GE Water System E4H Series User Manual

E4H SERIES  
WATER PURIFICATION MACHINES  
OPERATION AND  
MAINTENANCE MANUAL  
 
OPERATION AND MAINTENANCE MANUAL  
FOR GE OSMONICS  
E4H SERIES  
WATER PURIFICATION MACHINES  
TABLE OF CONTENTS  
Page  
1
1.0  
DESCRIPTION .........................................................................................................  
1.1  
1.2  
1.3  
1.4  
General Information and Principles of Operation .........................................  
Machine Nomenclature..................................................................................  
Machine Permeate Quality ............................................................................  
Economy and Deluxe Model Options ...........................................................  
1.4.1 Economy Model.................................................................................  
1.4.2 Deluxe Model Options.......................................................................  
Specifications for E-Series Machines............................................................  
1.5.1 Feed Water Requirements..................................................................  
1.5.2 Permeate (Product Water) Flow Rate ................................................  
1.5.3 Concentrate Flow Rate ......................................................................  
1.5.4 Typical Pure Water.............................................................................  
1.5.5 Final Operating Pressure....................................................................  
1.5.6 Pump ..................................................................................................  
1.5.7 Reverse Osmosis Membrane Element Rejection ..............................  
1
4
5
5
5
6
7
7
7
8
8
8
8
8
1.5  
2.0  
INSTALLATION ....................................................................................................... 10  
2.1  
2.2  
Mounting........................................................................................................ 10  
Piping............................................................................................................. 10  
2.2.1 Inlet Piping .............................................................................................. 10  
2.2.2 Valves Required for Clean-In-Place........................................................ 10  
2.2.3 Concentrate Outlet Connection ............................................................... 10  
2.2.4 Permeate Outlet Connection.................................................................... 10  
Electrical ........................................................................................................ 10  
2.3.1 Economy Electrical System............................................................... 11  
2.3.2 Deluxe Electrical System................................................................... 11  
2.3  
 
Page  
3.0  
4.0  
PREPARATION AND START-UP ............................................................................ 12  
3.1  
3.2  
Pretreatment for Water Purification............................................................... 12  
Start-Up.......................................................................................................... 12  
OPERATION AND MAINTENANCE ..................................................................... 18  
4.1  
4.2  
4.3  
4.4  
4.5  
4.6  
4.7  
Daily Log Sheets............................................................................................ 18  
Pre-Filter Cartridge........................................................................................ 18  
Flushing ......................................................................................................... 19  
Cleaning......................................................................................................... 19  
Draining Machine for Shipment.................................................................... 21  
Membrane Element Installation..................................................................... 22  
Membrane Element Replacement.................................................................. 23  
5.0  
OPTIONAL ACCESSORIES.................................................................................... 25  
5.1  
5.2  
5.3  
Level Controls................................................................................................ 25  
Filters and Water Softeners............................................................................ 25  
Storage Tanks................................................................................................. 25  
6.0  
7.0  
8.0  
9.0  
10.  
TROUBLESHOOTING............................................................................................. 26  
RETURN GOODS AUTHORIZATION (RGA) PROCEDURE .............................. 31  
WARRANTY............................................................................................................. 32  
START-UP DATA SHEET......................................................................................... 34  
DAILY LOG SHEET................................................................................................. 36  
 
Page  
LIST OF FIGURES  
1
2
3
4
Normal Versus Cross Flow Filtration....................................  
Membrane Element with Interconnectors..............................  
Cross Sectional View of Membrane Element........................  
Principles of Operation..........................................................  
1
2
2
3
LIST OF TABLES  
1.1  
1.2  
3.3  
4.4  
Feed Water Requirements ......................................................  
Typical Membrane Element Rejections/Passages..................  
Machine Recovery ................................................................. 16  
Dry Chemical Cleaners.......................................................... 20  
7
9
 
 
1.0 DESCRIPTION  
1.1 General Information and Principles of Operation  
Your E-Series reverse osmosis (RO) machine is a durable piece of equipment which, with  
proper care, will last for many years. These instructions give operating and maintenance  
details vital to the sustained performance of the machine.  
Reverse osmosis is the separation of one component of a solution from another component by  
means of pressures exerted on a semipermeable membrane element. Removal of ionic, organ-  
ic and suspended / dissolved impurities occurs during the RO process. Unlike a filter, which  
separates by “normal” filtration, the General Electric (GE) Osmonics membrane element sep-  
arates using a process called cross flow filtration. Feed water solution is separated into two  
streams, permeate and concentrate, and collected from both sides of the membrane element. A  
semipermeable RO membrane element, under sufficient pressure, allows passage of purified  
water while rejecting and concentrating dissolved and suspended solids.  
Figure 1.1  
Normal Versus  
Cross Flow Filtration  
GE Osmonics manufactures a patented spiral-wound membrane element package, with a tur-  
bulent flow design. This membrane element collects the purified water within a central tube,  
the permeate tube (Figure 1.2, Membrane Element with Interconnectors and Figure 1.3, Cross  
Sectional View of Membrane Element).  
1
 
Figure 1.2 - Membrane Element  
with Interconnectors  
Figure 1.3  
Cross Sectional View of  
Membrane Element  
2
 
Some operating definitions are provided to help you further understand your machine:  
Permeate Rate [Product Water Rate (Qp)] is the flow rate of purified water which has  
passed through the membrane element and out of the membrane element housing;  
expressed in gal/min (gpm) or gal/hr (gph) [in metric, liter/min (Lpm) or cubic  
meters/hour (m3/h)]. Specified permeate rates are normally at 77ºF (25ºC).  
Concentrate Rate [Waste Water Rate (Qc)] is the flow rate of water containing reject-  
ed solids to drain in gpm or gph (Lpm or m3/h).  
Feed Rate (Qf) is the flow rate of incoming water in gpm or gph (Lpm or m3/h).  
Feedwater rate equals permeate rate plus concentrate rate.  
Recovery equals permeate rate divided by feed rate and is expressed as a percentage.  
For example, 33% recovery means that out of a given feed rate, 33% is produced as  
purified water (permeate).  
Concentration equals the Total Dissolved Solids (TDS) concentration of a solution  
expressed as milligrams per liter (mg/L) or conductivity (microSiemens/cm).  
Cf  
Cp  
Cc  
Cavg  
=
=
=
=
Feed Concentration  
Permeate Concentration  
Concentrate Concentration  
Average Concentration in Machine  
Salt (Ionic) Rejection equals the percent of dissolved salt rejected by the membrane  
element, calculated from an average concentration over the membrane.  
Salt (Ionic) Passage equals (100% - rejection) or the percent of dissolved salts passed  
through the membrane element.  
An example of how to calculate salt rejection and recovery is given below:  
Figure 1.4  
Principles of Operation  
3
 
Given the system case in Figure 1.4 (Principles of Operation):  
Average Concentration (C ) = (Cf) 100 mg/L + (Cc) 146.9 mg/L  
avg  
2
(C ) = 123.5 mg/L TDS  
avg  
Rejection  
Passage  
=
=
(Cavg) 123.5 - (Cp) 6.2 x 100 = 95%  
(C ) 123.5  
avg  
(Cp) = 6.2 x 100 = 5.0%  
(C ) = 123.5  
avg  
Recovery = (Qp) 2 gpm x 100 = 33%  
(Q ) 6 gpm  
f
Flow Description - The feed water passes through a replaceable 5-micron cartridge  
pre-filter which removes bulk suspended solids. Filtered water then flows to the inlet con-  
trol valve. This solenoid-controlled diaphragm valve is wired to the ON/OFF switch and  
opens when the machine is turned ON, allowing water to flow to the pump inlet. When  
the machine is turned off, the valve closes, preventing non-turbulent flow through the  
membrane elements, which would lead to shortened membrane element life.  
The pump feeds water to the membrane element housings arranged in parallel and serial  
combinations. The direction of water flow is indicated by an arrow on each membrane ele-  
ment housing. Water is separated by the membrane elements within the membranes and  
leaves the membrane element housings in two streams: permeate and concentrate.  
Permeate from each membrane element housing is collected in a common manifold. The  
permeate then flows through a flow meter and to the outlet point of the machine.  
The concentrate leaves the last membrane element housing and flows to the flow control  
center (recycle/concentrate manifold). At this point, the recycle valve channels a prede-  
termined amount of concentrate into the pump inlet. Recycle increases recovery while  
maintaining adequate cross flow through the membrane elements. The other two ports of  
the flow control center lead to the concentrate valve and final pressure gauge. The con-  
centrate valve has three functions: It controls the amount of concentrate flowing to the  
drain; it controls the pressure within the machine; and it helps control the system recov-  
ery. An Autoflush solenoid is added to the flow control center with an additional tee. The  
concentrate then flows through a flow meter and to the outlet point of the machine.  
1.2  
Machine Nomenclature  
GE Osmonics E-Series water purification machines are numbered in such a way as to indi-  
cate the permeate flow and quality you can expect from the machine.  
4
 
Example:  
E4H-21K/ECN, 230, 6, 50-75  
E4H indicates the machine series  
H indicates horizontal membrane element housing configuration  
21K indicates the rated permeate flow in thousands of gallons per  
day @ 77ºF (25ºC),(i.e., 21K = 21,000 gallons per day)  
ECN indicates Economy Model and DLX indicates the Deluxe  
Model  
230 indicates 230 VAC, three-phase voltage to starter  
6 indicates 60 Hz operation, whereas 5 indicates 50 Hz operation  
50 - 75 indicates 50% to 75% recovery  
1.3  
1.4  
Machine Permeate Quality  
The permeate rejection performances are as follows:  
E4H machines use high rejection Osmo 415 - HR(PA) membrane elements, providing the  
ultimate in high purity water.  
Economy and Deluxe Model Options  
1.4.1 Economy Model  
E-Series Economy (ECN) model water purification machines have all the features  
necessary for safe, continuous production of high purity water. This assumes good  
quality feed water, adequate pretreatment and regular operator maintenance, each  
shift or daily, to the operation of the system.  
50% to 75% recovery  
Multi-stage centrifugal pump, SS construction (stainless steel castings with  
Noryl stages)  
Base model electrical package includes NEMA-1 enclosure with a  
110 VAC, 60 Hz or 220 VAC, 50 Hz single-phase control circuit; applies to  
all ECN models  
Automatic inlet shutoff valve  
Pre-filter housing and 5-micron cartridge pre-filter  
Pre-filter, post-filter, primary and final pressure gauges  
5
 
Digital concentrate and permeate flow meters  
Digital conductivity monitor, panel-mounted, for permeate quality monitor-  
ing  
Autoflush System - programmable, automated high-velocity membrane ele-  
ment flushing for the longest membrane element life; set at the factory and  
adjustable in the field  
Gauges, valves and rigid piping of stainless steel or plastic  
Membrane element housings, all 304 stainless steel (SS), with Noryl end  
caps  
316 SS concentrate and recycle valves  
All components in contact with the purified water (permeate) are either  
FDA-acceptable plastic [nylon, Noryl, polypropylene, polyvinyl chloride  
(PVC)] or stainless steel materials.  
All high pressure fittings are 304 SS.  
Alarms included: low inlet pressure and high amp draw.  
1.4.2 Deluxe Model Options  
The Deluxe (DLX) package contains all of the above Economy (ECN) standard  
features along with a PROGRAMMABLE LOGIC CONTROLLER (PLC) con-  
trol system.  
Multi-stage centrifugal pump, stainless steel construction (316 stainless  
steel end castings and other wetted parts, Noryl internals)  
Autoflush System - programmable, automated high-velocity membrane ele-  
ment flushing for the longest membrane life; set at the factory and  
adjustable in the field  
All high-pressure fittings are 304 stainless steel.  
Special electrical upgrade package includes PROGRAMMABLE LOGIC  
CONTROLLER (PLC) controller with alarm delay shutdown for low inlet  
pressure condition to prevent pump damage should pressure fall below  
15 psig (1 barg)  
Clean-In-Place (CIP) system  
Digital flow meter and conductivity controller  
Digital pH controller  
6
 
Alarms included: low inlet pressure, high amp draw, high / low pH  
1.5 Specifications for E-Series Machines  
1.5.1 Feed Water Requirements  
Table 1.1  
Feed Water Requirements  
Temperature  
Inlet Pressure  
35° - 77°F (2° - 25°C) Not to exceed  
85°F (29°C) unless specifically  
designed for higher temperatures  
Minimum: 30 psig (2.1 barg)  
Maximum: 60 psig (4.1 barg)  
Chlorine  
(continuous feed)  
For Osmo HR(PA) membrane ele-  
ments: 0 ppm  
Operating pH  
Pre-filter  
Soft water [less than 1 grain per gal-  
lon: 3.0 - 10.0 (gpg) or 17 mg/L hard-  
ness], acceptable pH: 5.5 - 6.0  
5 micron HYTREX cartridge  
(part number on machine label)  
Inlet Connections  
1.5-inch FNPT*  
1.5.2 Permeate (Product Water) Flow Rate  
Stated on the serial number label (assumes no permeate back pressure,  
2000 mg/L TDS maximum feed concentration, and rated temperature).  
To estimate permeate output with back pressure, use the formula below:  
(Permeate Flow on Label) x [(Operating Pressure) - (Permeate Back Pressure)]  
Operating Pressure  
Permeate Back Pressure:  
Permeate Outlet:  
Maximum: 80 psig (5.5 barg)  
1-inch FNPT  
*
FNPT: Female National Pipe Thread  
7
 
1.5.3 Concentrate Flow Rate  
Factory set as stated on serial number label  
Concentrate Outlet:  
1.5.4 Typical Pure Water  
Recovery:  
1-inch FNPT  
50 - 75%  
1.5.5 Final Operating Pressure  
Minimum:  
Maximum:  
200 psig (13.8 barg)  
235 psig (16.2 barg)  
1.5.6 Pump  
Multi-stage centrifugal, approximate primary operating pressure of 190 psig  
(13.1 barg), excluding line pressure.  
1.5.7 Reverse Osmosis Membrane Element Rejection  
Osmo HR(PA)  
Typical Ionic Rejection (TDS)  
95 - 98%  
Average Molecular Weight Cutoff* 150 MW*  
*
The Molecular Weight cutoff is based on the pore size of the membrane elements and the nature  
(size/shape) of the organic molecule.  
8
 
Figure 1.2  
Typical Membrane Element  
Rejections/Passages  
To estimate passage of salts for membrane elements other than SEPA-  
HR, take the passage for the SEPA-HR and multiply by the factor for the  
passage for the particular membrane element. The factors are:  
SALTS  
CATIONS  
Percent  
Maximum  
SEPA-SR is 1.6 times SEPA-HR passage  
SEPA-PR is 2.5 times SEPA-HR passage  
Percent Passage Concentration  
Name  
Symbol  
Rejection (Avg)  
Percent  
5-10  
*
*
5-10  
*
Operation of the SEPA-HR membrane element at pressures over 400 psig  
(27.6 barg) will reduce salt passage slightly. Operation at 200 psig (13.8  
bar) will increase the passage of monovalent ions by approximately 2.0  
times and the passage of multivalent ions will increase by 1.5 times the  
400 psig (27.6 bar) passage.  
+
Sodium  
Calcium  
Magnesium  
Potassium  
Iron  
Manganese  
Aluminum  
Ammonium  
Copper  
Nickel  
Zinc  
Strontium  
Hardness  
Cadmium  
Silver  
Na  
Ca  
Mg  
94-96  
96-98  
96-98  
94-96  
98-99  
98-99  
99+  
88-95  
98-99  
98-99  
98-99  
96-99  
5
3
3
5
2
2
1
8
1
1
1
3
3
3
5
3
+2  
+2  
+1  
K
+2  
Fe  
For SEPA membrane elements with larger pores than the SEPA-PR it is  
recommended that actual tests be run prior to estimating the permeate  
quality.  
+2  
Mn  
*
+3  
Al  
10-20  
3-8  
10-20  
10-20  
10-20  
-
+1  
NH4  
The maximum concentrations given in the table are the approximate  
concentrations resulting in an osmotic pressure of 500 psi (34.5 barg)  
for the solution.  
+2  
Cu  
Ni  
Zn  
Sr  
+2  
+2  
+2  
Compounds such as CaSO4 which have specific solubility limits can be  
controlled with proper addition of dispersants. Check with the factory for  
more information on Osmonics special line of dispersants.  
Ca & Mg 96-98  
*
+2  
Cd  
Ag  
Hg  
96-98  
94-96  
96-98  
10-20  
*
-
+1  
+2  
Mercury  
ORGANICS  
Maximum  
ANIONS  
Chloride  
Bicarbonate  
Sulfate  
Nitrate  
Fluoride  
Silicate  
Phosphate  
Bromide  
Borate  
Chromate  
Cyanide  
Sulfite  
-1  
Molecular  
W eight  
342  
360  
10,000 Up  
180  
Percent Concentration  
Cl  
94-95  
95-96  
99+  
4
4
1
5-8  
-1  
Rejection  
99.9  
99.9  
99.9  
99.0  
***  
Percent  
30-35  
30-35  
50-80  
15-20  
-
HCO3  
5-10  
5-15  
3-6  
5-8  
-
10-20  
5-8  
-
8-12  
4-12  
5-15  
10-20  
Sucrose Sugar  
Lactose Sugar  
Protein  
Glucose  
Phenol  
-2  
S O4  
-1  
N O3  
85-95  
94-96  
80-95  
99+  
10  
5
10  
-1  
F
-2  
SiO2  
94  
-3  
PO4  
1
Acetic Acid  
Formaldehyde  
Dyes  
60  
30  
***  
***  
99.9  
-
-
-
-1  
Br  
94-96  
35-70**  
90-98  
90-95**  
98-99  
99+  
5
-
6
-
1
1
-2  
-2  
B4O7  
CrO4  
400 to 900  
Biochemical  
Oxygen Demand  
Chemical  
Oxygen Demand  
Urea  
-1  
CN  
(BOD)  
90.0-99.9  
99.9  
-2  
S O3  
-
-2  
(COD)  
60  
Thiosulfate  
S2O3  
40-60 Reactssimilar to  
a salt  
99.9+  
-
* Must watch for precipitation; other ion controls maximum  
concentration  
Bacteria & Virus 50,000 to  
500,000  
Pyrogen  
1,000  
to 5,000  
99.9+  
-
** Extremely dependent on pH; tends to be an exception to the  
rule  
The following are typical rejections and passages for various salts and  
organics using the SEPA -HR membrane at 400 psig (27.6 bar) operat-  
*** Permeate is enriched in material due to preferential pas-  
sage through the membrane.  
ing pressure. Modules made with this membrane, such as the OSMO -  
HR, can be expected to give these same passages. As can be seen,  
multivalent ions tend to have less passage than do monovalent ions. If  
monovalent ions are combined with multivalent ions to form a salt, the  
passage will be controlled by the multivalent ion. In RO all ions must be  
combined as the salt form before passages can be considered.  
GASES, DISSOLVED  
Carbon Dioxide  
Oxygen  
C O2  
30-50%  
For estimating purposes, to obtain the expected permeate quality when  
handling a solution of salts,take a simple average of the feed concentra-  
tion and the  
concentrate concentration and multiply this figure by the average per-  
cent passage to calculate the average concentration of the  
permeate.Salts or organics that are complexed with organics of large  
molecular weights will tend to act like the organics with which they are  
complexed.  
O2  
Enriched in permeate  
30-70%  
Chlorine  
Cl2  
NOTE: The actual permeate water quality will vary with the inlet water quality and can only be veri-  
fied by actual analysis of the permeate stream.  
9
 
2.0  
INSTALLATION  
2.1  
Mounting  
E4H machines are equipped with a stand alone frame, 61-inch (155-cm) H x 132-inch (335  
cm) W x 34-inch (86 cm) D, which supports the machine. At least 45 inches  
(114 cm) of space should be allowed on each end of the membrane element housings for  
removal and loading of membrane elements. If 45-inches (114 cm) are not available, the  
entire membrane element housing may need to be removed for membrane element  
changes.  
2.2  
Piping  
2.2.1 Inlet Piping  
The feed water source is piped to the inlet using 1.5-inch NPT fittings. A CIP  
system is supplied with the DLX Model E4H. FOR ECN MODEL: To install a  
CIP system, remove plug and install valves on the E-Series machine as described  
in Section 2.2.2. If the inlet pressure is in excess of 60 psig (4.1bar) or fluctuates  
by more than 5 psig (0.4 bar), a pressure regulator should be installed ahead of the  
CIP tee.  
2.2.2 Required Valves for Clean-In-Place  
NOTE: Clean-In-Place (CIP) valves are only required for Economy (ECN)  
Models.  
IMPORTANT NOTE: GE Osmonics has installed a plugged pipe tee in the  
inlet line of the E4H units. This plug, when removed,  
will facilitate cleaning of the unit. A tee with (two)  
two-way valves or a single three-way valve should also  
be installed on the permeate and concentrate outlets to  
allow flow back to the cleaning tank. Never operate  
the machine with the concentrate or permeate lines  
blocked. Severe damage to the unit may result. (Refer  
to the attached drawing # 1163858 for a system flow  
schematic.)  
2.2.3 Concentrate Outlet Connection  
Install the CIP valve on the concentrate outlet tee, connect a 1-inch hose or pipe,  
and run it to an open drain. To avoid drainage from the machine while not in use,  
the concentrate outlet piping should be placed at a height at least equal to the  
height of the machine. A siphon break may also be installed in the concentrate line  
for added protection. The concentrate outlet hose can be any length, and the diam-  
eter should match the outlet on the machine. [Maximum back pressure is 60 psig  
(4.1 barg).]  
10  
 
2.2.4 Permeate Outlet Connection  
Install the CIP valve on the permeate outlet tee. The pure water (permeate) should  
be transported to the point of use via non-corroding-type tubing, pipe, or hose.  
Examples are: food-grade flexible nylon tubing, stainless steel tubing, or PVC  
hose. The permeate outlet is 1-inch FNPT.  
2.3  
Electrical  
The DLX and ECN E-Series models are supplied with a single-phase, 110 VAC 60 Hz or  
220 VAC 50 Hz control circuit and 8-foot cord which plugs into a three-prong  
grounded receptacle. For 220 VAC, 50 Hz units, plug must be customer-supplied. A  
20 amp dedicated service circuit is required for proper operation.  
For each model, the motor is wired at the factory to an overload protection magnetic motor  
starter which is controlled by a panel-mounted manual switch.  
The electrical system control circuit is separate from the motor voltage. Therefore,  
electrical wiring required in the field needs two supply voltages, the control circuit  
voltage and a separate three-phase motor voltage. All field wiring must comply with  
applicable local and national electric codes.  
2.3.1 Economy Electrical System  
STEPS  
1.  
2.  
Connect the control circuit power cord to 115 VAC, 60 Hz, or 220 VAC,  
50 Hz, single-phase power.  
Connect the magnetic motor starter 230/460 VAC or 220/380 VAC,  
three-phase power to match the motor voltage and phase. Check the tag  
(located on the motor starter) that indicates the factory wiring. A separate,  
fused disconnect for the motor wiring is required, with proper protection  
for the Hp and amp draw of the motor.  
Refer to drawing #1164309 for the ECN electrical diagram. The ECN  
circuit has a timing relay for delayed machine shutdown.  
2.3.2 Deluxe Electrical System  
STEPS  
1.  
2.  
Connect the control circuit power cord to 115 VAC, 60 Hz, or 230 VAC,  
50 Hz, single-phase power.  
Connect the magnetic motor starter 230/460 VAC or 220/380 VAC,  
three-phase power to match the motor voltage and phase. Check the tag  
(located on the motor starter) that indicates the factory wiring. A separate,  
fused disconnect for the motor wiring is required, with proper protection  
for the Hp and amp draw of the motor.  
11  
 
3.0  
PREPARATION AND START-UP  
3.1  
Pretreatment for Water Purification  
All systems will operate most efficiently on filtered water with a pH of less than 6.5 and a  
Silt Density Index (SDI) of 5 or below. If the machine is operated on higher pH water,  
other forms of pretreatment may be necessary. A water analysis prior to start-up of the  
machine is required. To minimize the chances of calcium carbonate, calcium sulfate, or  
other salt precipitation on the membrane, GE Osmonics evaluates each application and  
water condition and makes specific recommendations to ensure continuity of the mem-  
brane membrane element warranty. Data from the water analysis is processed with a com-  
puter program analysis to determine if potential problems exist. If the machine is to be run  
at a different location than was originally intended, a new water analysis is required for  
warranty consideration and should be sent to GE Osmonics for review and recommenda-  
tions for operation of the machine.  
Before entering the machine, the feed water must be filtered to 5 microns.  
Thin-layer composite (TLC) membrane element feed water must not contain the following  
chemicals or permanent loss of rejection and/or permeate flow may result:  
free chlorine  
formalin (until after a membrane elements have been run for 24 hours; thereafter,  
0.5% formaldehyde may be used as a biocide)  
iodine compounds  
quaternary germicides  
cationic surfactants  
detergents containing non-ionic surfactants  
cleaners not approved by GE Osmonics  
CAUTION: A water softener should not regenerate while the machine is running  
unless safeguards are used to be sure the machine is operated on softened  
water during regeneration.  
3.2  
Start-Up  
NOTE: If your machine is provided with the membrane elements installed in the hous-  
ings, proceed to 3.2.1. If your machine is provided with the membrane elements  
in shipping boxes, you must load the membrane elements in the housings prior  
to starting the machine. For membrane element loading instructions, skip to  
Section 4.6 (Membrane Element Installation). Upon completion of membrane  
element installation, return to Step 1 to continue your start-up procedure.  
12  
 
STEPS  
1.  
Re-check the function and integrity of your pretreatment equipment.  
Ensure that your water softener, activated carbon filters and iron filters  
(where applicable) have been leak-checked, backwashed, and thoroughly  
rinsed for service before starting up your RO unit.  
2.  
3.  
4.  
Attach the feed water pipe to the inlet of the machine.  
Check for leaks at all connection points.  
Turn ON the feed water gradually and check for leaks in the inlet piping.  
No flow should go through the machine while the power is OFF and the  
inlet solenoid is in the closed position.  
NOTE: When the machine is OFF, there should never be flow through  
the machine. Flow through the machine when it is OFF can ruin  
the membrane elements, and the inlet solenoid must be repaired.  
5.  
6.  
Attach tubing from permeate and concentrate outlet points and run the  
tubing to drain.  
Ensure that you have made provisions for both voltages required to oper-  
ate your machine. The machine requires two power sources: (1) the high  
voltage for the motor operation, and (2) the control circuit power supply.  
The factory provides the 110 VAC (or 220 VAC 50 Hz) power cord need-  
ed for the control circuit. The motor electrical service must be field-wired  
directly into the motor starter on the machine. Bring your motor service to  
terminals labeled “T” on the motor starter. Check the voltage label to  
ensure that you have brought the correct voltage to the starter.  
7.  
8.  
Be sure the power to the motor starter is de-energized.  
With the machine ON/OFF switch in the OFF position, plug in the facto-  
ry supplied 110 VAC (or 220 VAC 50 Hz) power cord.  
9.  
Open your concentrate and recycle flow control valves two complete  
turns. These valves are positioned on the flow control center of the  
machine. This piping is located on the left section of the machine, near  
the membrane element housings. The flow control center features a con-  
centrate flow control valve, a recycle flow control valve, and a pressure  
gauge sensor point piped into the panel-mounted pressure gauge.  
NOTE: The Autoflush valve is positioned in this flow control center.  
The proper adjustment of these valves is critical to the operation of the RO  
machine. The concentrate valve determines the amount of rejected water  
leaving the machine, and creates the operating pressure shown on the  
pressure gauge. The recycle valve returns unused reject flow back into the  
13  
 
inlet stream to the RO pump. It is important to balance the operating pres-  
sure and the respective flows of these valves to ensure that your machine  
is operating correctly. It is also important to understand the relationship of  
these two valves, the pressure gauge, and your RO pump. The pump has  
a fixed amount of flow produced, and the valves are the control devices to  
distribute this fixed flow amount. The pressure gauge is an indicator of  
applied membrane element pressure, at the flows set by the valves.  
10.  
Turn the ON/OFF switch to the ON position. Water will begin to flow  
through the machine at this point but the pump will not start. Allow the  
machine to operate in this manner for 10 minutes, to purge the air out of  
the machine. Verify alarm set points in the Lakewood 2450 Reverse  
Osmosis controller.  
Consult the Lakewood Model 2450 Installation and Operation Manual  
(P/N 1109695) for operating instructions. The factory alarm set points are  
as follows:  
Low Inlet Pressure  
Low pH  
12 psig (0.83 barg)  
2.0  
High pH  
8.0  
pH Control  
High Temperature  
5.6 - 6.2  
120°F (49°C)  
NOTE: The high-pressure pump should not be operating at this time.  
As your machine is filling check for leaks and repair as needed.  
Turn the ON/OFF switch to the OFF position.  
11.  
12.  
13.  
Energize the power source to the motor starter. The pump should not oper-  
ate at this point.  
14.  
Check the rotation of the high-pressure pump by briefly turning the  
ON/OFF switch to the ON position. Watch the motor, or coupling shaft,  
for direction of rotation. The motor should rotate clockwise as one looks  
at the motor end of the high-pressure pump. If the motor is not rotating  
clockwise, change any two of the three leads (for three-phase) in the  
motor starter and recheck rotation. Always turn the power off to change  
any wiring.  
WARNING: OPERATION OF THE PUMP BACKWARDS, EVEN  
FOR A SHORT TIME, CAN CAUSE DAMAGE TO  
THE PUMP.  
15.  
Turn the ON/OFF switch to the ON position. The high-pressure pump will  
operate and the machine will begin to build pressure. As you are operat-  
ing, be sure to watch the pressure gauge on the instrument panel. The  
machine is designed to operate at 220 psi (15.2 bar).  
14  
 
NOTE: Do not allow the pressure to exceed 250 psi (17.2 bar). If the  
pressure exceeds 250 psi (17.2 bar), open the concentrate flow  
control valve until the pressure gauge shows 250 psi (17.2 bar)  
or less.  
As the machine purges the air and fills with water, the pressure will grad-  
ually increase. You should see water flowing through the permeate and  
concentrate flow meters. If you do not see flow, turn the machine OFF and  
return to Step 1.  
WARNING: NEVER ALLOW THE MACHINE TO OPERATE  
WITHOUT ADEQUATE WATER PRESSURE. THIS  
CAN CAUSE SEVERE DAMAGE TO THE HIGH-  
PRESSURE PUMP  
.
16.  
Gradually close the concentrate flow control valve. As you close the  
valve, watch the pressure gauge and your concentrate flow meter. Close  
the valve until your concentrate flow meter displays your design flow, and  
you do not exceed 250 psi (17.2 bar). If you reach 250 psi (17.2 bar)  
before the valve is completely closed, open the recycle flow control valve  
one full turn, then continue to close the concentrate flow control valve.  
Continue to close the concentrate flow control valve until it is complete-  
ly closed and your pressure is below 250 psi (17.2 bar).  
The concentrate flow control valve has a drilled orifice to ensure a prede-  
termined amount of flow and pressure in the closed position. This orifice  
is sized to operate the machine at 75% recovery.  
17.  
With the concentrate flow control valve fully closed and the pressure  
below 250 psi (17.2 bar), gradually close the recycle flow control valve  
until the pressure reaches 250 psi (17.2 bar).  
Your machine is now operating at the design pressure and flow rates, in a  
75% recovery configuration. Your specific needs or conditions may dic-  
tate the need to operate the machine at a lower recovery. If you wish to  
operate in a recovery configuration lower than 75%, Step 18 (below) will  
explain the necessary steps.  
18.  
Your machine is equipped with flow meters and a pressure gauge that will  
assist you in setting alternate flow rates for variable recoveries. If you  
wish to operate at a recovery lower than 75% you must ensure that the  
flow rates for the permeate and concentrate are at desired levels. Some  
minor adjustments in the concentrate and recycle flow control valves may  
be necessary.  
See Table 3.1 (Machine Recovery) below for specified flow rates for var-  
ious machine recoveries. When you have selected your desired flow rate,  
gradually adjust the concentrate flow control valve to achieve desired  
flow and use the recycle valve to bring the operating pressure up to  
250 psi (17.2 bar).  
15  
 
Once the desired flow rate is achieved [250 psi (17.2 bar) operating pres-  
sure] no further valve adjustment is needed.  
The table below shows flow rates at 50%, 66% and 75% recovery for the  
E4H models. Use this table in adjusting flow rates.  
NOTE: Permeate flow rates are dependent upon temperature and con-  
ditions at your site. Contact your dealer if you have any ques-  
tions.  
Table 3.3  
Machine Recovery  
Permeate Flow  
[gpm (m3/h)]  
Concentrate Flow  
[gpm (m3/h)]  
at 50%  
at 66%  
at 75%  
at 50%, 60%, and 75%  
Recovery  
Recovery  
Recovery  
Recovery  
11.2 (2.6)  
15.0 (3.4)  
18.8 (4.3)  
26.2 (6.0)  
30.0 (6.8)  
E4H-16K  
E4H-21K  
E4H-27K  
E4H-38K  
E4H-43K  
11.25 (2.6)  
15.00 (3.4)  
18.75 (4.3)  
26.25 (6.0)  
30.00 (6.8)  
5.80 (1.3)  
7.73 (1.8)  
9.66 (2.2)  
13.52 (3.1)  
15.45 (3.5)  
3.75 (0.9)  
5.00 (1.1)  
6.25 (1.4)  
8.75 (2.0)  
10.00 (2.3)  
19.  
20.  
The system is now operational.  
Before putting the machine into final operation, continue to run the per-  
meate and concentrate streams to drain for at least 30 minutes. This is  
done to ensure that all of the bactericide has been removed from the mem-  
brane elements.  
21.  
22.  
Connect the permeate line to the point of use of the permeate. Check for  
leaks and ensure that you have no kinks in hoses, or blockage of any pip-  
ing on the permeate and concentrate outlet lines.  
Make any necessary final adjustments to flows and pressure according to  
Step 18.  
NOTE: The membrane elements in your machine are rated for certain  
flow rates at 77ºF (25ºC). Maximum flow rates are achieved  
when the membrane elements have been completely rinsed and  
on-line for at least 24 hours.  
16  
 
23.  
A Daily Log Sheet (Section 10.0) which includes general operating con-  
ditions (pressures, flows, concentrations, pH, and pretreatment condi-  
tions), and routine or special maintenance (flushing or cleaning as need-  
ed) must be kept. This Daily Log Sheet will be required by GE Osmonics  
if a warranty question arises.  
17  
 
4.0  
OPERATION AND MAINTENANCE  
The operation and maintenance of your GE Osmonics E4H Machine is relatively simple but  
requires regular data recording and routine preventative maintenance. We cannot emphasize too  
strongly the importance of filling out the daily log sheet during each operating shift. A data sheet  
was filled out upon start-up containing pertinent facts on the operation of your machine. These  
two records are invaluable in diagnosing the performance of the equipment and must be kept for  
reference. If you have questions concerning the operation of your machine or the method of data  
recording, contact the GE Osmonics Application Engineering Department.  
The three preventative maintenance procedures which must be done on a regular basis are as fol-  
lows:  
1.  
2.  
3.  
Change the pre-filter cartridge.  
Flush the machine daily.  
Clean the machine with approved GE Osmonics cleaners.  
See the following sections for specific maintenance procedures.  
4.1  
Daily Log Sheets  
A Daily Log Sheet (Section 10.0) which includes general operating conditions (pressures,  
flows and concentrations) and routine or special maintenance (pre-filter changes, flushing,  
cleaning, etc.) must be kept. Copies of the log can be made from the template. A copy of  
this log sheet will be required by GE Osmonics if a warranty question arises.  
4.2  
Pre-Filter Cartridge  
A 5-micron pre-filter is factory-installed to protect the membrane elements and valves  
from particles which may be in the feed water. The pre-filter uses two 20-inch (50.8-cm)  
diameter, 5-micron nominal rated cartridges. To order replacements, contact your  
distributor.  
The pre-filter cartridges must be replaced, at a minimum, once per week or after every 100  
hours of operation, whichever comes first. A pressure drop of 8 psig (0.6 bar) across the  
filter or more during operation indicates one or more cartridges need changing. Use only  
Osmonics approved filters rated for 5 microns or less. Do not attempt to clean used  
filters - install new replacements.  
IMPORTANT NOTE: Failure to change the pre-filter according to these requirements  
will void the warranty.  
18  
 
4.3  
Flushing  
The machine should be flushed at least daily to remove sediment from membrane element  
surfaces. To flush the unit:  
STEPS  
1.  
Open the concentrate valve until the pressure gauge indicates the minimum pres-  
sure designated on the nameplate. This increases the flushing action on the mem-  
brane element.  
NOTE: If pressure will not decrease to designated pressure, or if the concentrate  
rate does not increase when the valve is opened, the valve may be  
plugged.  
2.  
3.  
Operate the machine at the designated minimum pressure for 10 to 20 minutes.  
CAUTION: Do not operate the machine below the designated pressure  
without approval from GE Osmonics. Operation below the  
stated pressure may be detrimental to the pump.  
Close the concentrate valve and ensure that the proper concentrate flow rate is  
going to the drain (see the nameplate on the panel).  
NOTE: The Autoflush (AUF) system, available in DLX packages, automati-  
cally flushes the machine and eliminates the need for frequent manual  
flushing.  
4.4  
Cleaning  
Cleaning the E4H-Series machine on a regular basis is vital. Over time, contaminants  
build up to form a layer on membrane element surfaces, reducing the permeate flow and  
quality. If this build-up is not removed from the membrane element, it may cause perma-  
nent chemical damage and reduce membrane element life. A decrease in permeate flow  
and/or rejection of salts, or an increased pressure drop across the machine will indicate  
when cleaning is required. Cleaning may be required as often as once every week or as  
infrequently as every two months, depending upon the local water supply conditions.  
GE Osmonics recommends cleaning at least every month to ensure good membrane ele-  
ment performance and long membrane element life.  
GE Osmonics offers a full line of chemical cleaners for specific cleaning needs. See  
Table 4.4 (Dry Chemical Cleaners).  
19  
 
Table 4.4  
Dry Chemical Cleaners  
Cleaner  
Description  
Part Number  
Quantity  
Osmo AD-20  
Dry acid-surfactant for cleaning TLC, PA  
and CA membrane elements.  
1155420  
1155421  
1155422  
1155423  
8 x 4 lb. pkgs/case  
45 lb. pail  
100 lb. key  
300 lb. drum  
Osmo AK-110  
Osmo ET-70  
High pH alkaline cleaner for PA membrane  
elements. Recommended for situations  
where microbial fouling is a problem. DO  
NOT use on CA membrane elements.  
1155416  
1155417  
1155418  
1155419  
8 x 4 lb. pkgs/case  
45 lb. pail  
100 lb. key  
300 lb. drum  
Cleaner intended to deal with sulfate  
or iron precipitation fouling. Recommended  
for CA and PA membrane elements.  
1155424  
1155425  
1155426  
1155427  
8 x 4 lb. pkgs/case  
45 lb. pail  
100 lb. key  
300 lb. drum  
CLEANING PROCEDURE  
STEPS  
1.  
With the RO machine running, open the Clean-In-Place (CIP) permeate valve. After this  
valve has been opened, close the permeate service valve. Permeate water will flow into  
the CIP tank. Allow the water to run through the CIP tank and the CIP tank drain valve  
for a few minutes to ensure the tank is rinsed thoroughly. After a minute or so, close the  
CIP tank drain valve. The CIP tank should begin to fill with RO permeate. When the CIP  
tank has filled to the indicated full line, turn the ON/OFF switch on the RO machine to the  
OFF position.  
2.  
3.  
While the machine is OFF, open the CIP inlet valve. Divert the permeate and concentrate  
streams to the cleaning container for recirculation. Ensure that the pre-filter is clean. A  
CIP pump (supplied with DLX models only) is recommended to supply feed pressure into  
the machine.  
To circulate the cleaning solution through the machine with suction, remove the CIP plug.  
Use a non-collapsible suction hose or pipe to feed the machine.  
NOTE: Do not allow the machine pump to operate without concentrate flow. If pump  
prime is lost while cleaning on suction, positive inlet pressure is required to  
reprime. No air should be sucked into the inlet line during suction cleaning.  
20  
 
4.  
Turn the CIP ON/OFF switch to the ON position and recirculate the cleaning solu-  
tion through the machine. The cleaning solution should be recycled for approxi-  
mately 15 minutes or until the solution temperature reaches 85°F (29°C). If heat  
rise occurs too quickly, larger volumes of cleaning solution or the use of a heat  
exchanger will slow the temperature rise. Turn the CIP OFF and allow it to soak  
for 10 minutes.  
TLC MEMBRANE NOTE: It is best to clean at temperatures of  
100°F - 110°F (38°C to 43°C), but lower temper-  
atures will suffice. Do not allow the cleaning  
temperature to exceed 110°F (43°C). Allow the  
cleaning solution to recirculate for 10 minutes.  
Turn the machine off and allow the membrane  
elements to soak in the solution for approximate-  
ly 20 minutes.  
WARNING: DO NOT LEAVE THE CLEANING STRENGTH SOLU-  
TION IN THE MACHINE FOR A PERIOD LONGER THAN  
ONE HOUR. THE CLEANING SOLUTION MAY DAM-  
AGE THE MEMBRANE ELEMENTS AND/OR THE  
MACHINE DURING AN EXTENDED PERIOD OF CON-  
TACT.  
5.  
6.  
To flush the detergent from the machine, close the CIP inlet valve and divert the  
permeate and concentrate to drain by opening the CIP drain valve. Operate the  
machine as described in the flushing section (Section 4.3, Flushing) for at least one  
hour. The detergent is sufficiently flushed when the permeate conductivity is  
restored to nearly its previous level.  
To return the RO to service, open the permeate, concentrate valves so that flow is  
routed as intended in the service mode. Close the CIP permeate, CIP concentrate  
valves. The RO is now ready for operation.  
4.5  
Draining Machine for Shipment  
Prior to shipping or outside storage of a GE Osmonics E4H Machine, the system should  
be cleaned with the appropriate cleaner, flushed with water, and protected from biological  
attack with the appropriate solution for TLC membrane. The membrane element housings  
and piping lines of the machine must be completely drained. Any water remaining in the  
piping of a machine may freeze, causing damage to the piping, pump, membrane elements,  
etc. The party shipping or storing the machine is responsible for any damage resulting  
from freezing.  
STEPS  
1.  
2.  
Disconnect the inlet, concentrate and permeate outlets.  
Drain all water from the cartridge filter housing.  
21  
 
3.  
Remove the tubing connections on the inlets and outlets of the membrane element  
housings.  
4.  
5.  
6.  
Open the concentrate valve.  
Remove the drain plugs from all PVC manifolds.  
Be sure the flow meters are drained by disconnecting the bottom fitting of each  
flow meter.  
7.  
8.  
Allow the machine to drain for a minimum of eight hours or until the opened ports  
quit dripping.  
After draining is complete, reconnect all of the piping.  
4.6  
Membrane Element Installation  
NOTE:  
For machines with membrane elements not loaded at the factory, the fol-  
lowing steps are to be used for installation.  
CAUTION: The membrane element is packaged in a small amount of bactericide solu-  
tion to prevent biological growth; provide adequate ventilation when han-  
dling. The membrane element must be kept moist at all times in order to  
prevent possible damage to the membrane element material.  
STEPS  
1.  
Remove the membrane element bag containing the membrane element from the  
shipping tube.  
2.  
3.  
4.  
Cut the bag open as close as possible to the seal at the end of the bag, so that the  
bag may be re-used if necessary.  
Remove the membrane element from the bag and remove the foam protectors from  
each end of the membrane element.  
Remove the parts from the parts container (if included) and inspect. Make sure that  
all parts are clean and free from dirt. Examine the O-rings, brine seal, and perme-  
ate tube for nicks or cuts. Replace the O-rings or brine seal if damaged. Set the  
membrane element aside in a clean space and continue on to Step 5.  
5.  
6.  
Remove the end caps from both ends of all membrane element housings on your  
machine. This is done by loosening the clamp bolts at each end cap closure  
assembly.  
Determine the direction of fluid flow in the membrane element housing. (Be cer-  
tain to look at the “Direction of Flow” arrow for each membrane element housing.  
Direction of flow may vary within a given machine.)  
22  
 
7.  
8.  
9.  
Inspect the membrane element housing and clean as necessary to remove any con-  
taminants, obstructions, etc.  
Apply a small amount of O-ring lubricant to all O-rings on the end caps, and the  
brine seal on the membrane element.  
Insert the downstream end of the membrane element in the upstream end of the  
membrane element housing (i.e., load in the direction of flow; the brine seal is on  
the end of the membrane element that goes in last. For membrane element hous-  
ings with the flow arrow pointing up refer to Step 10.  
10.  
11.  
12.  
Insert the membrane element in the membrane element housing with a smooth and  
constant motion. When you reach the point where the brine seal is about to enter  
the housing, gently turn the membrane element to ensure the brine seal enters the  
housing without coming out of the brine seal groove.  
When all of your membrane elements are installed, you must close the membrane  
element housing by reinstalling the end caps and clamps. It is preferred to install  
the bottom end cap first, and tighten the clamp completely, before installing the  
top end cap.  
Reinstall the end caps by gently twisting the end cap while pushing it on to the  
permeate tube. Ensure that you do not pinch or fatigue any O-rings while pushing  
the end cap on. Push the end cap on until the outer diameter of the cap is flush with  
the outer diameter of the membrane element housing. Install the clamp halves, and  
tighten the bolts until the clamp halves meet.  
13.  
14.  
Reconnect any fittings that were removed when disassembling the membrane ele-  
ment housings.  
Return to Section 3.2 (Start-Up, Step 1).  
4.7  
Membrane Element Replacement  
As time progresses, the efficiency of the membrane element will be reduced. In general,  
the salt rejection does not change much until two-three years after installation, when oper-  
ated on properly pretreated feed water and when routine maintenance is performed. The  
permeate flow rate will begin to decline slightly after one year of operation but can be  
extended with diligent flushing and cleaning of the machine. High pH feed water and/or  
precipitation of hardness can cause premature loss in rejection and even flow rate. The fol-  
lowing procedure is to be followed to replace existing membrane elements in the machine.  
STEPS  
1.  
Remove the end caps and clamps from all of the membrane element housings.  
23  
 
2.  
3.  
Remove all the membrane elements from the membrane element housings in the  
direction of flow, where possible. If necessary, a membrane element can be  
removed against the direction of flow. A heavy duty pliers or channel lock pliers  
may be necessary to pull the old membrane element our of the membrane element  
housing.  
To reinstall replacement membrane elements, follow Steps 4 -14 (Section 4.6,  
Membrane Element Installation).  
NOTE: Do not operate the machine on water over 85°F (29°C).  
NOTE: Do not allow the machine to freeze unless it is totally drained. The  
machine must thaw a minimum of 24 hours before starting.  
24  
 
5.0  
OPTIONAL ACCESSORIES  
5.1  
Level Controls  
Float switches, pressurized storage switches or other level controls should be wired into  
the control circuit line prior to the switch on the unit. The following ensures that the inlet  
valve, instruments, and pump are not powered when storage tanks are full: float switch  
assembly with cord, counterweight, and plastic float (used with an atmospheric storage  
tank).  
5.2  
5.3  
Filters and Water Softeners  
Backwashable filters and softeners should be installed such that unfiltered or unsoftened  
water will not be fed to the machine while the RO unit is operating. Failure to do this may  
cause fouling or precipitation of calcium carbonate or other materials onto the membrane  
elements.  
Storage Tanks  
Fiberglass, polyethylene, and stainless steel storage tanks are available. All tanks are  
available with fittings installed at the factory. These tanks must be installed with even sup-  
port along the bottom.  
25  
 
6.0  
TROUBLESHOOTING  
TROUBLESHOOTING GUIDE  
POSSIBLE CAUSES  
SYMPTOM  
REMEDIES  
Low operating pressure  
Insufficient feed water pressure Open the feed pressure, open the  
or flow  
feed water valve, check for  
restrictions.  
Clogged pre-filter cartridge  
High flow rates  
Replace the pre-filter cartridge.  
Close the concentrate valve,  
check the permeate and concen-  
trate flow rates and adjust if nec-  
essary. Excessive permeate flow  
may indicate a damaged O-ring.  
Dirty or fouled membrane  
elements  
Flush and clean the membrane  
elements.  
Solenoid valve not opening  
Clean or replace the solenoid  
valve.  
Pump rotating backwards  
(three-phase power only)  
Switch any two of the three-  
phase leads to the motor starter.  
Insufficient electrical power  
Pump not operating correctly  
Low operating pressure  
Check the fuses or circuit break-  
er, measure the voltage.  
See the pump instructions.  
Low permeate flow rate  
See the possible causes for low  
pressure.  
26  
 
TROUBLESHOOTING GUIDE  
POSSIBLE CAUSES  
SYMPTOM  
REMEDIES  
Low permeate flow rate  
(continued)  
Dirty or fouled membrane  
elements  
Flush and clean the membrane  
elements.  
Operating on cold water less  
than 55ºF (13ºC)  
Install a hot/cold feed water  
tempering valve if more perme-  
ate flow is needed. Operate  
with a feed water temperature of  
72º - 77ºF (22º - 25ºC).  
Membrane elements installed  
backwards or damaged  
concentrate seal  
Install membrane elements in  
the direction of fluid flow.  
Flush and clean the machine  
immediately. Membrane ele-  
ments with damaged concentrate  
seals should be cleaned and may  
be returned for repair.  
Flow meter inaccurate  
Check the flow rate manually  
with a stopwatch and calibrated  
container.  
Concentrate valve plugged  
Remove the concentrate valve  
stem and/or disassemble the  
plumbing. Clean the valve.  
Low concentrate flow rate,  
normal or higher than  
normal pressure  
Concentrate outlet line restricted Examine the concentrate line for  
obstructions or kinks, repair or  
replace the tubing.  
Flow meter inaccurate  
Check the flow rate manually  
with a calibrated container.  
Pressure does not drop when  
concentrate valve opened  
Dirty concentrate valve  
Disassemble and clean the  
plumbing to the valve.  
27  
 
TROUBLESHOOTING GUIDE  
POSSIBLE CAUSES  
SYMPTOM  
REMEDIES  
High operating pressure  
Recycle or concentrate valve  
plugged  
Disassemble the plumbing to the  
recycle valve and remove for-  
eign particles. Check the con-  
centrate valve stem.  
Inaccurate pressure gauge  
Replace or calibrate the gauge as  
required.  
Restricted or reduced permeate  
flow rate  
See possible causes for low per-  
meate rate.  
Excessive pressure drop  
[over 50 psig (3.4 barg)]  
(high primary pressure - low  
final pressure)  
Restricted flow after pump  
outlet  
Check for blockage of the con-  
centrate flow at the inlets and  
outlets of membrane element  
housings.  
Telescoped membrane element  
covering membrane element  
housing outlet port  
Ensure that the anti-telescoping  
(ATD) is located properly on the  
membrane element.  
Severely fouled or dirty  
membrane elements  
Flush the machine, then clean it  
with detergent.  
Water flowing when machine is  
turned OFF  
Inlet solenoid valve not closing  
or seating properly  
Clean or replace the valve.  
Clean the membrane elements  
with detergent immediately.  
Water must not pass through the  
inlet when the machine is OFF.  
Declining rejection  
(high permeate conductivity)  
Dirty or fouled membrane ele-  
ments  
Flush and clean the membrane  
elements.  
28  
 
TROUBLESHOOTING GUIDE  
POSSIBLE CAUSES  
SYMPTOM  
REMEDIES  
Declining rejection  
(high permeate conductivity)  
(continued)  
O-ring seal broken or damaged  
Replace the O-ring, check the  
sealing surfaces on the O-ring  
groove, interconnectors, and end  
caps. Replace damaged parts.  
Change in incoming water  
quality  
Open the concentrate valve and  
flush. Test the water for pH,  
hardness, TDS, and iron content.  
A water analysis should be sent  
to GE Osmonics.  
Inaccurate conductivity  
monitor or fouled probe  
Calibrate the monitor with a  
solution of known conductivity  
or check the readings with  
another conductivity meter.  
Replace or clean the probe.  
Check the connections between  
the probe and monitor.  
Switch ON, unit not operating  
Pressurized storage switch or  
float switch has cut power to  
machine  
Check the permeate back pres-  
sure or position of float in the  
storage tank.  
Thermal overload in motor has  
tripped  
Allow the machine to cool;  
check the feed water supply  
and/or AMP draw to the motor.  
No power to machine  
Check the fuses or circuit break-  
ers, measure the voltage.  
Motor and/or pump not operat-  
ing properly  
See pump instructions. Contact  
GE Osmonics for possible repair  
or replacement.  
29  
 
TROUBLESHOOTING GUIDE  
POSSIBLE CAUSES  
SYMPTOM  
REMEDIES  
Electrical machine shutdown  
Alarm condition has turned  
machine OFF  
Restart the machine by pushing  
the alarm bypass. Check all  
possible alarm conditions: inlet  
pressure or motor starter  
overload.  
Motor starter overloaded, heater  
tripped  
Turn the switch OFF; rest the  
heater(s). Check the motor  
AMP draw and the line voltage.  
Timing relay defective/burned  
out  
Replace the relay.  
30  
 
7.0  
RETURN GOODS AUTHORIZATION (RGA) PROCEDURE  
If you wish to return good for repair, warranty evaluation and/or credit, please have your original  
sales order or invoice available when you call GE Osmonics. Call (800) 848-1750 and ask to speak  
with Customer Service. A GE Osmonics Customer Service 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 to GE Osmonics 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 returned must be rendered in a non-hazardous condition prior to shipping.  
IMPORTANT NOTE:  
Machines must never be shipped with water in them; this will void the  
warranty. Drain the machine completely before shipping and avoid  
freezing before draining. The machine should be sanitized (Section  
4.4, Cleaning) prior to draining (Section 4.5, Draining Machine for  
Shipment).  
31  
 
8.0  
WARRANTY  
Warranty Terms  
Subject to the terms and conditions set forth hereinafter, Seller (GE Osmonics, Inc. or any  
of its authorized subsidiaries) warrants to the original purchaser (hereafter the “Buyer”)  
that the products manufactured by Seller are free from defects in material and in work-  
manship for twelve (12) months from the Warranty Commencement Date (as defined  
below) only when used strictly in accordance with the applicable operating instructions  
and within the range of the operating conditions specified by Seller for each such product.  
This Warranty does not extent to equipment or components manufactured by others into  
which a Seller product has been incorporated or to equipment or components which have  
been incorporated into a Seller product but, if allowable, Seller hereby assigns, without  
warranty, to the Buyer its interest, if any, under any warranty made by the manufacturer of  
such equipment or component. This Warranty does not cover disposable items such as  
fuses, lamps, filters, cartridges, or other such disposable items, which must be replaced  
periodically under the normal and foreseeable operating conditions of the goods warrant-  
ed hereby.  
Warranty Commencement Date  
The Warranty Commencement Date for each Seller product shall be the later of the date  
of: (1) receipt by the Buyer, or (2) the date of installation at the Buyer’s premises provid-  
ed that such installation must occur within three (3) months of shipment from the Seller’s  
manufacturing facility in Minnetonka, Minnesota. In no event shall the Warranty  
Commencement Date exceed three (3) months from the shipment from the Seller’s manu-  
facturing facility. The Buyer shall provide proof of purchase in order to exercise rights  
granted under this Warranty. If requested by GE Osmonics, the Buyer must also provide  
proof of the installation date. Proof of installation shall be returned by Buyer to Seller  
within thirty (30) days after installation by virtue of supplying a Warranty Validation Card  
supplied with each Seller product fully completed and signed in ink by Buyer and the  
authorized installer of the product.  
Warranty Service  
SELLER’S OBLIGATION UNDER THIS WARRANTY IS LIMITED TO REPAIR OR  
REPLACEMENT (AT SELLER’S SOLE OPTION) OF ANY PRODUCT, OR COMPO-  
NENT THEREOF, PROVED TO BE DEFECTIVE IN MATERIAL OR WORKMAN-  
SHIP WITHIN THE COVERED WARRANTY PERIOD. The Buyer. at the Buyer’s risk  
and expense, shall be responsible for returning such product or component, upon obtain-  
ing a Return Goods Authorization (RGA) number from the Seller, freight prepaid, and in  
conformance with any special packaging and shipping instructions set forth on the opera-  
tion documentation or RGA instructions, or as otherwise reasonably required, to the  
Seller’s address set forth below, together with (1) RGA number issued by Seller at Buyer’s  
request; (2) proof of purchase and, if necessary, proof of installation date; (3) a description  
of the suspected defects; (4) the serial number of the Seller product alleged to be defec-  
tive; and (5) a description of the type of water pretreatment equipment which has been uti-  
lized in connection with the product, if any. Seller shall, in Seller’s reasonable discretion,  
be the sole judge of whether a returned product or component is defective in material or  
32  
 
workmanship. Required or replaced products or components shall be returned to the  
Buyer by the Seller, freight prepaid by Seller, via UPS ground or best way surface freight.  
In genuine emergency situation, Seller will (at Seller’s sole option) forward replacement  
parts to Buyer without waiting for authorized return of the questionable part(s). In such  
cases, Buyer will issue a purchase order or other payment guarantee prior to shipment. If  
the returned part is found to have been misused or abused, the defective part is not received  
by Seller within thirty (30) days, the Buyer will be invoiced for replacement part(s) pro-  
vided. This Warranty does not cover or include labor and/or travel to the Buyer’s premise  
or location or any other location. Charges will be made for the usual and customary Seller  
costs and associated expenses incurred by Seller in providing Warranty Service at any  
location other than Seller’s factory at the address set forth below, and Seller reserves the  
right to precondition such travel to Buyer’s premises upon prepayment of Seller’s antici-  
pated costs of attending such premises.  
Voidability of Warranty  
This Warranty shall be void and unenforceable as to any Seller product which has been  
damaged by accident, mishandling, abuse or has been repaired, modified, altered, disas-  
sembled or otherwise tampered with by anyone other than Seller or an authorized Seller  
service representative; or, if any replacement parts are not authorized by Seller have been  
used, or, the product has not been installed, operated and maintained in strict accordance  
and adherence with the operating documentation and manuals for such product. Any  
express warranty, or similar representation of performance set forth in the operation doc-  
umentation for a reverse osmosis or ultrafiltration membrane incorporated into a Seller  
product shall be void and unenforceable unless the feed water requirements set forth in the  
operating documentation for such product are unequivocally and strictly adhered to.  
Limitations and Exclusions  
THIS WARRANTY AND REMEDIES DESCRIBED HEREIN AND HEREIN ABOVE  
ARE EXCLUSIVE AND IN LIEU OF ANY AND ALL OTHER WARRANTY OR  
REMEDIES, EXPRESSED OR IMPLIED, INCLUDING WITHOUT LIMITATION,  
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PAR-  
TICULAR PURPOSE. IN NO EVENT SHALL THE SELLER BE LIABLE FOR ANY  
CONSEQUENTIAL, INCIDENTAL OR OTHER SIMILAR TYPES OF DAMAGES, OR  
FOR DAMAGES FOR THE LOSS OF PRODUCTION OR PROFITS, OR INJURY TO  
PERSON OR PROPERTY. NO PERSON HAS ANY AUTHORITY TO BIND SELLER  
TO OTHER THAN WHAT IS SET FORTH ABOVE.  
THIS WARRANTY GIVES THE BUYER SPECIFIC LEGAL RIGHTS AND THE  
BUYER MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM JURISDICTION  
TO JURISDICTION. THE PARTIES RECOGNIZE AND AGREE, THAT IN ALL  
RESPECTS THE LAWS OF THE STATE OF MINNESOTA SHALL APPLY TO AND  
SHALL GOVERN ANY INTERPRETATION OR LEGAL SIGNIFICANCE OF THIS  
DOCUMENT.  
33  
 
9.0  
START-UP DATA  
Customer:  
Model Number:  
Serial Number:  
Date:  
Tested By:  
Units (Circle One)  
Data  
Data  
Remarks  
°F  
gph  
°C  
Temperature  
gpm  
gpm  
gpm  
Lpm  
Lpm  
Lpm  
Lph  
Lph  
Lph  
/
/
/
/
/
/
Permeate Rate  
Concentrate Rate  
Total Flow Rate  
Recovery  
gph  
gph  
%
bar  
psi  
psi  
psi  
psi  
Pre-Filter Pressure  
Post-Filter Pressure  
Primary Pressure  
Final Pressure  
bar  
bar  
bar  
µS  
µS  
µS  
µS  
µS  
Feed TDS  
Concentrate TDS  
Average TDS  
Permeate TDS (manual)  
µ
Permeate TDS (meter S)  
% Passage  
(Perm TDS / Avg TDS)  
ppm  
Chlorine in Concentrate  
Low Pressure Switch  
Setting  
bar  
psi  
Pump Model Number  
Pump Serial Number  
34  
 
35  
 
36  
 
 
For more information:  
Call (952) 933 - 2277 for additional information (800) 848 - 1750 in the U.S., or visit www.gewater.com.  
Manufactured in the USA  
Asia/Pacific Operations  
1044/8 SOI 44/2  
Sukhumvit Road Prakanong  
Bangkok 10110  
THAILAND  
+66 2 38 14213 Phone  
+66 2 39 18183 Fax  
Euro/Africa Operations  
230 rue Robert Schuman  
ZA des Uselles  
F-77350 Le MØe sur Seine  
FRANCE  
Corporate Headquarters  
5951 Clearwater Drive  
Minnetonka, MN  
55343-8995  
USA  
+33 1 64 10 2000 Phone  
+33 1 64 10 3747 Fax  
(952) 933-2277 Phone  
(952) 933-0141 Fax  
' Copyright 2003, GE Osmonics  
Printed in USA, P/N 1163955 Rev.C  
 

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