SpectraPure PSP-600, PSP-1000, PSP-2700, PSP-1600 Operation And Maintenance Manual

Operations and Maintenance Manual

for

PSP Series

1

Water Purification Systems

PSP-600

PSP-1000

PSP-1600

PSP-2700

SpectraPure®Inc. 215 S. Industrial Drive, Suite 2A Tempe, Arizona 85281-2941 480.894.5437 Fax us toll-free 1.877.527.7873

Call us toll-free 1.800.685.2783 E-mail [e-mail] Visit us on the web www.spectrapure.com

Rev. 0 / April 21, 2005

2

Compact Design, Self-Contained Water Processing Unit
for Point-Of-Use or Point-Of-Entry Applications:

Easy to Install or Retrofi t: Four water connections and 115VAC or 230VAC.

Easy to Maintain: Uses Industry Standard components - no more proprietary parts or sole­sourcing. All fi lters and components are on the front panel for easy access.

Single membrane can be changed in minutes, no need to remove membrane housings and fi ttings
to change membrane.

Water conserving design features 50% recovery - produces 1 gallon of water while sending only
1 gallon to drain. Other RO systems may waste as much as 4 gallons to produce 1 gallon
purifi ed water.
expensive but environmentally unsatisfactory, especially in drought-stricken areas.

Concentrate recirculation loop decreases membrane fouling by rapidly fl ushing the membrane at a
high velocity, greatly increasing membrane life.

Time-delayed inlet solenoid valve operates for several seconds before pump activates, protecting
the pump from dry starts and pump-destroying cavitation.

Many municipalities charge for water coming in as well as sewage. Not only is that

of

Low-voltage microprocessor-based control system with Auto Flush and Pump Protection.
membrane after each use and protects pump from running dry, preventing premature pump
failure.

These systems may be engineered for use with a single reservoir, multiple storage tanks or a
bladder tank.

Liquid level controls and sediment fi lter are included.

* A water softener may be required in some hard water areas.

** Additional pre-treatment may be required for brackish water.

Flushes

Specifications for Back-Washable Carbon Pre-Filter (Required):

Power Requirements Single phase, 60 Hz., 115 VAC, .3 Amps
Safety System Interlock Prevents RO system from operating when
carbon fi lter is back washing
Dimensions Tank sizes are available starting at 1 cu.ft.

Specifications for Water Softener (Optional):

Power Requirements Single phase, 60 Hz., 115 VAC, .3 Amps
Safety System Interlock Prevents RO system from operating when
water softener is regenerating
Dimensions Tank sizes are available starting at 32K grain
capacity

SpectraPure®Inc. 215 S. Industrial Drive, Suite 2A Tempe, Arizona 85281-2941 480.894.5437 Fax us toll-free 1.877.527.7873

Call us toll-free 1.800.685.2783 E-mail [e-mail] Visit us on the web www.spectrapure.com

Specifications for PSP-750 & PSP-1000 Water Purification Unit:

Number of Membranes One 4.0” x 21” High Rejection (PSP-600)
One 4.0” x 21” High Production (PSP-1000)
Type of Membrane Low Pressure, Energy Saving TFC Membrane

Sediment Pre-Filter 20 in. 1 micron
Membrane Housing Material Stainless Steel
Operating Pressure 110 psig max
Operating Design Temperature 40°F to 86°F (4.5°C to 30°C)
Membrane Rejection greater than 98% average
RO System Recovery 50%

Feed fl ow (GPM) 1.0 GPM at 100 psi, 77 °F (PSP-600)

1.4 GPM at 100 psi, 77 °F (PSP-1000)
Concentrate Reject fl ow (GPM) 0.5 GPM at 100 psi, 77 °F (PSP-600)

0.7 GPM at 100 psi, 77 °F (PSP-1000)
Permeate Product fl ow (GPM) 0.5 GPM at 100 psi, 77 °F (PSP-600)

0.7 GPM at 100 psi, 77 °F (PSP-1000)
Production Rate,100 psi,1500ppm NaCl 750 GPD @ 77°F. (PSP-600)
1000 GPD @ 77°F. (PSP-1000)

3

System Inlet port 5/8” compression
Permeate Product port 1/2” compression
Concentrate Reject port 1/2” compression
RO (Reverse Osmosis) pump Rotary Vane Procon

Motor General Electric
Motor Horsepower 0.75 hp (1725 RPM) at 60 Hz
Power Requirements Single phase, 60 Hz., 115 VAC, 10.4 Amps
Single phase, 60 Hz., 230 VAC, 5.2 Amps
Dimensions 20 in. x 17 in. x 48 in.

SpectraPure®Inc. 215 S. Industrial Drive, Suite 2A Tempe, Arizona 85281-2941 480.894.5437 Fax us toll-free 1.877.527.7873

Call us toll-free 1.800.685.2783 E-mail [e-mail] Visit us on the web www.spectrapure.com

Specifications for PSP-1600 Water Purification Unit:

Number of Membranes One 4.0” x 40” High Rejection
Type of Membrane Low Pressure, Energy Saving TFC Membrane

Sediment Pre-Filter 20 in. 1 micron
Membrane Housing Material Stainless Steel
Operating Pressure 110 psig max
Operating Design Temperature 40°F to 86°F (4.5°C to 30°C)
Membrane Rejection greater than 98% average
RO System Recovery 50%

Feed fl ow (GPM) 2.2 GPM at 100 psi, 77 °F
Concentrate Reject fl ow (GPM) 1.1 GPM at 100 psi, 77 °F
Permeate Product fl ow (GPM) 1.1 GPM at 100 psi, 77 °F
Production Rate, 100 psi, 1500ppm NaCl 1600 GPD @ 77°F.

System Inlet port 5/8” compression
Permeate Product port 1/2” compression
Concentrate Reject port 1/2” compression
RO (Reverse Osmosis) pump Rotary Vane Procon

4

Motor General Electric
Motor Horsepower 0.75 hp (1725 RPM) at 60 Hz
Power Requirements Single phase, 60 Hz., 115 VAC, 10.4 Amps
Single phase, 60 Hz., 230 VAC, 5.2 Amps
Dimensions 20 in. x 17 in. x 48 in.

SpectraPure®Inc. 215 S. Industrial Drive, Suite 2A Tempe, Arizona 85281-2941 480.894.5437 Fax us toll-free 1.877.527.7873

Call us toll-free 1.800.685.2783 E-mail [e-mail] Visit us on the web www.spectrapure.com

Specifications for PSP-2700 Water Purification Unit:

Number of Membranes One 4.0” x 40” High Production
Type of Membrane Low Pressure, Energy Saving TFC Membrane

Sediment Pre-Filter 20 in. 1 micron
Membrane Housing Material Stainless Steel
Operating Pressure 110 psig max
Operating Design Temperature 40°F to 86°F (4.5°C to 30°C)
Membrane Rejection greater than 98% average
RO System Recovery 50%

Feed fl ow (GPM) 3.8 GPM at 100 psi, 77 °F
Concentrate Reject fl ow (GPM) 1.9 GPM at 100 psi, 77 °F
Permeate Product fl ow (GPM) 1.9 GPM at 100 psi, 77 °F
Production Rate, 100 psi, 1500ppm NaCl 2700 GPD @ 77°F.

System Inlet port 5/8” compression
Permeate Product port 1/2” compression
Concentrate Reject port 1/2” compression
RO (Reverse Osmosis) pump Multi-Stage

5

Motor Flint & Walling or Gould
Motor Horsepower 0.75 hp (1725 RPM) at 60 Hz
Power Requirements Single phase, 60 Hz., 115 VAC, 10.4 Amps
Single phase, 60 Hz., 230 VAC, 5.2 Amps
Dimensions 20 in. x 17 in. x 48 in.

SpectraPure®Inc. 215 S. Industrial Drive, Suite 2A Tempe, Arizona 85281-2941 480.894.5437 Fax us toll-free 1.877.527.7873

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Theory of Operation: Water Production System

The storage tank (11) is a non-pressurized tank of any size. When water is withdrawn
from the tank to a point below the low-level fl oat (or pressure switch) (12), the input
solenoid (2) is activated by the Reverse Osmosis System Controller (27). When
suffi cient input pressure (as displayed on the input pressure gauge (4)) is sensed by
the input pressure switch (5), the main pump (6) and motor (7) are energized. Water
that has passed through the sediment fi lter (1) then fl ows through the low pressure
manifold (3). The pump increases the input water pressure in the membrane (8) to a
conservative 100 psi as displayed on the system pressure gauge (21).

The water is split by the membrane into two streams: a pure water stream (permeate)
and a waste water stream (concentrate). The pure water stream passes through the
product fl ow meter (10) and the TDS monitor (18) and then into the storage tank.
(The TDS Meter indicates the purity of the product water going into the tank and aids
in determining when the RO membrane may be failing.) The tank will fi ll until water
reaches the high-level fl oat (or pressure switch) (13). This will activate the fl ush cycle
(covered later) and then shut the pump and motor down.

The concentrate stream is split into two streams in the high pressure manifold
(20). One stream goes to drain through the capillary tube fl ow restrictor (22) and
concentrate fl ow meter (23). The other stream goes through the pressure regulator
(24). The pressure regulator is used to adjust the system operating pressure. The
output of the pressure regulator is feed back into the input water supplying the pump.

6

The fl ush cycle, initiated by the high-level fl oat (or pressure switch), opens the
concentrate bypass solenoid (25). This allows the concentrated waste water (as well
as any hardness or particulates that may have accumulated on the surface of the
membrane) to be rapidly fl ushed down the drain. After 45 seconds, the pump and
motor will spin down before the input solenoid is turned off, protecting the pump from
a starvation / cavitation condition. For the next six minutes, the pure water fl ush pump
(9) is activated, fl ooding the membrane with a pure-water bath until the fi ll cycle starts
over again.

SpectraPure®Inc. 215 S. Industrial Drive, Suite 2A Tempe, Arizona 85281-2941 480.894.5437 Fax us toll-free 1.877.527.7873

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7

Schematic for All Systems Using One Open Tank

SpectraPure®Inc. 215 S. Industrial Drive, Suite 2A Tempe, Arizona 85281-2941 480.894.5437 Fax us toll-free 1.877.527.7873

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8

Schematic for All Systems Using Multiple Open Tanks

SpectraPure®Inc. 215 S. Industrial Drive, Suite 2A Tempe, Arizona 85281-2941 480.894.5437 Fax us toll-free 1.877.527.7873

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9

Schematic for All Systems Using Bladder Tank

SpectraPure®Inc. 215 S. Industrial Drive, Suite 2A Tempe, Arizona 85281-2941 480.894.5437 Fax us toll-free 1.877.527.7873

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10

PSP-600, PSP-1000 : Front Side View

SpectraPure®Inc. 215 S. Industrial Drive, Suite 2A Tempe, Arizona 85281-2941 480.894.5437 Fax us toll-free 1.877.527.7873

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11

SpectraPure®Inc. 215 S. Industrial Drive, Suite 2A Tempe, Arizona 85281-2941 480.894.5437 Fax us toll-free 1.877.527.7873

Call us toll-free 1.800.685.2783 E-mail [e-mail] Visit us on the web www.spectrapure.com

PSP-1600 : Front Side View

12

SpectraPure®Inc. 215 S. Industrial Drive, Suite 2A Tempe, Arizona 85281-2941 480.894.5437 Fax us toll-free 1.877.527.7873

Call us toll-free 1.800.685.2783 E-mail [e-mail] Visit us on the web www.spectrapure.com

PSP-2700 : Front Side View

Theory of Operation: Electronic Control System

The Reverse Osmosis System Controller (27) is the grey box on the front of the system.
Inside this box is a 24 VAC transformer, a power relay, and a microprocessor-based control
board. The transformer provides a safe voltage level for all control system functions. On
the front of the controller is the main power switch, system fuse (15 amp, slo-blow), and
two LEDs. The green LED blinks at a 1 second rate and indicates proper operation of the
control board. The red LED indicates error conditions. Currently, error conditions indicated
by the blinking red LED include: 1- fl oat switch faults and, 2- low feed water input pressure.

When water is withdrawn from the tank to a point below the low-level fl oat (or pressure
switch) (12) and the carbon fi lter cut-out switch is closed, the input solenoid (2) is activated.
When suffi cient feed-water input pressure is sensed by the input pressure switch (5), the
control board will activate the power relay which in turn will apply power to the main pump
(6) and motor (7). The pump / motor will boost the recirculating system pressure to 100­110 psi.

If, at any time during a fi ll cycle, the input pressure drops enough to de-activate the input
pressure switch, the main pump and motor will be powered down. The control board will
then attempt two more start sequences. If low input pressure is detected two more times,
the system will shut down completely and indicate the condition by the red blinking LED.
The controller will need to be powered down and a determination as to the cause of the
persistent low pressure condition will have to be made.

13

A normal fi ll cycle will terminate when the water reaches the high-level fl oat (or pressure
switch) (13). A fl ush cycle will begin with the input solenoid and main pump continuing to
operate while opening the concentrate bypass solenoid (25). The fl ush cycle will terminate
after 45 seconds; the bypass solenoid is turned off and the pump and motor will spin down
before the input solenoid is turned off, protecting the pump from a starvation / cavitation
condition. For the next six minutes, the pure water fl ush pump (9) is activated, fl ooding the

membrane with a pure-water bath until the fi ll cycle starts over again.

SpectraPure®Inc. 215 S. Industrial Drive, Suite 2A Tempe, Arizona 85281-2941 480.894.5437 Fax us toll-free 1.877.527.7873

Call us toll-free 1.800.685.2783 E-mail [e-mail] Visit us on the web www.spectrapure.com

14

All Systems : Electrical Schematic

SpectraPure®Inc. 215 S. Industrial Drive, Suite 2A Tempe, Arizona 85281-2941 480.894.5437 Fax us toll-free 1.877.527.7873

Call us toll-free 1.800.685.2783 E-mail [e-mail] Visit us on the web www.spectrapure.com

The Need for Pre-Treatment:

RO pre-fi ltration should be a combination of sediment ,carbon fi ltration, and water
softening The sediment fi lter brings the feed water NTU value to < 1 and the carbon fi lter
further reduce the sediment & turbidity levels in your fi lters reducing chlorine, chloramines
and VOC levels in the water down to acceptable levels. Because of the high recovery
of the pumped RO systems we highly recommend the use of a water softener ahead
of the reverse osmosis system. This will greatly increase membrane life and reduce
maintenance costs of the RO system.

Preventative Maintenance Standards:

To be able to properly service and maintain RO membrane systems it is important to
understand the system history, so the fi rst time a unit is serviced there should be a system
history card fi lled out and attached to the machine. Knowing what the settings were after
the last service will be very helpful in understanding what is required for service in the
future.

PM Requirements - Follow the procedures in this manual and,

15

Quarterly:

Change all pre-fi lters and o-rings

Clean fi lter housings

Inspect system for leaks

Check all system operating pressures

Check membrane production

Check membrane water quality

Record all information in a system history log

Annually:

In addition to above, sanitize all fi lter housings with Kay-5
sanitizer (one packet to 2.5 gallons of warm water) or similar product.
Follow standard sanitizing procedure, clean with mild detergent, rinse
with clear water, fi ll fi lter with sanitizer solution, and allow to air
dry or reassemble. Do not rinse the parts after sanitizer solution.

Inspect the tank for any algae growth and clean with Kay-5
sanitizer if necessary.

SpectraPure®Inc. 215 S. Industrial Drive, Suite 2A Tempe, Arizona 85281-2941 480.894.5437 Fax us toll-free 1.877.527.7873

Call us toll-free 1.800.685.2783 E-mail [e-mail] Visit us on the web www.spectrapure.com

16

Installation and Setup:

Carbon Filter and Water Softener Installation

Follow Diagram on page 7, 8, or 9 for sequence and hook-up of components of water
purifi cation system. Install per accepted plumbing standards and practices.

Important Note: On carbon fi lter or water softener not equipped with system lock-out controls,
never operate RO System during carbon fi lter backwash or water softener regeneration.
System lock out control is not necessary when used only with twin bed water softeners.

Plumbing Connections

1. Carbon Filter & Water Softener feed lines - 1” with bypass

2. Carbon Filter & Water Softener drain lines - 1/2” minimum

3. Feed water line to pre-fi lter on RO unit - 5/8” minimum.

4. Product water line to store - 1/2” blue tubing.

5. Reject water line to drain - 1/2” yellow tubing, see diagram at right.
Terminate 1” above drain pan. (must be separate from overfl ow line).

6. Tank overfl ow line to drain - 3/8” yellow tubing, see diagram at right.
Terminate 1” above drain pan. (must be separate from drain tubing).

drain

lines

1” min.

wall

Compression Fittings and Connections

For 1/4”, 3/8”, 1/2”, and 5/8” poly tubing to brass

compression fi ttings:

1. Cut the tubing end squarely and remove
internal and external burrs.

2. Remove compression nut from the
compression fi tting and slide it over the
tubing.

3. Slide the white plastic collar over the tubing.
NOTE: Smaller diameters have a tapered
collar while larger diameters (5/8”) have dual­tapered collars. Tapered collars must slope
towards the fi tting. See typicals at right.

4. Place the brass insert into the end of the
tubing.

5. Firmly insert assembly into fi tting until it
bottoms out.

6. Tighten nut securely, do not over-tighten.

fl oor

TAPERED

DUAL-TAPERED

drain pan

drain

SpectraPure®Inc. 215 S. Industrial Drive, Suite 2A Tempe, Arizona 85281-2941 480.894.5437 Fax us toll-free 1.877.527.7873

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Installation and Setup: (continued)

Water Purifi cation System Start-Up

1. Close shut-off valve ahead of the pre-fi lter.

2. Set the carbon fi lter (red handle) by-pass
valve to by-pass position.

3. Turn the black manual regeneration knob
(rotate clockwise one click from the service
position) on the carbon fi lter control head
to the backwash position. Make sure the
carbon fi lter is plugged into a 120V outlet.
Now slowly turn the red by-pass valve handle
located at the back of the carbon
service position to bleed air from tank. Do not
rapidly open this valve. Leave valve partially
open until the air has been bled from the tank.
Then fully open the valve.

4. Backwash the carbon fi lter for at least 15
minutes after air has been bled from the
tank and until the backwash is clear of black
carbon fi nes.

5. Return the carbon fi lter control head back
to the service position by rotating the black
manual backwash knob clockwise around to
the service position.

6.

Set time of day on the control valve on the
carbon fi lter by depressing the red button and
aligning the 24 hour gear to the current time.

7. On the skipper wheel, pull every third tab
outward (i.e. #1, 4, 7 and 10). This will
backwash the carbon fi lter every three days.

8.

Open the shut-off valve ahead of the pre-fi lter.

9. With RO system in the OFF position and
all plumbing and electrical connections
completed, rotate the input solenoid valve
lever to manually open the inlet solenoid
valve. The word “ON” should be visible.

10. Leave the valve open until air is purged from
the system, letting pressure build up to set
the low pressure switch.

11. Check feed water connections for any leaks.

fi lter to the

10

Low Pressure Switch shown set at

12

17

9

10 psi and is un-pressurized

SpectraPure®Inc. 215 S. Industrial Drive, Suite 2A Tempe, Arizona 85281-2941 480.894.5437 Fax us toll-free 1.877.527.7873

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Installation and Setup: (continued)

12. Shut the valve by turning lever to close the inlet solenoid
valve. The word “OFF” should now be visible.

13. At the control panel, turn the valve to the BYPASS
position, open all faucets and rinse the store pipes out for
10 minutes. Close all faucets. Return the control panel
valve to RUN.

14. Unplug the Delivery Pump so it will not run.

15. Turn the power switch on the control panel to the “ON”
position (UP). This will immediately open the inlet
solenoid valve. After 5 seconds, the RO pump will turn
on. This motor protection circuitry assures a fl ooded inlet
to the pump prior to pump start-up; eliminating dry starts
which could damage the pump.

16. After a few minutes of operation, use a 1/2” wrench to
loosen the nut on the threaded shaft of the pressure relief
valve, located beneath the high pressure manifold.

17. Adjust the pressure relief valve to 100 psi by turning the
brass handle. Rotate clockwise, when viewed from the
bottom, to increase the pressure and counter-clockwise
to decrease the pressure.

18. When adjusted to the proper pressure, lock the nut back
in place.

19. Check the product water to waste water ratio. It should
be approx. 1:1. Note: If not, contact the factory (the fl ow
restrictor may require adjustment).

20. Disconnect the line at the top of the Product Flow Meter.

Disconnect the drain line leaving the Tank Overfl ow Filter
and temporarily re-connect it to the Product Flow Meter.

18

16

17

.

Turn the switch on the Control Box to the up, or ON position.

21

22. Flush the new Mineral Additive Cartridge for 10 minutes.

23. Turn the switch on the Control Box to the down, or

OFF position.

24. Disconnect the temporary drain line at the top of the

Product Flow Meter. Re-connect the drain line to the Tank
Overfl ow Filter and re-connect the blue line (from the tank)

to the Product Flow Meter.

25. Re-connect the Delivery Pump power cord.

26. Check for leaks and carefully tighten any compression
fi ttings if necessary.

SpectraPure®Inc. 215 S. Industrial Drive, Suite 2A Tempe, Arizona 85281-2941 480.894.5437 Fax us toll-free 1.877.527.7873

Call us toll-free 1.800.685.2783 E-mail [e-mail] Visit us on the web www.spectrapure.com

18

Troubleshooting Guide:

This guide is to assist you in identifying the most common operating prob­lems you may experience with your water purification system.

PROBLEM PROBABLE CAUSE CORRECTIVE ACTION

Low system inlet pressure. Insuffi cient feed water

pressure or fl ow

Check feed pressure, open
feedwater valve, check for
restrictions.

19

Clogged pre-fi lter

Closed valve ahead of RO
System

Low system operating
pressure.

Low permeate fl ow rate Low operating pressure

Excessive Permeate fl ow
rate.

Pump not operating correctly

Defective pressure regulator
valve

Dirty or fouled membrane

Operating on cold water

Defective product water
membrane O-rings.

Damaged membrane
(possibly due to chlorine
damage)

Replace pre-fi lter cartridge.

Check for closed valves.

Repair or Replace pump.

Replace or repair valve.

See above possible causes
for low operating pressure.

Replace it.

If possible operate with a
feedwater temperature of 72­80 °F (22-27 °C).

Check product water tube
O-rings and replace if
necessary.

Replace membrane.

Water fl owing when system is
turned off

RO System cycles ON and
OFF.

SpectraPure®Inc. 215 S. Industrial Drive, Suite 2A Tempe, Arizona 85281-2941 480.894.5437 Fax us toll-free 1.877.527.7873

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Ruptured membrane

Inlet solenoid valve not
closing or seating properly

Insuffi cient system inlet
pressure

Replace membrane.
Clean valve or replace.

See above possible causes
for low system inlet pressure.

Troubleshooting Guide: (continued)

PROBLEM PROBABLE CAUSE CORRECTIVE ACTION

High product water
conductivity (declining
rejection)

Dirty or fouled membranes

Product water tube O-ring
seal broken or damaged

Replace membrane.

Replace O-ring, check
sealing surfaces on O-ring
groove, interconnectors and
end caps. Replace damaged
parts.

20

Power switch on, tank water
level below the low fl oat, unit
not operating

Membrane put in backwards
Float switch has cut power to

machine

Defective Float

Thermal overload in motor

No power to system

Motor and/or pump not
operating properly

Micro-switch on either carbon
fi lter or water softener not
functioning properly

Install membrane correctly.
Check position of fl oat in the

storage tank.

Replace Float.

Allow motor to cool and re­start system. Check amp
draw of motor.

Check fuses or circuit
breakers, measue voltage.

Repair or Replace pump/
motor.

Replace micro-switch.

SpectraPure®Inc. 215 S. Industrial Drive, Suite 2A Tempe, Arizona 85281-2941 480.894.5437 Fax us toll-free 1.877.527.7873

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Carbon fi lter or water softener
control valve not in service
position

Low system inlet pressure

Set the control valves to the
service position.

See previous page for
possible causes for low
system inlet pressure.