GE Osmonics Z-10000 Operation And Maintenance Manual Download

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Z Series RO System by GE Osmonics

CATALOG NUMBER

DESCRIPTION

PARTS (continued)

30151 Switch,

Temperature

30150 Transducer,

Temperature

30149

Temperature probe well, SS

41582

Valve, Ball, 1”, Electric

40700

Valve, Waste Flow

40863

QD, Female x 1” Hose Barb

40864

QD, Male x 1” NPT

50040

Grease Cartridge (non-submersible pump/motor only)
Valve, sample (1/4” NPT x barb)

60240

Clamp, worm gear, 3/4”

60280

Clamp, worm gear, 5/8”

60341 Tube,

1/8”

60370 Hose,

3/8”

50092 Hose,

5/8”

CLEANERS

14962

Membrane Cleaner, BIOSAN™ II, 1 gal, liquid

14963

Membrane Cleaner, BIOSAN™ II, 5 gal, liquid

1228792

Membrane Cleaner, Hi pH, 5 gal

1228791

Membrane Cleaner, Hi pH, 1 gal

1228654

Membrane Cleaner, Low pH, 5 gal

1228653

Membrane Cleaner, Low pH, 1 gal

TESTS

50033

Hardness Test Kit

14604

Silt Density Index (SDI) Test Kit

11656

Total Chlorine Test Kit

70001

Water Test Kit, AAMI Standards

1232143

Water Quality Test Strips

OPTIONAL

14899

Kit, membrane, SS housing

14900

Kit, membrane, FG housing

14778

Kit, TDS alarm relay

12214

Disinfect kit, 30 gal.

40291

1238339b – 16Oct03

7 - 4

Spare Parts List

Summary of Contents for Osmonics Z-10000

Page 1: ...GE OSMONICS Z SERIES REVERSE OSMOSIS SYSTEM Operation and Maintenance Manual P N 1238339 REV B 16 OCT 03 ...

Page 2: ......

Page 3: ...4 1 11 2 Flow Rates 1 15 1 11 3 Electrical Requirements 1 15 1 11 4 Dimensions Weights 1 16 1 11 5 Membrane Performance Characteristics 1 16 1 11 6 Environmental Requirements 1 16 1 12 Disposal 1 17 1 13 Electromagnetic Interference 1 17 1 14 Service Assistance 1 17 1 15 Return Goods Authorization RGA 1 18 1 16 Symbols and Abbreviations 1 19 CHAPTER TWO INSTALLATION GUIDELINES AND INITIAL SYSTEM S...

Page 4: ...n Leak Repair 4 8 4 3 Z Series Cleaning Indications 4 9 4 3 1 Cleaning Preparation 4 10 4 3 1 1 Cleaning Procedure 4 11 4 3 1 2 Post Cleaning Rinse Procedure 4 12 4 3 1 3 BIOSAN Low pH Cleaner Cleaning Procedure 4 13 4 4 Disinfection Procedure 4 15 4 4 1 Formaldehyde Disinfection Preparation 4 16 4 4 1 1 Formaldehyde Disinfection Procedure 4 17 4 4 1 2 Post Formaldehyde Disinfection Rinse Procedur...

Page 5: ...uge Vibrates Erratically 5 7 5 7 Excess Product Pressure 5 8 5 8 Product Flow Too Low 5 8 5 9 Product Flow Too High 5 9 5 10 Poor Apparent Water Quality 5 9 5 11 TDS Reading Too High 5 10 5 12 RO Pump Leaks at Inlet End 5 10 5 13 Leaks 5 10 5 14 RO Fails to Draw Disinfectant 5 11 5 15 Product Divert Controller and Valve Malfunction 5 11 CHAPTER SIX DRAWINGS 6 1 CHAPTER SEVEN SPARE PARTS LIST 7 1 1...

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Page 7: ...Z Series RO System by GE Osmonics Z Series RO System CHAPTER ONE GENERAL INFORMATION 1238339b 16Oct03 1 1 General Information ...

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Page 9: ...hanced and defined as follows WARNING Statements identifying conditions or practices that could result in personal injury or loss of life CAUTION Statements identifying conditions or practices that could result in equipment or other property damage NOTE Statements that provide further clarification READ THIS MANUAL Prior to operating or servicing this device this manual must be read and understood...

Page 10: ...smonics RO systems are not designed sold or intended for use in producing water for injection Furthermore GE Osmonics RO systems are not intended to be used outside of the device specifications and limitations as outlined in this manual and other related materials 1 5 Environmental Considerations Prior to the installation of the Z Series RO System it will be necessary to provide utilities and crea...

Page 11: ...art In climates where the winter water temperature drops significantly below 77 F it may be necessary to temper heat the water or increase the number of membranes in the RO unit WARNING The temperature of the tempered water should be monitored closely with a thermometer as high temperatures can damage the RO membranes and possibly harm the patient Refer to the inlet water requirements Section 1 11...

Page 12: ...ger piping tee after the first piece of pre treatment equipment before the RO unit The probe is used to measure the feed water temperature and is connected to the temperature switch inside the alarm monitor Carbon Filtration Carbon Filtration is a required component of a water purification system Two carbon filters must be used in series The carbon tanks are used to remove chlorine chloramine from...

Page 13: ... The standard is of submersible style the option has an open drip proof motor The RO pump discharge pressure is displayed as membrane supply on a 0 to 600 PSI panel mounted gauge Submersible style multi stage pumps are enclosed in a stainless steel housing The Air Bleed Valve is used to purge air from the housing Reverse Osmosis Membrane Assembly ROMA Three to six ROMA s may be included in the Z S...

Page 14: ...r Water Quality Monitoring Water Quality Monitoring is monitored in percent rejection and product output TDS Percent rejection is a comparison of the inlet water sensor and the product water sensor and is displayed in a 5 LED array on the front panel The product water TDS is monitored with a digital display on the front panel and is temperature compensated The high TDS alarm level can be set by a ...

Page 15: ... System On indicator lamp is lit whenever the power switch is in the ON position Low Feed Pressure Lamp The Low Feed Pressure indicator lamp is lit whenever the input water pressure drops below the inlet pressure switch setting approximately 10 PSI The indicator will go out when the water pressure returns above the pressure switch setting Pump Pressure Gauge The Pump Pressure Gauge reads the pump ...

Page 16: ...uate the RO system performance CAUTION RO units do not normally have TDS less than 0 5 mg L Verify this reading with an independent meter and take corrective action if required RO membranes may achieve this level of performance under optimum conditions good feed water Tank Level Controls The standard control is a float switch system An indicator lamp is lit on the controller assembly and the RO sh...

Page 17: ...th a Disinfect Alarm Monitor Disinfect key switch The Disinfect key switch is used to start the unit for the introduction of disinfectant cleaner into the unit The key switch locks out the inlet solenoid and low pressure switch CAUTION Ensure the RO Unit is prepared for disinfection operations prior to engaging the Disinfect key switch Temperature Alarm Monitor The Temperature Alarm Monitor monito...

Page 18: ...ion tank will handle a wide range of chemicals and its drop tube design minimizes fumes The flexible manifold enables quick and easy connection of the system Remote Monitoring An RO Status Monitor is available in either an external surface mount housing or flush mount panel for junction box installation with a variety of monitoring options that include water quality storage tank level distribution...

Page 19: ...th a brine solution and rinse the ion exchange bed afterwards The control valve is normally governed by a time clock alternate controls are available from the factory Scale control by chemical treatment is also available Storage Tank A storage tank is used to collect RO product water and store it until needed The reservoir system has internal features that with the distribution pump running contin...

Page 20: ...nto regeneration or backwash This is required to be able to connect the RO interlock circuitry to the equipment 2 Any device provided by another company that is required to be interlocked to the RO unit so it does not operate run during a specific period of the devices operation must have a normally open micro switch that when activated closed can return a 24VAC signal to the RO unit controller 1 ...

Page 21: ... 24 9 600 36 340 Z 12000 8 33 31 55 12 000 45 425 Z 14400 10 37 85 14 400 54 510 Direct Units Z 6000 4 17 15 77 6 000 22 712 Z 8000 5 56 21 03 8 000 30 283 Z 10000 6 94 26 29 10 000 37 854 Z 12000 8 33 31 55 12 000 45 425 1 11 3 Electrical Requirements 1 RO Units Voltage Hertz Amps Phase Hp 230 60 24 1 5 208 60 20 27 5 3 5 7 5 230 60 16 24 3 5 7 5 460 60 8 5 12 5 3 5 7 5 2 Product Divert Controlle...

Page 22: ...e Direct Feed 225 PSI 10 PSI Indirect Feed 250 PSI 10 PSI 1 11 6 Environmental Requirement Minimum Maximum Ambient Temperature 4 C 39 F 32 C 90 F Storage Temperature 2 C 36 F 32 C 90 F Altitude N A 10 000 feet CAUTION This equipment must not be allowed to freeze Irreparable harm to various components including RO membranes may result NOTE The user operator should recognize that moisture can be cau...

Page 23: ...vice technician or manufacturer for help 1 14 Service Assistance If service assistance is required please take the following steps Consult the troubleshooting section of this manual Chapter 5 If the problem cannot be identified and corrected by any of the procedures found in that section then Contact your Facility Equipment Technician If the technician is unable to help then Call GE Osmonics Techn...

Page 24: ...ice A representative will provide instructions and a return authorization number which needs to be clearly written on the outside of the box used to ship your materials All equipment must be shipped with the freight prepaid by the customer Call our Customer Service Center with any questions or issues concerning freight claims and a representative will discuss your situation All materials to be ret...

Page 25: ...anadian Standards Association cc Cubic Centimeters cf Cubic Foot feet cfu ml Colony Forming Units per milliliter cm Centimeters DI Deionization F Fahrenheit FDA Food and Drug Administration Ft Foot feet GPD Gallons Per Day GPM Gallons Per Minute GHT Garden Hose Thread gr Grains GAC Granular Activated Carbon HP Horse Power HPLC High Pressure Liquid Chromatography HZ Hertz lbs Pounds LED Light Emitt...

Page 26: ... Million psi Pounds Per Square Inch PVC Polyvinyl Chloride QD Quick Disconnect RO Reverse Osmosis ROMA Reverse Osmosis Membrane Assembly SF Speed fit TB Terminal Barrier Strip Main TB1 Example TB1 9 refers to the terminal marked number 9 on the Main Terminal Barrier Strip TF Thin Film TFC Thin Film Composite TDS Total Dissolved Solids UL Underwriters Laboratory VAC Volts Alternating Current WFI Wa...

Page 27: ...Z Series RO System by GE Osmonics NOTES 1238339b 16Oct03 1 21 General Information ...

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Page 29: ...Z Series RO System by GE Osmonics Z Series RO System CHAPTER 2 INSTALLATION GUIDELINES AND INITIAL SYSTEM START UP 1238339b 16Oct03 2 1 Installation Guidelines and Instructions ...

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Page 31: ...on Mount the Product Divert Valve Assembly on the wall between the RO unit and the storage tank or the next purification device in the treatment stream The valve assembly should be within 5 feet of the Product Divert Controller See the Product Divert Valve installation drawing in Chapter Six for specific details 4 Temperature Alarm Monitor a Location Mount the Temperature Alarm Monitor on an acces...

Page 32: ...on to the drain in accordance with the local plumbing code c Make wiring connections from the Product Divert Controller to the RO unit controller with the wire provided as shown in the Product Divert wiring schematic in Chapter Six d Plug the supplied power cord on the Product Divert Controller into the 115VAC outlet 3 RO Interlock a Connect RO Interlock wire to the terminals in the RO control box...

Page 33: ...ter Six for specific details 5 Storage Tank Level Controls a Connect the Low Tank Level Switch to terminals TB3 7B and TB3 8B b Connect the High Tank Level Switch to terminals TB3 9B and TB3 10B c When the low level monitoring option is chosen with the RO Status Monitor the dedicated float switch will connect to terminals TB3 4B and TB3 6B NOTE Operation of this unit without level switches i e Dir...

Page 34: ...the atmosphere Close the valve when water is seen flowing from this valve a The Product Divert Valve will open b The RO will auto flush for the preset time duration c The motor will begin operation after a brief time delay d The Product Divert Valve will close after an approximate two minute start up delay 4 Reference operation 2 3 2 Rotation Verification as applicable 5 Adjust the Waste Flow Valv...

Page 35: ...kwards Reverse two legs of the power at the fused disconnect box Repeat rotation verification instructions until increase in flow and pressures are achieved 2 Non Submersible Multi Stage Pumps a Energize the unit and check the motor rotation If the rotation does not match the arrow on the pump motor turn the unit off and reverse two legs of power at the main power wires at the fused disconnect box...

Page 36: ... the appropriate testing 2 Operate the RO unit with product and waste flows to drain for at least 15 minutes after the product water quality has stabilized before drawing the water sample 3 Hold the product line over the container and run product water for approximately 1 minute 4 Aseptically remove the lid from the sample bottle and rinse the bottle twice with RO product water 5 Fill the bottle c...

Page 37: ...Z Series RO System by GE Osmonics NOTES 1238339b 16Oct03 2 9 Installation Guidelines and Instructions ...

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Page 39: ...Z Series RO System by GE Osmonics Z Series RO System CHAPTER 3 SYSTEM OPERATION 1238339b 16Oct03 3 1 System Operation ...

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Page 41: ...opens and product water diverts to drain for an approximate two minute start up delay NOTE The TDS must be below the alarm set point for the product divert valve to close 6 The RO will Auto flush for the preset duration During this cycle the pressure gauges will appear as follows a Pre filter pressure gauges should read between 25 and 100 PSI within 15 seconds of turning on system b Supply and Was...

Page 42: ...fter the pretreatment carbon tanks It is imperative that thin film element equipped RO units be operated on chlorine free feed water NOTE Carbon filtration is a required component of a water purification system AAMI recommends that two carbon filters be used in series When chlorine chloramine breakthrough is noted after the first tank the first tank must be removed the second put in its place and ...

Page 43: ...Z Series RO System by GE Osmonics NOTES 1238339b 16Oct03 3 5 System Operation ...

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Page 45: ...Z Series RO System by GE Osmonics Z Series RO System CHAPTER FOUR ROUTINE MAINTENANCE 1238339b 16Oct03 4 1 Routine Maintenance ...

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Page 47: ...tes 141 142 143 144 and 145 for applicable record logs 4 1 1 Daily Maintenance 1 Measure the feed water hardness level and record value in the pretreatment log NOTE Check the softener output for hardness at the end of the operational day to confirm adequate softener capacity 2 Observe and record salt level in the brine tank if applicable 3 Observe and record the Chlorine Chloramine concentrations ...

Page 48: ...nit for the preset time 11 Observe the normal illumination of the visual indicators on the Temperature Alarm Monitor 4 1 2 Monthly Maintenance 1 Check the pre filter at least monthly for core discoloration If discoloration is observed the pre filters will require more frequent changing or additional pre filtration Reference section 4 2 4 Pre Filter Cartridge Replacement Procedure if a change is re...

Page 49: ...using submersible motor only The three screws should be evenly tightened to provide the best possible seal 4 1 5 Annual Maintenance 1 An AAMI Water Quality Analysis of the product water should be conducted at least yearly Reference section 2 4 Product Water Analysis Procedure 2 Check the monitoring for accuracy 3 Check the gauges for correct functioning 4 Check the ball valves for correct operatio...

Page 50: ...eal out of its seat If either of these problems occurs the pump will leak and may be damaged beyond repair Do not force grease into bearing frame 5 Allow the RO to run for an additional 5 minutes or more While the RO is running some grease may exit the bearing frame from the open port This is normal and should not be a concern After the RO has been running for some time re install the plug into th...

Page 51: ...ubmerging beyond the threads 3 Allow the probe to acclimatize for a minimum of 5 minutes 4 Slowly increase the water bath temperature until the monitor indicates red light RO Unit Interlock Check the water bath temperature with a thermometer for 90 F 1 F Adjust the set point as required NOTE The set point is adjusted through the hole on the left side of the monitor with a screwdriver Clockwise rot...

Page 52: ...eaded Connection Leak repair WARNING Any piping change making contact with product water should be disinfected prior to continued use CAUTION Any leak from any part of the system should be corrected as soon as possible Left unattended leaks can cause secondary damage necessitating expensive repairs NOTE Use FDA NSF approved silicone sealant when used on threaded connections 1 Prior to performing m...

Page 53: ...tion Many of these foulants are prevented by proper selection of pretreatment equipment while others are treatable only with more sophisticated designs Regardless of the foulant it is essential to clean the membrane promptly once the need for cleaning is indicated The longer a foulant is allowed to remain in contact with the RO membrane the more difficult it will be to remove In severe cases repea...

Page 54: ...rganic matter from the RO membrane WARNING The solution is a mild irritant to eyes and skin It is recommended that protective gloves and eye protection be worn when handling the cleaner Follow all applicable Material Safety Data Sheet MSDS precautions and OSHA Standards WARNING Label machine with appropriate warning signs such as Do Not Use Contains Cleaner to prevent use of the RO until it is pro...

Page 55: ...he cleaning tank 8 Remove the RO waste line from drain and connect to an upper connection port on the cleaning tank 9 Open the Disinfect Inlet Valve and the Waste Flow Valve counter clockwise on the RO unit 10 Turn on the RO unit When the RO system is equipped with a Disinfect Alarm Monitor and RO Status Monitor cleaning operations may commence only when both disinfect key switches are activated t...

Page 56: ...urn off the pump 5 Rotate the Disinfect Inlet Valve to the closed position 6 Remove the Disinfect Inlet Valve cleaning line from cleaning tank and connect to drain 7 Turn on the RO unit power switch and allow RO to rinse for five minutes RO systems with the Disinfect Alarm Monitor and RO Status Monitor must have both disinfect key switches placed in the off normal operation position to continue ri...

Page 57: ...re Close the valve when water is seen flowing from this valve 2 Turn off the RO unit power switch 3 Label machine with appropriate warning signs such as Do Not Use Contains Cleaner to prevent use of the RO until it is properly rinsed 4 Remove the RO product line from the Product Divert Valve Assembly RO Product Water connection and connect to one of the upper connection ports on the cleaning tank ...

Page 58: ...secure 10 Adjust the pump pressure to 100 psi or less and circulate the cleaning solution for 15 minutes This will allow more flow of cleaner on the reject side of the RO membrane to flush particulates away CAUTION The BIOSAN will foam this is normal Keeping the return hose under the liquid level in the tank may minimize the foam Damage to the pump may occur if foam is drawn into the pump 11 Turn ...

Page 59: ... concern such as for Hemodialysis Disinfect the Z Series RO every week for one month after installation This will ensure that bacteria levels in the fluid paths will be controlled Sample the purified water for bacteria before each disinfection After one month of no growth samples the interval between disinfecting may be increased Disinfection should occur when any growth is detected This will inhi...

Page 60: ...ns Disinfectant to prevent use of the RO until it is properly rinsed CAUTION New or replacement thin film membranes must be rinsed to drain with normal pressures for a minimum of six 6 hours before first exposure to formaldehyde or irreversible damage may occur Disinfecting Materials Description GE Osmonics Part Number Disinfection Cleaning Kit 12214 Formaldehyde 37 Solution Not Provided by GE Osm...

Page 61: ...er a Use the RO unit to fill the disinfect tank with 9 gallons of product water and turn off the RO b Add 1 gallon of 37 formaldehyde to the disinfect tank and mix well NOTE Ten gallons of solution is adequate for the V Series RO if the unit is directly feeding a distribution loop and the loop is to be disinfected at the same time a larger volume of solution may be required 5 Connect a disinfect l...

Page 62: ... Alarm Monitor will use the RO unit power switch to turn off the pump and stop circulation RO systems without a Disinfect Alarm Monitor will use the Disinfect Start key switch to turn off the pump 14 Remove the RO waste and product lines from the disinfect tank and connect to drain Loop piping disinfection will require the loop output to be connected to drain Direct Feed RO units having the loop d...

Page 63: ...nd loop flow is being returned to the unit 3 Turn on the RO unit power switch and allow the RO to rinse for 10 minutes RO systems with the Disinfect Alarm Monitor and RO Status Monitor must have both disinfect key switches in the off normal operation position to continue rinse operations 4 Slowly open the Disinfect Inlet Valve and allow water to rinse to drain A low pump feed pressure condition ma...

Page 64: ...terials b Clean the membranes with an acid such as 0 1 HCl or 0 4 phosphoric acids Calcium and Iron Cleaner may be used as an alternate It is essential that all iron and other transition metals be removed from the membrane surface c Any deposits on the membrane must be removed with a Silt and Organics cleaner Removal of these deposits which harbor microorganisms will maximize the effectiveness of ...

Page 65: ...xide compounds and are common in dialysis facilities The products referred to in this procedure typically have 20 hydrogen peroxide and 4 peroxacetic acid before dilution Other products are available with these same chemicals in different ratios and are not acceptable for use in the Z Series RO Actril and other compounds with different combinations of these chemicals must not be used on polyamide ...

Page 66: ...n by mixing 13 ounces 400 milliliters of disinfectant concentrate to 10 gallons 38 Liters of RO product water 1 Use the RO unit to fill the disinfect tank with 10 gallons of product water and turn off the RO 2 Add 13 ounces 400 milliliters of disinfectant concentrate to the disinfect tank and mix well 5 Connect a disinfect line hose between the Disinfect Inlet Valve on the RO and the lower connect...

Page 67: ...nd stop circulation RO systems without a Disinfect Alarm Monitor will use the Disinfect Start key switch to turn off the pump 12 Remove the RO waste and product lines from the disinfect tank and connect to drain Loop piping disinfection will require the loop output to be connected to drain Direct Feed RO units having the loop disinfected will require the loop return ball valve mounted vertically j...

Page 68: ...fect key switches in the off normal operation position to continue rinse operations 4 Slowly open the Disinfect Inlet Valve and allow water to rinse to drain A low pump feed pressure condition may be created if this valve is opened too far 5 Close the Disinfect Inlet Valve and disconnect drain hose 6 Turn the power switch ON and OFF in alternating one minute cycles to rinse out any trapped disinfe...

Page 69: ... C immediately and assayed within a 24 hour period Obtain the samples wearing long sleeves and a mask using a mid stream clean catch type procedure to prevent contamination of samples 4 5 1 Product Water Culture Procedure WARNING This procedure must be completed at all points of use e g dialysis stations re use stations on at least a monthly basis 1 Read and understand all applicable instructions ...

Page 70: ...r with an organic cartridge to remove formaldehyde fumes DO NOT BREATHE FUMES OR ALLOW FORMALDEHYDE TO COME IN CONTACT WITH SKIN OR EYES Refer to the MSDS supplied by the manufacturer of the formaldehyde formalin product WARNING Label machine with appropriate warning signs such as Do Not Use Contains Disinfectant to prevent use of the RO until it is properly rinsed 1 Follow the operations instruct...

Page 71: ... section 4 4 Disinfection Procedure b Follow the operations for BIOSAN cleaning and do not rinse the RO unit after the solution has been circulated in the machine Reference section 4 3 1 3 BIOSAN Cleaning Procedure WARNING After storage the RO unit must be completely rinsed of BIOSAN and a bacterial culture performed and interpreted before use reference sections 4 3 1 2 Post Cleaning Rinse Procedu...

Page 72: ...Z Series RO System by GE Osmonics NOTES 1238339b 16Oct03 4 28 Routine Maintenance ...

Page 73: ...Z Series RO System by GE Osmonics Z Series RO System CHAPTER FIVE TROUBLESHOOTING 1238339b 16Oct03 5 1 Troubleshooting ...

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Page 75: ...ssure 5 7 5 6 Pressure Gauge Vibrates Erratically 5 7 5 7 Excess Product Pressure 5 8 5 8 Product Flow Too Low 5 8 5 9 Product Flow Too High 5 9 5 10 Poor Apparent Water Quality 5 9 5 11 TDS Reading too High 5 10 5 12 RO Pump Leaks at Inlet End 5 10 5 13 Leaks 5 10 5 14 RO Fails to Draw Disinfectant 5 11 5 15 Product Divert Controller and Valve Malfunction 5 11 1238339b 16Oct03 5 3 Troubleshooting...

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Page 77: ...atus of interlocks and correct lockout condition i Temperature Alarm ii Pretreatment Interlock 5 Motor Starter a Check power to magnetic starter b Check contactor thermal overload Correct the condition that would have caused the thermal overload to trip Reset overload as necessary c Replace starter relay as necessary 6 Power Switch a Replace power switch as necessary 7 Pressure Switch a Verify tha...

Page 78: ...rter overload switch for proper amperage setting more than full motor amps but less than 125 of motor full load amps b Verify line voltage and motor amperage draw c Correct the condition that would have caused the thermal overload to trip Reset overload as necessary 5 3 Motor Runs Hot 1 Voltage too low or too high a Check voltage against serial number label and motor label correct condition 2 Curr...

Page 79: ...w Waste Pressure 1 Pump Pressure a Verify pump rotation b Inspect motor and pump coupling for wear at shaft key non submersible only 2 Low Operating Pressure A Waste or Product Flow Too High a Adjust waste flow to equal product flow rate b Adjust system pressure B Incorrect Pump Rotation 3 phase motors only a Switch any two of three power leads to unit at service disconnect C Faulty Pressure Relie...

Page 80: ...all pressure relief valve on product line 5 8 Product Flow Too Low 1 Waste Flow Too Low a Adjust waste pressure regulator 2 Low Feed Water Temperature a Install or adjust temperature blending valve 3 Membrane Fouled Or Scaled a See test report for original flow rate b Clean membrane following procedure outlined in manual 4 Center Tube Of ROMA Collapsed From Operating At High Temperatures a Correct...

Page 81: ...ust flow 5 10 Poor Apparent Water Quality 1 Waste Flow Too Low a Open waste flow control valve 2 Waste Pressure Too Low a Adjust waste pressure regulator 3 Product Flow Too High a See section 5 9 4 Membrane Scaled Or Fouled a Verify condition of pretreatment equipment b Reference the membrane cleaning procedure to remove scale 5 Erroneous Meter Readout a Verify water quality with independent meter...

Page 82: ...ions c Replace inlet water sensor probe d Replace product water sensor probe percent rejection e Replace monitor circuit board 6 Membrane Failure a Replace membrane 7 Change In Feed Water TDS a Verify feed and product water quality with independent meter b Softener problem rinsing out high levels of salt 5 12 RO Pump Leaks At Inlet 1 Inlet Connection Leaking a Tighten inlet fitting 2 Mechanical Se...

Page 83: ...alve Malfunction 1 Connections a Ensure the Product Divert Controller power cord is connected to the appropriate outlet b Check outlet and circuit breaker fuse panel for power c Verify the wire lead connections inside the Product Divert Controller and to the Divert Valve and RO controller are correctly and securely attached Reference the wire connection diagrams in Chapter 6 for a visual descripti...

Page 84: ...Z Series RO System by GE Osmonics NOTES 1238339b 16Oct03 5 12 Troubleshooting ...

Page 85: ...Z Series RO System by GE Osmonics Z Series RO System CHAPTER SIX DRAWINGS 1238339b 16Oct03 6 1 Drawings ...

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Page 87: ...Z Series RO System by GE Osmonics WASTE FLOW VALVE FLUID PANEL ASSEMBLY PRESSURE REGULATOR VALVE ASSEMBLY AIR BLEED VALVE 1238339b 16Oct03 6 3 Drawings Z Series RO Indirect Feed Component Layout ...

Page 88: ...NG VALVE RO BYPASS VALVE VALVE PREFILTER ASSEMBLY DISINFECT VALVE INLET WATER SOLENOID HIGH PRESSURE PUMP ASSEMBLY ROMA AUTO FLUSH ASSEMBLY 1238339b 16Oct03 6 4 Drawings Note Part of the frame has been removed to expose components Z Series RO Indirect Feed Component Layout ...

Page 89: ...Z Series RO System by GE Osmonics PRESSURE REGULATOR VALVE WASTE FLOW VALVE FLUID PANEL ASSEMBLY CONTROLLER ASSEMBLY 1238339b 16Oct03 6 5 Drawings Z Series RO Direct Feed Component Layout ...

Page 90: ...Z Series RO System by GE Osmonics Note Part of the frame has been removed to expose components Z Series RO Direct Feed Component Layout 1238339b 16Oct03 6 6 Drawings ...

Page 91: ...Z Series RO System by GE Osmonics 1238339b 16Oct03 6 7 Drawings Z Series RO Typical Indirect System Pretreat Diagram ...

Page 92: ...READED FITTING TO RECEIVE A MALE THREADED PVC FITTING BY ZYZATECH CONDUCTIVITY OR RESISTIVITY MONITOR PROBE TYP 4 pls O 2 MICRON HYDROPHOBIC VENT FILTER FM DFS ALARM LOW LEVEL UV LAMP LOOP RETURN TYP 4 pls BY OTHERS LOOP SUPPLY DISTRIBUTION BOOSTER PUMP S RO WASTE RO UNIT W FLOAT SWITCHES STORAGE TANK 5 PUMP SWITCHING CONTROLLER DI LOOP CONNECTION WITH QUICK DISCONNECT FS FM FM FM FILTERS ELECTRIC...

Page 93: ...Z Series RO System by GE Osmonics 1238339b 16Oct03 6 9 Drawings Z Series RO Typical Direct System Pretreat Diagram ...

Page 94: ... MONITOR D A M DISINFECT ALERT SAFETY DISCONNECT PRODUCT DIVERT CONTROL BOX 4x4 ELEC BOX FLUSH MOUNTED WITH 10FT WHIP FOR RO BY OTHERS DI CONNECTION VALVE 1 2 4 3 D A M FLOW SWITCH OTHERS SHALL SUPPLY A FEMALE THREADED FITTING TO RECEIVE A MALE THREADED PVC FITTING LOOP RETURN BY OTHERS TYP 4 pls PROBE TYP 4 pls BY ZYZATECH CONDUCTIVITY OR RESISTIVITY MONITOR DFS FM LOOP PSI RELIEF UV LAMP FM LOOP...

Page 95: ... FLUID PANEL DEPTH 32 5 HEIGHT 75 WIDTH 30 CONTROLLER RO BYPASS PORT 3 4 FNPT WASTE WATER PORT 3 4 FNPT PRODUCT WATER PORT 3 4 FNPT FEED WATER PORT 3 4 FNPT HOUSING PREFILTER FRONT PUMP CASING SUCTION PORT DISINFECTANT CLEANER REAR Millenium RO Z Series RO Typical Unit Diagram Input Manifold 50 60Hz ...

Page 96: ...Z Series RO System by GE Osmonics 1238339b 16Oct03 6 12 Drawings Z Series RO Indirect Feed Flow Diagram ...

Page 97: ...Z Series RO System by GE Osmonics 1238339b 16Oct03 6 13 Drawings Z Series RO Direct Feed Flow Diagram ...

Page 98: ...D TB1 2 PSI 4 2 1 TR1 1 CR2 8 SWITCH OVERRIDE 12 SWITCH HI LEVEL TB3 9B TB3 10B A 7 B 2 A B TR2 TR1 PRESSURE LAMP RED 0 6 SEC DELAY INLET SOLENOID TB3 1A 2 TB2 8B TB2 8A CR1 T3 T2 T1 TB1 6A TB4 1B CR6 5 12 CR7 8 J4 11 J4 12 9 1 3 DISINFECT SWITCH SECONDARY 24 VAC SUPPLY POWER MONITOR RELAY COIL TIME DELAY RELAY COIL INDICATING LAMP DIVERT PRODUCT TB4 7B TB3 3B TB3 5B INTERLOCK CR3 14 13 A B 7 2 L1...

Page 99: ...RMINAL LOCAL DAM FROM MONITOR PCB 5 9 TB1 3A TB1 8A TB4 6A CR4 CR3 WASTE FLUSH SOLENOID 9 12 8 A CR3 4 12 TB2 7A TB3 10B TB3 7B TB3 9B TB3 8B HI LEVEL SWITCH LO FLOAT SWITCH 12 1 9 13 B OVERRIDE SWITCH 8 CR2 CR2 5 CR2 14 1 TB3 1A TR1 5 CR1 1 CR1 8 4 CR1 SWITCH DISINFECT DIS 3 1 12 PSW POWER SWITCH TB1 5A TB3 5A 14 13 CR6 2 5 12 11 8 7 J4 10 2 1 24 25 V10 XFM2 TB1 6A TB2 7 TB2 8 TB2 9 12 CR7 8 J4 1...

Page 100: ...DUCT HOSE DISINFECTION CLEANING CONNECTION FOR SYSTEM RO SYSTEM WASTE HOSE SUCTION DISINFECTANT SUCTION HOSE PRODUCT TANK DISINFECT CONNECTION FOR NORMAL OPERATION WASTE DRAIN MANIFOLD REF TO LOOP OR STORAGE TANK SAMPLE VALVE REF RO WASTE TO DRAIN HOSE PRODUCT HOSE PRODUCT OUTPUT 1238339b 16Oct03 6 16 Drawings Z Series RO Typical Whisperflow Pump Connections for Disinfection ...

Page 101: ...Z Series RO System by GE Osmonics 1238339b 16Oct03 6 17 Drawings I O OFF ON Z Series RO Typical Controller ...

Page 102: ...es RO System by GE Osmonics 1238339b 16Oct03 6 18 Drawings TB1 TB2 CR7 CR6 3 TR1 LOAD T1 INPUT 2 1 TR2 B A F3 CR3 CR1 CR4 4 CR2 B XFM 1 A B F2 XFM 2 A B F1 A B 6 A TB3 9 TB4 Z Series RO Relay Operation Detail ...

Page 103: ...Z Series RO System by GE Osmonics 1238339b 16Oct03 6 19 Drawings INPUT 3 1 2 LOAD Z Series RO Control Box Chassis Major Component Locations ...

Page 104: ...BLACK 12 11 10 9 3 ORANGE RED BLK GRN BLK BLU BLK OR BLK 7 6 4 5 RED 2 1 RED BLACK RO STATUS MONITOR PRD DIVERT 2 3 2 1 CHEM FEED TR2 5 HIGH FLOAT 1 HIGH FLOAT 2 LOW FLOAT 1 BLACK RED 4 2 3 RED 1 TR2 8 OVER TEMP ALARM RO CONTROLLER TIMER 1238339b 16Oct03 6 20 Drawings NOTE Operation of this unit without level switches i e Direct Feed requires a jumper to be installed typically installed at factory...

Page 105: ...HT YEL BLK 11 9 10 12 J2 7 8 6 4 2 3 5 RO STATUS CIRCUIT 1 CON12 CON PROBE 3 4 5 GREEN YELLOW ORANGE 7 WHITE 6 BLUE TO REJ SEL SW CONDUCTIVITY PROBE BOARD ASSY KEY TB 2 TB 3 WHITE RED 1 2 5 4 3 HEAT SHRINK SHIELD GREEN BLACK TH 10K PROBE ORANGE BLACK WHITE WHITE BROWN RED GREEN PURPLE BLUE BLACK YELLOW 11 10 9 8 12 1 3 4 2 5 6 7 KEY 1 10 9 8 5 6 7 4 3 2 FEED PROBE REJ PRODUCT REJ PROBE REJ PCB 6 5...

Page 106: ...Z Series RO System by GE Osmonics Z Series RO Disinfect Alarm Monitor Wiring Connections 1238339b 16Oct03 6 22 Drawings ...

Page 107: ...Z Series RO System by GE Osmonics 1238339b 16Oct03 6 23 Drawings Z Series RO Fluid Panel ...

Page 108: ...Z Series RO System by GE Osmonics 1238339b 16Oct03 6 24 Drawings 40396 40674 12905 12095 40675 12904 Z Series RO Fluid Panel Assembly Rear View ...

Page 109: ...Z Series RO System by GE Osmonics 1238339b 16Oct03 6 25 Drawings 40397 40640 40080 40087 40727 Z Series RO Pressure Regulator Assembly ...

Page 110: ...Z Series RO System by GE Osmonics 1238339b 16Oct03 6 26 Drawings Z Series RO Waste Flow Control Valve Assembly ...

Page 111: ...USING SS FLAIRED END SCREW 5 16 18 X 1 1 4 MEMBRANE ADAPTER FLOW ARROW LABEL 41309 HOUSING ENDCAP O RING EXTERNAL O RING INTERNAL 1 2 PLUG 41410 80350 42055 41413 41409 41408 PART NO DESCRIPTION NYLOK NUT CLAMP HALF 41410 41409 13395 13394 13393 41409 41309 1229990 13393 1235145 13395 SEE BELOW 1238339b 16Oct03 6 27 Drawings Z Series RO Reverse Osmosis Membrane Assembly ROMA Components ...

Page 112: ...LEASE OF TUBE PUSH TUBE ATTACH LOCKING CLIP BETWEEN COLLET FLANGE AND FITTING TEETH THAT GRIP TUBE O RING PROVIDES SEAL COLLET HAS STAINLESS STEEL CONTRIBUTE TO LEAKAGE INTERNAL COMPONENT REPLACEMENTS ARE NOT LEAKS CHECK FOR IMPROPER TUBE INSERTION OR TUBE ROUTING THAT MAY NOTE FITTING IS NOT DESIGNED TO BE DISASSEMBLED IF THE FITTING PUSH TUBE INTO FITTING TO SECURE AVAILABLE PUSH IN FITTNGS Push...

Page 113: ...NCY NORMAL RUN EXTREME DANGER TO PATIENTS AND USE OVERRIDE FUNCTION ONLY EQUIPMENT WHEN IN OVERRIDE MODE AUTOMATIC SHUTDOWN FUNCTION OF WHEN SWITCH IS IN OVERRIDE THIS SAFETY DEVICE IS ELIMINATED OVERRIDE 800 633 3080 SEATTLE WASHINGTON R O UNIT INTERLOCK Over Temperature Alarm General Components ...

Page 114: ...Z Series RO System by GE Osmonics Over Temperature Probe Probe Installation 1238339b 16Oct03 6 30 Drawings ...

Page 115: ...Z Series RO System by GE Osmonics 1238339b 16Oct03 6 31 Drawings Over Temperature Alarm Electrical Schematic Reference Only ...

Page 116: ...WG FTTNG CONDUIT 1 2 ST CONDUIT CRFLX UNSHLD 1 2 INDICATOR 1 2 110V RED FUSE 3AMP SLO BLO 60627 PART NO 60362 30044 30080 20089 20036 1236373 41507 20114 30044 FRONT VIEW WITH COVER CLOSED CAUTION SERVICING TO QUALIFIED SERVICE DO NOT REMOVE COVER REFER RISK OF ELECTRIC SHOCK PERSONNEL 450016 C 20036 TO VALVE 1236373 60362 20114 9 2 1 8 3 5 4 6 7 10 20089 30080 41507 60627 Product Divert General C...

Page 117: ... A SPRING RETURN CHECK VALVE MINIMUM 1 2 PSI CLAMP WORM GEAR 1 40169 ALL THREADED PARTS TO BE WRAPPED WITH TEFLON TAPE HOSE 1 ID 125PSI GRY 1 PVC TEE FEMALE 40926 2 40169 PART NO 1228209 41582 40926 40864 40863 40386 60343 40611 1 NOTES 1228209 40386 WALL MOUNTING REFERENCE 40169 FROM RO PRODUCT DESCRIPTION 3 DRAIN LINE 40863 60343 40864 2 PLS TO STORAGE TANK OR DIRECT TO LOOP 41582 40611 TO CONTR...

Page 118: ...8 3 24V HOT RED TB4 7 ON RO NEUTRAL WHITE WHITE VALVE GREEN F1 B A BLACK 3 AMP SLO BLO BLACK OPEN CLOSE RED NO 1 DIVERT PRODUCT CR5 24V AC NEUTRAL BLACK 1 TB4 1 ON RO 4 3 2 5 6 14 13 9 8 7 10 TB1 1 9 5 4 12 8 A B L1 Product Divert Product Divert Connection to RO Controller 1238339b 16Oct03 6 34 Drawings ...

Page 119: ...Z Series RO System by GE Osmonics NOTES 1238339b 16Oct03 6 35 Drawings ...

Page 120: ...Z Series RO System by GE Osmonics This page intentionally left blank 1238339b 16Oct03 6 36 Drawings ...

Page 121: ...Z Series RO System by GE Osmonics Z Series RO System CHAPTER SEVEN SPARE PARTS LIST 1238339b 16Oct03 7 1 Spare Parts List ...

Page 122: ...Z Series RO System by GE Osmonics This page intentionally left blank 1238339b 16Oct03 7 2 Spare Parts List ...

Page 123: ...Timer 1234711 Cycle Timer Auto Flush 1234732 Valve Solenoid 1 1235402 Motor Contactor Delay Timer Relay 1235403 Motor contactor 7 5 Hp 1236035 Power Switch 1236350 Printed Circuit Board Conductivity 20007 Disinfect Switch 20089 Relay 24 VAC 20120 Fuse 1 Amp 20127 Lamp 1 2 24 VAC Red 21144 Lamp 1 2 24 VAC Green 30080 Relay Socket 8 Pin Small 30110 Relay Socket Adjustable Timer 30118 1 Float Switch ...

Page 124: ...8 60370 Hose 3 8 50092 Hose 5 8 CLEANERS 14962 Membrane Cleaner BIOSAN II 1 gal liquid 14963 Membrane Cleaner BIOSAN II 5 gal liquid 1228792 Membrane Cleaner Hi pH 5 gal 1228791 Membrane Cleaner Hi pH 1 gal 1228654 Membrane Cleaner Low pH 5 gal 1228653 Membrane Cleaner Low pH 1 gal TESTS 50033 Hardness Test Kit 14604 Silt Density Index SDI Test Kit 11656 Total Chlorine Test Kit 70001 Water Test Ki...

Page 125: ... 8GA Franklin 30400 Overload Thermal 7 5 11 Amp 30399 Overload Thermal 10 14 Amp 30398 Overload Thermal 13 19 Amp 30401 Overload Thermal 18 25 Amp 30397 Overload Thermal 24 32 Amp 10327 Pump only Whisperflow 7 5Hp High Pressure 10261 Pump only Whisperflow 5Hp 10251 Pump only Whisperflow 7 5Hp Low Pressure Suggested Stock Items Suggested Stock Items if applicable to unit Optional Refer to equipment...

Page 126: ...Z Series RO System by GE Osmonics NOTES 1238339b 16Oct03 7 6 Spare Parts List ...

Page 127: ......

Page 128: ... 633 3080 in the U S or visit www gewater com Corporate Headquarters Kent Operations 5951 Clearwater Drive 7848 South 202nd ST Minnetonka MN Kent WA 55343 8995 98032 1345 USA USA 952 933 2277 Phone 253 395 2200 Phone 952 933 0141 Fax 253 395 2363 Fax ...

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GE Osmonics Z-10000, Operation And Maintenance Manual

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