GE E4-2200, E4-8800, E4-11000, E4-6600, E4-4400 Operation And Maintenance Manual
...
E4, E4LE, EZ4 Series
Water Purification Machines
Operation and Maintenance Manual
2,200 GPD to 13,200 GPD
8.3 m
3
/day to 50 m3/day
July 4, 2014
Document PN 1161875, Rev G
http://www.gewater.com
1
TABLE OF CONTENTS
1. DESCRIPTION .......................................................................................................................................... 4
1.1. Definitions ................................................................................................................................................. 4
1.1.1. Permeate Rate (Product Water Rate) [Qp] ........................................................................ 4
1.1.2. Concentrate Rate (Reject Rate) [Qc] .................................................................................... 4
1.1.3. Feed Rate [Qf] ................................................................................................................................ 4
1.1.4. Reverse Osmosis (RO) ................................................................................................................ 4
1.1.5. Membrane Elements .................................................................................................................. 5
1.1.6. CIP ...................................................................................................................................................... 6
1.1.7. Average Pressure [P
1.1.8. Concentration ............................................................................................................................... 6
1.1.9. Salt (Ionic) Passage ..................................................................................................................... 6
1.1.10.Recovery .......................................................................................................................................... 6
1.1.11.Salt (Ionic) Rejection ................................................................................................................... 6
1.2. Machine Nomenclature ...................................................................................................................... 7
1.3. Specifications for E-Series Machines ........................................................................................... 8
2. INSTALLATION ........................................................................................................................................ 8
2.1. Mounting the Unit ................................................................................................................................. 8
2.2. Plumbing ................................................................................................................................................... 8
2.3. Installing Clean-In-Place Valves ..................................................................................................... 9
2.4. Concentrate Outlet Connections .................................................................................................... 9
2.5. Feed Water Requirements .............................................................................................................. 10
2.6. Transporting Pure Water (Permeate) to Point-of-Use ........................................................ 10
2.7. Pressure Correction Factors ........................................................................................................... 10
2.8. Electrical .................................................................................................................................................. 11
2.8.1. Single-Phase Electrical ............................................................................................................ 11
2.8.2. Three-Phase Electrical ............................................................................................................ 11
2.9. Machine Control................................................................................................................................... 12
2.9.1. Economy Model ......................................................................................................................... 12
2.9.2. Deluxe Model ............................................................................................................................... 12
3. PREPARATION AND STARTUP ........................................................................................................12
3.1. Pretreatment for Water Purification ........................................................................................... 12
3.2. Machine Start-Up Preparation ...................................................................................................... 13
3.3. Machine Start-Up ................................................................................................................................ 13
3.4. Temperature Correction Factor .................................................................................................... 14
3.5. Autoflush Timer .................................................................................................................................... 15
3.5.1. Programming the Autoflush Timer .................................................................................... 15
3.6. Calibrating the Conductivity Probe ............................................................................................. 15
4. OPERATION AND MAINTENANCE .................................................................................................16
Daily Flushing for the Economy Model ............................................................................ 16
4.1.1.
4.1.2. Daily Flushing for the Deluxe Model ................................................................................. 17
4.2. Pre-filter Cartridge .............................................................................................................................. 17
] ............................................................................................................ 6
AVG
2
4.3. Membrane Element Cleaning ........................................................................................................ 17
4.3.1. Step Wise Cleaning ................................................................................................................... 17
4.3.2. Procedure to Clean with a CIP Pump ............................................................................... 18
4.4. Suction Cleaning .................................................................................................................................. 19
4.5. Changing Out Membrane Elements ........................................................................................... 20
5. TROUBLESHOOTING ..........................................................................................................................22
6. SPARE PARTS LIST ...............................................................................................................................26
7. RETURN GOODS AUTHORIZATION (RGA) PROCEDURE .......................................................26
8. WARRANTY/GUARANTEE .................................................................................................................26
9. START-UP DATA ...................................................................................................................................26
10. DAILY LOG DATA FOR GE WATER AND PROCESS TECHNOLOGIES MEMBRANE
MACHINES ........................................................................................................................................................26
List of Tables
Table 1. Flow Specifications for E4 Machines, 50-75% Recovery ................................................ 8
Table 2. Connections ........................................................................................................................................ 8
Table 3. Feed Water Requirements ......................................................................................................... 10
Table 4. Pressure Correction Factors ...................................................................................................... 10
Table 5. Troubleshooting Guide ................................................................................................................ 22
List of Figures
Figure 1. Normal vs. Crossflow Filtration .................................................................................................. 5
Figure 2. Membrane Element with Interconnectors ............................................................................ 5
Figure 3. Cross-Sectional View of Membrane Element ...................................................................... 6
Figure 4. Principle of Operation ..................................................................................................................... 7
Figure 5. Three-Phase Allen Bradley Motor Starter ............................................................................ 12
Figure 6. Conductivity Probe Display ........................................................................................................ 16
Figure 7. Clean-In-Place Pump and Tank Hook-Up ........................................................................... 18
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1. DESCRIPTION
Your E-Series reverse osmosis (RO) machine is a durable piece of equipment which,
with proper care, will last for many years. These instructions give operation and
maintenance details vital to the sustained performance of the machine. Please read
this manual completely before operating your machine.
1.1. Definitions
The operating definitions provided below will help you further understand your
machine and this manual.
1.1.1. Permeate Rate (Product Water Rate) [Q
The flow rate of purified water, which has passed through the membrane and out of
the membrane element, expressed in gal/min (gpm) or gal/hr (gph) or liter/min (lpm)
or cubic meters/hour (m3/h). Specified permeate rates are based on a feed water
temperature of 77 F (25C). Permeate rate will vary with temperature.
1.1.2. Concentrate Rate (Reject Rate) [Q
The flow rate of water containing rejected solids to drain in gpm or gph (lpm or m3/h).
1.1.3. Feed Rate [Q
The flow rate of incoming water in gpm or gph (lpm or m3/h). Feed water rate equals
permeate rate plus concentrate rate.
]
f
]
c
]
p
1.1.4. Reverse Osmosis (RO)
The separation of one component of a solution from another component by means of
pressure exerted on a semipermeable membrane. In other words, reversing the
natural passage of a liquid from a concentrated solution to a more dilute solution by
using external pressure. Removal of ionic, organic, and suspended /dissolved
impurities occurs during the RO process. Unlike a filter, which separates by “normal”
filtration, the membrane element separates using a process called crossflow
filtration. Feed water solution is separated in to two streams, permeate and
concentrate, and collected from both sides of the membrane. A semipermeable RO
membrane, under sufficient pressure, allows passage of purified water while rejecting
and concentrating dissolved and suspended solids.
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Figure 1. Normal vs. Crossflow Filtration
1.1.5. Membrane Elements
Membrane elements are the key to reverse osmosis. Interleaved layers of
semipermeable membrane, spacer and permeate carrier spiraled around a central
permeate tube make up the element. The spacer allows for movement of the
concentrate past the membrane, and the permeate carrier carries the purified water
out of the membrane element. GE Water & Process Technologies manufactures a
patented spiral wound membrane element with a turbulent flow design. This
membrane module collects the purified water within the central tube, the permeate
tube. The E8 RO machine utilizes between 8 and 20 membrane elements.
Figure 2. Membrane Element with Interconnectors
5
Figure 3. Cross-Sectional View of Membrane Element
1.1.6. CIP
The abbreviation for clean-in-place.
1.1.7. Average Pressure [P
PP
FinalPrimary
AVG
]
2
1.1.8. Concentration
Concentration equals the Total Dissolved Solids (TDS) concentration of a solution
expressed as parts per million (ppm) or conductivity (microSiemens/cm).
Cf = Feed Concentration
Cp = Permeate Concentration
Cc = Concentrate Concentration
C
= Average Concentration in Machine
avg
1.1.9. Salt (Ionic) Passage
The percent of dissolved salts passed through the membrane or 100% minus
rejection.
1.1.10. Recovery
Permeate rate divided by feed rate, expressed as a percentage. For example, 33%
recovery means that out of a given feed rate, 33% is produced as purified water
(permeate).
1.1.11. Salt (Ionic) Rejection
The percent of dissolved salt rejected by the membrane, calculated from an average
concentration over the membrane.
6
An example of how to calculate salt rejection and recovery is given below.
Figure 4. Principle of Operation
Given the system case in the figure above:
Average Concentration,
CC
pAvg
Rejection
Passage
C
Avg
C
p
C
Avg
100
8.3mg/L
237.5mg/L
CC
C
Avg
cf
2
8.3mg/L237.5mg/L
237.5mg/L
%5.3100
375mg/L100mg/L
2
%5.96100
Recovery
Q
p
100
Q
f
18gpm
24gpm
%75100
TDS 237.5mg/L
1.2. Machine Nomenclature
E-Series water purification machines are numbered in such a way as to indicate the
permeate flow you can expect from the machine and other specifications.
Example: RO,E4-4400-DLX,460,6,HR(PA)
RO indicates the machine is a reverse osmosis machine.
E4 indicates the machine series (E) and 4-inch housings/membrane elements
4400 indicates the rated permeate flow in thousands of gallons per day at 77F
(25C), i.e. 4400 = 4400 gallons per day
DLX indicates the deluxe model and ECN indicates the economy model
460 indicates 460 VAC, 3-phase voltage to starter. Standard models offer 460
VAC, 60 Hz, 3-phase and 380 VAC, 50 Hz, 3-phase.
6 indicates 60 Hz operation, (50 Hz operation is also available and is indicated by
a 5 in place of the 6.
7
HR(PA) indicates that the machine includes high rejection (HR) polyamide (PA)
membranes. Low energy membranes are also available and are indicated by
LE(PA).
1.3. Specifications for E-Series Machines
The machine flow specifications listed in Table 1 below are based on 77°F (25°C) and
2,000 ppm NaCl.
Table 1. Flow Specifications for E4 Machines, 50-75% Recovery
Model E4-2200 E4-4400 E4-6600 E4-8800 E4-11000 E4-13200
Units
Permeate Rate
Concentrate
Rate
Feed Rate
gpm
(m3/h)
1.5 (0.3) 3 (0.7) 4.5 (2.0) 6 (1.4) 7.5 (1.7) 9 (2.1)
1.5-0.5
(0.3-0.1)
3.0-2.0
(0.6-0.4)
gpm
(m3/h)
3.0-1.0
(0.7-0.2)
6.0-4.0
(1.4-0.9)
gpm
(m3/h)
4.5-1.5
(1.0-0.3)
9.0-6.0
(3.0-2.3)
gpm
(m3/h)
6.0-2.0
(1.4-0.5)
12.0-8.0
(2.8-1.9)
gpm
(m3/h)
7.5-2.5
(1.7-0.9)
15-10
(3.4-2.6)
gpm
(m3/h)
9.0-3.0
(2.1-0.7)
18-12
(4.2-2.8)
2. INSTALLATION
2.1. Mounting the Unit
When installing your new GE 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 cm) is required at the end of each membrane element housing and 24inches (61 cm) behind the machine.
2.2. Plumbing
The feed water source must be able to provide water quantity and pressures to
maintain an operating feed water pressure of 30 - 60 psig (2.1 - 4.1 barg). If the feed
water pressure with the machine is in excess of 60 psig (4.1 barg) or fluctuates by
more than 5 psig (0.34 barg) a pressure regulator should be installed up stream of the
machine Inlet. If proper water pressure cannot be maintained to the RO, a booster
pump may need to be installed in front of the pretreatment to provide the proper
water quantity and pressure for the operation of the machine.
Table 2. Connections
Model
E4-2200
E4-4400
E4-6600
Inlet
inches (cm)
0.75 (1.9) 0.5 (1.27) 0.5 (1.27)
0.75 (1.9) 0.5 (1.27) 0.5 (1.27)
0.75 (1.9) 0.5 (1.27) 0.5 (1.27)
Permeate
inches (cm)
Concentrate
inches (cm)
8
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