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G01

SPD Owner's Manual

33

Appendix 1

Keyence Ladder Program

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Summary of Contents for SPD2H

Page 1: ... OSMOSIS WATER PURIFICATION SYSTEM INSTALLATION OPERATION MAINTENANCE TROUBLESHOOTING Applied Water Engineering Inc 2759 South 300 West Suite G Salt Lake City UT 84115 USA Phone 801 486 7774 Fax 801 484 9265 awewater xmission com awewater com ...

Page 2: ......

Page 3: ...r The other items are identified in the photographs and minimally below Moving counterclockwise from the top left of Figure 1 Front Inside View we identify the following items The Filter Vent Valve is used after filter replacement to vent air to drain The Pump Vent Valve is used after start up to vent air in the pump housing to drain The Annulus Drain Valve is opened during rinsing following disin...

Page 4: ...mp during disinfection The Fill Tank Solenoid Valve is opened when the Fill Tank pushbutton is pressed during normal operation It closes automatically when the disinfection tank is full The keyswitch must be in the clockwise position for operation The Capillary is a short length of 1 4 OD tubing that sets the amount of the reject flow to drain The Flush Valve bypasses the capillary and increases t...

Page 5: ...l Tank Solenoid Valve Flush Valve Reject to Tank Valve Venturi Supply Valve Disinfection Tank Main Shut Off Valve Filter Vent Valve Pump Vent Valve Annulus Drain Valve Product Dump Solenoid Valve Product Return Check Valve Product Pressure Regulator Submerged Pump Reject to Drain Check Valve Reject Pressure Regulator Disinfection Check Valve Capillary ...

Page 6: ...s the wire connections to the submerged pump power cable The Pump Torque Clamp transfers the start up torque of the pump to the system frame Figure 3 shows the view in the right side of the control panel where the electrical controls are located The Keyence programmable logic controller is the brain of the system The Main Control Fuse protects the primary of the control transformer The In Line Fus...

Page 7: ... Controls Feed Pressure Switch A Feed Pressure Switch B Pump Outlet Pressure Switch Pump Wiring Box Pump Torque Block Franklin Pump Control Box Control Transformer Main Control Fuse In Line Fuse Keyence PLC Contactor Conductivity Transformer Auxiliary Circuit Board Conductivity Monitor ...

Page 8: ...brating the conductivity probes and setting the conductivity alarm level The Monitor Selector Switch determines whether the meter displays the product conductivity or 0 1 times the feed conductivity The Circuit Breaker Power Switch serves as the main on off control of the system The Operation Mode Switch selects whether the system is operating in the normal service and rinse mode or in disinfectio...

Page 9: ... Flowmeter P Gauge Alarm Horn Mute Button Low Feed Pressure Flashes if high pressure High Conductivity Prefilter Pressure Drop Monitor Alarm Adjustments Product Dump Conductivity Monitor Monitor Selector Switch Power Switch Fill Tank Button Key Switch Mode Selection Switch ...

Page 10: ...inlet flow When the green flush valve is opened the capillary is bypassed and drain flow increases When the reject to tank valve is opened the reject water that would otherwise flow to drain is directed into the disinfection tank In disinfection mode a portion of the high pressure reject water passes through the green handled venturi supply valve to drive the venturi The venturi lifts the water fr...

Page 11: ...G01 SPD Owner s Manual 9 FIGURE 5 ...

Page 12: ...he clamp Remove the existing stub pipe placed for shipping The drain pipe can be run level or with a slight downward pitch to a U trap and into a sanitary sewer line Feed Water Presoftened and dechlorinated feed water enters the system at a 3 4 FPT plastic fitting on the left side Do not undersize the feed water piping to this point A minimum pipe tube hose ID of 3 4 inch is recommended If the sea...

Page 13: ...ld start If the low feed warning light comes on and the pump stops turn the system on and off again to reset it After several minutes the operation should stabilize with about 20 PSI of feed water pressure 185 to 195 PSI pump outlet pressure and up to 50 PSI product pressure Check for leaks Before the system is used productively it should be put in a disinfection cycle Disinfection Instructions Ne...

Page 14: ...k manganese particulates collected on the prefilter elements Examination of the inside of fittings downstream of the prefilter will indicate the extent of deposits to be expected on the membrane If the deposits are heavy use of a finer 1 micron prefilter may be warranted Acid cleaning is done following a similar procedure as disinfection Page 14 and is discussed further on Page 22 The volume of wa...

Page 15: ...still exists This is because of disinfectant trapped in the dead ended tubing to the pressure gauges or anywhere that was not or cannot be properly rinsed Hazards of Leaks The recommended Minncare TM disinfectant is very corrosive to most metals and several plastics If any of the diluted disinfectant leaks to the outside at tubing connections the spilled disinfectant has the potential of destroyin...

Page 16: ...5 Inspect for any leaks 6 Put on gloves and eye protection 7 Measure out 350 ml of Renalin into a suitable container and add the disinfectant to the 5 gallon jug Do not spill Any spills of Renalin concentrate must be copiously rinsed and wiped up with a sponge towel or vacuum The disinfectant should be circulating through the pump membrane modules and back to the disinfection tank The disinfectant...

Page 17: ...roduct Dump Valve must remain open 17 Open the flush valve as much as possible without letting the machine shut off due to low pump inlet pressure to hasten the initial rinse The progress of the rinsing is indicated by the product water conductivity falling relative to what it normally is 18 After the product conductivity is within 1 or 2 microSiemens cm of the normal value close the Flush Valve 1...

Page 18: ...k in Service position Using the key turn the Disinfection Lock switch CCW to normal and store the key 31 After 5 minutes start the system again by toggling the Power Switch off and on again There will probably still be a slight residual of disinfectant rebound which is detectable by the Product water conductivity quickly falling to a low value but higher than that noted in Step 21 After a minute o...

Page 19: ...n this condition until it is manually turned off and on again with the power switch Low feed pressure shutdowns should not be tolerated Whatever is causing the inadequate feed water flow should be corrected After a 30 second start up delay the High Conductivity lamp will be illuminated whenever the product water conductivity exceeds the alarm point The factory set alarm point is 20 ppm but the ala...

Page 20: ...e pump contactor R1 and to the control transformer A primary tap on the transformer supplies 115 volts AC to the conductivity monitor through an inline fuse The secondary side of the transformer provides 24 volts AC An auxiliary circuit board rectifies and regulates the 24 volts for use by a Keyence PLC programmable logic controller This board also contains an opto isolator for accepting the alarm...

Page 21: ... inside Note the running capacitance has been changed from the 10 F supplied by Franklin to 20 F This improves the power factor and efficiency of the motor and reduces noise If relay contactor R1 is working properly and all the components in the Franklin box are OK then an inability of the pump to run properly indicates a problem with the submerged pump assembly ...

Page 22: ...G01 SPD Owner s Manual 20 FIGURE 7 ...

Page 23: ... pressure drop LED comes on Prefilter Changing Procedure Turn off the system After removing the front cover turn off the main shut off valve Open the filter vent valve The blue filter sumps screw off counterclockwise looking up A plastic wrench is included to loosen the bowls Note Use the wrench only for loosening the sumps hand tighten only The inside of the sump should be rinsed thoroughly when ...

Page 24: ...ing The effectiveness of the solution is enhanced by adding 0 5 by weight of sodium EDTA ethylenediaminetetraacetic acid to the caustic If the system has been protected by an operating softener the caustic cleaning is usually effective at restoring lost flux Caustic cleaning may result in severe discoloration of the cleaning solution An overnight soak is recommended If caustic cleaning is done aci...

Page 25: ... top and bottom sides must then be removed Remove the bottom tubing piece first and thread on a 1 FPT cap to minimize spillage Use a small pipe wrench to grab the tubing compression nuts Then loosen the SS band clamps at top and bottom Carefully pull out the module Disassembly of Module The RO spiral wound element must be removed from the pressure vessel for replacement First holding the module up...

Page 26: ... on Page LEAKS Even though they don t prevent operation of the system leaks are a nuisance and should be fixed when detected Leaks can be classified in 3 types a leak at a pipe thread joint b leak in a compression or instant fitting and c leak from a broken part Pipe thread joints are sealed with several wraps of 1 2 wide TFE thread tape If turning the fitting in one turn does not stop a leak then...

Page 27: ...the wire leads from the pump mostly back into the pipe nipple on the pump housing and secure with tape Remove the ground wire from the pump torque clamp Unbolt one of the small angle brackets that sandwich the torque rod that extends from the black aluminum torque clamp Loosen the 1 4 20 clamp nut and rotate the clamp Then unthread the torque rod from the clamp Undo the upper most tubing nut on th...

Page 28: ...tion of the tightening bolt relative to the pen marks Undo the band clamp that holds to casing together with a 9 16 wrench or nut driver Remove the band clamp Now the pump and motor assembly can be pulled out of the lower portion of the casing by pulling on the SS outlet pipe Use extra caution to avoid cutting the pump wires on any sharp edges Be careful of Loosen bolt on torque clamp Compression ...

Page 29: ...g Free Play The shaft free play should be no less than 0 010 inches and no greater than 0 045 inches Too much free play indicates a worn out thrust bearing Rotation The shaft may be initially stuck but should rotate easily after several turns Motor Replacement The motor manufacturer recommends that the motor lead assembly not be reused on a new motor due to the possibility of inadequate sealing fr...

Page 30: ...ed in the original assembly A difference in lengths can be adjusted by shortening or lengthening the 2 PVC pipe piece located in the bottom of the pump housing Before installing a replacement motor or pump compare the overall length of the bolted assembly compared to that of the existing pump motor assembly ...

Page 31: ...ntinuity If it is OK then the solenoid valve should be removed and repaired or replaced If the feed water is shut off nothing will work Symptom Pump will not start but there is pump inlet pressure If the loud click of the contactor is heard shortly after the system is turned on then the pump is getting the signal to turn on If this click cannot be heard the failure is in the feed pressure switch A...

Page 32: ...ilable at a glance If the needle on the meter does not move when the display is shifted from feed to product it indicates the rejection is 90 If the needle when indicating product is only half the value of the feed then rejection is 95 If the needle when indicating product is only one fourth of the value of the feed then rejection is 97 5 This is illustrated below for several different feed waters...

Page 33: ...G01 SPD Owner s Manual 31 ...

Page 34: ...witch Above limit 006 High conductivity Above limit 007 Disinfection Tank fill PB Momentary 008 Disinfection tank high Below level 009 Disinfection tank low Below level 010 Mute Button Momentary 011 Key Turned 012 013 014 015 PLC OUTPUTS 500 Conductivity Alarm LED 501 Product Dump LED and solenoid 502 High Pressure Pump MS 503 Change Prefilter LED 504 Low Feed Pressure Shutdown LED 505 Product to ...

Page 35: ...G01 SPD Owner s Manual 33 Appendix 1 Keyence Ladder Program ...

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