GE E4-1100 Installation, Operation And Maintenance Manual Download

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OSMONICS

E4, E4LE, EZ4 SERIES

WATER PURIFICATION

MACHINES

INSTALLATION, OPERATION,

AND MAINTENANCE

MANUAL

GE Infrastructure
Water & Process Technologies

Summary of Contents for E4-1100

Page 1: ...OSMONICS E4 E4LE EZ4 SERIESTM WATER PURIFICATION MACHINES INSTALLATION OPERATION AND MAINTENANCE MANUAL GE Infrastructure Water Process Technologies ...

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Page 3: ...2 8 2 Three Phase Electrical 5 2 9 Machine Control 6 2 9 1 Economy Model 6 2 9 2 Deluxe Model 6 2 10 Pretreatment for Water Purification 7 2 11 Machine Start Up Preparation 7 2 12 Machine Start Up 7 2 13 Temperature Correction Factors 9 2 14 Recovery 10 2 15 Autoflush Timer 11 2 15 1 Programming the Autoflush Timer 11 2 15 2 Setting Up the Autoflush Timer Clock 11 2 15 3 Programming the Autoflush ...

Page 4: ...ing 19 2 21 Changing Out Membrane Elements 20 2 22 Troubleshooting 22 LIST OF FIGURES Figure Description 2 1 Three Phase Allen Bradley Motor Starter 6 2 2 Setting Up the Correct Time on the Autoflush Timer 11 2 3 Programming the Timer 13 2 4 Conductivity Probe Display 15 2 5 Clean In Place Pump and Tank Hook Up 18 LIST OF TABLES Table Description 2 1 Connections 1 2 2 E Series Feed Water Requireme...

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Page 6: ...nd pressures to main tain an operating feed water pressure of 30 60 psig 2 1 4 1 barg If the feed water pressure with the machine is in excess of 60 psig 4 1 barg or fluctuates by more than 5 psig 0 34 barg a pressure regulator should be installed up stream of the machine Inlet If proper water pressure cannot be maintained to the RO a booster pump may need to be installed in front of the pretreatm...

Page 7: ... permeate and concentrate to drain for flush ing at start up WARNING NEVER OPERATE THE MACHINE WITH THE CONCENTRATE OR PER MEATE LINES BLOCKED SEVERE DAMAGE TO THE UNIT MAY RESULT 2 4 Concentrate Outlet Connections Connect proper size drain line to the concentrate outlet Table 2 1 and run to an open drain The drain capacity needs to be large enough to properly drain the feed water flow of the RO T...

Page 8: ... permeate and concen trate piping sizes Refer to Connections Table 2 1 for inlet permeate and concen trate piping sizes WARNING MACHINE DAMAGE MAY OCCUR IF PERMEATE BACK PRESSURE EXCEEDS 60 PSIG 4 1 BARG DURING OPERATION 3 Temperature Inlet Pressure Chlorine continuous feed Operating pH Silt Density Index SDI Typical 50 85 F 10 29 C Limits 33 104 F 0 16 40 C Minimum 30 psig 2 1 barg Maximum 60 psi...

Page 9: ... MACHINE DAMAGE MAY OCCUR WARNING INSTALLING A CHECK VALVE WILL PREVENT REVERSE FLOW THROUGH THE MEMBRANE ELEMENT WHEN THE MACHINE IS NOT IN OPERATION REVERSE FLOW WHEN THE MACHINE IS NOT IN OPERATION CAN SEVERELY DAMAGE THE MEMBRANE ELEMENTS 4 BACK PRESSURE 10 psig 0 7 barg 20 psig 1 4 barg 30 psig 2 0 barg 40 psig 2 7 barg 50 psig 3 4 barg 60 psig 4 1 barg LOSS OF PERMEATE FLOW E4 EZ4 E4LE 5 10 ...

Page 10: ...tarter box or by checking electrical specifications on the pump The motor is wired for 460 Volts 60 Hertz three phase voltage from the factory Figure 2 1 Three Phase Allen Bradley Motor Starter The pump motor can be rewired to 208 or 230 Volts If this is done a wiring change must be made internally in the pump motor and a higher amperage relay and starter may need to be installed All field wiring ...

Page 11: ...ponents in series After all field wiring is complete and complies with local and national electrical codes move onto Section 2 10 Pretreatment for Water Purification NOTE External control contacts are normally closed dry contacts 2 9 2 Deluxe Model To remotely control the Deluxe Model DLX with float switches and or pre treatment lockout remove the jumper between terminals 2 and 3 and wire in the f...

Page 12: ...posite TLC polyamide PA membrane ele ments in your machine Daily water checks are recommended to ensure the integri ty of your pretreatment and RO system 2 11 Machine Start Up Preparation Check the function and integrity of your pretreatment equipment Ensure that your water softener and activated carbon filters have been leaked checked and properly flushed before starting up your RO machine CAUTIO...

Page 13: ...ROTATION i e BACKWARDS A NOTICEABLE DROP IN FLOWS AND PRESSURES WILL RESULT IF PUMP MOTOR OPERATES BACK WARDS FOR ANY LENGTH OF TIME PUMP DAMAGE MAY RESULT After correct rotation has been verified you are now ready to start the machine and set the flows and pressures 9 With the recycle and concentrate orifices still two 2 turns open and ade quate feed water available start the machine by turning t...

Page 14: ...C use the Temperature Correction Factor Table Technote 113 The proper adjustment of the recycle and concentrate valves are critical to the correct operation of the machine CAUTION Optimum recovery will vary according to water quality 2 13 Temperature Correction Factor If the temperature of the inlet feed water is not 77 F 25 C refer to Technote 113 for Temperature Correction Factors NOTE Optimum r...

Page 15: ... GPM 11 6 3 06 11 6 3 06 3 9 1 0 23 2 6 1 15 4 4 1 E4 Series Recovery Units Permeate Rate Concentrate Rate 50 Concentrate Rate 75 Feed Rate 50 Feed Rate 75 6600 50 75 LPM GPM 17 3 4 6 17 3 4 6 5 8 1 5 34 7 9 2 23 1 6 1 8800 50 75 LPM GPM 23 1 6 1 23 1 6 1 7 7 2 0 46 2 12 2 30 8 8 2 11000 50 75 LPM GPM 28 9 7 6 28 9 7 6 9 6 2 5 57 8 15 3 38 5 10 2 13200 50 75 LPM GPM 34 7 9 2 34 7 9 2 11 6 3 06 69 ...

Page 16: ...to 15 minute duration per 24 hours To do this follow the procedure below 2 15 2 Setting Up the Autoflush Timer Clock IMPORTANT Before proceeding with setting the timer and programming the unit press the RESET KEY to clear all data After press ing the RESET KEY the display may show A M this is in mili tary time mode If the machine is in Military Time do the following Figure 2 2 Setting Up the Corre...

Page 17: ...set when setting the time The timer cannot be programmed unless the day of the week is entered Each year in the spring press the Button to advance the time one hour Daylight Savings Time In the fall press the button to set the timer back one hour Daylight Savings Time 2 15 3 Programming the Autoflush Timer Clock This timer will accept up to 20 programs Each program consists of the fol lowing 1 ON ...

Page 18: ...Day Key just as in the initial programming Hour and minute can be changed with the h and m Keys 2 15 6 Deleting a Program To delete one or a few programs Press the Prog Key until the desired pro gram is displayed 1 Press the m Key to 59 and press once again to blank out 2 Press h Key to 11 P M and press once again to blank out 3 Press the Clock Key display will flash for several seconds and then e...

Page 19: ...g Up the Autoflush Timer Clock PROBLEM Time of day was set while holding the Clock Key down but days are still flashing SOLUTION Current day of week was not set while holding down the Clock Key See Setting Up the Autoflush Timer Clock Section 2 15 2 PROBLEM It is 10 A M and a ON program for 8 A M was entered but the output is not ON SOLUTION The ON or OFF was not entered as part of the program ON ...

Page 20: ...epared solu tion 3 Immerse and agitate Conductivity Probe and wait for the reading to stabilize 4 Calibrate the meter by adjusting the CAL adjustment screw until the Liquid Crystal Display LCD display reads 13 mS of the solution The meter is now calibrated NOTE The alarm function on the conductivity meter is not used on E4 EZ4 E4LE Series machines Figure 2 4 Conductivity Probe Display 15 ...

Page 21: ... 2 Clean the RO membrane elements with approved cleaners at least quarterly depending on feed water quality 3 Flush the RO machine daily 2 17 1 Daily Flushing for the Economy Model If your E4 Series machine is an ECN Model it needs to be manually flushed daily The DLX E4 Series machine is equipped with an Autoflush Timer Section 2 15 Autoflush Timer A daily manual flush must be performed To flush ...

Page 22: ...permeate flow rate and affecting the quality of the permeate 2 19 1 Step Wise Cleaning This RO machine and many others have a centrifugal pump on them Centrifugal pumps are not designed to draw water They are designed to operate with flooded suction only The manufacturer recommends using a Clean In Place CIP or booster pump to provide water pressure and flow to the RO machine pump from the CIP con...

Page 23: ... CIP configuration and the cleaning solution mixed in the container you are now ready to start the CIP process Follow the Steps below STEPS 1 Check to ensure that the feed permeate and concentrate valves and line are open and unrestricted in the tank loop 2 Start the CIP and RO machine pumps together As they start up observe all RO machine pressures and flows 3 Recycle the cleaning solution for ab...

Page 24: ...e Section 2 19 2 Procedure to Clean with a CIP Pump STEPS 1 Arrange the RO and the CIP container in a closed loop situation with the cleaning solution reference Section 2 19 Membrane Element Cleaning 2 Move the L1 and L2 wires on the pressure switch across to the motor termi nals Figure 2 1 Three Phase Allan Bradley Motor Starter The wires can also be temporally jumped 3 Open the inlet feed valve ...

Page 25: ...rin or poly water 2 Load the down flow membrane elements first by inserting the membrane element into the membrane element housing with the brine seal end of the membrane element up Slowly turn the membrane element as you lower it into the membrane element housing As you reach the bottom of the hous ing slowly guide the PVC stem or stinger on the end of the membrane element into the head of the en...

Page 26: ...21 5 Reattach the housing clamp and tighten 6 Next reconnect the permeate and concentrate lines The machine is ready for start up ...

Page 27: ...ber 3 Serial number 4 Weekly log sheets 5 Detailed description of problem 22 POSSIBLE CAUSE Insufficient feed water pressure or flow Clogged pre filter High flow rates Dirty or fouled membrane elements Solenoid valve not opening PROBLEM Low Operating Pressure SOLUTION Open the feed pressure open the feed water valve check for restrictions Replace the cartridge Close the concentrate valve check the...

Page 28: ...ads to the motor starter Check the fuses or circuit breaker measure the voltage See pump instructions See possible causes for low pressure Flush and clean membrane elements Install a hot cold feed water tem pering valve if more permeate flow is needed Operate with a feedwa ter temperature of 72 75 F 22 25 C Install membrane elements in the direction of fluid flow Flush and clean the machine immedi...

Page 29: ...pressure SOLUTION Remove the concentrate valve step and or disassemble the plumbing Clean the valve Examine the concentrate line for obstructions or kinks repair or replace the tubing Check the flow rate manually with a stop watch and calibrated container Disassemble and clean the plumbing to the valve Disassemble the plumbing to the recycle valve and remove foreign particles Check the concentrate...

Page 30: ... the membrane elements Flush the machine then clean it with detergent Clean or replace the valve Clean the membrane elements with deter gent immediately Water must not pass through the inlet when the machine is OFF Flush and clean the membrane elements Replace the O ring check the seal ing surfaces on the O ring groove interconnectors and end caps Replace the damaged parts Open the concentrate val...

Page 31: ...chine shutdown SOLUTION Check the permeate back pressure or position of float in the storage tank Allow the machine to cool check the feed water supply and or amp draw to the motor Check the fuses or circuit breakers measure the voltage See the pump instructions Contact GE Infrastructure for possible repair or replacement Restart the machine by pushing the alarm bypass Check all possible alarm con...

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