GE OSMONICS E4 Series User manual

OSMONICS

E4, E4LE, EZ4 SERIESTM

WATER PURIFICATION

MACHINES

INSTALLATION, OPERATION,

AND MAINTENANCE

MANUAL

GE Infrastructure

Water & Process Technologies

INSTALLATION, OPERATION AND

MAINTENANCE MANUAL

E4, E4LE, AND EZ4 SERIES

WATER PURIFICATION MACHINES

TABLE OF CONTENTS

Page

2.0 INSTALLATION 1

2.1 Mounting the Unit 1

2.2 Plumbing 1

2.3 Installing Clean-In-Place Valves 2

2.4 Concentrate Outlet Connections 2

2.5 Feed Water Requirements 2

2.6 Transporting Pure Water (Permeate) to Point-of-Use 3

2.7 Pressure Correction Factors 4

2.8 Electrical 5

2.8.1 Single-Phase Electrical 5

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 Timer Clock 12

2.15.4 Programming Twenty-Four Hour or Seven Day Schedules 13

2.15.5 Changing a Program 13

2.15.6 Deleting a Program 13

2.15.7 Troubleshooting the Autoflush Timer 14

2.16 Calibrating the Conductivity Probe 15

Page

2.17 Operation and Maintenance 16

2.17.1 Daily Flushing for the Economy Model 16

2.17.2 Daily Flushing for the Deluxe Model 16

2.18 Pre-Filter Cartridge 17

2.19 Membrane Element Cleaning 17

2.19.1 Step Wise Cleaning 17

2.19.2 Procedure to Clean with a CIP Pump 17

2.20 Suction Cleaning 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 Requirements 3

2.3 Pressure Correction Factors 4

2.4 Flow Specifications for E4-Series Machines 10

2.0 INSTALLATION

2.1 Mounting the Unit

When installing your new GE Infrastructure Water & Process Technologies reverse

osmosis (RO) machine, allow at least 45-inches (114 cm) above the machine for mem-

brane element removal and loading. If space is not available, the entire membrane

element housing can be removed for membrane element change outs. If the mem-

brane element housings are to be removed to change out the membrane elements,

at least 6-inches (15.2 cm) is required at the end of each membrane element housing

and 24-inches (61 cm) behind the machine.

2.2 Plumbing

The feed water source must be able to provide water quantity and 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 pretreatment to provide the proper water quantity

and pressure for the operation of the machine.

Table 2.1

Connections

* Low Energy Membrane Elements

INLET

inches (cm)

0.75 (1.90)

E4/EZ4/E4LE*

MACHINE

2200

4400

6600

8800

11000

13200

PERMEATE

inches (cm)

0.50 (1.27)

0.75 (1.90)

CONCENTRATE

inches (cm)

0.50 (1.27)

0.75 (1.90)

2.3 Installing Clean-In-Place Valves

NOTE: Clean-In-Place (CIP) valves are not included with the machine. The CIP

valves must be purchased and installed by the customer.

When installing the CIP valves, a three-way valve should be installed in the inlet feed

stream of the machine. The tees on the permeate and concentrate lines should be

installed with two-way valves. All valves should be installed in a manner that will

allow circulation of the cleaning chemicals through the machine and back to the CIP

container during cleaning.

CAUTION: If CIP valves are not installed when machine is installed, provisions

must be made to bypass 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. The maximum concentrate back pressure is 60 psig (4.1 barg) for the

RO machine.

CAUTION: Operation above 60 psig (4.1 barg) concentrate back pressure may

damage the machine.

2.5 Feed Water Requirements

The following feed water requirements must be met before installing your new E4

machine to ensure quality permeate and extended membrane element life. Refer to

Table 2.2 (E-Series Feed Water Requirements) for feed water information.

Table 2.2

E-Series

Feed Water Requirements

* American Standard for Testing Materials

2.6 Transporting Pure Water (Permeate) to Point-of-Use

The pure water, or permeate, is in an aggressive state and should only be transport-

ed from the machine to the point-of-use in food grade flexible nylon, stainless steel

(SS) tubing, or polyvinyl chloride (PVC) material for the inlet, 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.

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 psig (4.1 barg)

0 parts per million (ppm)

5.5 - 8.5

Less than or equal to 5 to minimize

membrane element fouling and

extend cleaning intervals.

Refer to ASTM* standard D4189.

2.7 Pressure Correction Factors

It is often necessary to operate RO machines with permeate back pressure. Permeate

back pressure will decrease permeate production. See Table 2.3 (Pressure Correction

Factors) to calculate loss of permeate.

Table 2.3

Pressure Correction

Factors

WARNING: IF PERMEATE BACK PRESSURE EXCEEDS 60 PSIG (4.1 BARG)

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.

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%

10% 20%

15% 30%

20% 40%

25% 50%

30% 60%

PRESSURE

CORRECTION

FACTOR (PCF)

E4/EZ4 E4LE

0.95 0.90

0.90 0.80

0.80 0.70

0.70 0.60

0.60 0.50

0.50 0.40

2.8 Electrical

This RO machine requires two supply voltages; the control voltage and the

pump motor voltage.

2.8.1 Single-Phase Electrical

The control voltage can be connected to either a 115 VAC, 60 Hertz or

220 VAC, 50 Hertz single-phase power supply. The RO control circuit

should always be installed on at least a 15 Amp, single-phase dedi-

cated circuit. Reverse osmosis machines with 115 VAC, single-phase

control voltage include an eight-foot (2.4 m) cord which plugs into a

three-prong grounded receptacle. All machines shipped with a

220 VAC, single-phase control circuit are shipped with an eight-foot

electrical cord, but customers must provide electrical plug.

2.8.2 Three-Phase Electrical

The three-phase pump motor requires a 15 AMP dedicated circuit.

Always verify correct voltage and Amp rating by checking voltage tag

on the starter 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 must comply with applicable local and national electrical

codes.

After checking the voltage tag on the motor starter to ensure the

available voltage and amperage are correct, connect the provided

three-phase power to the motor starter (Figure 2.1). This can be done

by connecting the three phase power to the top of the starter relay

terminals: L1, L2, and L3. A separate, fused disconnect for the motor

wiring with proper protection for the Horsepower and Amp draw of

the motor is recommended. All field wiring must comply with applic-

able local and national electrical codes. See Figure 2.1 for three-

phase Allen Bradley Starter Hook-Up.

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