OptiPure BWS1500 Maintenance Manual

BWS1500

Advanced Membrane

Separation System

Installation, Operation

& Maintenance Manual

Rev. 2.1

BWS1500-iom-manual_v2-1.indd
©2016 Procam Controls, Inc. All Rights Reserved

Manufactured By:

OptiPure Div. of

Procam Controls, Inc.

2605 Technology Drive, Bldg. 300

Plano, TX 75074

P: 972.881.9797 F: 972.422.6262

BWS1500 System Installation, Operation & Maintenance 2

General Information

Safety Warning

Electrical work should be performed by a qualied

electrician in accordance with all applicable
codes and regulations.

Service Contact

For local maintenance and service information
please contact your nearest Authorized Service
Representative. Service inquiries may be directed
to technical support at:

OptiPure div. of Procam Controls, Inc.
2605 Technology Dr. Bldg. 300
Plano, TX 75074 USA

Phone #: [phone]
Fax #: [phone]

E-mail correspondence to:
[e-mail]

Safety Instructions

1. Please read and follow these instructions
when connecting and using the system.

2. To avoid electrical shock, never touch the

inside of the electrical box. Only a qualied

technician should open the electrical box.

3. Never use the system if the power cord or

oat switch cable has been damaged. Do not

allow anything to rest on the power cord or

oat switch cable, and keep the cords away

from any place where people may trip over
them.

4. When disconnecting from the electric socket
hold the plug, not the cord.

5. If the processor does not function properly,
especially if there is an unusual sound or
smell coming from it, immediately unplug
the processor. Call your authorized service
representative.

Environmental Conditions

The BWS1500 is certied to operate under the

following conditions:

1. Altitude up to 2000 m.

2. Ambient temperature of 40-105°F (5 - 40°C).

3. Max relative humidity 80% at 88°F (31°C).

4. Main supply voltage not to exceed +/- 10%.

5. Installation category II.

6. Pollution degree II.

7. Indoor use only, protect from elements.

Explanation of Symbols

The following symbols are used on the water
processor. The symbols and their explanation is
given below:

Earth ground:

6. Unplug the processor and RP pump from the
AC outlet prior to any service.

7. Locate the RP Assembly as close as possible
to an AC outlet.

8. Securely bolt processor to wall before
operating.

9. Avoid cross-connections and install on cold
water supply only.

10. Use approved Air-Gaps when connecting to
drain lines.

11. Do not exceed system pressure rating and
use water hammer arrestors when water
hammer is evident.

12. Turn off Feed-Water supply before lter or

membrane cartridge replacement.

WARNING: Hazardous Voltage:

BWS1500 System Installation, Operation & Maintenance 3

Getting To Know Your System

The BWS1500 Advanced Membrane Separation System is designed specically for users that desire the abil­ity to customize the TDS (Total Dissolved Solids) level or “Mineral Content” of the treated water. The BWS1500
utilizes a precision multi-turn Blending Valve to accomplish this with great accuracy. This system design maxi-

mizes the ability to accurately blend a calculated percentage of the ltered water with the product water exiting

the Membrane, providing an Optimized Water to your equipment with the characteristics that you desire.

120VAC
Power Cord

(Coming from bot­tom rear of bracket)

- Plug in to standard
wall outlet.

Emergency
Bypass Valve -

User can switch from
Optimized Water to
Untreated Water
when needed, by turn­ing handle horizontal.

Feed water
Inlet 3/8” Push-To-Connect -

Connect to Water Supply
Valve.

3@ CTO-Q
Pre-Filters
PN: 300-05830

1 2 3

Blending
Valve - Allows precise adjust-

ment of optimized water TDS
(mineral content).

System Status Display & Bypass Switch

- LEDs show state of system. Bypass Switch turns
Processor OFF when system is in Emergency
Bypass.

Operating Pressure Gauge

Shows feed pressure only when processor is
operating (when level in storage tank is low).

Water Quality Indicator -

Operates momentarily, push purple
button to turn on. Push “IN” button
for the TDS of the water going into
your equipment. Push “OUT” button

for the TDS of the puried water

from the membrane.

Underside of Processor:

Reject Water Outlet

- 1/4” Push-to-Connect

- Connect to drain per local
regulations.

Optimized Water Outlet

- 3/8” Push-To-Connect

- Connect to Optimized Water Storage
Tank Inlet

Reject Flow Control Valve

NOTE: Never close Reject Flow Control Valve nor

limit Reject ow to less than Permeate ow!

Sample Port

- 3/8” Push-to-Connect - Used to ush pre
lters, gather a water sample, measure pro-

duction, or drain water from storage tank.

Pressurized
Optimized Water to Equipment Outlet

- 1/2” gray hose

- Connect to End User Equipment

Storage Tank/RP Return Line

-1/2” gray hose

- Connect to Repressurization Assembly Outlet

Normal

Operation

Items in green circles show a nor-

mal operating condition/position.

BWS1500 System Installation, Operation & Maintenance 4

175 Gallon
Optimized Water
Storage Tank
with Separate RP
Pump

Absolute 0.2
micron
Hydrophobic
Air-Breather/
Filter

RP Pump Outlet

- Connect to Storage

Tank/RP Return Line con­nection on Processor

Optimized Water to
Storage Tank Inlet - 3/8”

Push-to-Connect - Connect
to Optimized Water Outlet on
Processor.

Items in green circles show a nor-

mal operating condition/position.

Tank Inlet Divert Valve

- Normally in Down position.
Turn handle to Up position
to divert Optimized water to
sample port.

High Level Float Switch
Cable

- Connect to Processor “Tank
Electrical Connection.”

Normal

Operation

50 Gallon

Optimized Water
Storage Tank/RP
Pump Assembly

Tank Outlet
Valve

Repressurization
Pump
120VAC - Plug in to

standard wall outlet.

Buffer Tank
Valve

- Shown in
normal position

Buffer Tank

- Pre-charged air

bladder - 20 psi

Repressuriza­tion Assembly
Outlet

- 1/2” Hose Barb ­Connect to Storage
Tank/RP Return
Line connection on
Processor

BWS1500 System Installation, Operation & Maintenance 5

Installation Requirements

This section and the next provide the water, electrical
and space requirements for the BWS1500. Pay

special attention to the feed-water chemistry
requirements. Operating a system on water supplies

outside of these parameters may lead to premature
membrane failure. This product is for commercial
use only and must be installed and maintained in
accordance with manufacturer’s guidelines and local
regulatory plumbing and electrical codes.

Operating parameters

Typical Membrane TDS* rejection:
97+%
Feed Temperature: 40 - 100° F (4 - 38° C)
Feed pressure: 50 - 80 psi

(3.4 - 5.9 bar) at 3 gpm
Production** (at 77°F, 60 psi)
1500 gals/day,

62.5 gals/hr, 1.0 gpm
Recovery: up to 40%.

IMPORTANT NOTE: The nominal production rate

is strictly dependent on feed water temperature
and pressure. Reduced temperature or
pressure will reduce production. For example:
Operating pressure of 30 psi will cut production

by 50%. 48˚F feedwater will cut production by

50%.

Location

The system should be installed indoors, in the
proximity of the equipment (within 25 feet) and
protected from the elements. Do not let the processor
or storage tank freeze or be exposed to rain or direct
sunlight.

Post-treatment

Treated water stored in a tank may absorb organic
compounds from the tank, which can affect water
taste and odor. If product water is for consumption, an

optional post-treatment lter, such as an OptiPure
FX or QT carbon lter, should be installed after the

tank. If used, it is best installed as close to the point of
use as possible. Other specialized post-treatment is
also available.

Feed water connection

An adequate ow and pressure of water to the unit is

essential for successful operation. Provide a dedicated
3/4” water line to the vicinity of the installation. Install

a full-ow ball valve and pressure gauge with 3/4”

female pipe thread (user supplied) for connection to
installation hardware provided with the system. A 1/2”
male pipe thread x 1/2” push-to-connect adapter is
included in the installation kit.

*TDS (total dissolved solids) create conductivity in water and are
expressed in ppm or mg/l (parts per million or milligram per liter).
System Reject % depends on blended water setting.

**Nominal production @ 77°F (25°C) @ 500 ppm based on a 24 hr
day. Actual production will vary based on variations in blend setting,
water temperature, pressure, and TDS.

Drain

A drain should be located within 5 feet of the location

of the unit. Drain must allow a minimum ow of 5

gallons per minute. Compliance with most local
plumbing codes requires installation of an approved air
gap in the drain line. The drain connection should be
accessible for system set-up and service.

Electrical requirements

A power source with two outlets should be located
within 5 feet of the location of the unit.

Processor 120V, 60Hz 6 Amps
RP Pump 120V 60Hz 8 Amps

Feed-water chemistry

Feed TDS Up to 1200 ppm
Feed pH 6 - 10
Hardness 28 grains or less
Free chlorine <2 mg/l
Iron (Fe) 0.1 mg/l max.
Turbidity <0.05 NTU
Manganese 0.05 mg/l max.

Hydrogen sulde 0.0 mg/l

A water analysis must be conducted before installing
the system, or the information requested above can
be obtained from your local water utility. If your water
analysis shows that any of these parameters are not
within range, additional pretreatment and/or higher
frequency of maintenance may be required. Contact
your OptiPure distributor for assistance. The presence

of silica or occulants such as alum or cationic

polymers in the feedwater may cause membrane
fouling and may require special chemical pretreatment
or periodic membrane cleaning. Please note that
membrane failure due to fouling is not covered by the
warranty.

Storage Tank/RP Pump

The tank must be located within 10 feet of the water

processor unit. The oor beneath the storage tank

should be smooth, clean and free of sharp objects that
could puncture the bottom of the tank. Note: The tank

is atmospheric, with a sub-micron, hydrophobic air

breather lter.

For a 175 Gallon Tank, the separate RP Pump must
be placed next to the tank at a height even with the
bottom of the tank, or on a stand no more than 6”
above the bottom of the tank.

Optimized Water Lines to Equipment

Tubing, piping and associated ttings connecting

Optimized water lines to equipment shoud be food
grade material that meets NSF Std 51 or 61 with a
minimum pressure rating of 75 PSI. Optimized water
may react with most metal piping imparting a bad
taste. Plastic pipe or reinforced opaque beverage
tubing are acceptable choices for Optimized water
distribution. The larger inside diameter tubing or hose,
the better to minimize pressure drop.

BWS1500 System Installation, Operation & Maintenance 6

Equipment Dimensions

50 Gallon Tank
Repressurization Assembly

Processor
Left Side

Processor
Front View

View

IMPORTANT - ALLOW A MINIMUM OF 24” IN FRONT OF THE PROCESSOR FOR
MAINTENANCE AND SERVICE. DO NOT MOUNT SYSTEM ABOVE THE CEILING
OR IN A LOCATION THAT IS NOT EASILY ACCESSIBLE. WHEN THE 50 GAL. TANK
ASSEMBLY IS FULL OF OPTIMIZED WATER IT WILL WEIGH 450 LBS (THE 175 GAL.
TANK, 1500 LBS). ALWAYS LOCATE THE STORAGE TANK WHERE IT CAN BE AC­CESSED DURING SERVICE.

Allow 3”
to remove
cartridges

175 Gallon Tank
with Repressurization
Pump

BWS1500 System Installation, Operation & Maintenance 7

Typical Installation with 50 Gal. Atmospheric Tank

Important: Plumbing should be performed by a qualied plumber in accordance with local codes.

Power

120VAC, 2A

Tank High Level Float Switch Cable

Feed

Water

When installing, keep lines from the Processor to
the equipment as short as possible to minimize

pressure loss.

IMPORTANT - PROTECT PROCESSOR AND
TANK/RP PUMP FROM THE ELEMENTS. DO NOT
INSTALL IN DIRECT SUNLIGHT OR WHERE EX­POSED TO FREEZING TEMPERATURES OR RAIN.

Repressurization
Assembly

Power Cord

User-Supplied

Water Supply
Valve &

Pressure Gauge

Buffer Tank Valve

(Normally Open)

Emergency

Bypass Valve

Feed Water Line

- 1/2” Gray Hose with hose barb
inserts at both ends - from Water

Supply Valve to Feed Water Inlet

Repressurization
Assembly Outlet
(Hose Barb)

Processor

Operating
Pressure
Gauge

Feed

Water

Inlet

CTO-Q

1

Reject

Water

Outlet

Bypass
Switch

CTO-Q

Pre-Filter

2

(to Drain)

System
Status

CTO-Q

Pre-Filter

3

Optimized

Water

Outlet

Reject

Water

Water Quality
Monitor

Blending
Valve

-Set to
req'd
TDS
reading!

Pre-Filter

Sample
Port

Optimized
Water
to Eqpt

Storage
Tank/RP
Return

Drain Line - Black -

from Reject Outlet to Drain

Repressurization

120VAC

Processor

Control High

Level Float

Switch

(inside tank)

Air
Breather

Pump

Buffer
Tank

Low Level
Float Switch

(inside tank, with
Control Box at­tached to Buffer
Tank bracket)

Bypass

Pressurized Water Line

- 1/2" Gray Hose with hose barb inserts at both ends - from
Repressurization Assy Outlet to Storage Tank/RP Return

Optimized Water Line

Optimized
Water to
Storage Tank
Inlet (on valve)

Tank Inlet Divert Valve

(Valve normally in Down
position. Turn to Up position
to bypass Repressurization
Assy.)

Safety Float
Valve

(inside tank)

- Blue - from Optimized Water Outlet to Tank Inlet

Optional

Optimized Water
Storage Tank

- 50 gal. Atmospheric

Carbon
Post­Treatment

Optimized Water Line - 1/2" Gray Hose

with hose barb insert - Make connection to

distribution and (optional) post-treatment.

Optimized
(Treated)
Water to
Equipment

BWS1500 System Installation, Operation & Maintenance 8

Typical Installation with 175 Gal. Atmospheric Tank

Important: Plumbing should be performed by a qualied plumber in accordance with local codes.

Power Cord

When installing, keep lines from the Processor to the
Equipment as short as possible to minimize pressure loss.

IMPORTANT - PROTECT PROCESSOR AND TANK/RP PUMP
FROM THE ELEMENTS. DO NOT INSTALL IN DIRECT
SUNLIGHT OR WHERE EXPOSED TO FREEZING TEMPERA­TURES OR RAIN.

Storage Tank/
Repressurization Pump

Optimized Water to
Storage Tank Inlet (on valve)

Power

120VAC, 2A

Feed

Water

Power Cord

High Level Switch Cable

User-Supplied

Water Supply
Valve &

Pressure Gauge

Emergency

Bypass Valve

Feed Water Line

- 1/2” Gray Hose with hose barb
inserts at both ends - from Water

Supply Valve to Feed Water Inlet

Processor

Operating
Pressure
Gauge

Feed

Water

Inlet

CTO-Q

1

Reject

Water

Outlet

Bypass
Switch

CTO-Q

Pre-Filter

2

(to Drain)

System
Status

CTO-Q

Pre-Filter

3

Optimized

Water

Outlet

Reject

Water

Water Quality
Monitor

Blending
Valve

-Set to
req'd
TDS
reading!

Pre-Filter

Sample
Port

Optimized
Water
to Eqpt

Storage
Tank/RP
Return

Drain Line - Black -

from Reject Outlet to Drain

Safety Float Valve

(inside tank)

Processor Control
High Level Float
Switch

(inside tank)

Optimized Water

Storage Tank

- 175 gal. Atmospheric

Tank Outlet

Valve

Optimized Water Line

- Blue - from Optimized Water Outlet to Tank Inlet

Air
Breather

Tank Inlet Divert Valve

(Valve normally in Down
position. Turn to Up position to
measure water production.)

Pressurized Water Line

- 1/2" Gray Hose with hose barb inserts at both ends - from
Repressurization Assy Outlet to Storage Tank/RP Return

Repressurization

Pump

120VAC

RP Outlet

Optional
Carbon
Post­Treatment

Optimized Water Line - 1/2" Gray Hose

with hose barb insert - Make connection to

distribution and (optional) post-treatment.

Optimized
(Treated)
Water to
Equipment