OP1200
OP1200
Advanced Membrane
Separation System
Installati on, Operation
& Maintenance Manual
Rev . 1
Manufactured By:
OptiPure Div. of
Procam Controls, Inc.
2605 Technology Drive, Bldg. 300
Plano, TX 75074
P: 972.881.9797 F: 972.422.6262
OP1200-iom-manual_v1.indd
©2015 Procam Controls, Inc. All Rights Reserved
OP1200 System Installation, Operation & Maintenance 2
General Information
Safety Warning
Electrical work should be performed by a qualifi 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 #: 972.881.9797
Fax #: 972.422.6262
E-mail correspondence to:
techsupport@optipure.net
Environmental Conditions
The OP1200 is certifi 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:
WARNING: Hazardous Voltage:
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 qualifi ed
technician should open the electrical box.
3. Never use the system if the power cord or
fl oat switch cable has been damaged. Do not
allow anything to rest on the power cord or
fl 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.
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 fi lter or
membrane cartridge replacement.
OP1200 System Installation, Operation & Maintenance 3
The OP1200 Advanced Membrane Separation System is designed to purify feed water and remove dissolved
minerals, and then add back a consistent amount of a balanced blend of TDS (Total Dissolved Solids), or mineral
content, in the treated water, providing an Optimized Water to your equipment with the characteristics that you
desire.
Getting To Know Your System
Feed water
Inlet 3/8” Push-To-Connect -
Connect to Water Supply
Valve.
3@ CTO-Q
Pre-Filters
PN: 300-05830
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 purifi ed water
from the membrane.
Emergency
Bypass Valve -
User can switch from
Optimized Water to
Untreated Water
when needed.
Optimized Water Outlet
- 3/8” Push-To-Connect
- Connect to Optimized Water Storage
Tank Inlet
Operating
Pressure Gauge
Reject Water Outlet
- 1/4” Push-to-Connect
- Connect to drain per local
regulations.
1
2
3
Storage Tank/RP Return Line
-1/2” gray hose
- Connect to Repressurization Assembly Outlet
Pressurized
Optimized Water to Equipment Outlet
- 1/2” gray hose
- Connect to End User Equipment
Sample Port
- 3/8” Push-to-Connect - Used to fl ush pre
fi lters, gather a water sample, measure pro-
duction, or drain water from storage tank.
MA-Q15 Mineral Addition
Cartridge
120VAC
Power Cord
(Coming from bot-
tom rear of bracket)
- Plug in to standard
wall outlet.
Reject Flow Control Valve
NOTE: Never close Reject Flow Control Valve
nor limit Reject fl ow to less than Permeate fl ow!
System Status Display & Bypass Switch
- LEDs show state of system. Bypass Switch turns
Processor OFF when system is in Emergency
Bypass.
Underside of Processor:
OP1200 System Installation, Operation & Maintenance 4
Optimized Water to
Storage Tank Inlet - 3/8”
Push-to-Connect - Connect
to Optimized Water Outlet on
Processor.
Absolute 0.2
micron
Hydrophobic
Air-Breather/
Filter
Repressurization
Assembly Outlet
- 1/2” Hose Barb -
Connect to Pressurized
Water Inlet on Processor
Repressurization
Pump
120VAC - Plug in to
standard wall outlet.
Buffer Tank
- Pre-charged air
bladder - 20 psi
175 Gallon
Optimized Water
Storage Tank
with Separate RP
Pump
50 Gallon
Optimized Water
Storage Tank/RP
Pump Assembly
Buffer Tank
Valve
- Shown in
normal position
Tank Level Float Switch
Cable
- Connect to Processor “Tank
Electrical Connection.”
Tank Inlet Divert Valve
- Normally in Down position.
Turn handle to Up position
to divert Optimized water to
sample port.
(on back
side of tank)
Tank Outlet
Valve
RP Pump Outlet
- Connect to Storage
Tank/RP Return Line con-
nection on Processor
OP1200 System Installation, Operation & Maintenance 5
Installation Requirements
This section and the next provide the water, electrical
and space requirements for the OP1200. 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 2.5 gpm
Production** (at 77°F, 60 psi)
1200 gals/day,
50 gals/hr, 0.83 gpm
Recovery: up to 33%.
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 fi lter, such as an OptiPure
FX or QT carbon fi 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 fl ow and pressure of water to the unit is
essential for successful operation. Provide a dedicated
1/2” water line to the vicinity of the installation. Install
a full-fl ow ball valve and pressure gauge with 1/2”
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.
Drain
A drain should be located within 5 feet of the location
of the unit. Drain must allow a minimum fl ow of 2
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 sulfi 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 fl 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 fl 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 fi 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 (not at a higher elevation).
Optimized Water Lines to Equipment
Tubing, piping and associated fi 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.
*TDS (total dissolved solids) create conductivity in water and are
expressed in ppm or mg/l (parts per million or milligram per liter).
**Nominal production @ 77°F (25°C) @ 500 ppm based on a 24
hr day. Actual production will vary based on variations in water
temperature, pressure, and TDS.
OP1200 System Installation, Operation & Maintenance 6
Equipment Dimensions
50 Gallon Tank
Repressurization Assembly
175 Gallon Tank
with Repressurization
Pump
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 16 GAL.
TANK, 140 LBS). ALWAYS LOCATE THE STORAGE TANK WHERE IT CAN BE AC-
CESSED (OR IS ACCESSIBLE) DURING SERVICE.
Allow 3”
to remove
cartridges
Processor
Front View
Processor
Left Side
View
OP1200 System Installation, Operation & Maintenance 7
Typical Installation with 50 Gal. Atmospheric Tank
Important: Plumbing should be performed by a qualifi ed plumber in accordance with local codes.
Feed Water Line
- 1/2” Gray Hose with hose barb
inserts at both ends - from Water
Supply Valve to Feed Water Inlet
Feed
Water
Optimized
(Treated)
Water to
Equipment
Feed
Water
Inlet
Optimized Water Line
- Blue - from Optimized Water Outlet to Tank Inlet
Drain Line - Black -
from Reject Outlet to Drain
Reject
Water
(to Drain)
User-Supplied
Water Supply
Valve &
Pressure Gauge
Reject
Water
Outlet
Tank Switch Cable
Optimized
Water
to Eqpt
Optional
Carbon
Post-
Treatment
Power
120VAC, 2A
Optimized Water Line - 1/2" Gray Hose
with hose barb insert - Make connection to
distribution and (optional) post-treatment.
CTO-Q
Pre-Filter
CTO-Q
Pre-Filter
CTO-Q
Pre-Filter
MA-Q15
Emergency
Bypass Valve
Operating
Pressure
Gauge
Water Quality
Monitor
Optimized
Water to
Storage Tank
Inlet
(on valve)
Repressurization
Assembly Outlet
(Hose Barb)
1
2
3
4
Processor
Optimized Water
Storage Tank
- 50 gal. Atmospheric
Storage
Tank/RP
Return
Optimized
Water
Outlet
Sample
Port
Pressurized Water Line
- 1/2" Gray Hose with hose barb inserts at both ends - from
Repressurization Assy Outlet to Storage Tank/RP Return
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 EX-
POSED TO FREEZING TEMPERATURES OR RAIN.
Repressurization
Assembly
Safety Float
Valve
(inside tank)
Air
Breather
Repressurization
Pump
120VAC
Buffer
Tank
Buffer Tank Valve
(Normally Open)
Tank Inlet
Divert Valve
(Valve normally
in Down position.
Turn to Up position
to bypass Repres-
surization Assy.)
Processor
Control Float
Switch
(inside tank)
Bypass
Bypass
Switch
System
Status
Loading...