GE E4H User Manual
E4H SERIES
WATER PURIFICATION MACHINES
OPERATION AND
MAINTENANCE MANUAL
OPERATION AND MAINTENANCE MANUAL
FOR GE OSMONICS
E4H SERIES
WATER PURIFICATION MACHINES
T
ABLE OF
CONTENTS
Page
1.0 DESCRIPTION ......................................................................................................... 1
1.1 General Information and Principles of Operation ......................................... 1
1.2 Machine Nomenclature.................................................................................. 4
1.3 Machine Permeate Quality ............................................................................ 5
1.4 Economy and Deluxe Model Options ........................................................... 5
1.4.1 Economy Model................................................................................. 5
1.4.2 Deluxe Model Options....................................................................... 6
1.5 Specifications for E-Series Machines............................................................ 7
1.5.1 Feed Water Requirements .................................................................. 7
1.5.2 Permeate (Product Water) Flow Rate ................................................ 7
1.5.3 Concentrate Flow Rate ...................................................................... 8
1.5.4 Typical Pure Water............................................................................. 8
1.5.5 Final Operating Pressure.................................................................... 8
1.5.6 Pump .................................................................................................. 8
1.5.7 Reverse Osmosis Membrane Element Rejection .............................. 8
2.0 INSTALLATION ....................................................................................................... 10
2.1 Mounting........................................................................................................ 10
2.2 Piping ............................................................................................................. 10
2.2.1 Inlet Piping .............................................................................................. 10
2.2.2 Valves Required for Clean-In-Place ........................................................ 10
2.2.3 Concentrate Outlet Connection ............................................................... 10
2.2.4 Permeate Outlet Connection.................................................................... 10
2.3 Electrical ........................................................................................................ 10
2.3.1 Economy Electrical System............................................................... 11
2.3.2 Deluxe Electrical System................................................................... 11
Page
3.0 PREPARATION AND START-UP ............................................................................ 12
3.1 Pretreatment for Water Purification ............................................................... 12
3.2 Start-Up.......................................................................................................... 12
4.0 OPERATION AND MAINTENANCE ..................................................................... 18
4.1 Daily Log Sheets............................................................................................ 18
4.2 Pre-Filter Cartridge ........................................................................................ 18
4.3 Flushing ......................................................................................................... 19
4.4 Cleaning ......................................................................................................... 19
4.5 Draining Machine for Shipment .................................................................... 21
4.6 Membrane Element Installation..................................................................... 22
4.7 Membrane Element Replacement.................................................................. 23
5.0 OPTIONAL ACCESSORIES.................................................................................... 25
5.1 Level Controls................................................................................................ 25
5.2 Filters and Water Softeners............................................................................ 25
5.3 Storage Tanks................................................................................................. 25
6.0 TROUBLESHOOTING............................................................................................. 26
7.0 RETURN GOODS AUTHORIZATION (RGA) PROCEDURE .............................. 31
8.0 WARRANTY ............................................................................................................. 32
9.0 START-UP DATA SHEET......................................................................................... 34
10. DAILY LOG SHEET................................................................................................. 36
Page
LIST OF FIGURES
1 Normal Versus Cross Flow Filtration .................................... 1
2 Membrane Element with Interconnectors.............................. 2
3 Cross Sectional View of Membrane Element........................ 2
4 Principles of Operation .......................................................... 3
LIST
OF T
ABLES
1.1 Feed Water Requirements ...................................................... 7
1.2 Typical Membrane Element Rejections/Passages.................. 9
3.3 Machine Recovery ................................................................. 16
4.4 Dry Chemical Cleaners .......................................................... 20
1.0 DESCRIPTION
1.1 General Information and Principles of Operation
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 operating and maintenance
details vital to the sustained performance of the machine.
Reverse osmosis is the separation of one component of a solution from another component by
means of pressures exerted on a semipermeable membrane element. Removal of ionic, organic and suspended / dissolved impurities occurs during the RO process. Unlike a filter, which
separates by “normal” filtration, the General Electric (GE) Osmonics membrane element separates using a process called cross flow filtration. Feed water solution is separated into two
streams, permeate and concentrate, and collected from both sides of the membrane element. A
semipermeable RO membrane element, under sufficient pressure, allows passage of purified
water while rejecting and concentrating dissolved and suspended solids.
Figure 1.1
Normal Versus
Cross Flow Filtration
GE Osmonics manufactures a patented spiral-wound membrane element package, with a turbulent flow design. This membrane element collects the purified water within a central tube,
the permeate tube (Figure 1.2, Membrane Element with Interconnectors and Figure 1.3, Cross
Sectional View of Membrane Element).
1
Figure 1.2 - Membrane Element
with Interconnectors
Figure 1.3
Cross Sectional View of
Membrane Element
2
Some operating definitions are provided to help you further understand your machine:
Permeate Rate [Product Water Rate (Qp)] is the flow rate of purified water which has
passed through the membrane element and out of the membrane element housing;
expressed in gal/min (gpm) or gal/hr (gph) [in metric, liter/min (Lpm) or cubic
meters/hour (m
3
/h)]. Specified permeate rates are normally at 77ºF (25ºC).
Concentrate Rate [Waste Water Rate (Q
c
)] is the flow rate of water containing reject-
ed solids to drain in gpm or gph (Lpm or m3/h).
Feed Rate (Q
f
) is the flow rate of incoming water in gpm or gph (Lpm or m3/h).
Feedwater rate equals permeate rate plus concentrate rate.
Recovery equals permeate rate divided by feed rate and is expressed as a percentage.
For example, 33% recovery means that out of a given feed rate, 33% is produced as
purified water (permeate).
Concentration equals the Total Dissolved Solids (TDS) concentration of a solution
expressed as milligrams per liter (mg/L) or conductivity (microSiemens/cm).
C
f
= Feed Concentration
C
p
= Permeate Concentration
C
c
= Concentrate Concentration
C
avg
= Average Concentration in Machine
Salt (Ionic) Rejection equals the percent of dissolved salt rejected by the membrane
element, calculated from an average concentration over the membrane.
Salt (Ionic) Passage equals (100% - rejection) or the percent of dissolved salts passed
through the membrane element.
An example of how to calculate salt rejection and recovery is given below:
Figure 1.4
Principles of Operation
3
Flow Description - The feed water passes through a replaceable 5-micron cartridge
pre-filter which removes bulk suspended solids. Filtered water then flows to the inlet control valve. This solenoid-controlled diaphragm valve is wired to the ON/OFF switch and
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 element life.
The pump feeds water to the membrane element housings arranged in parallel and serial
combinations. The direction of water flow is indicated by an arrow on each membrane element housing. Water is separated by the membrane elements within the membranes and
leaves the membrane element housings in two streams: permeate and concentrate.
Permeate from each membrane element housing is collected in a common manifold. The
permeate then flows through a flow meter and to the outlet point of the machine.
The concentrate leaves the last membrane element housing and flows to the flow control
center (recycle/concentrate manifold). At this point, the recycle valve channels a predetermined amount of concentrate into the pump inlet. Recycle increases recovery while
maintaining adequate cross flow 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 the
drain; it controls the pressure within the machine; and it helps control the system recovery. An Autoflush solenoid is added to the flow control center with an additional tee. The
concentrate then flows through a flow meter and to the outlet point of the machine.
1.2 Machine Nomenclature
GE Osmonics E-Series water purification machines are numbered in such a way as to indicate the permeate flow and quality you can expect from the machine.
4
Given the system case in Figure 1.4 (Principles of Operation):
Average Concentration (C
avg
) = (Cf) 100 mg/L + (Cc) 146.9 mg/L
2
(C
avg
) = 123.5 mg/L TDS
Rejection = (Cavg) 123.5 - (Cp) 6.2 x 100 = 95%
(C
avg
) 123.5
Passage = (Cp) = 6.2 x 100 = 5.0%
(C
avg
) = 123.5
Recovery = (Qp) 2 gpm x 100 = 33%
(Qf) 6 gpm
Example: E4H-21K/ECN, 230, 6, 50-75
• E4H indicates the machine series
• H indicates horizontal membrane element housing configuration
• 21K indicates the rated permeate flow in thousands of gallons per
day @ 77ºF (25ºC),(i.e., 21K = 21,000 gallons per day)
• ECN indicates Economy Model and DLX indicates the Deluxe
Model
• 230 indicates 230 VAC, three-phase voltage to starter
• 6 indicates 60 Hz operation, whereas 5 indicates 50 Hz operation
• 50 - 75 indicates 50% to 75% recovery
1.3 Machine Permeate Quality
The permeate rejection performances are as follows:
E4H machines use high rejection Osmo 415 - HR(PA) membrane elements, providing the
ultimate in high purity water.
1.4 Economy and Deluxe Model Options
1.4.1 Economy Model
E-Series Economy (ECN) model water purification machines have all the features
necessary for safe, continuous production of high purity water. This assumes good
quality feed water, adequate pretreatment and regular operator maintenance, each
shift or daily, to the operation of the system.
• 50% to 75% recovery
• Multi-stage centrifugal pump, SS construction (stainless steel castings with
Noryl stages)
• Base model electrical package includes NEMA-1 enclosure with a
110 VAC, 60 Hz or 220 VAC, 50 Hz single-phase control circuit; applies to
all ECN models
• Automatic inlet shutoff valve
• Pre-filter housing and 5-micron cartridge pre-filter
• Pre-filter, post-filter, primary and final pressure gauges
5
• Digital concentrate and permeate flow meters
• Digital conductivity monitor, panel-mounted, for permeate quality monitoring
• Autoflush System - programmable, automated high-velocity membrane element flushing for the longest membrane element life; set at the factory and
adjustable in the field
• Gauges, valves and rigid piping of stainless steel or plastic
• Membrane element housings, all 304 stainless steel (SS), with Noryl end
caps
• 316 SS concentrate and recycle valves
• All components in contact with the purified water (permeate) are either
FDA-acceptable plastic [nylon, Noryl, polypropylene, polyvinyl chloride
(PVC)] or stainless steel materials.
• All high pressure fittings are 304 SS.
• Alarms included: low inlet pressure and high amp draw.
1.4.2 Deluxe Model Options
The Deluxe (DLX) package contains all of the above Economy (ECN) standard
features along with a PROGRAMMABLE LOGIC CONTROLLER (PLC) control system.
• Multi-stage centrifugal pump, stainless steel construction (316 stainless
steel end castings and other wetted parts, Noryl internals)
• Autoflush System - programmable, automated high-velocity membrane ele-
ment flushing for the longest membrane life; set at the factory and
adjustable in the field
• All high-pressure fittings are 304 stainless steel.
• Special electrical upgrade package includes PROGRAMMABLE LOGIC
CONTROLLER (PLC) controller with alarm delay shutdown for low inlet
pressure condition to prevent pump damage should pressure fall below
15 psig (1 barg)
• Clean-In-Place (CIP) system
• Digital flow meter and conductivity controller
• Digital pH controller
6
• Alarms included: low inlet pressure, high amp draw, high / low pH
1.5 Specifications for E-Series Machines
1.5.1 Feed Water Requirements
Table 1.1
Feed Water Requirements
1.5.2 Permeate (Product Water) Flow Rate
Stated on the serial number label (assumes no permeate back pressure,
2000 mg/L TDS maximum feed concentration, and rated temperature).
To estimate permeate output with back pressure, use the formula below:
Permeate Back Pressure: Maximum: 80 psig (5.5 barg)
Permeate Outlet: 1-inch FNPT
7
Temperature
Inlet Pressure
Chlorine
(continuous feed)
Operating pH
Pre-filter
Inlet Connections
35° - 77°F (2° - 25°C) Not to exceed
85°F (29°C) unless specifically
designed for higher temperatures
Minimum: 30 psig (2.1 barg)
Maximum: 60 psig (4.1 barg)
For Osmo HR(PA) membrane elements: 0 ppm
Soft water [less than 1 grain per gallon: 3.0 - 10.0 (gpg) or 17 mg/L hardness], acceptable pH: 5.5 - 6.0
5 micron HYTREX cartridge
(part number on machine label)
1.5-inch FNPT*
(Permeate Flow on Label) x [(Operating Pressure) - (Permeate Back Pressure)]
Operating Pressure
* FNPT: Female National Pipe Thread
8
1.5.3 Concentrate Flow Rate
Factory set as stated on serial number label
Concentrate Outlet: 1-inch FNPT
1.5.4 Typical Pure Water
Recovery: 50 - 75%
1.5.5 Final Operating Pressure
Minimum: 200 psig (13.8 barg)
Maximum: 235 psig (16.2 barg)
1.5.6 Pump
Multi-stage centrifugal, approximate primary operating pressure of 190 psig
(13.1 barg), excluding line pressure.
1.5.7 Reverse Osmosis Membrane Element Rejection
Osmo HR(PA)
Typical Ionic Rejection (TDS) 95 - 98%
Average Molecular Weight Cutoff* 150 MW*
* The Molecular Weight cutoff is based on the pore size of the membrane elements and the nature
(size/shape) of the organic molecule.
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