Watts R14-06-1111000 User Manual

ALAMO WATER REFINERS

REVERSE OSMOSIS

INSTALLATION AND OPERATION MANUAL

R14-SERIES

Alamo Water Refiners, Inc.

13700 Hwy. 90 West

San Antonio, TX 78245

U.S.A. 210-677-8400

www.alamowater.com

IMPORTANT

Please read the entire manual before proceeding with the installation and startup:

 Do not use where the water is microbiologically unsafe.

 Always turn off the unit, shut off the feed water, and disconnect 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.

NOTES

Changes in operating variables are beyond the control Alamo Water Refiners, Inc. 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 a RO system depends on proper operation and maintenance of the system. This includes the initial system startup and operational startups and shutdowns. Preventing 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 is 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 a 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 B. Overview C. Pre-treatment

II. Controls, Indicators, and Components

A. Figure # 1 General System Drawing B. Figure # 2 Package One Controller Drawing C. Figure # 3 Package Two Controller Drawing

III. Operation

A. Installation B. Plumbing Connections C. Electrical Connections D. Startup E. Controllers F. Operation and Maintenance Log G. Trouble Shooting

IV. Replacement Parts List

V. Membrane Replacement

VI. Appendix

Flow Rate Guidelines

Temperature Correction Factors

Filmtec Technical Information - Cleaning and Disinfection of Filmtec RO Membranes

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

Productivity (Gallons per day / Gallons per mi nut e)

Maximum production based on standard m embranes 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

R14-02 R14-03 R14-04 R14-05 R14-06

3600 / 2.5 5400 / 3.75 7200 / 5.0 9000 / 6.25 10800 / 7.5

98 % 98 % 98 % 98 % 98 %

4 x 40 4 x 40 4 x 40 4 x 40 4 x 40

Number Of Membranes Per Vessel Pressure Vessel Array Number Of Membranes Prefilter (System ships with one 5 micron cartridge) Feed Water Connection Product Water Connection Reject Water Connection Feed Water Required

Feed water required will be less if reject recycle is used.

Feed Water Pressure (Minimum) Drain Required Electrical Requirement

230 VAC, 3-ph, 60 Hz (Other voltages available)

Multistage Centrifugal Pump TEFC Motor (Horse Power)

Dimensions L x W x H (Inches) Shipping Weight (Estimated Pounds)

1 1 1 1 1

1:1 1:1:1 1:1:1:1 1:1:1:1:1 1:1:1:1:1:1

2 3 4 5 6 20" BB 20" BB 20" BB 20" BB 20" BB 1" NPT 1" NPT 1" NPT 1" NPT 1" 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 3/4" NPT

9 gpm 10 gpm 10 gpm 12 gpm 13 gpm 20 psi 20 psi 20 psi 20 psi 20 psi

9 gpm 10 gpm 10 gpm 12 gpm 12 gpm

15 amps 15 amps 15 amps 15 amps 15 amps

15 stages 15 stages 15 stages 18 stages 18 stages

5 5 5 5 5

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

400 500 600 700 800

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.

RO Membrane Feed Water Product Water

Reject Water

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 seperatly. 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

- These foulants should be removed to less than 0.1 ppm. Special media

filters and/or chemical treatment is commonly used.

- The pH is often lowered to reduce the scaling potential.

: Reported on the analysis as SiO2. Silica forms a coating on membrane surfaces when

Silica 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 (see figure 1)

A. Controller - Controls the operation of the system and displays the product water

quality. There are three controllers available. Controller # 1 has an on/off switch and an input for tank level. Controller # 2 has an on/off switch, tank level input, low pump suction pressure shutdown, and a product water TDS meter. Controller # 3 is the CI1000 (shown).

B. Reject Control Valve - Controls the amount of reject flow. If the reject recycle option

is included, two reject control valves will be present.

C. Pump Discharge Valve - Used to throttle the pump. D. Prefilter Pressure Gauges - Indicates the inlet and outlet pressure of the prefilter. The

difference between these two gauges is the prefilter differential pressure. E. Pump Discharge Pressure Gauge - Indicates the pump discharge pressure. F. Reject Pressure Gauge - Indicates the reject pressure. G. Reject Flow Meter - Indicates the reject flow rate in gallons per minute (gpm). If the

reject recycle option is included, two reject flow meters will be present. 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. Included only with controller option # 1 & 2. L. RO Feed Pump - Pressurizes the RO feed water. M. RO Membrane Vessels - Contains the RO membranes.

Separate motor starter

enclosure used only with

CI 1000 controller.

Figure 1

Figure 2

Controller Package One

Figure 3

Controller Package Two

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 the motor starter (Figure # 2, or 3). Attach the power supply ground to the chassis ground. It will 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. Move the controller on/off switch to the on position. Move the switch back to the off

position after the pump starts and look at the motor fan as the pump stops to determine if the pump rotation is correct. If the CI 1000 Controller is included (controller option # 3), put the

key switch in the on position and press the start / stop button to turn the pump on and off. There is a 10 second delay before the pump starts. See the controller section for more details. The fan should rotate in a counterclockwise direction when viewed from the top.

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. (Figure #2 item #1) 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

E. Controllers

Two controller options are available.

Controller option # 1 is a basic controller with an on / off switch, low pressure, tank level, and pretreatment interlock (see figure # 2).

Automatic low pressure reset If the unit shuts down due to low pressure, a red light on the front of the controller will illuminate. The controller will automatically restart the unit after a user selected time delay. The user selects the delay time by positioning a jumper cap inside the controller (see attached drawing).

Tank Level / Pretreatment Indicator If the unit shuts down due to a high product tank level or pretreatment interlock, an amber lamp will illuminate. The lamp will turn off and the unit will restart when the condition clears. The same lamp is used for both tank level and pretreatment interlock.

Controller operation

1. When the power switch is turned on, the pump will run as long as the circuit between the

tank level terminals and the interlock terminals are closed, and the low pressure switch contacts are open.

2. To install a tank level switch, remove the jumper wire from the terminal strip and connect the

level switch to the terminals. The RO pump and inlet valve will turn on when the level switch contacts are closed (tank not full), and turn off if the level switch contacts open (tank full).

3. To install a pretreatment interlock, remove the jumper wire from the terminal strip and

connect the normally closed pretreatment switch contacts to the terminals. The RO pump and inlet valve will turn on when the switch contacts are closed, and turn off if the switch contacts open.

4. If the low-pressure contacts close continuously for five (5) seconds, the RO pump and inlet

valve will turn off and the low pressure light will illuminate. The controller will automatically restart the unit after the user selected time delay. Turning the controller off then back on will manually reset a low pressure shutdown.

Note: Use the plastic lever to push the terminal strip contacts open. Insert the bare end of the wire into the terminal and release the lever. The lever can be moved from one terminal to another as needed. One lever is included with each controller.

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