstall the retaining rings in both ends of the pressure vessel. 16. Once all the membranes are replaced, reinstall the product piping connections. 17. Check all connections and vessels carefully. The RO unit is now ready to be put back into service.

5.4 TROUBLESHOOTING PROBLEM: CONTROL POWER IS OFF

Cause Action Power source disconnect is opened or fuses have blown.

Check the power source and fuses.

RO unit Control Panel disconnect switch may be open.

Verify that the RO unit Control Panel disconnect switch is closed.

RO unit Control Panel fuses may be blown.

Check the fuses and replace them if necessary.

RO unit Control Panel low voltage circuit breaker may be tripped.

Check the Control Panel low voltage circuit breaker and reset it if necessary.


PROBLEM: RO UNIT WILL NOT START

Cause Action The RO unit pre-treatment interlock may be engaged because of a filter backwash or a softener regeneration cycle.

Check the operational status of the pre-treatment system. Check out the Control Panel circuitry to ensure the proper jumpers have been installed.

Low feed pressure fault may have caused the RO unit to drop out of service.

Turn the RO unit switch to the OFF position and then to the ON position. Allow the RO unit to restart, and check that the feed pressure is at least 10 psi.

The RO unit Control Panel motor overload may have tripped.

Reset the motor overload and observe the operation of the RO unit to determine if this was a transient trip or if there is a more serious electrical problem.

The RO unit Control Panel may have an electrical component failure.

Inspect all components of the Control Panel.

The RO unit level control failure. Inspect all components and connectivity into the controller- PLC. Upper level must be connected at slot #1, and lower level at slot #4. Sometimes that wiring is installed in inverse way.

PROBLEM: RO UNIT WILL NOT START IN THE AUTO MODE

Cause Action The RO unit pretreatment interlock may be engaged because of a filter backwash or a softener regeneration cycle.

Check the operational status of the pretreatment system. Check out the Control Panel circuitry to ensure the proper jumpers have been installed.

The RO water storage tank may be full. No action is required. unit is in standby mode, storage tank full indicator should be on.

The RO water storage tank level sensing device may be broken or require adjustment.

Inspect the electrical functioning of the RO water storage tank level sensing device. Inspect the settings of the RO water storage tank level sensing device.

PROBLEM: AUTOMATIC FEED WATER VALVE WILL NOT OPEN

Cause Action Solenoid valve may have failed. Replace the solenoid valve.

Feed water valve actuator may have failed. Repair or replace the actuator.


PROBLEM: RO UNIT PRODUCTIVITY IS LOW

Cause Action RO unit operating pressure is too low. Readjust the RO unit operating pressure.

RO unit product back pressure is excessive. Check the pressure of the RO unit product plumbing, it should not exceed 25 psig. If it does, determine what is causing the pressure drop and reduce it.

RO unit feed water temperature is colder then usual. (Lower feed water temperatures require a higher operating pressure.)

Check the RO unit feed temperature. If it has decreased, increase the operating pressure to compensate for this low temperature operation.

RO unit membrane elements may be fouled. Determine the nature of the foulant and clean the membrane elements.

Flow Indicator readings not accurate. Verify correct operation of flow indicators. Clean out or replace if necessary.

RO pretreatment failure. Inspect all pretreatment systems for problems.

PROBLEM: RO UNIT REJECTION IS LOW

Cause Action Inadequate operating pressure. Increase RO unit operating pressure by further

opening the pump discharge valve.

RO unit recovery is too high. Reduce RO unit recovery to match values listed in RO operating spec sheet in Appendix.

Shift in feed water chemistry (oxidants in feed water).

Check feed water chemistry. If substantially different from the original design feed water chemistry, have a new performance projection run to determine what the rejection rate characteristic should be.

Mechanical leak in the membrane element system.

Inspect all RO element product tube adapter o-ring seals.

RO feed water temperature increase. Check feed water temperature. Install or adjust temperature controls, if necessary.

RO unit concentrate to waste flow out of adjustment.

Check flow parameters and adjust system.

RO unit membrane elements may be fouled. Determine the nature of the foulant and clean the membrane elements.


PROBLEM: CAN NOT ACHIEVE PROPER FLOW READINGS

Cause Action Flow indicators not operating correctly. Check for obstruction in piping, clean out flow

indicator bore and replace if necessary.

Control valves not properly adjusted. Reset the control valves.

Control valve may have failed. Check that there are no obstructions or damage to the control valves. Check seats on ball valves for excessive wear.


6.0 CONTROLLER - PLC

1 General

The instrument is a combined control instrument of a reverse osmosis controller and an on-line

conductivity instrument. With RO representative operation program, the instrument can make status

control, operation test and on-line monitoring of water quality conductivity. (combining PLC controller

and conductivity meter).

Imageable controlling panel with progress chart, the instrument adopts unique process flow and

graphical control panel with LED indicator lamp embedded for each pump, valve and corresponding

point of pressure checking, the interface is friendly; menu-driven operation is used, multiple groups of

parameters can be set and modified, the requirements of automatic operation are met.

Since entering in the market, The instrument has achieved mature technology after several improvement

and edition upgrading. It is very suitable to manage automatic operation in first-stage producing water

system. The instrument can achieve manual and automatic operation with extra electric element, it make

difficult problem easier to solve, and simplifying working element is a fashion.

2 Process Flow Selections

There are two typical operation modes for RO system : Fig A water supply with raw water tank in front;

Fig B tap water as direct water supply. This instrument can operate in both modes in A and B.

Flush vale

Flush valve

Level of raw

water

Raw

water

tank

Waste outlet

Low press pump

Pre

-pro

cess

ing

1

Pre

-pro

cess

ing

2

Pre

-pro

cess

ing

3

Direct drain valve

Sa fety

filtering

Low press protection

Inlet valve

High press pump

High press protection

RO membrane

Pure

water

tank

Fig. 1-A First level RO process flow with raw water tank

Fig. 1-B First level RO process flow with direct water supply

Safety

filtering

Low press protection

High press protection

High press pump

RO membrane

Flush valve

Pure water tank

Inlet valve

Tap water Low press pump

Waste outlet

Low feed protection

Pre

-pro

cess

ing

1

Pre

-pro

cess

ing

2

Pre

-pro

cess

ing

3

Direct drain valve


3 Functions and Main Technical Specifications

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 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.

4 Main technical specifications:

1. Power voltage: AC 220V±15% 50Hz Power consumption: ≤3W

2. Environment conditions: 1) temperature: 0～50℃; 2) humidity: ≤85%RH

3. Measuring range: 0～200μS /cm accuracy: 1.5 level

4. Load capacity of output contact: 3A/250V AC (the magnetic valve should be driven through

intermediate relay)


5. Operation pressure of conductance cell: 0～0.5Mpa

6.Medium temperature:5～50℃

7.Temperature compensation: automatic temperature with 25℃ as reference temperature

8. Distance of measuring range: less than 30m (the ex-factory configuration of electrode cable is 5m

unless there is a special agreement)

9. Display mode: 3 1/2-digit LED digital display

10. Electrode selected: 1.0cm-1

11. outline dimensions: 96×96×130mm meter board hole: 92×92mm (height×width)

12.Status signal collect: DC up-pull electric potential

13. Controlling output mode: ON relay output, single element connect

14. Instrument panel hole: 91*91mm(height*width)

5 Front Panel Illustration

Fig. 2 Front panel


The display board is shown in the above figure, there are three areas from up to down: I, II and III.

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.

6 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:

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

1. 0 0 0 1 0 0. 0 C━ 0 3

B. 0 0 5

A. 0 0 5

Setting of electrode constant

Setting of conductivity limit value

Setting of flush time at start-up

Setting of flush time at water level

Setting of flush interval


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.)

7 Rear Panel Illustration

Since small relay is used in the controller, when driving larger inductive load, intermediate relay or

contactor must be used, direct driving is not allowed.

Note: ZJ—intermediate relay CJ---magnetic contactor (refer to appendix for type selection)

The rear connecting terminals are shown in the diagram, the definitions of the terminals are:

Terminals from up to down on the left:

9----output contact terminal of high pressure pump on/off control (normally open, passive)

10---contact terminal of conductivity over limit control (normally open, passive)

11--- output contact terminal of low pressure pump on/off control (normally open, passive)

12--- output contact terminal of inlet magnetic valve on/off control (normally open, passive)

High pressure pump

Conductivity over limit

Low pressure pump

Inlet valve

Flush valve

Common terminal at power side

Power control side

Conductance electrode

Status detection side

Common terminal at detection side

Reset

External control switch

Low feed of raw water

Low pressure of high pressure water supply

Over pressure of high pressure pump

High water level of pure water tank

Green Red White Yellow

Fig. 3 Rear panel connection diagram


13--- output contact terminal of flush magnetic valve on/off control (normally open, passive)

14---a common terminal used jointly by the control signals of terminal 9, 10, 11, 12 and 13.

15, 16---connection terminal of 220V commercial power.

Terminals from up to down on the right:

1---input terminal of high water level detection switch of pure water tank (normally open, close in

case of low water level of pure water tank)

2---input terminal of booster pump over pressure detection switch (normally close, switch off in case

of over pressure)

3---input terminal of insufficient low pressure detection switch (normally open, close at a preset

pressure)

4---input terminal of raw water low feed detection switch (normally open, close when water exists)

If your system has a raw water tank as shown in Fig. 1-A, this terminal is connected to the

normally open contact of the raw water tank low level limit, it will close when water exists; if your

system adopts direct water supply from tap water as shown in Fig. 1-B, then this terminal is

connected to the normally open contact of the pressure switch of low feed protection, and it will

close when water pressure is normal.

5---terminal of external operation switch of controller ,ECS (the system operates when it is switched

on ). The ECS switch may be controlled by the key switch installed on the cabinet panel, if a key

switch is not used, please connect terminal 5 and 8 in short circuit.

6---Reset signal, may be connected to a reset button on the cabinet panel, used for reset of high

and low pressure alarms.

8--- a common terminal used jointly by the detection signals of terminal 1,2,3,4,5 and 6.

Terminals from left to right in the middle:

22---input wire of conductance electrode (green wire)

23---input wire of conductance electrode (red wire)

25---input wire of conductance electrode (white wire)

26---input wire of conductance electrode (yellow wire)

Rest terminals including terminal 7, 17,18,19,20,21,24 are not internally connected.

8 Electrode installation

Conductivity electrode is one of the elements of conductivity controller, it should be installed


correctly, the measurement results would be not correct if the electrode was installed in the pipe where

there is air bubbles between conductance cell or dead water, The installation should be performed

strictly according to the following drawing:

Notes:

a) The electrode should be installed at a lower location in the pipe where the flow speed is steady and

air

bubbles are seldom generated.

b) No matter the conductance cell is horizontally or vertically installed, it should be deeply inserted into

the moving water.

c) The conductivity signal is weak electronic signal and its collecting cable should be separately

installed. They should not be connected to the same group of cable joint or terminal board with the

power line.

d) conductivity electrode use professional cable, when it needs to be lengthened, the length of the cable

(<30m) should be agreed on before delivery, the correctness of the measurement results would be

affected if temporary measure is adopted.

e) It is suggested that a conductivity transmitter should be used when the measurement distance

between the meter and primary element(conductivity electrode) is relatively longer.

9 Maintenance

a) The conductance cell, as a sophisticated component, can not be disassembled. Unless necessary the

Measuring electrode

Fluid outflow direction Right-angle tee flow-

through cell

Fluid inflow direction

Fig.4 Pipeline installation method


electrode cell should not be taken out of measurement cell .Conductance cell should be cleaned

regularly for keeping surface clean. when the electrode platinum black coating is dirty, soak it in 10%

dilute hydrochloric acid for two minutes , then rinse it with pure water to keep the surface clean.

b)The measurement cable is special cable and should not be changed at will or it will cause significant

error.

c) The special auxiliary electrode cell should be used in case of damage .

10 Achieve automatic reverse flushing electric connection

To avoid frequently start-ups and stops of the RO system caused by low pressure of water supply in

pretreatment flushing and regeneration. That will make system shocking. RO controlling system and

water supply capacity of pretreatment should induct connection control.

Use control relay J1, the timer connect point of pretreatment, to force the RO system to stop in

reverse flushing of pretreatment or regeneration. J1-1 ,the connect point of electric of J1, connect to

extra control circuit of the system. Then the system shock will be removed.

In order to make sure the normal operation of the water supply pump, avoid the affection of the stop

of RO. The connect point of J1-3 and RO controller should be parallel connected, which make sure the

normal operation of the system.

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