Watts R44-24-1111000 User Manual
REVERSE OSMOSIS
INSTALLATION AND OPERATION MANUAL
Model # R44
IMPORTANT
Information specific to this system is printed in Italics.
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 plant 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 plant 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 more serious problems. The best insurance against problems leading to
membrane failures is to maintain a log on the operation of the RO system, water quality, and
temperature. 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
B. Figure # 2
C. Figure # 3
III. Operation
A. Installation
B. Plumbing Connections
C. Electrical Connections
D. Startup
E. Controller
F. Operation and Maintenance Log
G. Trouble Shooting
IV. Replacement Parts List
V. Membrane Replacement
VI. Appendix
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
Maximum 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%). May be operated on other feed waters
with reduced capacity.
Quality (Typical Membrane Percent Rejection) Based on membrane
manufactures specifications, overall system percent rejection may be less.
Recovery (without reject recirculation)
Recovery (with reject recirculation, depending on feed water)
Membrane Size
Number Of Membranes Per Vessel
Pressure Vessel Array
Number Of Membranes
Prefilter Housing (System ships with one set of 5 micron cartridges)
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)
R44-16 R44-20 R24-24
28,800 / 20 36,000 / 25 43,200 / 30
98 % 98 % 98 %
70 %
75 %
70 %
75 %
70 %
75 %
4 x 40 4 x 40 4 x 40
4 4 4
2:2 3:2 4:2
16 20 24
7 round x 20” 7 round x 20” 7 round x 20”
2" NPT 2" NPT 2" NPT
1 1/2" NPT 1 1/2" NPT 1 1/2" NPT
1" NPT 1" NPT 1" NPT
29 gpm 36 gpm 43 gpm
20 psi 20 psi 20 psi
Drain Required
Electrical Requirement
230 VAC, 3-ph, 60 Hz (Other voltages available)
Multistage Centrifugal Pump (Model)
TEFC Motor (Horse Power)
Dimensions L x W x H (Ft.)
Shipping Weight (Estimated Pounds)
29 gpm 36 gpm 43 gpm
30 amps 30 amps 30 amps
V40B12 V40B12 V40B12
10 10 10
16 x 3 x 6 16 x 3 x 6 16 x 3 x 6
1400 1600 1800
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 antiscalents 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 or
less is specified by most membrane manufacturers and three or less is recommended.
Iron & Manganese - These foulants should be completely removed (less than 0.1 ppm). Special
media filters and/or chemical treatment is commonly used.
pH - pH is often lowered to reduce the LSI. The membranes have a pH operating range of 2-11.
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 (see figure 1)
A. Controller - Controls the operation of the system and displays the product water
quality.
B. Reject Control Valve - Controls the amount of reject flow.
C. Reject Recycle Control Valve – Controls the amount of reject recycle flow.
D. Pump Discharge Valve - Used to throttle the pump.
E. Prefilter Inlet Pressure Gauge - Indicates the inlet pressure of the prefilter.
F. Pump Suction Pressure Gauge – Indicates the prefilter outlet and pump suction
pressure. The difference between this gauge and the prefilter inlet gauge is the
prefilter differential pressure of the prefilter.
G. Pump Discharge Pressure Gauge - Indicates the pump discharge pressure.
H. Membrane Feed Pressure Gauge – Indicates the membrane feed pressure.
I. N/A
J. Reject Pressure Gauge - Indicates the reject pressure.
K. Reject Flow Meter - Indicates the reject flow rate in gallons per minute (gpm).
L. Reject Recycle Flow Meter – Indicates the reject recycle flow in gpm.
M. Product Flow Meter - Indicates the product flow rate in (gpm).
N. Prefilter Housing - Contains the RO prefilters.
O. Automatic Inlet Valve - Opens when pump is on and closes when the pump is off.
P. Low Pressure Switch - Sends a signal to the controller if the pump suction pressure is
low.
Q. RO Feed Pump - Pressurizes the RO feed water.
R. RO Membrane Vessels - Contains the RO membranes.
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 system inlet. (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. The
disconnect and fuses should be sized accordingly.
2. Verify that the disconnect switch is de-energized using a voltmeter.
3. Connect the outlet of the disconnect switch to the top of the motor starter relay. (Figure
#2 or #3. Attach the power supply ground to the controller ground.
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 controller on/off switch is in the off position.
3. Close the pump discharge completely then open it one turn. Note: All valves on this unit
turn clockwise to close.
4. Install four 20" five micron filter cartridges in the prefilter housing.
5. Open the reject control valve completely by turning it counterclockwise.
6. Close the reject recycle control valve completely by turning it counterclockwise.
7. Open the feed water shutoff valve installed in step III-B-1 above.
8. Engage the safety switch or disconnect (installed in step III-C-1 above) to apply electrical
power to the RO system.
9. 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. The fan should rotate in the direction indicated by the arrows on the
pump. Continue with the startup if the pump is rotating in the proper direction. If the
pump rotation is backwards, reverse the rotation by shutting off the power and swapping any
two of the three power lines connected in step III.C.3 above
10. Turn the system on and allow the product and reject water to go to drain for 15 minutes.
11. Adjust the reject control valve, the reject recycle control valve and the pump discharge valve
until the desired flows are achieved. Closing the reject valve increases the recycle and
product flow and decreases the reject flow. Closing the reject recycle valve increases the
reject and product flow and decreases the recycle flow. Opening the pump discharge valve
increases all of the flows. See the temperature correction table in the appendix to determine
the flow rates for different operating temperatures.
12. Allow the product water to flow to drain for 30 minutes.
13. Turn off the system and connect the product line to the point of use. The product water line
should never be restricted. Membrane and/or system damage may occur if the product line is
blocked.
14. Restart the system and record the initial operating data using the log sheet in the next section.
15. See the controller section for detailed information about the controller.
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