US Filter M SERIES - 2000 Operation And Maintenance Manual

Operation and

Maintenance

Manual

for

M SERIES - 2000

Reverse Osmosis Systems

For Dialysis Applications

Serial # ________________________

8/97 MANOWNROSM REV F-

CAUTION

The Food and Drug Administration has found this device (System) to be
substantially equivalent to devices (Systems) intended for use in specific
medical device applications. The System may not be modified,
reconfigured, or used in a medical application other than that for which it
is labeled. Modifica tio n o f this system is a violation of federal law and will
void all warranties.

INDICATIONS

Use of the US Filter Reverse Osmosis System is indicated when water for use in the preparation of
dialysate fails to consistently meet the m inimum requirements specified in the ANSI/AAMI approved
American National Standard for Hem odialysis Systems, RD5, 1981. The US Filter Reverse
Osmosis System may be used with any proportioning dialysis machine having a compatible water
demand.

CONTRAINDICATIONS

There are no absolute contraindications to reverse osm osis water t r eat m ent.

CAUTIONS AND WARNINGS

Procedures using the Reverse Osmosis System must be per formed under the direction of a
physician.

Prior to operating or servicing t his device, t his m anual must be read and understood. If som ething
is not clear, call for assistance before proceeding. Keep this and other associated m anuals for
future refer ence and for new operators or qualified ser vice personnel.

All electrical work should be performed by a qualified electrician in accordance with the latest
edition of the National Electrical Code, as well as local codes and regu lat ions.

To avoid electrical shock hazard, do not remove covers or panels when power is supplied to the
device. Do not operate the device when covers or panels are removed.

WARNING

A faulty pump motor or wiring can be a serious shock hazard if it or
surrounding water are accessible to human contact. To avoid this danger,
DO NOT remove any grounding wire from the system.

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DISCLAIMER STATEMENT

This operation and maintenance manual is intended to be used with the supplier information
provided in the Appendix. These manuals should provide complete and accurate information to
meet your operating and/or service req uir em ent s based on the information available at the time of
publication. However, US Filter Corporation (“US Filt er”) assumes no responsibility for t he
technical content of the supplier literature.

This manual should be read fully and understood bef or e installation, operation or maintenance of
the system is attempted. The information in this manual may not cover all operating details or
variations or provide for all conditions in connection with installation, operation and maintenance.
Should questions arise which are not answered specifically in this manual, contact your local
Culligan Dealer.

US Filter reserves the right to make engineering refinem ent s that may not be reflected in these
manuals. The material in these manuals is for informational purposes and is subj ect t o change
without notice and should not be construed as a commitment by US Filter . US Filt er assumes no
responsibility for any errors that m ay appear in t his document. This manual is believed to be
complete and accurate at the time of publication. In no event shall US Filter be liable for incidental
or consequential damages in connection with or arising from the use of this m anual.

Copyright 1999 United States Filter Corporation
Printed in the United States of America. All rights reserved.

THIS BOOK OR PARTS THEREOF MAY NOT BE REPRODUCED IN ANY FORM
WITHOUT THE WRITTEN PERMISSION OF THE PUBLISHERS.

PROPRIETARY RIGHTS STATEMENT

This manual discloses information in which US Filter has pr oprietary rights. Neither receipt nor
possession of this manual confers or t ransfers any right to the client, and by its r et ention hereof,
the client acknowledges that it will not reproduce or cause t o be r eproduced, in whole or in part, any
such information except by written permission fr om US Filter. The client shall have the right t o use
and disclose to its employees the information cont ained her ein for the purpose of operating and
maintaining the US Filter equipm ent, and for no other purpose.

In the event the content of this m anual is alt er ed or section/items are omitted during a reproduction,
in whole or in part, and instructions or definit ions within the r eproduction result in personal injury to
those who follow the altered instructions, the burden of responsibility for personal injur y falls solely
on the party who affects the reproduction.

MANUAL USER’S GUIDE

This manual describes the procedures necessary to install, oper at e, and maintain your US Filter
liquid treatment system. Please r ead t his manual carefully before installing and operating your
equipment. The equipment warranty may be voided if installation or operation instructions ar e not
followed correctly.

Warnings, Cautions, and Notes are used to attract attention to essential or crit ical information.
Warning s and Caut ions will appear before the text associated with them, and notes can appear
either before or aft er associated text.

WARNING

Warnings indicate condition, practices, or procedures which must be
observed to avoid personal injury or fatalities.

CAUTION

Cautions indicate a situation that may cause damage or destruction of
equipment or may pose a long term health hazard.

NOTE:

Notes are used to add information, state exceptions, and point out areas that
may be of greater interest or im por t ance.

EQUIPMENT SUPPORT

US Filter continually strives to provide safe, ef ficient, trouble-f r ee equipment using the optimum
technology for your application. If problems should develop, contact your local Culligan dealer.

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MANOWNROSM

1.0 INTRODUCTION

1.1 System Function...................................................................................................1-1

1.2 Quality Assurance/Quality Control......................................................................1-1

1.3 Functions of the System Components..................................................................1-2

2.0 SYSTEM INSTALLATION

2.1 Precautions Before Installation............................................................................2-1

2.2 Unpacking............................................................................................................2-1

2.3 System Location...................................................................................................2-1

2.4 Power Requirements............................................................................................2-1

2.5 Water Requirements.............................................................................................2-2

2.6 Permeate Line ......................................................................................................2-2

2.7 Accessory Sensors (Pretreatment Interlock and Tank Level)..............................2-2

2.8 Setting the Flush Cycle Time (Optional).............................................................2-3

2.9 Before Power Turn On.........................................................................................2-3

2.10 Installation of Reverse Osmosis Membrane(s)....................................................2-3

INTRODUCTION

3.0 OPERATING INSTRUCTIONS

3.1 Controls and Indicators........................................................................................3-1

3.2 Initial Startup of Reverse Osmosis System..........................................................3-1

3.3 Initial Flushing of the System..............................................................................3-2

3.4 Normal Operations...............................................................................................3-2

3.5 Shutdown (Less Than 4 Days).............................................................................3-3

3.6 Prolonged Shutdown (Greater Than 4 Days).......................................................3-3

4.0 SYSTEM MAINTENANCE

4.1 General.................................................................................................................4-1

4.2 Sanitizing the Reverse Osmosis Membrane(s) ....................................................4-1

4.3 Maintenance Summary Log.................................................................................4-10

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INTRODUCTION

5.0 TROUBLESHOOTING

5.1 System Inoperative...............................................................................................5-1

5.2 Low System Pressure...........................................................................................5-1

5.3 Low Percent Recovery.........................................................................................5-1

5.4 High Percent Recovery ........................................................................................5-1

5.5 Low Salt Rejection...............................................................................................5-2

5.6 Low Calcium Rejection .......................................................................................5-2

5.7 System Keeps Shutting Off..................................................................................5-2

5.8 System Shutoff, Low Pressure.............................................................................5-2

5.9 System Shutoff, High Temperature......................................................................5-3

5.10 Low Permeate Flow Rate.....................................................................................5-3

5.11 Motor Overload Shutdown ..................................................................................5-3

5.12 Controller Malfunction ........................................................................................5-3

6.0 warranty

6.1 General Limited Warranty...................................................................................6-1

6.2 Water System Limited Warranty..........................................................................6-1

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7.0 appendix...........................................................................................................................7-1

TABLE # DESCRIPTION PAGE

4-1 Sanitization Times and Concentrations for Polyamide.................................................4-2

Thin Film Composite Cartridges

4-2 Cleaning Solutions for Polyamide Thin Film ................................................................4-8

Composite Membranes

4-3 Storage Solutions for Polyamide Thin Film Composite Cartridges 4-10

2

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MANOWNROSM

INTRODUCTION

1. 0 INTRODUCTION

Congratulations on your selection of th is US Filt er Corporation water purification system. This
system is designed and manufactured to t he highest standard of qualit y and f ully test ed and
inspected by competent personnel. In order to g et maximum performance, we ask you to read
all of the following instructions before installing and operating this system. Any warranty offered
will be void unless directions are followed exactly.

This manual is divided into sections for easy reference. Review this manual thoroughly and
then return to section 2.0 System Inst allat ion for step-by-step installation instruct ions.

If you need technical assistance in operating or m a int aining your unit, call your local US Filter
representative or should you require fur ther assistance call US Filter Technical Support at t he
phone number provided on the cover of this manual.

1.1

1.2

SYSTEM FUNCTION

The function of a Reverse Osmosis ( RO ) system is t o separ ate contaminants from a
water supply using a Reverse Osmosis (RO) membrane. T he system pr oduces pur ified
water that is low in inorganic salts, organic mat t er and bacteria. The purified water can
be used as a direct feed to a distribution system or stored in a reservoir.

RO systems operate on the principle of passing water t hr ough the membrane under
high pressure. Most of the water passes through the membrane and is purified. A
portion of the water containing the im purities is not passed through the membr ane and
is rejected to drain. Pref ilt er s are used in many systems to reduce the amount of
particulate contamination reaching the m e m br ane t hus insuring the membrane does not
become clogged.

Please refer to general m em brane specifications and System Specifications Sheet in t he
Appendix for other parameters impor t ant to the operation of the system.

QUALITY ASSURANCE/QUALITY CONTROL

Quality Assurance and Quality Control are words that mean many things to many
people. All too often they are used as "catch" phr ases t hat sound good but mean little.
At US Filter we have defined these phrases into a series of engineering and
manufacturing practices and contr ol pr ocedur es to insure that you, our customer,
receive the finest product available in the world. We will continue to update these
practices and procedures in an effort to improve our systems and to insure that they
continue to reflect state- of-the-art technolog y and reliabilit y.

Quality assurance is the cornerstone of our quality program. It beg ins with the select ion
and qualification of components and materials. Before suppliers ar e select ed, their
products must meet or exceed rigid standards set by our Quality Assurance
Department. From that point, our incoming material inspection insures only reliable
components will be used to manufacture systems. Numerous checks are performed as
the system passes through the manufact ur ing pr ocess. The completed system must
pass a series of tests before release to insure the system meets technical and
performance specificat ions. In the Appendix is a copy of our Quality Control for m for
your system.

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3

INTRODUCTION

Quality audits do not improve products. They do, however, insure that a system m eets
or exceeds specifications required for your system.

Customer feedback is also an impor t ant element of our progr am . Division heads meet
on a routine basis to review customer feedback and initiat e act ions t hat result in process
and product improvements.

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1.3

FUNCTIONS OF THE SYSTEM COMPONENTS
A. Low Suction Pressure Switch

A low suction pressure switch is incorporated into the system for t he pr ot ection
of the high pressure pump. If the inlet pressure on the pump suct ion falls below

0.69 bar (10 psig) for longer than three seconds the switch activates a safety
shutoff in the contr oller .

B. Reverse Osmosis Pump

The RO system contains a submersible pump driven by an AC motor. The pump
motor is turned on and off by a mot or st arter relay. The pump motor star t er also
contains an overload relay.

C. High Pump Pressure Switch

A high pump pressure switch is utilized in the system to prevent damag ing
pressures from reaching t he RO membranes. This switch immediately shuts of f
the RO pump if the pressure exceeds safety limits.

D. Pump Throttle Valve

A pump throttle valve is used to control the pressure and volume of water
supplied to the RO membranes.

E. Reverse Osmosis Membranes

The prefiltered water enters t he RO housing and passes over the surface of the
RO membrane. A portion of t he feedwater continues out of the system thr ough
a reject needle valve. The remainder of t he water per m eat es the membrane and
is directed to a distribution pipeline or to an accessory storage reservoir. Percent
conversion (the ratio of RO product water to feedwater) will vary depending on
water quality and the application.

F. Reject Throttle Valve

The water exiting the RO membranes is cont r olled by a reject throttle valve.
Closing the valve increases the pressure to the membranes and reduces the
amount of water to drain.

G. Reject Recirculation (Opt ional)

If the system is provided with the reject recir culation option, it permits part of the
reject water to be returned to the inlet of the high pressure pump. This may
allow the conservation of water depending on the water chemistry.

H. Product Recirculation

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I. Autoflush (Optional)

J. Controller

INTRODUCTION

Product recirculation permits excess product water to be returned to the inlet of
the high pressure pump. This function is used when capacity exceeds demand,
conserving water and increasing percent rejection (water quality).

In the TANK FEED and STANDBY modes, an optional solid state timer
automatically opens the reject solenoid valve for one minute every hour,
bypassing the throttle valve. This flush cycle is programmable for 1, 2, or 4
minutes per hour as determined by the fouling characteristics of the feedwater.
In the DIRECT FEED mode the autoflush function is inhibited.

The controller has the following capabilities:

1. Low pressure shut down - T he pum p m ot or is shut down when the inlet
water pressure falls below 0.69 bar (10 psi). Ther e is a 3 second delay to
prevent shutdown during momentary pressure losses.

2. High pressure shutdown - The pump motor is shut down when the
pressure exceeds a set point (determined by the choice of membr anes)
to prevent damage to the pump or element s.

3. High temperature shutdown - The pump motor is shut down on high
temperature to protect t he RO membranes from exposure to damaging
temperatures.

4. Low percent r ejection alarm - The alarm function is activated when the
percent rejection falls below determ ined limits to warn the operator if the
product water quality no longer meets specifications.

5. Pum p st ar tup delay - There is a ten second delay after turning on the unit
before the pump starts.

6. Automatic flush - The system automat ically flushes each hour when the
system is in the STANDBY mode or the TANK FEED mode.

7. Tank full shutdown - The system g oes into STANDBY when a signal from
a level switch indicates that a storage tank is full (optional).

8. Interlock - This feat ur e st ops t he system when the pret r eat m ent
equipment is in the regeneration cycle and rest ar t s the system
automatically when the regeneration cycle is completed.

K. Accessories

In order to comply with AAMI standards for audible alarm capabilit y, an
accessory audible alarm is necessary. This alarm can be remotely mounted
providing monitoring in an area away from the unit for safety and convenience. If
the system is used to feed a storage r eser voir, a level switch is necessary to
provide a signal to the controller while in the TANK FEED mode.

L. Wat er Quality Monitor

The controller is designed to measure the conductivity of the feedwater to the
system as well as the conductivity of the product water. It automat ically
calculates the percent of impurit ies being rejected by the RO membranes. The

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INTRODUCTION

M. Alarms

MANOWNROSM

readings are on an LCD display. A more detailed description of this module can
be found in the Reverse Osmosis Controller, Operating Instructions in the
Appendix of this manual.

The controller is equipped with a visual alarm for the following conditions:

Low Feed Pressure
High Pressure to Membranes
High Feed Temperature
Tank Full
Pr et r eatment Interlock

Low Percent Rejection

As these units are normally installed in a location away from patient areas for
noise containment, an accessory audible alarm is necessary to comply with
AAMI standards. The controller generates a signal to drive this alarm for t h e
following conditions:

Low Feed Pressure
High Pressure to Membranes
High Feed Temperature
Low Percent Rej ection

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MANOWNROSM

SYSTEM INSTALLATION

2. 0 SYSTEM INSTALLATION

2.1

CAUTION

NOTE:

2.2

PRECAUTIONS BEFORE INSTALLATION

The following are feedwater source requirements:

A. Inlet pressure of 0.69 to 6. 9 bar (10 to 100 psig) at design feed flow.
B. Temperature of between 2°C (35 °F) and 40°C (104°F). Recommended

operating temperature is 25°C (77°F).

C. Free chlorine concentration must be non-detectable on a cont inuous basis ( < 0. 1

mg/l).
If the free chlor ine level is gr eater than 0.1 mg/l, a carbon filter or bisulfite system

should be used as pretreatment to remove chlorine from the feedwater entering
the RO unit. Chlorine will cause irreversible damage to t he m e m br anes.

D. Langelier Saturation Index (LSI) of the reject must be negat ive at t he system's

operating recovery to avoid fouling the membranes.

pH must be between 4 and 11. Chlorine must be l ess than 0.1 mg/l.

If feedwater does not meet t he above requirements or there is some doubt,
contact your US Filter representative f or recommendations.

UNPACKING

2.3

2.4

The RO systems are shipped completely assembled. Pressure switches, g auges,
control box, pump, valves and regulators are all pre-mounted on the main frame and
factory set to correct values. Carefully remove from the packing cr ate to avoid damage
to gauges, RO membranes, etc. Do not drop or handle with excessive roughness to
prevent damage to the electronic components and t o prevent damage to the piping
joints.

SYSTEM LOCATION

A drain capable of handling the flow of reject water during system flushing should be
located as close to the system as possible. The reject line should be secur ed so that
during the high velocity flush the line is not dislodged from the drain.

POWER REQUIREMENTS

The power requirements for t he system ar e given on the system I.D. plate just above
the controller enclosure. The system should be connected with a multiconductor,
grounded cable to a disconnect switch box. The switch box should be located within
approximately 10 feet of the system for the convenience of technicians servicing the
unit.

The system is provided with a motor starter to permit coor dinat ed over- cur r ent
protection as defined by the National Electrical Code.

Ground the power cable to the ground connection in the mot or starter housing box.
Branch circuit conductors supplying the motor shall have an amperage capacity of not

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7

SYSTEM INSTALLATION

less than 125% of the motor full load current rating as def ined by the Nat ional Elect r ic
Code.

MANOWNROSM

2.5

2.6

2.7

WATER REQUIREMENTS

The inlet water supply must be adequate to provide the minim um flow requirement
shown on the System Specifications sheet in the Appendix. The inlet line should be
sized to deliver this flow with a minimum pressure of 0.69 bar (10 psig) at the RO unit.
A shutoff valve within 10 feet of the unit and a cleaning connection should be provided.
A sample valve to check feedwater quality is also recommended.

PERMEATE LINE

The permeate line should have sufficient int ernal diameter to minimize line pressure
drop. It is recommended that a sm all sample valve be placed in the product line to
facilitate sampling of the permeate water quality. A flow meter is supplied with the unit
to continuously measure the permeate flow rate. The flow meters supplied are fluid
calibrated to obtain accurate flow measurement s. Any replacement flow meter should
also be fluid calibrated.

ACCESSORY SENSORS (PRETREATMENT INTERLOCK AND TANK LEVEL)

Provisions have been made for shutdown by accessory sensors, provided such sensors
are equivalent to a single pole single throw switch. The shut down is such that nor m al
operation will resume automatically when the failure is rem oved.

A. Remove the lower panel from the control box and the attached integrated

controller circuit to expose the terminal connections.

2.8

B. See the Reverse Osmosis Controller, Oper at ing Instructions in the Appendix to

connect PRETREATMENT INTERLOCK, HI GH TANK LEVEL and MID TANK
LEVEL sensors.

NOTE:

If only a high tank level switch is used, a switch should be select ed with a built
in “dead band” in order to prevent the RO pump from cycling. Using a switch
without a “dead band” could cause the motor starter to fail and can contribute
to low product water quality.

C. These terminals are normally closed. An open circuit is necessary to shut down

the system.

D. To connect the accessory, remove the shorting wire and connect a single pole

single throw normally closed sensor between the respective terminals. It is
recommended that shielded cable, properly grounded, be used to avoid radio
signal interference with these functions.

SETTING THE FLUSH CYCLE TIME (OPTIONAL)

See the see the Reverse Osmosis Controller, O per at ing Instructions in the Appendix.

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SYSTEM INSTALLATION

2.9

BEFORE POWER TURN ON

The controller should be installed in the controller housing before connecting electrical
power to the unit.

WARNING

Once the inlet water is plumbed to the system and the electr ical power is connected, t he
electrician should verify correct motor rotation. Please refer to the Pump Information
included in the Appendix.

CAUTION

CAUTION

Place the system in the DIRECT FEED mode and turn the POWER switch to ON.

2.10

INSTALLATION OF REVERSE OSMOSIS MEMBRANE(S)

RO units are normally shipped with the membranes installed and preser ved in sodium
bisulfite solution. However, should the need arise, the following procedures may be
followed to install membranes:

Personal injury and permanent damage to the controller can result if the
controller is installed with power on the unit .

Verify that all retaining rings are in place on the RO membrane housi ngs
before turning on the pump.

Be sure the product water will not enter the user system during startup.
The RO system must be operated for four hours to flush out the
preservative solution before connecting to the user system.

A. See the Appendix for a diagram of the individual components of the membrane

assembly. Before sliding the mem br anes int o the fiberglass housing, install the
proper product tube adapters on/in the pr oduct tube. Lightly lubricate the o-rings
with glycerin.

B. Load the RO membrane into the f iber glass housing from the direct ion in which

the feedwater will enter, inserting t he end without t he chevron seal first. Before
the chevron seal enters the housing lightly lubricate t he chevron seal with
glycerin before it enters the housing and press the membrane to the end of t he
housing.

C. Place an end plug into the RO housing end opposite from loading end. Using

snap ring pliers secure the end plug with the retaining ring. Press the membrane
into the end plug to seat. Hoses should be connected to end cap before
insertion into the housing.

WARNING

Never engage or disengage retaining rings without wearing safety
glasses.

D. Install the adapter and end plug on the feed end and secure it with a snap ring.

CAUTION

Never allow the RO membrane to dry out once it has been wet, or
irreversible damage will result.

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MANOWNROSM

OPERATING INSTRUCTIONS

3. 0 OPERATING INSTRUCTIONS

3.1

3.2

CAUTION

CONTROLS AND INDICATORS

The controls and indicators used in the operation of the system are outlined in the
Appendix (Figure 1.1). The operator must be thoroughly familiar with the contr o ls and
their respective functions for pr oper oper ation and in order to maintain the qualit y of the
permeate and eliminate unnecessary shutdowns.

INITIAL STARTUP OF REVERSE OSMOSIS SYSTEM
A. The operator should verify that appropriat e pretreatment is in place and

operating satisfactorily. I nappropriate or inoperative pretreatment can dam age
the membranes and result in water which does not meet AAMI recommended
standards.

B. Make all water, electrical, and drain connections according t o inst allation

instructions.

C. Verify that the Key switch is in the OFF position (see the Reverse O s m osis

Controller, Operating I n st r uctions in the Appendix). Turn on the inlet water and
the electrical power at the remote disconnect. Dir ect product water to the drain
until proper operation of the system is verified and product quality is known to be
within specifications.

Verify that all RO housing retaining rings are in pl ace and engaged.

D. Turn on the Key switch and press the power button. Place the controller in t he

Direct Feed Mode.

E. Check for proper pump rotation. Slowly close the pump throttle valve (Figure

1.1) and record the pressure indicated on t he PUMP PRESSURE gaug e

upstream of the valve. Immediately turn the system off. DISCONNECT THE
POWER and switch any two electrical leads in the pump starter. Turn the
system on and again close the pump throttle valve and record the pump
discharge pressure. Do not run the system for more than a few seconds
with the pump discharge valve closed. The lead hookup that gave the
highest discharge pressure indicates the cor r ect r otation. (Please refer to the
Pump Installation and Operating Instr uct ions, included in the Appendix of this
manual for information concerning motor rotation and any other electrical
requirements.)

CAUTION

Do not run the motor for more than 30 seconds backwards or irreversible
pump damage may result. The membrane pressure should not be
allowed to exceed 24.15 bar (350 psi g) duri ng t he procedure.

F. Adjust the reject thr ottle valve (Figure 1.1 in the Appendix) to give the design

product flow indicated on the System Specifications sheet in the Appendix. DO
NOT exceed 24.15 bar (350 psig) membr ane pr essur e.

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OPERATING INSTRUCTIONS

G. If your RO system is equipped with the rej ect r ecirculation option, set the reject

recirculation flow to zero, but DO NO T exceed pressure to membrane limits
(24.15 bar/350 psig). Open t he r eject valve further if necessary to avoid over
pressuring the system.

MANOWNROSM

CAUTION

3.3

Do not use reject recirculation option for the f i rst 24 hours of operation
to avoid recirculating preservative chemicals which can permanently
damage the membranes.

H. Set the percent rejection alarm set t ing to 90%.
I. Check for plumbing leaks and make appropriate repairs as necessary. All

systems are leak checked at the f act ory but vibration during transit can cause
new leaks to develop.

J. Once the system is checked out and operating cor r ect ly, place t he controller in

the desired mode. Read the next section on initial f lushing before directing
product water to the RO water storage tank or user system.

INITIAL FLUSHING OF THE SYSTEM

Since the RO membrane is shipped moist with sodium bisulf ite preservative solution,
initial flushing of the system is r equired. Before operating a new system, and also after
the replacement of a RO mem br ane, perform the following steps:

A. Place the outlet of the permeat e at a convenient drain.
B. Turn on the feedwater and the system pump (as outlined in Operating

Instructions, Initial Star t up of the Reverse Osmosis System section of t h is
manual) and let the system run for 24 hour s. This will flush residual bisulfite
solution and any particulate impurities from t he m e m br anes, housings and
plumbing of the system.

3.4

12

C. Permeate quality will increase slowly for 1 hour. Monitor the inlet quality vs. the

permeate quality by observing the conductivity meter outputs.

NOTE:

The system should have better than 90% rejection within 2 hours as the
membranes equilibrate. If the permeate quality does not improve, ref er t o
section 5.0 Troubleshooting.

D. After flushing, t ur n off the system and reconnect the per m eat e line. The system

is now ready to be put into a normal operating mode.

NORMAL OPERATIONS

The following procedure is for oper ating a U.S. Filter RO system that has been installed
and initial flushing has been completed. Refer to the Reverse Osmosis Contr oller ,
Operating Instructions in the Appendix for control location and identif icat ion.

A. Initiate operation by pressing the POWER button.
B. If the controller is in t he STANDBY or TANK FEED mode, allow the system to

complete the flush cycle before proceeding .

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MANOWNROSM

C. Place the controller in the DIRECT FEED m ode.
D. After five minutes of operation to allow the system to stabilize, verify and record

E. Set the percent rejection alarm to t he lim it s prescribed by the physician. The

F. After perf or m ing checks and recording the r esult s r e set the MODE SELECTION

OPERATING INSTRUCTIONS

the operating data in the daily log sheet ( s am ple in Appendix). Follow the
procedures outlined in the Maintenance Summary section of this m anual.

alarm limits for the pur poses of monitoring shall be calculated based on the
feedwater analysis and initial rejection characterist ics and shall cor r espond t o t he
highest rejection coefficient at which contaminants reach unsafe limit s. Consult
your US Filter representative for t he det ermination of these limits. Under no

circumstances is it recommended that the alarm be set at l ess than 90%.

SWITCH to the desired location if necessary. If a storage tank is ut ilized, set the
MODE SELECTOR SW I TCH to the TANK FEED position. If no storage tank is
used, set the MODE SELECTION SWITCH to the DIRECT FEED position. The
system is now ready to begin dialysis.

3.5

CAUTION

3.6

SHUTDOWN (LESS THAN 4 DAYS)

If the system is not to be run for up to 4 days, the system should be placed in the
STANDBY mode of operation. This will allow the system to return to operation at any
time with no adverse affects on the permeate or m em br anes.

If the shutdown is due t o a malfunction, be sure to disconnect the
electrical power and turn off the water supply before making repairs or
replacements.

PROLONGED SHUTDOWN (GREATER THAN 4 DAYS)

When the system is going to be inactive for more t han 4 days (not in a STANDBY
mode), perform the following steps:

A. Turn off the feedwater source.

Bisulfite Sanitization (4 days to 1 month shutdown)

Drain water from the system and pump in a 0.5% sodium bisulfite solution
to prevent biological growth in the elements.

or
Formaldehyde Sanitization (shutdowns exceeding 1 month)

Drain water from the system and pump in a solution of 3% formaldehyde
to prevent biological growth and kill residual bact eria.

B. Remove the prefilter cartr idges and discard. Clean the prefilter housing, leaving

the cleaned components to dry during the shutdown period.

C. Turn off the feedwater and electrical power until the system is to be placed into

operation again.

D. To resume system operation, f ir st drain the solution from the RO housings,

install new prefilter cartridges, disconnect the permeate line from t he reservoir

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13

OPERATING INSTRUCTIONS

and run to drain. Then turn on the feedwater and start the system, run the
permeate water to drain for 4 hours to flush the system. The product water
should be analyzed with the Fast Formalert or other formaldehyde test kit until
detection limits are reached. Reattach t he per m eate line and start the system as
outlined in the Operating Instr u ct ions, Normal Operations section of this manual.

MANOWNROSM

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MANOWNROSM

SYSTEM MAINTENANCE

4. 0 SYSTEM MAINTENANCE

4.1

4.2

GENERAL

Routine customer maintenance procedures consists of periodic replacement of the RO
membranes and the filter car tridges in the prefilter unit and sanitization of the RO
membranes and the storage reservoir. Cleaning/sanitizing is recommended every four
to eight weeks. The RO mem br anes should have a life of about 3 years if used
properly. In addition, the system's external surface should be kept clean by occasionally
wiping down all surfaces with a dust-free cloth and visually checking for cr acked glass
on gauges, loose fitting s, and broken or missing hardware.

Whenever prefilters or RO membranes are r eplaced, inspect the serviceability of the
o-ring seals prior to assembly. Inspect o-r ing s for signs of deterior at ion or cr acking, and
replace as required. It helps to lubr icat e o-rings with glycerin before reassembly.

SANITIZING THE REVERSE OSMOSIS MEMBRANE(S)

Periodically, the RO Systems may require sanitization in order to maintain the
performance of the RO membrane, and to ensure a low bacterial count in the product
water. How frequently the system is sanitized depends on the quality of the water
needed for your particular application. Monitor bacter ial levels in the feed and
permeates as needed. When bacterial levels increase above an acceptable level for the
application, sanitize the system.

The choice of the sanitizing agent depends on its compatibility with the polyamide thin
film composite RO cartridges and system components, and the agent’s effectiveness as
a sanitant. Three commonly used sanitants are formaldehyde, hydrogen peroxide and
peracetic acid.

CAUTION

Chlorine is not compatible with thin film composite cartridges, and must
not be used to sanitize them.

A. Different Sanitizing Agents

CAUTION

When using formaldehyde to sanitize thin film composite cartridges, the
cartridges must have been in use for 24 hours prior to sanitization, or a
severe loss in flow rate may occur.

1. Formaldehyde

Formaldehyde is one of the most eff ective agents used for sanitization. It

is compatible with most materials, is highly active as a biocide over a
relatively wide pH range, and easily penetrates the RO membrane, t hus
ensuring that the downstream side of t he filter is sanitized. But,
formaldehyde is difficult t o flush from the system after sanitization, has an
objectionable odor, and causes irritation to the eyes and nasal passages.
In addition, formaldehyde is a suspected carcinog en. Even so,
formaldehyde is commonly used for sanitizing RO car tridges.
Formaldehyde, in solution, is purchased as formalin, which is a 37%
solution of the formaldehyde g as st abilized with methanol.

15

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SYSTEM MAINTENANCE

2. Hydrogen Peroxide
Advantages of using hydrogen peroxide are that it has no t oxic vapors, is

biodegradable, is easily disposable, has good biocidal activity, and
breaks down into oxygen and water, which does not harm the
environment. Because of these qualities, oper ators can be assured that
they are not handling toxic materials.

3. Peracetic Acid

Advantag es of using peracetic acid are that it has no t oxic vapors, is

biodegradable, easily disposable, and has good biocidal activity.
Because of these qualities, operators can be assured that they are not
handling toxic materials. Peracetic acid decomposes into oxygen, water,
and acetic acid, which does not harm the environment. Several peracetic
acid solutions are commercially available, including; Minncare and
Renalin Dialyzer Reprocessing Concentrate, both products of Minntech
Corporation, and P3-Oxonia Active, a product of Henkel Corporation. For
ordering informat ion call t he number provided on the cover of this
manual.

B. Selecting a Sanitant

Table 4-1 lists the type and concentration of sanitizing agent that should be used
for polyamide thin film composit e cartridges, as well as the minimum contact
time for sanitization.

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Sanitant Sanitant Concentration Sanitant Contact Time

Formaldehyde * 2-3% 30-60 minutes
Hydrogen Peroxide ** up to 2000 ppm (0.2%) 30-60 minutes
Peracetic Acid ** up to 2000 ppm (0.2%) 30-60 minutes

Table 4-1: Sanitization Times and Concentrations for Polyamide Thin Film Composi t e

Cartridges.

* When using formaldehyde to sanitize thin film composit e car t ridges, the cartridges must

have been in use for 24 hours prior to sanitization.

** When using hydrogen peroxide or peracetic acid with thin film composite mem branes, the

temperature should not exceed 25° C (77° F). Also, the presence of iron or heavy metals
can cause membrane degradation. Clean the m em branes first if iron is pr esent in the feed
water.

C. Testing for Residual Sanit ant

16

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MANOWNROSM

D. Methods of Sanitization

SYSTEM MAINTENANCE

After flushing t he sanit ant from the RO system, t he per m eate water should be
checked for residual levels of sanitizing ag ent before the system is placed back
on line. Use the following guidelines to determine if the system is clear of
residual sanitizing agents.

1. Formaldehyde

The product water should be analyzed with the Fast Formalert or other

formaldehyde test kit unt il det ection limits are reached.

2. Hydrogen Peroxide

T he product water should be analyzed with a hydrogen peroxide test kit.

3. Peracetic Acid

The product water should be analyzed with the Minncare Residual Test

Strip or other peracetic acid test kit. For ordering information call the
number provided on the cover of this manual.

Sanitization is most effective when the RO system is operat ing at normal
pressure and flows. This allows the maximum amount of sanitant to penetrate
through the membrane, ensuring adequate sanitization of the product side of the
system. Three methods of sanit ization may be used: Continuous I njection,
Recirculation and Static Soak.

1. Continuous Injection Method

I n t his m et hod of sanitization, an accessory chemical feed system injects

concentrated sanitant into the feed line while the RO is operating at
normal flows and pressure. Both the product and rej ect streams are sent
directly to drain.

The continuous injection method is most typically used to sanitize with

hydrogen peroxide. It is not practical for formaldehyde sanitization
because the dilution ratio used for f or m aldehyde (1: 10 to 1:20) would
require the use of a very large chemical feed pump. The advantages of
the continuous injection method are minimal chemical handling and
minimal dead legs in the system piping. One disadvantage is the
relatively high chemical consumption.

T he basic steps for continuous injection sanitization are as follows:

a. Rej ect and pr oduct lines from the RO are diverted t o drain.
b. T he system is placed in t he normal operating mode.
c. An accessory chemical feed system is turned on to inject

concentrated sanitant into the f eed water. The sanitant is diluted
by the feed water to the recommended concentration.

d. T he system is left running in the normal oper at ing mode for 30 to

60 minutes.

e. T he chem ical feed pump and the RO system are shut down, and

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the sanitant solution is allowed to sit in the system (optional).

17

SYSTEM MAINTENANCE

f. The RO is run in the normal oper ating mode with the product

2. Recirculation Method

T his method requires an accessory tank and booster pum p. A sanitant

solution is prepared in the tank and fed t o the RO system via the booster
pump. The product and reject streams are diverted to the tank and the
sanitant is recirculated through t he system for a period of time.

The advantages of the recirculation m et hod of sanitization are minimal

usage of chemical, and ease in obtaining the proper sanitant
concentration. In addition, the accessory tank and boost er pump may
also be used for system cleaning.

The following steps provide a general guideline for the recirculation
method of sanitization.

a. A bat ch of sanitant, typically 40 to 100 gallons (160 to 400 lit er s) ,

b. T he pr oduct and reject lines are diverted to the tank .

MANOWNROSM

diverted to drain until all residual sanitization chemical is flushed
from the system.

is prepared in the tank by diluting sanitization chemical with water.

CAUTION

c. The feed to the RO is connected t o t he out let of a booster pump,

which pumps sanitant out of the tank.

d. T he booster pump is turned on and the RO is run in the norm al

operating mode for 30 to 60 minutes.

Monitor the solution temperature during recirculation. Do not allow t he
temperature to exceed 25°°°° C.

e. T he boost er pump and the RO system are shut down and the

sanitant is allowed to sit in the system (optional).

f. The RO is switched back to the norm al feed source and run in the

normal operating mode with the product divert ed to drain until all
residual sanitization chemical is flushed from the system .

g. T he t ank and booster pump are drained and flushed with clean

water.

3. Static Soak Method
This sanitization method may be used in combination with either

recirculation or continuous injection sanitization for heavily bio-fouled
systems. In this method, sanitant is intr oduced into the system and then
the system is shut down. The membranes are allowed to soak in the
sanitant solution for a period of time ranging from as little as 30 minutes
up to several days (check with your US Filter representative for
recommended maximum soak time).

O ccasionally a system must be sanit ized without a chemical feed system

or an accessory tank and booster pump. In this case it is possible to
perform a static soak sanit ization by placing concentr at ed sanitant in the
RO system prefilter housing , or by manually injecting it into the feed line.

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MANOWNROSM

SYSTEM MAINTENANCE

The RO pump is then turned on briefly to flush the sanitant into the
system. The system is then shut down so that the cartridg es m ay soak in
the sanitant solution. The drawback of this method of introducing
sanitant is the sanitization chemical is not evenly distributed throughout
the RO system. Localized areas of high sanitant concent ration could
degrade the RO membranes. Also, the length of time that the RO pump
is turned on will be different with each model of RO system and the
means used to introduce the sanitant.

CAUTION

Do not use the static soak method of sanitiz at i on with any chemical other
than formaldehyde.

E. Cleaning the System

When the RO systems are properly operated, they do not require frequent
cleaning. In time, however, the RO membr ane car t ridges can become fouled to
a point where system performance is adversely aff ect ed, resulting in diminished
product output or salt rejection. When the product flow rate drops by 10% and/or
the salt content in the product water rises noticeable, this may indicate fouling of
the cartridge membrane. However, other factors such as temperature
decreases, or malfunctioning pretreatment systems, pressure controls and
pumps may also cause these conditions. It is important t o r ule out these factors
before cleaning the system.

Clean the cartridges if the system performance (based on flow rate or salt
rejection) decreases because of mem br ane fouling. An increase in the feed t o
reject differ ent ial pressure also indicates that cleaning is needed. Membrane
foulants include colloidal materials such as aluminum and silica compounds,
precipitated metal hydroxides of iron and manganese, biological films, and
calcium or magnesium carbonate scale.

The type of cleaning solutions (See Table 4- 2) , and the sequence in which they
are used, depends on the type of foulant pr esent ( organic compounds, metal
hydroxides, Ca/Mg carbonates, etc.). The need for frequent cleaning ( t wice a
week or more), may indicate that pret r eat m ent is inadequate. This section
includes general guidelines for developing a cleaning procedure for your
particular application.

F. Effects of Foulants on RO System Performance

1. Colloidal fouling

Causes product flow rate to decrease, and salt passage to incr ease,

usually in that order. RO systems that operat e on high SDI feed water
are prone to colloidal fouling.

2. Metal hydroxide (iron, m anganese)

Causes a significant and rapid decrease in the product flow rate, and an

increase in salt passage.

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SYSTEM MAINTENANCE

3. Biological fouling
Causes a biofilm to form on the membrane surface. This biofilm inhibits

the membrane’s ability to reject salt, and therefore salt passage
increases. The product flow rate may also decrease, but not necessar ily
at a rapid rate.

4. Scaling

Causes a decrease in the product flow rate and an increase in salt

passage.

G. Factors to Consider when Cleaning RO Cartr idg e

1. Use RO product water for cleaning and rinse solutions.

Use RO pr oduct water to prepare cleaning solutions, and as flush water

between each cleaning step. If RO product water is not available, use
softened filtered t ap water. Com pletely flush the system between
applications of diff er ent cleaning solutions.

2. Increase flow rates and decrease pressure.

Dur ing cleaning, reject flow rates should be as high as possible without

exceeding the maximum design flow of the system. The reject regulating
valves should be fully opened to minimize transmembrane pressure.
Transmembrane flow keeps f oulant s within, or on t he m em br ane surface
during cleaning. Optimally, a hig h flow, low pressure accessory cleaning
pump should be used.

MANOWNROSM

3. The temperature must not exceed 35° C.

T he temperature of the cleaning solut ion m ust not exceed 35° C. It may

be necessary to install a heat exchanger to prevent the temperat ure from
exceeding 35° C. The optimum temper at ure of the cleaning solution is
25° C to 30° C. Cold water reduces the effectiveness of the cleaning
solution.

H. Choosing the Correct Cleaning Method

1. Recirculation Method (try this first)

This is the cleaning method of choice. Recir c ulat e each cleaning solution

through the RO system for 45 to 90 minutes. Recirculation cleaning
requires an accessory recirculation tank and pum p. The system is fed
from the tank, and t he r eject and product lines are diverted to the tank .
The RO system should be placed in the manual flush mode dur ing
recirculation with the inlet pneumatic valve and accessory motorized 3­way valve open, and the RO pump off.

CAUTION

If the system temperature approaches the maximum recommended
operation temperature during recirculation, shut down the system and
allow it to cool of f before continuing the recirculation.

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MANOWNROSM

SYSTEM MAINTENANCE

If the cleaning solution becomes hig h ly discolored during recirculation,
discard it and repeat the application. If any cleaning solution becomes
highly discolored during the first applicat ion, the soak and flush method
may be more applicable.

2. Soak and Flush Method

Pum p t he cleaning solution into the RO system, soak the car tridges for

15 to 60 minutes, then flush the unit t o drain. Flush the system until the
cleaning solution exiting the system is clear, or near ly clear. Repeat soak
and flush cycles until discolored solution is no longer being flushed from
the system. Use this method when the recirculation met hod is not
effective.

3. Flush Residual Cleaning Agents Using Reduced Pressure

Flush t he cleaning chemical from the system, starting with a 10 to 15

minute manual flush cycle. Then place the system in the operat e mode,
and for the first t en minutes, reduce the feed pressure to approximately
half of the normal oper at ing pressure by opening the reject thr ot tle valve.
This prevents residual foulants f r om being impacted into the membrane.
After ten minutes, ret urn the system to normal operating pressur e, and
continue flushing until the product water is clear of all residual cleaning
agents.

I. Testing for Residual Cleaning Agents After Flushing

Use the following guidelines to determine if the system is clear of residual
cleaning agents.

1. Acids and Bases

The pH of the product water would be equal to, or near ly eq ual t o, the pH

of the feed water.

2. Sodium Bisulfite

T he conductivity of the product should be equal to, or less than, t he

conductivity of the product before cleaning.

3. EDTA/Na-EDTA

T he conductivity of the product should be equal to, or less than, t he

conductivity of the product water before cleaning. If the guidelines f or
residual EDTA in the product water are more str ingent, use the Hach
Model ED-3 EDTA test kit. For order ing information call the number
provided on the cover of this manual.

Table 4-2: Cleaning Solutions for Polyamide Thin Film Composite Membranes.

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21

SYSTEM MAINTENANCE

MANOWNROSM

Metal

Oxides

(Fe, Mn)

Inorganic

Salts

(CaCO

3

Silica Biofilms Organics

)
HCI, pH 2-2.5 x x x x
Citric acid, 1% pH 4 (adjust with NaOH) x x
Oxalic acid, 1% x
Citric Acid 2% Ammonium Bifluoride, 2%

x

pH 2, 30° C. maximum
NaOH, pH 12 x x
Sodium Bisulfite*, 1%, pH6 x
NaEDTA 0.1% pH6 x x
NaEDTA 0.1% NaOH 0.1% pH 12, 30° C.

xxx

max.
NaOH, 0.1% Sodium Dodecylsulfate,

xx

0.1% pH 12, 30° C. max.
Sodium Triphosphate, 1.0%

xx

Trisodiumphosphate, 1.0% Na-EDTA,

1.0%
Phosphoric Acid, 0.5% x x
Sulfamic Acid, 0.2% x x
Sodium Hydrosulfite, 2.4% x

* Prepare sodium bisulfite using a buffered solution of 0. 1% Na2CO3 or 0.15% NaHCO

J. Preparing the Cleaning Solutions

Use the following procedures to make 10 liters (L) of solution. For lar ger
volumes, increase chemical amounts accordingly. The total volume of cleaning
solution depends on the system size. A minimum of 100 liters is r ecom m ended.

WARNING

Use caution when preparing these solut i ons. Wear safety glasses,
gloves, and a protective apron. Consult the appropriate Material Safety
Data Sheets (MSDS) before w orki ng with any chemicals.

3

1. 1% Oxalic Acid, pH 2-4

Add 100g anhydrous oxalic to 8.8L RO water in your cleaning tank. To

adjust the pH to 3.0, add 1.2L of 1.0N NaOH.

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MANOWNROSM

2. 2% Citric Acid, pH 3-5
Add 200g of anhydrous citric acid to 9L RO water.

3. 1% Sodium Bisulfite, pH 5-6

Add 15g of sodium bicarbonate (NaHCO

(Na2CO
(NaHSO

) to 10L of RO water. Add 100g anhydrous sodium bisulfite

3

). The pH of the solution is approximat ely 5. Adding sodium

3

bicarbonate or sodium carbonate befor e t he sodium bisulfite, adjusts the
pH and minimizes sulfur dioxide gas liberation.

4. 0.1% EDTA/Na-EDTA, pH6
(EDTA is ethylene, diamine, tetra acetic acid.) Add 10g of Na-EDT A t o

10L RO water. Add 10g EDTA. pH is approximately 6.

5. Hydrochlor ic Acid, pH2
Add 0.5L of 1.0N HCl to 9.5L RO water . This amount of HCI will vary,

depending on the buffering capacity of the makeup water. Check the
addition of acid with a pH meter.

6. Sodium Hydroxide, pH12

The amount of NaOH needed will vary, depending on the makeup water

quality. If solid NaOH pellets ar e available, add 4.0-40g to 10L of RO
water. Check the addition of caustic with a pH meter . If 50% NaOH is
used, start with 5ml per 10 liters, and add until a pH of 12 is reached.

SYSTEM MAINTENANCE

) or 10g of sodium carbonate

3

K. Shutdown Procedures

1. Shor t-Term Shutdown (Less than 48 hours)

T he RO systems may be shut down for up to 48 hours with no adverse

effects to the system or cartridges. No special re-startup pr ocedur es ar e
required.

2. Long-Term Shutdown (Greater t hen 48 hour s)

I f the RO system is shut down for longer than 48 hours, fill the system

and cartridges with a sanitizing solution to prevent the growth of bact er ia
and to help maintain proper flow rate. The following table lists the
recommended concentrations of stor age solutions of the RO cartridg es.

Storage Solution Concentration

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SYSTEM MAINTENANCE

MANOWNROSM

Aqueous solution of glycerin (by weight) or
propylene glycol mixed with sodium bisulfite

20% glycerin or propylene glycol, 1% sodium
bisulfite

(by weight).
Formalin (see caution below)
Sodium Bisulfite

1% Formaldehyde
1% Sodium Bisulfite

Table 4-3: Storage Solutions for Polyamide Thin Film Composite Cartridges.

CAUTION

New thin film composi t e cart r i dge M UST be operated for a mini mum of 24
hours before contact with formal i n, or a permanent reduct i on i n f l ow rate
may occur.

4.3

MAINTENANCE SUMMARY LOG

(See Reverse Osmosis System Maintenance Log in the Appendix.)

NOTE:

The maintenance schedule for monitoring as outlined, is a m inim um f o r t he
protection of the reverse osmosis system. A more frequent monitoring
schedule may be necessary for patient safety. Consult your US Filter
representative for assistance.

A. Feedwater

1. Check pressure daily; record weekly. Adjust as necessary to maint ain

0.69 to 6.9 bar (10 to 100 psi).

2. Monitor feed and permeate conductivity and record weekly.

3. If there is a possibility of the pr esence of chlorine in the feedwater,

measure free chlorine weekly. (It must be non-detectable or the
membranes may be damaged).

4. If there is a possibility of sig nificant pH variations (i.e. the f eed is pH
controlled) monitor and record pH weekly by independent pH meter or
litmus paper.

5. Measure tot al calcium monthly.

B. Coarse Prefilter (If Applicable)

1. Measure differential pressure daily; recor d weekly.

2. Change prefilter when the differential pressure is greater than 0.69 bar

(10 psi) or every 6 months, whichever occurs sooner.

C. Prefilter

1. Measure differential pressure daily; recor d weekly.

24

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MANOWNROSM

SYSTEM MAINTENANCE

2. Change prefilter when the differential pressure is greater than 0.69 bar
(10 psi) or every month, whichever occurs sooner.

3. Inlet pressure regulator screen should be cleaned once a month.

D. Pump

1. Check pressures daily; record weekly.

2. If the pressures have fallen off, check product and reject flows.

E. Conductivity

1. Observe feed and permeate conductivity daily; and record weekly.

2. Record percent salt rejection weekly.

F. Flow Rates

1. Check daily and record permeate and reject flow rate weekly.

2. Calculate the percent recovery using the following formula:

Permeate Flow Rate
100 X  = % Recovery
Permeate Flow Rate + Reject Flow Rate

T he percent recovery should not exceed the design value shown on the

System Specifications sheet in the Appendix. If minimizing water usage
is critical, the percent recovery should be maintained near, but not above
the maximum value. Operating with too high a per cent recovery will lead
to premature fouling of the membrane.

G. Calcium

Measure the feed and permeate calcium and calculate the percent r ejection
using the following form ula:

Calcium Inlet - Calcium Permeate
100 X  = % Ca Rejection
Calcium Inlet

H. Bacteria

Measure the number of bacteria from the permeate line weekly. Record the
results as colony forming units per m illiliter (CFU/ml). Sanitize as necessary.

I. If the maintenance log shows steady deteriorat ion in results (product flow,

percent rejection, etc.) cor r ect ive action should be taken. (Described in section

5.0 Troubleshooting.)

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25

MANOWNROSM

TROUBLESHOOTING

5. 0 TROUBLESHOOTING

5.1

5.2

CAUTION

SYSTEM INOPERATIVE
A. Check to see if power is available to the unit and turned on.

B. Check to see that the motor st arter relay is engaging, and if the control lights

come on but the pump does not start. With an ohm meter , check to see if the
motor starter coil is burned out. Reset the overload relay to determine if an
overload condition has caused the relay to disengage.

C. With a voltmet er check that power is being supplied to the motor . I f proper

voltage is going to the motor but it does not run, call US Filter Technical Support.

D. Check for proper function of the controller circuit board. Replace if necessary.
LOW SYSTEM PRESSURE

A. Verify the pump is running and the system is not in t he flush mode.
B. If pressure is low at system startup, st op system im m ediately and verify pump

rotation is clockwise.

Do not run pump backwards for more than 30 seconds or irreversible
damage will result.

C. Check to verify that the reject , reject recirculation, and product flows are normal.

If not, adjust to design flow rates using the System Specif icat ions sheet in the
Appendix.

5.3

5.4

D. If the flows cannot be adjusted to the desired flow rates, slowly close the pump

discharge throttle valve to observe the maximum discharge pr essure. Do this
only briefly and do not completely close the valve. The pressure should be
greater than 27.6 bar (400 psig).

E. If pump pressure is okay, check pr efilters for plugging/high differential pressure.
F. If the pump pressure is t oo low, repair or replace the pump. Check the

pump/motor coupling to be sure it is not slipping on the pump or the motor shaft.

LOW PERCENT RECOVERY
A. Check reject flows and pressures to be sure t hey are norm al.

B. If feed to membr ane pr essure equals system maximum and the permeate f low is

low, the RO membranes are beginning t o fail. They should be cleaned or
replaced.

HIGH PERCENT RECOVERY
A. Check pressures and flows.

B. Set the reject pressure to 13.8 bar ( 200 psig).

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27

TROUBLESHOOTING

C. If the permeate flow is high after adjusting the pr essur es and flows, the RO

membrane o-rings may be leaking. Check percent rejection and/or calcium
rejection.

MANOWNROSM

5.5

5.6

LOW SALT REJECTION
A. Check flows per the System Specifications sheet in t he Appendix, and adjust if

necessary.

B. Another possibility is high CO

permeates the membrane. High CO

content in the feedwater water. CO2 readily

2

content water will also have a pH of less

2

than 6.0.

C. Low temperatures can affect percent rejection.
D. RO membrane o-rings may not be seated corr ectly. Remove the membrane and

verify that the o-rings are seated corr ect ly.

E. RO membrane requires cleaning or r eplacem ent.
LOW CALCIUM REJECTION

A. Check flows per the System Specifications sheet in t he Appendix and adjust if

necessary.

B. Low temperature can also affect t he calcium r ejection.
C. RO membrane o-rings may not be seated corr ectly. Remove membrane and

verify that the o-rings are in good condit ion and seat ed cor r ect ly.

D. The RO membrane requir es cleaning or replacement.

5.7

5.8

SYSTEM KEEPS SHUTTING OFF
A. Observe the control box lights to see if t hey indicate t he cause for system

shutdown.

B. Overload relay tripped. If the overload relay requires resetting fr equently check

the amperage draw of the pump. I f the amperage draw of the pump is high
check for pump damage or pum p pressure levels out of specifications.

C. If an optional sensor is being used (T ank Level, Pretreatment Inter lock), check to

verify the sensor is not shutting off the system.

D. If the controller itself is malfunctioning, r eplace the controller circuit board

module.

SYSTEM SHUTOFF, LOW PRESSURE
A. Check the differ ent ial pr essur e across sediment prefilters. I t should be less than

0.69 bar (10 psig).

B. Check the pump suction pressure. It should be greater than 0.69 bar (10 psig) .
C. Verify the low pressure switch is operating properly.

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MANOWNROSM

TROUBLESHOOTING

5.9

5.10

SYSTEM SHUTOFF, HIGH TEMPERATURE
A. Check permeate flow. Without permeate flow, water will heat up.

B. Check incoming water temperature.
C. The high temperature shut down is activated at 35°C ± 3°C (95°F ± 5°F).
D. The temperature thermist or is located in the feed conductivity probe. The probe

may be replaced if it is giving an erroneous tem per ature indication.

LOW PERMEATE FLOW RATE
A. Adjust the pump throttle valve to increase membr ane feed pressure. Do not

exceed 24.15 bar (350 psig).

B. Permeate piping should be of suf ficient I.D. to prevent back pr essur e on the

system.

C. For low temperature effect s, check permeate flow rate versus temperatur e cur ve

in the Appendix.

D. If adjusting the pum p t hr ottling valve does not improve permeate flow rate, t he

RO membranes are fouled and should be cleaned with an appropriate medium.
Depending on the type of fouling suspect ed, various regeneration/cleaning
solutions may be used. Consult your US Filter representative f or advice.

CAUTION

5.11

5.12

Certain solutions, especially those containing chl ori ne or bromi ne, can
permanently damage the membranes.

MOTOR OVERLOAD SHUTDOWN
A. Motor overload shutdown is caused by excessive amp draw. An overload relay

is provided with the motor magnetic starter t o shut the system down if it runs
above the service factor amp rating of the motor.

(Service Factor amp = full load amps x service factor)

B. Check flows per the System Specifications sheet in t he Appendix, and adjust if

necessary. Running pump beyond the rated flow capacities can cause deviation
in amp draw.

C. Perform an insulation resistance test following the procedure in the Pump

Installation and Operating Instruct ions Manual in the Appendix of t h is m anual. If

the ohm values are less than 20 megohm replace the mot or leads.

D. Liquid end of pump may be damaged or binding.
CONTROLLER MALFUNCTION

The control box may be changed out in its entirety, if necessary, or the controller board
may be replaced independently.

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WARRANTY

6. 0 WARRANTY

6.1

GENERAL LIMITED WARRANTY

United States Filter Corporation ("U SF") warrants the products manufactured by it
against defects in materials and workmanship when used in accordance with the
applicable instructions for a period of one year from the date of shipment of the
products. USF MAKES NO OTHER WARRANTY, EXPRESSED OR IMPLIED.
THERE IS NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE. The warranty provided herein and the data,
specifications and descriptions of USF products appearing in USF’s publi shed
catalogs and product literature may not be al ter ed ex cept by express wri tten
agreement signed by an officer of USF. Representations, oral or written, which are
inconsistent with this w arr anty or such publications are not authoriz ed and i f gi v en,
should not be relied upon.

In the event of a breach of the foregoing warranty, USF’ s sol e obli g ati on shall be to
repair or replace, at its option, any pr oduct or par t ther eof that prov es defectiv e i n
materials or workmanship within the warranty per i od, pr ov i ded the customer
notifies their US Filter representative dealer promptly of any such defect. The
exclusive remedy pr ov i ded her ei n shall not be deemed to have failed of its
essential purpose so long as USF is willing and able to repair or replace any
nonconforming USF product or part. USF shall not be li abl e for consequenti al
damages resulting from economic loss or pr operty damages sustained by a
customer from the use of its products.

6.2

WATER SYSTEM LIMITED WARRANTY

United States Filter Corporation (“ USF” ) warrants the water systems manufactured
by it, BUT EXCLUDING MEMBRANES AND CARTRIDGES, against defects in
materials and workmanship w hen used i n accor dance with the applicable
instructions and within the operating condi ti ons specified for the sy stems for a
period of one year from the earlier of: (i) the date of instal lati on; or ( ii ) 120 days
following the date of shipment. USF MAKES NO OTHER WARRANTY,
EXPRESSED OR IMPLIED. THERE IS NO WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. The
warranty prov i ded herei n and the data, speci fications and descr i ptions of USF
systems appearing in USF’s publi shed catal og s and pr oduct l iter atur e may not be
altered except by expr ess written agreement signed by an officer of USF.
Representations, oral or wri tten, which are inconsistent with thi s warranty or such
publications are not authorized and i f gi v en, shoul d not be r eli ed upon.

In the event of a breach of the foregoing warranty , U SF’ s sole obl i g ation shal l be to
repair or replace, at its option, any pr oduct or par t ther eof that prov es defectiv e i n
materials or workmanship within the warranty per i od, pr ov i ded the customer
notifies their US Filter representativ e pr omptl y of any such defect. The cost of
labor for the first ninety (90) day s of the above warranty period is incl uded i n the
warranty; thereafter, labor costs shal l be at the customer’ s expense. The exclusive

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31

WARRANTY

remedy provided herei n shall not be deemed to have failed of its essential purpose
so long as USF is willing and able to repair or replace any nonconforming USF
system or component part thereof. USF shall not be liable for conseq uenti al
damages resulting from economic loss or pr oper ty damages sustained by any
customer from the use of its process systems.

Products or components manufactured by companies other than USF or its
affiliates (“Non-USF Products”) are covered by the Warranty, if any, extended by
the Product manufacturer. USF hereby assigns to the purchaser any such
warranty: however, USF EXPRESSLY DISC LAIMS AN Y WARRANTY,
WHETHER EXPRESSED OR IMPLIED, THAT THE NON-USF PRODUCTS ARE
MERCHANTABLE OR FIT FOR A PARTICULAR PURPOSE.

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MANOWNROSM

APPENDIX

7. 0 APPENDIX

GLOSSARY OF TERMS

The terms commonly used in reverse osmosis are def ined below:

++

--

3

ANION - Negatively charged ion, such as CO
CATION - Positively charged ion, such as Ca
CONCENTRATE (REJECT) - Concentrated portion of the feed remaining outside the

membrane which is discarded.
CONDUCTIVITY - A measure of salt concent r a t ion due t o t he ability of dissolved solids (ions) to

conduct electricity, usually expressed as micromhos/cm.

CONVERSION - Percent of feedwater converted into permeate.
FEED - The feedwater pumped into a permeat or under high pressure.
OSMOSIS - Osmosis is the diffusion of a solvent (s uch as pur e water) from a dilute saline

solution into a more concentrated saline solution through a semipermeable membrane
separating the two solutions.

OSMOTIC EQUALIZATION - Osmotic equalization is reached when no further water transport
takes place due to equalization of the solute concentration on both sides of the mem br ane.

OSMOTIC HEAD - Osmotic head (pressure) is the chang e in head r esult ing from water
transport through the sem iperm eable membrane separating two saline solutions of different
concentrations.

PASSAGE - Ratio of permeate to feed concentration of a particular dissolved mat er ial,
expressed in percent.

PERMEATE (PRODUCT) - The purified portion of t he feed passing through the mem br ane.
REVERSE OSMOSIS (RO) - The process by which incoming fluid (feed) is f orced under high

pressure through a RO membr ane. A por tion of the fluid with concentrated ionic mat er ials
(concentrate) remains upstream of the membrane and is discarded (unless it is of interest in a
particular application). The highly purified portion (permeate) which passed throug h the
membrane would then be collected for use (as in a water purification application).

, SO

--

, HCO

4

--

, Cl-, NO

3

3

, Mg++, Fe++, Na+, K+, etc.

-

, etc.

REVERSE OSMOSIS (RO) M EMBRANE - An RO membrane is a semipermeable membrane
generally in sheet or hollow fiber form which reje ct s not only dissolved mater ials, but also
organics, submicron size colloidal materials and bacteria which may contaminate a high purity
water system. The process is not absolute and therefore most RO membranes are defined by
their rejection characteristics.

SOLUTE - Material (salts) dissolved by solvent (water).
TOTAL DISSOLVED SOLIDS - Tota l dissolved inorgani c salts present in the permeator

streams.

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