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Troubleshooting

If the system production declines or
the unit stops working, check the
mechanical components for any
visual problems. Listed below are the

items to check for two of the most
commonly encountered problem
conditions: LOW SYSTEM
PRESSURE and ABNORMAL

PERMEATE FLOW. Also refer to the
RO troubleshooting matrix on page
37.

LOW SYSTEM PRESSURE

Low system pressure occurs when

sufficient feed water pressure and
flow are not obtained. This causes
the high-pressure RO pump to
cavitate. Failure to provide the

proper feed will result in lower
system pressure that may result in
low production and poor rejection.
Check the following components:

1. PUMP:

Isolate the pump and determine how
much pressure can be achieved.

This can be determined by checking
the pump discharge pressure gauge
at this point. If the system is not
equipped with this gauge,

disconnect the hose that runs from
the pump to the pressure vessel.
Install a pressure gauge. The
pressure of the pump must reach at

least 190 psi when the flow is
restricted.

2. PRE-FILTER:

Check the differential in the pre-filter
gauges to determine if the filter
needs to be replaced. If the

system is not equipped with these
gauges, examine the pre-filter
cartridge to make sure that it is not
clogged and does not restrict feed

flow to the pump. Replace, if
necessary.

3. LOW FEED WATER FLOW

RATE:

Determine that the unit is getting a
sufficient volume of feed water.
Disconnect the feed water hose from

the machine and place it in a one-
gallon bucket. Measure the time it
takes to fill the bucket to determine

the feed flow. (Feed flow is
measured in gallons per minute, so
divide 1 gallon by the time in minutes
to obtain the flow rate).

Refer to the System Specifications
(Table 1 on page 6, or Table 2 on
pages 7) for the required feed flow.

4. INLET SOLENOID VALVE:

(see

pointer 15 on the diagram of
your system):

Feed water enters the system
through an automatic solenoid shut-
off valve, which is normally closed.
Ensure that the solenoid opens when

the RO pump starts. The system can
be operated without the solenoid for
troubleshooting. Remove the
solenoid to see if it is contributing to

the problem. Normally, cleaning the
solenoid diaphragm will correct any
malfunction of the solenoid.

5. ELECTRIC:

Check to ensure that there are no
electrical fuses blown and that all

EPRO 150-8000 O&M MANUAL Rev.04/03 Page 35 of 55

Содержание EPRO Series

Страница 1: ......

Страница 2: ...r EPRO XP Installation 18 Fig 5 EPRO XP System 20 Fig 6 EPRO A Series System 21 Fig 7 EPRO P Series System 21 Fig 8 EPRO WM Series Picture 22 Fig 9 EPRO XP Series Picture 22 Operation Maintenance 23 Pump Throttle Valve Fig 10 Pump Curves 25 Membrane Cleaning 27 Fig 11 Pressure Vessel Tools 30 Fig 12 Pressure Vessel Diagram 30 Are Carbon Fines Fouling Your Membranes 31 Activated Carbon Filter Start...

Страница 3: ...5 Micron Filter Cartridge 1 10 X 3 8 Clear Hose 1 10 X 3 8 Black Tube 1 10 X1 2 Garden Hose 2 Hose Connections EPRO 1500 8000 SYSTEMS 1 5 Micron Filter Cartridge 2 10 X Black Tube 2 Clamps 2 Hose Connections EPRO 150 8000 O M MANUAL Rev 04 03 Page 1 of 55 ...

Страница 4: ...e membrane and are left behind What is a semi permeable membrane A semi permeable membrane is very similar to your skin The membrane is made of thin multi layered sheets with microscopic pores that let water pass through while acting as a barrier to stop dissolved particles like salt THE REVERSE OSMOSIS MEMBRANE ELEMENT CONCENTRATE WATER containing salts is rejected by the membrane and does not en...

Страница 5: ...behind dissolved particles This process purifies the water often reducing total dissolved solids content by 99 MEMBRANE BRINE WATER FIG 2A REVERSE OSMOSIS APPLIED PRESSURE BRINE WATER WATER BRINE Osmotic Pressure Crane Environmental systems use semi permeable spiral wound thin film membranes to separate and remove dissolved solids organic material pyrogens submicron colloidal matter viruses and ba...

Страница 6: ...Fig 2B Reverse Osmosis System EPRO 150 8000 O M MANUAL Rev 04 03 Page 4 of 55 ...

Страница 7: ...it a 300 gallon atmospheric storage tank a liquid level control and a re pressurization system A variety of storage tanks and re pressurization systems are available The WM series are reverse osmosis systems suitable for wall mounted installation to save floor space REJECTION AND RECOVERY The amount of total dissolved solids TDS rejected by the membrane is expressed as a percentage For example a 9...

Страница 8: ...Table 1 EPRO 150 8000 O M MANUAL Rev 04 03 Page 6 of 55 ...

Страница 9: ...Table 2 EPRO 150 8000 O M MANUAL Rev 04 03 Page 7 of 55 ...

Страница 10: ...15VAC or 230VAC at 60 Hz or 220VAC at 50 Hz The three phases are available in 230 460VAC at 60Hz or 220 380VAC at 50 Hz Ensure that the electrical circuit supplying the system is compatible with the requirements of the specific EPRO model Note We recommend that a licensed electrician install your unit in accordance with local and national electrical codes Each EPRO system excluding the EPRO 4500 t...

Страница 11: ...EPRO 1500 to 8000 are multi stage centrifugal pumps Follow these guidelines for proper operation of both pumps The pump must NEVER be run dry Operating the pump without sufficient feed water will damage the pump ALWAYS feed the pump with filtered water The rotary vane type pump is especially susceptible to damage from sediment and debris EPRO 150 8000 O M MANUAL Rev 04 03 Page 9 of 55 ...

Страница 12: ...Water Systems projected output is based on feed water with a TDS of 500 ppm or less at 77 F Higher TDS and or lower temperature will reduce system production Note It is very important to meet feed water requirements Failure to d so will cause membranes to foul and void the warranty 1 grain 0 ppm 0 ppm 0 05 ppm 1000 ppm 1 ppm 5 40 F 80 F 3 11 8 C 27 C 0 01 ppm 20 60 psi 1 ppm Pressure Temperature T...

Страница 13: ... vibrations For wall mounted units attach the system to the wall securely hardware not provided Additional instructions for XP series installation are provided on page 18 and 19 Carefully inspect your system before start up Check all plumbing and electrical connections Connections may have loosened during shipment The following hoses are shipped loose to assist in installation A 10 clear braided i...

Страница 14: ... the membrane CAUTION the plumbing in the permeate line can contaminate the high quality water produced by the EPRO system ensure that the components are compatible with the application The pH of the RO permeate will normally be 1 2 points lower than the feed water pH A pH of 6 5 or lower can be very aggressive to some plumbing materials such as copper piping 10 Locate the concentrate waste outlet...

Страница 15: ... machine contains a preservative solution that can be harmful if digested Discard the product and concentrate water from the first one 1 hour of operation Turn the concentrate control valve until the concentrate pressure gauge indicates a pressure of 50 psi Flush the machine at 50 psi for one 1 hour to remove the preservative from the system Check for leaks All Crane Environmental reverse osmosis ...

Страница 16: ...ff valve Ensure that the valve opens when the system turns on allowing water flow through the system and closes when the system turns off stopping water flow through the system This will save water and prevent premature fouling of the reverse osmosis membrane Complete Table 4 Operation Log on page 15 with your Start Up data and return to Crane Environmental to validate your reverse osmosis system ...

Страница 17: ...PRESSURE psi CONCENTRATE PRESSURE psi DIFFERENTIAL PRESSURE psi PUMP DISCHARGE PRESSURE psi PERMEATE FLOW GPM CONCENTRATE FLOW GPM FEED FLOW GPM RECOVERY FEED TEMPERATURE o F FEED CONDUCTIVITY mg L PERMEATE CONDUCTIVITY mg L REJECTION FEED pH PERMEATE pH SCALE INHIBITOR FEED PPM ACID FEED PPM SODIUM BISULFITE FEED PPM FEED WATER IRON mg L FREE CHLORINE mg L HARDNESS PPM CaCO3 TURBIDITY NTU EPRO 15...

Страница 18: ...RE VALVE 7 CONCENTRATE FLOW METER 8 PERMEATE FLOW METER 9 WASTE RECYCLE VALVE 10 INLET SOLENOID VALVE 11 PUMP 12 MOTOR 13 PRESSURE VESSEL SEE BELOW 14 CONTROL BOX LOW PRESSURE OPTIONS FLOAT SWITCH INDICATES THAT THE ITEM IS OPTIONAL NOTE THE SIZE AND NUMBER OF THE PRESSURE VESSLES VARIES ACCORDING TO EPRO MODEL EPRO 150 8000 O M MANUAL Rev 04 03 Page 16 of 55 ...

Страница 19: ...RE VALVE 7 CONCENTRATE FLOW METER 8 PERMEATE FLOW METER 9 WASTE RECYCLE VALVE 10 INLET SOLENOID VALVE 11 PUMP 12 MOTOR 13 PRESSURE VESSEL SEE BELOW 14 CONTROL BOX LOW PRESSURE OPTIONS FLOAT SWITCH INDICATES THAT THE ITEM IS OPTIONAL NOTE THE SIZE AND NUMBER OF THE PRESSURE VESSLES VARIES ACCORDING TO EPRO MODEL EPRO 150 8000 O M MANUAL Rev 04 03 Page 17 of 55 ...

Страница 20: ...ttom of the storage tank Use Teflon tape to prevent leaking Plumb from the storage tank suction tube to the inlet nose cone on the re pressurization pump Make sure that the check valve is pointing in the direction of the water flow 3 Connect the line from the re pressurization system to the point of use This will be from the cross fitting on the bottom of the pressure tank piping 4a Level Control ...

Страница 21: ...et 2 psi below the cut in pressure see example below 7 Priming After the storage tank is filled the re pressurization system must be primed and started Prime the pump by removing the pressure gauge and pouring water into the pump Reinstall the pressure gauge in the fitting Move the lever on the side of the pressure switch to the START position Open the drain valve slightly to allow air to escape d...

Страница 22: ...OTOR OR CONTROL BOX TO FLOAT SWITCH 5 LEAD to ELECTRIC POWER SOURCE 6 FLOAT SWITCH 7 FLOAT BALL 2 8 ATMOSPHERIC STORAGE TANK 9 CHECK VALVE 10 SUCTION LINE 11 PRESSURE SWITCH 12 PUMP MOTOR 13 PRESSURE SWITCH 14 POINT OF USE 15 PRESSURE GAUGE EPRO 150 8000 O M MANUAL Rev 04 03 Page 20 of 55 ...

Страница 23: ...Fig 6 EPRO A Series Fig 7 EPRO P Series EPRO 150 8000 O M MANUAL Rev 04 03 Page 21 of 55 ...

Страница 24: ...Fig 8 EPRO WM Series Fig 9 EPRO XP Series EPRO 150 8000 O M MANUAL Rev 04 03 Page 22 of 55 ...

Страница 25: ...the feed water flow rate if the system is not equipped with waste recycle Waste Recycle Valve pointer 9 on FIG 3 and 4 This valve allows you to recycle some of the concentrate water back to the feed of the pump This will increase the recovery of the EPRO system An optional waste recycle flow meter allows you to measure how much concentrate is recycled THE AMOUNT OF WASTE WATER RECYCLED IS LIMITED ...

Страница 26: ...atment 3 Where minimal maintenance is important an auto flush can increase the time between membrane cleaning 4 For high TDS total dissolved solids applications where the TDS exceeds 500 ppm consider installing an auto flush 5 For high recovery applications use of a recycle valve consider using auto flush 6 For systems that may remain inoperative for long periods of time a fast flush should be ins...

Страница 27: ...mp Curves As the feed water temperature decreases and or the feed water TDS increases the system will require a higher operating pressure to produce the specified permeate flow An EPRO 1500 installed in Florida may provide the specified permeate flow of 1 gpm at 130 psi however the same EPRO 1500 installed in Maine much colder feed water may require 190psi to produce this same amount of permeate T...

Страница 28: ...EPRO 1500 3000 50 HZ EPRO 4500 6000 50 HZ EPRO 1500 3000 60 HZ EPRO 4500 6000 60 HZ EPRO 150 8000 O M MANUAL Rev 04 03 Page 26 of 55 ...

Страница 29: ... cleaning solution to remove inorganic salts such as CaCO3 CaSO4 BaSO4 and metal oxides i e iron from reverse osmosis membranes Do not use sulfuric acid because it may cause calcium sulfate to precipitate on the membrane s Acceptable cleaning solutions all compositions given by weight Crane Environmental Cleaning Solution 3 1 lb per 15 gal of RO water A solution of 0 2 hydrochloric acid HCl A solu...

Страница 30: ...f the pre filter pointer 2 on FIG 3 and 4 from the cleaning solution tank Ensure a flooded inlet to the pump or positive feed pressure 4 Feed the permeate and the drain tubes back to the cleaning solution tank so that the solution will re circulate during cleaning 5 Turn on the reverse osmosis pump Adjust the concentrate control valve drain restrictor pointer 5 on FIG 3 and 4 to a concentrate pres...

Страница 31: ...tion of the feed flow This protects the brine seal from folding over The brine seal should ALWAYS be on the feed side of your membrane Do not pull the membrane out using the permeate port as this may cause damage 6 Replace the membrane Always feed the new membrane into the feed end of the pressure vessel Feed the membrane in the direction of water flow Failure to do so may cause damage to the brin...

Страница 32: ...Fig 11 Membrane Removal Tools Fig 12 Pressure Vessel Housing Membrane EPRO 150 8000 O M MANUAL Rev 04 03 Page 30 of 55 ...

Страница 33: ...using bowl with acid without overflowing and then attach the housing bowl back on to the inlet outlet head 8 Open feed water supply line to the RO slowly and push the red button on top of the prefilter head down to vent any air out of the housing bowl 9 Start the RO unit and allow it to run 15 to 30 seconds depending on size of RO adjust the Concentrate valve to maintain the RO pressure at 100 psi...

Страница 34: ...n projections for the system Sample the Feed water and Permeate TDS to determine Rejection If RO membrane s are still not producing proper flow and Rejection repeat the above procedures Note If the RO membrane s are producing proper flow and Rejection the Recycle valve if so equipped may be opened to increase Recovery EPRO 150 8000 O M MANUAL Rev 04 03 Page 32 of 55 ...

Страница 35: ...e of the lower distributor 1 Connect the feed water backwash drain and service lines to the filter s controller unit per the manufacturer s instruction manual included with the unit Allow a 6 8 air gap on the drain line connection to the main drain 2 Connect the proper electrical power connections for automatic units per the manufacturer s instruction manual included with the unit 3 Direct the ser...

Страница 36: ...s 1 through 7 at least 2 3 times to remove all loose Carbon fines throughout the media bed Perform a Chlorine test before the Carbon filter and record the PPM level of Chlorine residual 10 Perform a Chlorine test after the Carbon filter and record the PPM level of Chlorine residual MUST BE ZERO for feed water supply to the RO unit Perform the WHITE cup test the water should be clear with NO Carbon...

Страница 37: ...r gauges to determine if the filter needs to be replaced If the system is not equipped with these gauges examine the pre filter cartridge to make sure that it is not clogged and does not restrict feed flow to the pump Replace if necessary 3 LOW FEED WATER FLOW RATE Determine that the unit is getting a sufficient volume of feed water Disconnect the feed water hose from the machine and place it in a...

Страница 38: ... check the current draw 9 LEAKS Check the system for leaks as this can result in low pressure ABNORMAL PERMEATE FLOW Permeate flow should be within 15 of the rated production after correcting for feed water temperatures above or below 77 F see table 2 Check your permeate flow meter to determine the permeate flow rate If the system does not have a permeate flow meter measure the time it takes to fi...

Страница 39: ...DIUMBISULFATEAT REDUCEDPh FORMALDEHYDE DISENFECTION CHLORINATION ANDDECHLORINATION REPLACECARTRIDGEFILTERS DECREASEDor SLIGHTLY INCREASED DECREASED NORMAL ANYSTAGE ORGANICFOULING DESTRUCTIVETESTING ACTIVATEDCARBONOROTHER PRETREATMENT CLEANWITH HIGHPhCLEANER INCREASED INCREASED DECREASED MOSTSEVEREIN FIRSTSTAGE CHLORINE OXIDATION CHLORINEANALYSISOF FEEDWATER DESTRUCTIVEELEMENT TEST CHECKCHLORINEFEE...

Страница 40: ...EPRO 150 8000 O M MANUAL Rev 04 03 Page 38 of 55 ...

Страница 41: ...EPRO 150 8000 O M MANUAL Rev 04 03 Page 39 of 55 ...

Страница 42: ...EPRO 150 8000 O M MANUAL Rev 04 03 Page 40 of 55 ...

Страница 43: ...eferred to above Services Any services Crane provides hereunder whether directly or through subcontractors shall be performed in accordance with the standard of care with which such services are normally provided in the industry If the services fail to meet the applicable industry standard Crane will for a period of 1 year from the date of completion re perform such services at no cost to Buyer Re...

Страница 44: ... All parcel post shipments will be prepaid the cost of which shall be added to the invoice Parcel post shipments will be uninsured unless otherwise requested Equipment requiring the use of large traveling cranes for erection and shipment cannot be held after completion without incurring additional charges 4 ACCEPTANCE a Buyer shall inspect all shipments of equipment or other goods within 10 days o...

Страница 45: ...e to the Buyer who placed the order for standard equipment As it relates to any specially designed non standard equipment ordered a 25 charge will be levied if canceled prior to incurring related engineering drafting and production time If engineering drafting and production time has been incurred 100 of the selling price plus additional costs incurred will be charged to the Buyer who placed the o...

Страница 46: ...sed to run Outputs RO pump 120V 1HP 240V 3HP Inlet Solenoid 120 240V 5A Flush Solenoid 120 240V 5A Cables Power 120V 8 12AWG SJT w 15A plug 240V 8 12AWG SJT w 20A plug RO PUMP 4 12AWG SJTw 8 fork terminals Inlet Solenoid 4 18AWG SJT w attached solenoid connector Flush Solenoid 4 18AWG SJT w attached solenoid connector Time Delays RO Start 8 seconds Tank Full 5 seconds Tank Full Restart 2 seconds L...

Страница 47: ...6 For 120VAC operation 1jumper is installed between J4 and J6 For 120VAC operation 1 jumper is installed between J4 and J6 and a second jumper is installed between J3 and J5 NOTE The pump and solenoid outputs will be the same voltage as the controller Connect the pump and solenoid cables to the end devices Input Wiring Connect the low pressure pretreat and level switches to the corresponding termi...

Страница 48: ...en returning it to the auto position reset the controller Auto Reset If the auto reset jumper is in the on position when a low pressure shut down occurs the unit will attempt to restart after the auto reset delay this should be approximately 15 minutes If the low pressure condition has cleared the unit will continue to run Otherwise the unit will again shut down and the auto restart will continue ...

Страница 49: ... switch closes the unit will restart Flush If the flush option is installed the unit will enter a flush mode every 10 hours This flush will occur whether the unit is running or not When the flush occurs the inlet and flush solenoids will open and the RO pump will start The amber Flush lamp will light The flush will last for 5 minutes NOTE A low pressure or pretreat condition will cancel the flush ...

Страница 50: ...sponding input or output LED INPUT OUTPUT DS5 Tank Full Low Input DS6 Tank Full High Input DS7 Pretreat Input DS8 Low Pressure Input DS9 RO Pump Output DS10 Inlet Solenoid Output DS11 Flush Solenoid Output Controller Has No Power Verify that the voltage jumpers J3 J6 are in the correct position for the supplied power Verify that the correct power is being applied to the power in terminals L1 and L...

Страница 51: ...igh input and the tank full low input must be jumpered Verify that DS6 is on when the tank IS NOT full If DS6 is off reverse the operation of the tank level switch and check the level switch wiring If dual level switches are used the upper switch must be connected to tank full high and the lower switch must be connected to tank full low When the water level in the tank is below both switches DS5 a...

Страница 52: ...CE 1 WIRING DIAGRAM MAIN CONTROL BOX 120 240VAC 50 60HZ 1PH Referred to as box CE1 B on 3 PH diagrams EPRO 150 8000 O M MANUAL Rev 04 03 Page 50 of 55 ...

Страница 53: ...LR2D1312 LR2D1316 5HP LR2D1321 LR2D1314 LR2D1316 LR2D1321 7 5HP LR2D1322 LR2D1316 LR2D1321 LR2D1322 FUSERATING 1HP 15AMP 15AMP 15AMP 15AMP 1 5HP 15AMP 15AMP 15AMP 15AMP 3HP 20AMP 15AMP 15AMP 20AMP 5HP 30AMP 15AMP 20AMP 30AMP 7 5HP 45AMP 20AMP 30AMP 45AMP FUSEMACOLANO 1HP ZFU18 ZFU18 ZFU18 ZFU18 1 5HP ZFU18 ZFU18 ZFU18 ZFU18 3HP ZFU14 ZFU18 ZFU18 ZFU14 5HP ZFU15 ZFU18 ZFU14 ZFU15 7 5HP 45AMPFUSE ZF...

Страница 54: ...208 240V 3PH WIRING SCHEMATIC ALSO REFER TO CE 1 WIRING DIAGRAM on page 6A CE1 B on this diagram EPRO 150 8000 O M MANUAL Rev 04 03 Page 52 of 55 ...

Страница 55: ...220V 50HZ 3PH 380 415V 50HZ 3PH WIRING SCHEMATIC ALSO REFER TO CE 1 WIRING DIAGRAM on page 6A CE1 B on this diagram EPRO 150 8000 O M MANUAL Rev 04 03 Page 53 of 55 ...

Страница 56: ...380V 3HP 3PH WIRING SCHEMATIC ALSO REFER TO CE 1 WIRING DIAGRAM on page 6A CE1 B on this diagram EPRO 150 8000 O M MANUAL Rev 04 03 Page 54 of 55 ...

Страница 57: ...THIS PAGE INTENTIONALLY LEFT BLANK FOR NOTES EPRO 150 8000 O M MANUAL Rev 04 03 Page 55 of 55 ...

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