Installation, Operation
and Maintenance Manual
Commercial Reverse Osmosis Systems
Series PWR4021
PURE WATER
!
CAUTION: Please read the entire manual before proceeding with the installation and startup. Your failure to follow any
attached instructions or operating parameters may lead to the
product’s failure, which can cause property damage and/or
personal injury.
• Do not use where the water is microbiologically unsafe.
• Pretreatment must be sufficient to eliminate chemicals that
would attack the membrane materials.
• Always turn off the unit, shut off the feed water, and discon-
nect the electrical power when working on the unit.
• Never allow the pump to run dry.
• Never start the pump with the reject valve closed.
• Never allow the unit to freeze or operate with a feed water
temperature above 100°F.
Save manual for future reference.
Please refer to Section 6 of this manual for operating parameters
according to your specific feed water Silt Density Index (SDI). For all
other settings according to your specific feed water quality, please
contact your Watts representative. A chemical analysis of the feed
water should be conducted prior to the initial sizing and selection of
this system.
Notes
Changes in operating variables are beyond the control of Watts. The
end user is responsible for the safe operation of this equipment.
The suitability of the product water for any specific application is the
responsibility of the end user.
Successful long-term performance of an RO system depends on
proper operation and maintenance of the system. This includes
the initial system startup and operational startups and shutdowns.
Prevention of fouling or scaling of the membranes is not only a matter of system design, but also a matter of proper operation. Record
keeping and data normalization are required in order to know the
actual system performance and to enable corrective measures when
necessary. Complete and accurate records are also required in case
of a system performance warranty claim.
Changes in the operating parameters of an RO system can be
caused by changes in the feed water or can be a sign of trouble.
Maintaining an operation and maintenance log is crucial in diagnosing and preventing system problems. For your reference, a typical log
sheet is included in this manual.
Table Of Contents
I. Introduction
A. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. RO Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. Pre-treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
II. Controls, Indicators, and Components
A. General System Component Identification – Figure #1 . . . . . . 3
B. Controller Drawing – Figure #2 . . . . . . . . . . . . . . . . . . . . . . . . 4
III. Operation
A. Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
B. Plumbing Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
C. Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
D. Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
E. Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F. Operation and Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 10
G. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13
IV. Replacement Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
V. Membrane Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
VI. Appendix
Flow Rate Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Temperature Correction Factors . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
IOM-WQ-PWR4021
Series PWR4021
Note: Do not use with water that is microbiologically unsafe or
of unknown quality without adequate disinfection before or after
the system.
I. Introduction
The separation of dissolved solids and water using RO membranes
is a pressure driven temperature dependent process. The membrane
material is designed to be as permeable to water as possible while
maintaining the ability to reject dissolved solids.
The main system design parameters require the following:
• Internal flows across the membrane surface must be high enough
to prevent settling of fine suspended solids on the membrane
surface.
• The concentration of each dissolved ionic species must not exceed
the limits of solubility anywhere in the system.
• Pre-treatment must be sufficient to eliminate chemicals that would
attack the membrane materials.
A. Specifications
PWR40213023 PWR40213033 PWR40213043 PWR40213053 PWR40213063
Productivity (gallons per day / gallons per minute) Maximum production based on standard
membranes and feed water of 25°C, SDI < 3, 1000 ppm TDS, and pH 8. Individual membrane
productivity may vary (± 15%).
Quality (typical membrane percent rejection) Based on membrane manufactures
specifications, overall system percent rejection may be less.
Recovery without reject recycle 29 % 39 % 50 % 57 % 62 %
Recovery with reject recycle (adjustable) 50 % 50 % 75 % 75 % 75 %
Membrane Size 4 x 40 4 x 40 4 x 40 4 x 40 4 x 40
Number Of Membranes Per Vessel 1 1 1 1 1
Pressure Vessel Array 1:1 1:1:1 1:1:1:1 1:1:1:1:1 1:1:1:1:1:1
Number Of Membranes 2 3 4 5 6
Prefilter (system ships with one 5 micron cartridge) 20" BB 20" BB 20" BB 20" BB 20" BB
Feed Water Connection 1" NPT 1" NPT 1" NPT 1" NPT 1" NPT
Product Water Connection
Reject Water Connection
Feed Water Required (feed water required will be less if reject recycle is used) 9 gpm 10 gpm 10 gpm 12 gpm 13 gpm
Feed Water Pressure (minimum) 20psi 20psi 20psi 20psi 20psi
Drain Required 9 gpm 10 gpm 10 gpm 12 gpm 12 gpm
Electrical Requirement 230 VAC, 3-ph, 60 Hz (other voltages available) 15 amps 15 amps 15 amps 15 amps 15 amps
TEFC Motor (horse power) 5 5 5 5 5
Dimensions L x W x H (inches) 60 x 18 x 56 60 x 18 x 56 60 x 18 x 56 60 x 18 x 56 60 x 18 x 56
Shipping Weight (estimated pounds) 400 500 600 700 800
3600 / 2.5 5400 / 3.75 7200 / 5.0 9000 / 6.25 10800 / 7.5
98 % 98 % 98 % 98 % 98 %
3
⁄4" NPT
3
⁄4" NPT
3
⁄4" NPT
3
⁄4" NPT
3
⁄4" NPT
3
⁄4" NPT
3
⁄4" NPT
3
⁄4" NPT
3
⁄4" NPT
3
⁄4" NPT
B. RO Overview
Reverse osmosis systems utilize semipermeable membrane elements to separate the feed water into two streams. The pressurized
feed water is separated into purified (product) water and concentrate
(reject) water. The impurities contained in the feed water are carried
to drain by the reject water. It is critical to maintain adequate reject
flow in order to prevent membrane scaling and/or fouling.
RO Membrane
Feed Water Product Water
Reject Water
2
C. Pretreatment
The RO feed water must be pretreated in order to prevent membrane damage and/or fouling. Proper pretreatment is essential for
reliable operation of any RO system.
Pretreatment requirements vary depending on the nature of the feed
water. Pretreatment equipment is sold separately. The most common
forms of pretreatment are described below.
Media Filter - Used to remove large suspended solids (sediment)
from the feed water. Backwashing the media removes the trapped
particles. Backwash can be initiated by time or differential pressure.
Water Softener - Used to remove calcium and magnesium from
the feed water in order to prevent hardness scaling. The potential
for hardness scaling is predicted by the Langelier Saturation Index
(LSI). The LSI should be zero or negative throughout the unit unless
approved anti-scalents are used. Softening is the preferred method
of controlling hardness scale.
Carbon Filter - Used to remove chlorine and organics from the
feed water. Free chlorine will cause rapid irreversible damage to the
membranes.
The residual free chlorine present in most municipal water supplies
will damage the thin film composite structure of the membranes
used in this unit. Carbon filtration or sodium bisulfite injection should
be used to completely remove the free chlorine residual.
Chemical Injection - Typically used to feed antiscalant, coagulant,
or bisulfite into the feed water or to adjust the feed water pH.
Prefilter Cartridge - Used to remove smaller suspended solids and
trap any particles that may be generated by the other pretreatment.
The cartridge(s) should be replaced when the pressure drop across
the housing increases 5 - 10 psig over the clean cartridge pressure
drop. The effect of suspended solids is measured by the silt density
index (SDI) test. An SDI of five (5) or less is specified by most membrane manufacturers and three (3) or less is recommended.
Iron & Manganese - Iron should be removed to less than 0.1 ppm.
Manganese should be removed to less than 0.05 ppm. Special media filters and/or chemical treatment is commonly used.
pH - The pH is often lowered to reduce the scaling potential.
Silica: Reported on the analysis as SiO2. Silica forms a coating on
membrane surfaces when the concentration exceeds its solubility.
Additionally, the solubility is highly pH and temperature dependent.
Silica fouling can be prevented with chemical injection and/or reducing the recovery.
II. Controls, Indicators, and
Components
A. General System Component Identification
A Controller - Controls the operation of the system and displays
the product water quality. This system uses the micro-electronic
based CI-1000 controller.
B Reject Control Valve - Controls the amount of reject flow. A
separate reject recycle water control valve is included to regulate
waste water recovery.
C Pump Discharge Valve - Used to throttle the pump.
D Prefilter Pressure Gauges - Indicates the inlet and outlet pres-
sure of the prefilter. The difference between these two gauges is
the prefilter differential pressure.
E Pump Discharge Pressure Gauge - Indicates the pump dis-
charge pressure.
F Reject Pressure Gauge - Indicates the reject pressure.
G Reject Flow Meter - Indicates the reject flow rate in gallons per
minute (gpm). A reject recycle flow meter is also included.
H Product Flow Meter - Indicates the product flow rate in gallons
per minute (gpm).
I Prefilter Housing - Contains the RO prefilter.
J Automatic Inlet Valve - Opens when pump is on and closes
when the pump is off.
K Low-pressure Switch - Sends a signal to the controller if the
pump suction pressure is low.
L RO Feed Pump - Pressurizes the RO feed water.
M RO Membrane Vessels - Contains the RO membranes.
(See Figure 1)
Separate motor starter
enclosure used only with
CI 1000 controller.
Figure 1
Figure 1
3
B. Controller Drawing
Figure 2
CI-1000 Controller
4
III.Operation
A. Installation
1. The water supply should be sufficient to provide a minimum of
20 psig pressure at the design feed flow.
2. Proper pretreatment must be determined and installed prior to
the RO system.
3. A fused high voltage disconnect switch located within 10 feet of
the unit is recommended. This disconnect is not provided with
the RO system.
4. Responsibility for meeting local electrical and plumbing codes
lies with the owner /operator.
5. Install indoors in an area protected from freezing. Space allowances for the removal of the membranes from the pressure
vessels should be provided. This system requires 42" minimum
clear space on each side.
B. Plumbing Connections
Note: It is the responsibility of the end user to ensure that the
installation is done according to local codes and regulations.
1. Connect the pretreated feed water line to the inlet side of the
prefilter housing. (Figure # 1 item # 1) A feed water shutoff valve
should be located within 10 feet of the system.
2. Temporarily connect the outlet of the product water flow meter
to drain. (Figure # 1 item # 2) The product water line should
never be restricted. Membrane and/or system damage may occur if the product line is blocked.
3. Connect the outlet of the reject water flow meter to a drain. (Figure # 1 item # 3) The reject drain line should never be restricted.
Membrane and/or system damage may occur if the reject drain
line is blocked. An air gap must be located between the end
of the drain line and the drain. The use of a standpipe or other
open drain satisfies most state and local codes and allows for
visual inspection and sampling.
C. Electrical
Note: It is the responsibility of the end user to ensure that the
installation is done according to local codes and regulations.
1. A safety switch or fused disconnect should be installed within 10
feet of the system.
2. Verify that the disconnect switch is de-energized using a voltmeter.
3. Connect the outlet of the disconnect switch to the terminals on
top of the motor starter (Figure # 2). Attach the power supply
ground to the chassis ground. It may be necessary to drill a hole
in the enclosure and install a water tight strain relief or conduit
connector. The hole size and location must be determined by
the installer. Check the pump motor nameplate for the amperage draw at various voltages to determine the wire size required.
4. Do not apply power to the RO unit at this time.
D. Startup
1. Verify that the pretreatment equipment is installed and working
properly. Verify that no free chlorine is present in the feed water.
2. Verify that the on/off switch is in the off position.
3. Verify that the pump discharge valve (Figure # 1 item C) is open.
4. Install a 20" five micron filter cartridge in the prefilter housing.
(Figure #1 item I)
5. Open the reject control valve completely (Figure # 1 item B) by
turning it counterclockwise.
Close the reject recycle control valve completely if the reject
recycle option is included.
6. Open the feed water shutoff valve installed in step III-B-1 above.
7. Manually open the inlet solenoid valve (figure #1 item J) by turning the white lever located near the valve outlet.
8. Water will flow through the system and to drain through the
reject flow meter (figure # 1 item G).
9. Manually close the inlet solenoid valve after the air has been
purged from the system, or after 10 minutes, whichever occurs
first.
10. Close the pump discharge valve half way. (Figure # 1 item C)
11. Engage the safety switch or disconnect (installed in step III-C-1
above) to apply electrical power to the RO system.
12. On the CI-1000 controller, put the key switch in the on position
and press the start / stop button to turn the pump on. Press
the start / stop button again when the pump turns on to turn
the pump off and look at the motor fan as the pump stops to
determine if the pump rotation is correct. There is a 10 second
delay before the pump starts. See the controller section for more
details. The fan should rotate in the direction of the rotation
arrow located on the pump. Continue with the startup if the
pump is rotating in the proper direction. If the pump is rotating
backwards, change the rotation by disconnecting the power and
reversing any two of the wires on the power inlet. Verify proper
pump rotation before continuing.
13. Turn the system on.
14. Adjust the reject control valve(s) (figure # 1 item B) and the pump
discharge valve (Figure # 1 item C) until the desired flows are
achieved. Closing the reject valve increases the product flow and
decreases the reject flow. Opening the pump discharge valve
increases both the reject flow and the product flow. See the flow
rate guidelines and temperature correction table in the appendix
to determine the flow rates for different operating temperatures.
15. Allow the product water to flow to drain for 30 minutes.
16. Turn off the system and connect the product line to the point of
use. (Figure # 1 item # 2) The product water line should never be
restricted. Membrane and/or system damage may occur if the
product line is blocked.
17. Restart the system and record the initial operating data using the
log sheet in the next section.
Note: See the controller section of this manual for more
installation and operation information
5
Note: It is very important to vent the mechanical seal
during startup. Failure to vent the seal may result in
premature seal failure.
Vented
Priming
Plug
Drain
Plug
Back off needle
valve to vent air.
Retighten to 25 in.lbs. when vent port
runs a steady stream
of water.
E. Controllers
The controller for this system is the CI 1000 controller. This is a
microprocessor-based controller with a product water conductivity
meter. A separate manual for this controller begins on the next page.
6
Reverse Osmosis Controller
Operations and Maintenance Model #CI-1000
Introduction
The CI-1000 Reverse Osmosis Controller is designed to control and
monitor the operating parameters of a reverse osmosis water purification system. Information is displayed on a back-lit liquid crystal
display, and on individual light-emitting diodes (LEDs). Functions and
controls are operated through snap-dome switches (see Figure 2).
Features
Temperature Compensated Conductivity Monitor
Water Temperature Monitor
Three Modes of Operation: Stand-by, Tank Feed, and Direct Feed
Pretreatment Interlock
Tank Full Shutdown
Inlet Valve Control
Pump Control
Low Feed Pressure Sensing with Automatic Reset
Autoflush with Adjustable Flush Time
Diverter Valve Output
Specifications
Power Requirements: The controller can operate with a power
source of 115 or 230 VAC single phase. A multi-function power inlet
is used to select the proper input voltage.
Fuse: 1 amp 250 volt slow blow, located inside the power inlet
receptacle.
Environment: The controller can operate at a temperature from 0° to
60° C (32° to 140°F). Relative humidity must not exceed 95 percent.
Conductivity Monitor: The conductivity monitor measures the product water quality and displays this information in micro-mhos/cm.
The display is temperature compensated to 25°C (770°F).
Outputs
Inlet Solenoid: A 24 VAC output is provided to power the inlet
solenoid. This output always energizes 12 seconds before the pump
turns on, and de-energizes 12 seconds after the pump turns off.
Flush Valve: A 24 VAC output is provided to power the optional
reject solenoid valve. This output will energize during the flush cycle.
This is an optional accessory.
Motor Starter: A 24 VAC output is included to provide controlled
pump operation. This output powers the coil of the magnetic starter
relay. This output is energized depending on other operating parameters.
Auxiliary Output: A 24 VAC output that energizes under certain conditions, depending upon the mode selected for it in the configuration.
This output is intended to power a relay or some other low current
device. The maximum current available is one ampere. Two modes
are selectable for this output:
Diverter: Output energizes when the product quality is below
the set point. The diverter valve is not included with the system.
Alarm: Output energizes for final detection of low-pressure
conditions and low water quality conditions. No alarm hardware
is included with the system.
Inputs
WARNING: All the inputs described below are dry contacts.
Do not apply voltage to these contacts or permanent damage
to the controller will result.
Conductivity Probe: There are four inputs for the conductivity
probe, two for the thermistor and two for the conductivity. Only
probes with a cell constant of 1.0 and a thermistor with a nominal
resistance value of 20K at 25' C will work with this controller.
Low-pressure Switch: This is a dry contact that signals the system
to shut down if the pump suction pressure falls below the desired
value. This is a normally open contact. When a circuit is not complete between the two terminals, the system will operate. If contact
is made between the two terminals, the system will shut down. The
LCD display and a LED will indicate when the system is shut down
due to low-pressure. The controller can be programmed to automatically restart. This is described in Section III, Operation.
Tank Level: This is a dry contact that signals the system to shut
down when the storage tank is full. This contact is normally closed.
When a circuit is complete between the two terminals the system will
operate. If contact is broken between the two terminals, the system
will shut down if it is operating in the tank feed mode. A LED will
indicate when the tank is full. The system will restart itself when the
contact is closed. The switch for this function in not provided with
the controller.
Pretreatment Interlock: This is a dry contact that signals the system
to shut down when a pretreatment device is not functioning, or regenerating. This could be used on a water softener, multi media filter,
chemical feed pump, differential pressure switch, etc. This contact is
normally open. When a circuit is not complete between the two terminals the system will operate. If the contact is= closed the system
will shut down. A LED will indicate when the system is shut down
due to pretreatment interlock. The system will restart itself when the
contact is opened.
Mode Descriptions
The stand-by mode is intended to place the system in a temporary
non-operational mode. When the system is placed in this mode it
will operate for the amount of time set for the flush cycle. If the flush
time is set for zero the system will operate for one minute. After this
cycle is complete the pump will turn off and the inlet valve will close.
The system will repeat this cycle once every hour. When the system
is flushing, the amount of time remaining in the flush cycle will be
indicated on the last line of the display. When the system is idle, the
amount of time remaining until the next flush will be indicated. When
the pump is running, the reject valve and diverter valve outputs are
energized.
The tank feed mode is intended to be used when the system is
feeding a storage tank. When in this mode the system will shut down
when the tank level switch (not provided) has an open contact. The
flush cycle is also enabled in this mode. If the autoflush option has
been included on the system, the controller will activate the flush
cycle when the system is turned on and once every hour. When the
system is flushing, the amount of time remaining in the flush cycle will
be indicated on the last line of the display. When the system is not
flushing the amount of time until the next flush will be indicated. The
system will still flush every hour even if the tank is full. During a full
tank condition the system is essentially in standby. When the system
is flushing, the diverter valve output is energized. If the flush time is
set for zero the system will not flush when the tank is full.
The direct feed mode is intended to be used when the system is
feeding a distribution loop or another piece of equipment. In this
mode the system will not flush and the tank level switch is disregarded. When the system is in this mode, the total number of hours
the system has been operated will be indicated on the last line of the
display.
7
Controls (see Figure 2)
NOTE: Refer to Section III, Operation for detailed instructions
on operating the controls .
Start / Stop Button: This button turns the system on and off.
Select Button: This button is used to select a function or parameter
so that it can be reviewed or changed.
Up Arrow. This button increases the value of, or advances to the
next option of, the function selected.
Down Arrow. This button decreases the value of, or advances to the
next option of, the function selected.
Accept Button: Pressing this button causes the controller to store
current values or options in memory.
Alarm Reset Button: This button is used to reset the system after a
shut down due to; low-pressure or overload.
Key Switch: This switch which serves as a master power switch.
When the system is turned on the key may not be removed. If the
system is turned off the key may be removed.
Indicators (see Figure 2)
Multi Function Display: This is a back-lit liquid crystal display. It
provides information to the operator regarding water quality, system
options, etc.
There are six individual LED's to indicate the following conditions:
(See Front View drawing)
On: Indicates when the system is on.
Overload: Indicates that the system has shut down due to an over-
load condition on one of the outputs.
Low Quality: Indicates that the quality of the water is below the
setpoint.
Tank Full: Indicates when the system is shut down due to a full storage tank. The system will only shut down in the tank feed mode
Pretreatment Interlock: Indicates when the system is shut down
due to external pretreatment equipment.
Low-pressure: Indicates that the system has shut down due to low
pump feed pressure.
Configuration Screen
Press the SELECT button to view the configuration screen. The
software revision level is displayed in the upper right corner of this
screen. While the configuration screen is displayed, the SELECT
button moves the highlight cursor to the next field. The up and down
arrows change the value of the highlighted field. The ACCEPT button
saves all of the values and brings up the timer screen. The RESET
button discards all changes and brings up the timer screen. If no
input is detected for a continuous 30 seconds, the controller will
discard all changes and return to the operation screen. An asterisk
appears next to a field whenever the value of the field equals the
value stored in memory. The configuration screen contains the following field with their options:
Mode: (direct feed, tank feed, and standby)
Low Quality: (2-200 micromhos) This is the set point for the diverter
valve. When the product water conductivity is equal to or greater
than value selected, the diverter valve output will be energized and
the low quality LED will turn on.
Autostart: (on/off) if “on” is selected, the system will automatically
restart after a power loss. If "off" is selected, the unit will not restart
after a power loss.
Low-pressure Retry: (0-10) This is the number of times the system
will attempt to restart after a low-pressure shutdown.
Low-pressure Delay: (15-90 seconds in 15 second increments)
This is the amount of time between attempts to restart after a lowpressure shutdown.
Autoflush: (0-10 minutes) This is the length of the flush cycle. The
system will flush for this amount of time every hour in tank feed and
standby modes.
Inlet Delay Time: (10,30,60,120,300,600 seconds) This is the
amount of time that the inlet valve stays open after the pump turns
off.
Auxiliary Output Mode: This selects whether the auxiliary output
should be used for a diverter valve (default) or an alarm output.
Noted in the configuration menu as “Aux. Out”
Low Water Quality Alarm Delay: (0,5,10,30,60, 120,300,600 seconds) This selects the delay between the detection of a low quality
water condition and the activation of the auxiliary output. This only
applies if the auxiliary output is configured as an alarm output. Noted
in the menu as “L/Q Alarm Delay”
Operation
The key switch must be in the ON position (see Figure 2).
Contrast Adjustment
Press the up or down arrow when the home screen is displayed to
increase or decrease the contrast of the display.
Operation Screen
When the Start/Stop button is pressed the inlet valve will open.
After a 12 second delay the pump will start. The system will operate
according to the information stored in memory. The product water
conductivity is displayed in the large numbers at the top center of the
display. The temperature is displayed as degrees Celsius in the top
right corner of the display. The mode of operation is displayed below
the product water quality. Flush time information or pump run hours
are displayed on the bottom of the display.
Timer Screen
Pressing either the ACCEPT or the RESET button from the configuration screen brings up the timer screen. The controller has three
timers (hour meters). Two are user resetable and one is not. All of
these timers count up when the pump is running. The two user resetable meters are labeled PREFILTER and MEMBRANE. Pressing the
reset button when either of these timers are highlighted will reset the
timer to zero. The SELECT button moves the highlight cursor to the
next timer. Press Accept while the membrane meter is highlighted to
exit and return to the operation screen.
Calibration Screen
This screen is used to calibrate the conductivity and temperature.
Press ACCEPT and RESET at the same time to bring up this screen.
The temperature and conductivity fields on the last two lines of the
display can be adjusted using the up and down arrows. Use the
arrow keys to input the correct temperature and then press the
ACCEPT button. The conductivity will now be highlighted. Use the
arrow keys to input the correct conductivity and press the ACCEPT
button. Always calibrate the temperature first. (Note: the new values
are only saved when the ACCEPT button is pressed while the field is
highlighted.) When the desired values are entered press the RESET
button to return to the operation screen. You can only enter the calibration screen if the conductivity and temperature readings
8
Pop-Up Screens
Under certain circumstances a pop-up screen may be displayed.
These look like a window that partially blocks out the screen behind
it. The conditions that display pop-up screens are:
Low Inlet Pressure
Pretreatment Interlock
Overload Conditions
Trying to calibrate if the temperature and/or conductivity is not stable.
Service and Maintenance
The CI-1000 Reverse Osmosis Controller is designed for ease of
maintenance and minimum service. Since the highest quality of
electronic semiconductor components are used in this design, it
is not likely that circuit malfunctions or failures will occur. It is our
recommendation that service be limited to identifying malfunctions at
the board level and that component level troubleshooting be referred
to the factory.
Field failures that most frequently occur are:
- Improper or broken wiring connections
- Incorrect wiring of the motor starter
- Improper grounding
- Cable run is too long
- Water in connectors
- Dirty probes
- Defective probes
Troubleshooting
DESCRIPTION OF PROBLEM POSSIBLE CAUSE OR SOLUTION
System shuts down on low-pressure but pressure is okay. 1. Check the pressure switch set point
Pressing the Start/Stop button does not turn the system on. 1. Verify that the key switch is on
Conductivity monitor does not display the proper reading. 1. Calibrate the controller
Erratic conductivity display 1. Conductivity probe wiring may be too close to high voltage lines.
2. Possible short in wiring to pressure switch
3. Defective pressure switch
4. Orifice in pressure switch may be plugged
2. Verify that the circular connector on the bottom of the controller is attached
3. Check the fuse in the power inlet
2. Check the wiring to the conductivity probe
3. Clean the conductivity probe
4. Replace the conductivity probe
2. Check for moisture in the connection between the probe and the lead wire.
9
REMARKS
PRE FILTER
PRE FILTER
FEED WATER
FEED WATER
FEED WATER
OUTLET
PRESSURE
INLET PRESSURE
CHLORINE LEVEL
HARDNESS
TEMP
PPM
FEED TDS PPM PRODUCT TDS
REJECT
PRESSURE
PRESSURE
DISCHARGE
REJECT GPM PUMP
GPM
DATE PRODUCT
F. PWR4021 Operation and Maintenance Log
10
Note: Change the prefilter when the differential pressure increases by 5 - 10 psi over the clean differential pressure.
Clean the RO membrane(s) when the product flow drops by 15% or more. (See appendix)
G. PWR4021 Troubleshooting
RO Membrane Troubleshooting Guide
SYMPTOMS
SALT PASSAGE PERMEATE FLOW PRESSURE DROP LOCATION POSSIBLE CAUSES VERIFICATION CORRECTIVE ACTION
Normal to increased Decreased Normal to increased Predominantly
first stage
Normal to increased Decreased Normal to increased Predominantly
first stage
Increased Decreased Increased Predominantly
last stage
Normal to moderate
increase
Decreased or mod-
Decreased Normal to moderate
increase
Can occur in any
stage
Decreased Normal All stages Organic fouling Destructive testing, e.g. IR
erately increased
Increased Increased Decreased Most severe in
the first stage
Increased Increased Decreased Most severe in
the first stage
Increased Normal to increased Decreased At random O-ring leaks, End or side
Increased Normal to low Decreased All stages Conversion too high. Check flows and pressures
Metal oxide Analysis of metal ions in
cleaning solution.
Colloidal fouling SDI measurement of feed/
X-ray diffraction analysis of
cleaning sol. residue.
Scaling (CaSO
4, SiO2)
BaSO
4, CaSO3,
Analysis of metal ions in
cleaning sol. Check LSI of
reject. Calculate maximum
solubility for CaSO
2 in reject analysis.
SiO
4, BaSO4,
Biological fouling Bacteria count in permeate
and reject. Slime in pipes
and vessels.
reflection analysis.
Chlorine oxidant attack Chlorine analysis of feed.
Destructive element test.
Abrasion of membrane by
crystalline material
Microscopic solids analysis
of feed. Destructive element test.
Probe test. Vacuum test.
seal glue leaks.
Colloidal material passage.
against design guidelines
Improved pretreatment to remove metals. Cleaning with acid cleaners.
Optimize pretreatment system for
colloid removal. Clean with high pH,
anionic detergent formulation.
Increase acid addition and scale
inhibitor for CaSO
3 and CaSO4. Reduce
recovery. Clean with an acid formulation for CaCO
3, CaSO4 and BaSO4.
Shock dosage of sodium bisulfite.
Continuous feed of low conc. bisulfite
at reduced pH. Peracetic acid sterilization. Clean with alkaline anionic surfactant. Chlorine dosage upstream with
dechlorination. Replace cartridge filters.
Optimization of pretreatment system
(e.g. coagulation process.) Resin/
activated carbon treatment. Clean with
high pH detergent.
Check chlorine feed equipment and
dechlorination equipment.
Improved pretreatment. Check all filters
for media leakage.
Replace O-rings. Repair or replace
elements.
Reduce conversion rate. Calibrate
sensors. Increase analysis and data
collection.
11
Motor Troubleshooting Chart
PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION
Motor fails to start Blown fuses Replace fuses with proper type and rating
Overload trips Check and rest overload in starter.
Improper power supply Check to see that power supplied agrees with motor nameplate and load factor.
Open circuit in winding or control switch Indicated by humming sound when switch is closed.
Mechanical failure Check to see if motor and drive turn freely. Check bearing and lubrication.
Short circuited stator Indicated by blown fuses. Motor must be rewound.
Poor stator coil connection Remove end bells, locate with test lamp.
Rotor defective Look for broken bars or end ring.
Motor may be overloaded Reduce load.
Motor Stalls One phase connection Check lines for open phase.
Wrong application Change type or size. Consult manufacturer.
Overload motor Reduce load.
Low motor voltage See that nameplate voltage is maintained. Check connection.
Open circuit Fuses blown, check overload relay, stator and push buttons.
Motor runs and then dies down Power failure Check for loose connections to line, to fuses and to control.
Motor does not come up to speed Not applied properly Consult supplier for proper type.
Voltage too low at motor terminals because of line drop. Use higher voltage on transformer terminals or reduce load. Check connections. Check
Broken rotor bars or loose rotor. Look for cracks near the rings. A new rotor may be required as repairs are usually temporary.
Motor takes too long to accelerate Open primary circuit Locate fault with testing device and repair.
Excess loading Reduce load.
Poor circuit Check for high resistance.
Defective squirrel cage rotor Replace with new rotor.
Applied voltage too low Get power company to increase power tap.
Wrong rotation Wrong sequence of phases Reverse connections at motor or at switchboard.
Motor overheats while running
under load
Motor vibrates after correcting
have been made
Unbalanced line current on
polyphase motors during normal
operation
Scraping noise Fan rubbing air shield Remove interference.
Noisy operation Airgap not uniform Check and correct bracket fits or bearing.
Hot bearings general Bent or sprung shaft Straighten or replace shaft.
Hot bearings ball Insufficient grease Maintain proper quantity of grease in bearing.
These instructions do not cover all details or variations in equipment nor provide for every possible condition to be
met in connection with installation, operation or maintenance. Chart courtesy of Marathon Electric.
Overloaded Reduce load.
Frame or bracket vents may be clogged with dirt and
prevent proper ventilation of motor.
Motor may have one phase open Check to make sure that all leads are well connected.
Grounded could Locate and repair.
Unbalanced terminal voltage Check for faulty leads, connections and transformers.
Motor misaligned Realign
Weak support Strengthen base.
Coupling out of balance Balance coupling.
Driven equipment unbalanced Rebalance driven equipment.
Defective ball bearing Replace bearing.
Bearing not in line Line properly.
Balancing weights shifted Rebalance motor.
Polyphase motor running single phase Check for open circuit.
Excessive end play Adjust bearing or add washer.
Unequal terminal volts Check leads and connections
Single phase operation Check for open contacts
Fan striking insulation Clear fan.
Loose on bedplate Tighten holding bolts.
Rotor unbalance Rebalance.
Excessive belt pull Decrease belt tension.
Pulleys too far away Move pulley closer to motor bearing.
Pulley diameter too small Use larger pulleys.
Misalignment Correct by realignment of drive.
Deterioration of grease, or lubricant contaminated Remove old grease, wash bearings thoroughly in kerosene and replace with new grease.
Excess lubricant Reduce quantity of grease: bearing should not be more than ½ filled.
Overloaded bearing Check alignment, side and end thrust.
Broken ball or rough races Replace bearing: first clean housing thoroughly.
conductors for proper size.
Open vent holes and check for a continuous stream of air from the motor.
12
RO System Troubleshooting
PROBLEM CORRECTIVE ACTION
General
High Product Water TDS
Membrane expanded. Replace membrane.
Membrane attack by chlorine Carbon pre-filter may be exhausted. Replace with a new cartridge.
Clogged pre-filter-creates pressure drop and low reject flow. Replace pre-filter cartridge.
Feed pressure too low. Feed pressure must be at least 20 psi.
Insufficiently flushed post-filter cartridge. Flush post-filter with pure water.
Brine seal on membrane leaks. Determine if seal or O-ring is bad. Replace as needed.
No Product Water or Not Enough Product Water
Feed water shut off. Turn on feed water.
Low feed pressure. Feed pressure must be at least 20 psi. Consider booster pump.
Pre-filter cartridge clogged. Replace pre-filter cartridge.
Membrane fouled. Determine and correct cause; replace membrane.
Product check valve stuck. Replace check valve fitting.
Low pump discharge pressure Open pump discharge valve, replace pump
Membrane fouled. Determine and correct cause; replace or clean membrane.
Product check valve stuck. Clean or replace check valve.
Low pump discharge pressure Adjust reject valve or replace pump
IV. Replacement Parts List
A list of common replacement parts is provided below. All of these
parts are not used on every system and all of the parts are not listed.
Contact you dealer for replacement parts assistance.
ITEM NUMBER DESCRIPTION
1 Pre filter housing 20" Big Blue
2 RO Membrane Pressure Vessels 4" x 40" SS
3 Pressure Gauge, 2", 0-100psi, Dry
4 Pressure Gauge, 2
5 Flow Meter 1-10 gpm (product)
6 Flow Meter 1-10 gpm (reject)
7 Motor Starter Contactor, 16 amps, 24 volt coil
8 Overload Relay 8 - 14 amps
9 Overload Relay 6 - 8.5 amps
10 Pump & Motor CR2-180U 5hp, 3-Phase
11 Low-pressure Switch, 6.5psi
12 Inlet Solenoid Valve, 1", 24 volt coil
13 Watts 4 x 40 RO Membranes
14 CI 1000 Controller
15 Conductivity Probe
16 Autoflush Solenoid Valve,
1
⁄2", 0-400psi, LF
1
⁄2", Brass, 24 volt coil.
V. Membrane Replacement
1. Turn off the system and close the feed water shutoff valve.
2. Disconnect the membrane feed hoses by loosing the brass fittings between the end of the hoses and the pressure vessel end
caps.
3. Remove the retaining “U” pins from the pressure vessels.
4. Push the old membrane out of the vessel in the direction of the
feed flow. (See flow arrows on the right side of figure #1)
5. Record the serial numbers of the new membranes.
6. Lightly lubricate the brine seals on the new membranes with
clean water.
7. Install the new membranes in the direction of flow with the brine
seal end going in last.
8. Lightly lubricate the end cap internal and external O-rings with
glycerin.
9. Install the end caps and secure them with the “U” pins.
10. Install the membrane feed hoses.
11. Verify that all retaining “U” pins are installed.
12. Follow the start up procedure in section III-D.
Flow Direction
13
Membrane
Brine
Seal
VI. Appendix
The following tables are intended as a guide to determining the flow
rates for the PWR4021 series RO systems. All flows are in gallons
per minute (GPM).
Nominal flows for systems with reject recycle and a feed water
Silt Density Index less than 3.
MODEL NUMBER PWR40213023 PWR40213033 PWR40213043 PWR40213053 PWR40213063
Product 2.5 3.75 5 6.25 7.5
Reject 2.5 3.75 1.7 2.1 2.5
Reject Recycle 3.6 2.2 3.3 2.6 2.1
Nominal flows for systems with reject recycle and a feed water
Silt Density Index of 3 to less than 5.
MODEL NUMBER PWR40213023 PWR40213033 PWR40213043 PWR40213053 PWR40213063
Product 2.3 3.5 4.3 5.2 6.3
Reject 2.3 3.5 1.4 1.7 2.1
Reject Recycle 4.3 3 3.9 3.1 2.3
Temperature Correction Factors
°C °F CORRECTION FACTOR
30 86 1.16
29 84.2 1.13
28 82.4 1.09
27 80.6 1.06
26 78.8 1.03
25 77 1.00
24 75.2 0.97
23 73.4 0.94
22 71.6 0.92
21 69.8 0.89
20 68 0.86
19 66.2 0.84
18 64.4 0.81
17 62.6 0.79
16 60.8 0.77
15 59 0.74
14 57.2 0.72
13 55.4 0.70
12 53.6 0.68
11 51.8 0.66
10 50 0.64
9 48.2 0.62
8 46.4 0.61
7 44.6 0.59
6 42.8 0.57
5 41 0.55
Multiply the nominal product flow at 25° C by the temperature correction factor to
determine the flow at various other temperatures.
14
CI-1000 Controller
15
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are the only remedies for breach of warranty. EXCEPT FOR THE APPLICABLE PRODUCT WARRANTY, IF ANY, WATTS MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED. TO THE FULLEST EXTENT
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THE POSSIBILITY OF SUCH DAMAGES.
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IOM-WQ-PWR4021 1105 EDP# 2915864 © 2011 Watts
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