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OPERATION AND MAINTENANCE MANUAL

1. 24 SCREEN DESCRIP TRONS PS Say ake ue EG aie aie sS 25 SF ee eicere e 25 SC EGIN weds eg CW s D n q OE Hw ds 27 SELES Zeres ee EE ROG E 28 Warnung ie wor aka See uba aka 28 Startup edd Soe nd Do te oe 30 ADJUSTMENTS ce S sus S Saa UR Ge Ge eee eee ae 31 TDS Conductivity es OS OS 31 Display Contra Eer 3 eZ este VERE E 31 FLOW METERING Sy UO ped mae E Un NUR Sn M DES 4 32 Flow Meter ao ee oe te ee eee eee 32 BLOW Meter Calibration cie eed eed 32 BLOW Ke S de wwe kup eU E Le 34 Flow Setpoint S SUS W S S EUR ES 34 Row ODE Ka CORN cy ve u Qa veis 35 MOW Jia ETIS cM ues wd y Sa ees MNP alte 35 TD BONIS S IO ES AR ES 36 pH Sensor eee oak eee tates hae Sake eee Ss 36 PH Sensor hu sisan tees Doe ted Soe ted Eee bent 36
2. High pump pressure operates in the same manner except the pump pressure sensor input must exceed the value programmed in setpoint 03 High Pump Pressure and the delay is programmed in setpoint 04 High Pump Delay NOTE The high pump pressure alarm generated by the pressure sensor can be disabled by programming Setpoint 03 to 0000 If the system shuts down for a low or high pressure fault and the Setpoint 20 Auto Reset Time is programmed to a time other than 0 the time remaining before the system attempts the automatic restart is indicated after the caus of the shutdown on the first line of the display If Setpoint 20 is programmed to 00 the low or high pressure shut downs can only be reset by pressing the Reset key Low Pump Pressure The pump pressure sensor has an additional setpoint for a low pump discharge pressure alarm When the RO unit is operating if the pump pressure drops below the value programmed in setpoint 05 Low Pump Pressure Limit the alarm lamp will light and LOW PUMP PRESSURE will show on the alarm display This alarm is disabled when the RO pump is off and during flush This setpoint does not cause RO system shutdown If Setpoint 05 is programmed to 000 the low pump pressure alarm is disabled Differential Pressure Alarms If the optional differential pressure sensors are installed high differential pressure setpoints 06 Prefilter Differential and 07 Max Membr
3. 4 20 MA ANALOG INPUTS PRESSURE AND TEMPERATURE O FEED PRESSURE SENSOR PUMP PRESSURE SENSOR PERMEATE COND TDS SENSOR ENT COND TDs SENSOR TESTING SENSOR POWER TO CHECK THE 15V DC SUPPLY WHICH POWERS ALL 4 20 PRESSURE AND TEMPERATURE SENSORS CONNECT THE DIGITAL MULTIMETER COMMON LEAD AS SHOWN AND CONNECT THE LEAD TO THE TOP INPUT TERMINAL OF THE TERMINAL STRIP AS SHOWN THE VOLTMETER READING SHOULD BE 14 5 15 5 VOLTS DC IF THE READING IS VERY LOW OR 07 DISCONNECT ALL RED WIRES ONE AT TIME WHILE CHECKING THE VOLTAGE IF THE READING JUMPS UP WHEN ONE 8 si NOTE OF THE RED WIRES IS DISCONNECTED seattle EITHER THAT CABLE OR SENSOR IS TEMPERAUTRE amp SHORTED AND MUST BE REPAIRED OR OUTPUTS REPLACED TESTING SENSOR OUTPUTS TO CHECK A SENSOR OUTPUT CONNECT THE LEAD AS SHOWN AND CONNECT THE LEAD TO THE BLACK INPUT TERMINAL OF THE SENSOR BEING TESTED THE VOLTMETER READING SHOULD BE BETWEEN 1 09 AND 5 00 VOLTS IF THE SENSOR IS WORKING PROPERLY IF THE READING IS HIGH CHECK FOR OVER RANGE HI PRESS AND IF SO CORRECT THE CONDITION IF THE PRESSURE ON THE SENSOR IS WITHIN ITS RANGE AND THE VOLTAGE IS ABOVE OR BELOW THE 1 5 VOLT RANGE RE PLACE THE SENSOR TESTING TDS COND INPUTS TO TEST THE TDS COND SENSORS AND THE PC BOARD CIRCUITRY DISCONNECT THE GREEN AND WHITE WIR
4. Spare Parts TER NOTE To avoid damaging the coupling halves Grundfos offers an extensive list of spare parts For a current list of these parts refer to All ensure that portion of the keyway on the Product Spare Parts Service Kits Price List Form L SK SL 002 motor shaft lies within the gap between the two coupling halves Figure 9 11 LCPTL003 CR I amp O_Rev0104 qxd 1 26 2004 11 58 AM Page 12 WARNING RUBBER GLOVES AND BOOTS BE WORN AND METAL TERMINAL BOXES AND MOTORS ARE GROUNDED BEFORE ANY WORK WHEN WORKING WITH ELECTRICAL CIRCUITS USE CAUTION TO AVOID ELECTRICAL SHOCK IT IS RECOMMENDED THAT IS DONE FOR YOUR PROTECTION ALWAYS DISCONNECT THE PUMP FROM ITS POWER BEFORE HANDLING Preliminary tests Supply voltage How to measure Use a voltmeter set to the proper scale measure the voltage at the pump terminal box or starter On single phase units measure between power leads L1 and L2 or L1 and N for 115 volt units On three phase units measure between Power leads L1 and L2 Power leads 12 Power leads L3 and L1 What it means When the motor is under load the voltage should be within 10 of the nameplate voltage Larger voltage varia tion may cause winding damage Large variations in the voltage indicate a poor electrical supply and the pump should not be operated until these variations have been corre
5. P 32PPM The permeate water quality in PPM is shown If the selected unit of measure is microsiemens the PPM will be replaced with uS If the permeate reading is out of range the display will show 2 97 7 percent rejection is calculated displayed If the feed sensor is not installed or if either sensor reading is out of range the display will show REJ E 31PSI If the optional feed pressure sensor is installed the feed pressure in PSI or BAR will be shown If the sensor is not installed the display will show F OK if the low pressure switch is not activated If the low pressure switch becomes activated the display will show F LO P 196PSI If the optional pump pressure sensor is installed the pump discharge pressure in PSI or BAR will be shown If the sensor is not installed the display will show P OK if the high pressure switch is not activated If the high pressure switch becomes activated the display will show F HI 68EF The permeate water temperature in EF or EC or if the feed sensor is installed the feed water temperature 26 HRS 1734 6 2 38 196PSI 51 5 178PSI 7 51 18PSI Figure 10 2 If no alarms are present pressing the Display key advances the display to screen 2 Screen 2 displays additional data for the ROTrol II On all pressure readings the pressure shown will be in PSI or BAR based on the pressure unit
6. LCPTL003 CR I amp O_Rev0104 qxd 1 26 2004 11 58 AM Page 13 F Diagnosing specific problems Problem Possible cause Remed The pump does not run 4 5 No power at motor Fuses are blown or circuit breakers are tripped Motor starter overloads are burned or have tripped out Starter does not energize Defective controls Motor is defective Defective capacitor Single phase motors Pump is bound Check for voltage at motor teminal box If no voltage at motor check feeder panel for tripped circuits and reset circuit Turn off power and remove fuses Check for continuity with ohmmeter Replace blown fuses or reset circuit breaker If new fuses blow or circuit breaker trips the electrical installation motor and wires must be checked Check for voltage on line and load side of starter Replace burned heaters or reset Inspect starter for other damage If heater trips again check the supply voltage and starter holding coil Energize control circuit and check for voltage at the holding coil If no voltage check control circuit fuses If voltage check holding coil for shorts Replace bad coil Check all safety and pressure switches for operation Inspect contacts in control devices Replace worn or defective parts or controls Turn off power and disconnect wiring Measure the lead to lead resistances with ohmmeter RX 1 Measure lead to ground values with ohmmeter RX 100K Record measured val
7. HOM shay p eeu ese ep de oy Sea ere S eae 36 pH Setpoint 3 EI aie men ee Sic SU seem ES SEI EIS 38 ABARM DIVERT RELAY BOARD REGGIO RSS 40 TROUBLE SHOOLING a5 ve neat 41 Bude A S a evinced a 41 TOOLS TESE ek Seed 41 System InoperatiVvOicacag wa m m UR S EE TS LET 41 Zi terzi s er etate eios e s ere dos 42 RO Pump Wai lb Operaqte ceeXoneoelu uim IRE E De EIS 42 Inlet Valve WLLL cuna dengue W 42 Pump Will ODperateusciewdaue sm pem eH xax 43 RO Unit Not Flushing or Not Flushing Correctly 43 Pressure Sensor Readings Incorrect or not Reading 43 TDS Conductivity sig RERO VERS 44 Incorrect TDS Conductivity Readings eck tans Hewes 45 Keypad Problems ssn cose dle sid dmm Re se ae ele e 45 oreen SK TODS ate eee E ME ES 45 No Resding From buy see od eee keret 45 No Reading From 1 Flow Sensor ees 46 iv Elow Sensor Rea
8. p 127 2 to 6 PANEL THK a 1008 BACK CONNECT XUC VARIATION GAUGE SIZE ss m c 0 5 31 28 49 64 INCH 2 VA 264 1 1 29 wg am Treo T o2 ws as mere INCH 1 4 3 DIMENSIONS IN ARE INCHES Ordering Example Below 63 1008S Tube Socket Q Case Size Material Code code on 63 63mm 1008 Bronze Brass 2 Soldered 100 100mm 4 63 63mm 1008 AISI 316 2 Stainless Steel AISI 316 Stainless Steel Welded 100 100mm 4 22 ACROSS 78 FLATS 1 ae NPT 1 4 7 DIAMETER 4OLES ON H DIAMETER BOLT CIRCLE 1 11 ACROSS Ag FLATS dM K V NPT DIA S MN NN suc s ETT 75 3 2e 3 2 2 How To Order and Case Dimensions L 02 0 1500 Connection Location Code Variations Standard Ranges Dual Scale Dial Single Scale Dial Dry V4 NPT Throttle psi psi Inner Arc kPa Outer Arc iquid Fill Device 3lycerine Ys NPT 1008A or AL 0 15 0 15 0 100 Wired 0 30 0 30 0 200 St St Tags 0 60 0 60 0 400 0 100 0 100 0 700 1 0 160 0 160 0 1100 one 0 200 0 200 0 1400 100 0 300
9. HHOH ROTROL IID PC BOARD 0505050550 sho O rO rO amp dure jibseoeocesoos D sss 2 1 ME WE V TT TU lb RELAY EXPANSION C PC BOARD O 8 a 28222964 ROTROL WITH OPTIONAL RELAY EXPANSION Figure 17 40 TROUBLESHOOTING CAUTION Hazardous voltages are present when power is applied to the unit Care should b taken when troubleshooting any of the input power or relay output circuits When disconnecting or connecting any board or accessory be sure power to the unit has been turned off Before replacing any PC boards and accessories or making any adjustments to the unit please refer to the appropriate troubleshooting section for the proper testing methods Incorrect adjustments can mask problems or can cause further problems Check all setpoints and verify proper values for each setpoint In the event you are unable to determine the cause of a failure you can contact R amp D Specialties for further assistance Please make note of the events leading up to the failure the exact failure what LED s if any that are on what readings are shown on the display etc before contacting technical support The more information you have when you contact us the easier it will be to determine the source of the problem Technical support can be contacted by Fax at 915 561 5696 by email at trproc rdspec com or by phone at 915 561
10. xs sm ele PE S 5 Prefilter Differential Pressure Sensor 5 Membrane Differential Pressure Sensor 6 Switch ewe ee Dah VS NS ENSE 6 Tank Full P mp Off Switehlus xke NEUE EUR 6 Dane Pump sS Watt Cie yt E Dens ern 6 Tani TOW 7 Low Feed Pressure Switch su ws ss w le neces 7 High Punp Pressure SwirtohDs lowees9d4 2v co es ae ae ete dha sie Ghee 7 PReb Re at LockoutuVsSwrtohu6 RI UE wie Alarm Divert Qutp ts cus Seda Vad gale 7 Alarm weer date Su ee E ee E b RU 7 de Rea suk MEE SE SEE 7 SETPOINT O ece wu ah a a ee Se Se kus S Dre Sieh ete Se doa db 3 Standard SSDBGTITES Zx wu Sum x ee nace 3 Displaying Changing Setpoint aser diost ana aeaa a eck 7 FUNCT TONS s Qosa aus ws oho are She L 8 Standard e ls were viet Se anew e el 8 PUN CEO Opera et Oe tee ee 8 was ku Sea ede hee eed th 9 SYSTEM RAST EO Nese
11. C1 K4 T4 EXAMPLE CATALOG NUMBER 2 7 9 E P2 COIL CLASS VOLTAGE SEAT SEAL SQ SEAL amp O RING MATERIAL GC Valves SQUARE SEAL p Sheet 2 df 2 Lock ap TS WASHER A CS WASHER QD 48 NAME PLATE AiD ST dii HOUSING O RING GS SPRING NC 25 WASHE P e q0P PLATE 1 SPRING WASHER amp D a C D PLUNGER SPRING BRACKET OPTION PLUNGER ASSY 5 6 419 1 Iu HE HOUSING DIAPHRAGM SPRING m EXP PROOF OPERATOR LJ PARTS INCLUDED N UNIVERSAL KIT FIG 1 EXPLODED VIEW OF TYPICAL 5201 VALVES N C BRACKET Coption CO ds ANS WASHER BOLT D B D wr ah Ce 9 8 LOCK WASHER TUBE AND C3 dD SPACER ASE ASSY EDD PLATE AD HOUSING PLATE DI APRA e WASHER WASHER d au 1460 gt ou ed ODED WASHER TURE HEAD CAED vASNER EA O RING W SEAT OW qd b HOUSING 1 EXP PROOF OPERATOR TEFLON RING A C ONLY PARTS INCLUDED iN UNIVERSAL KIT FIG 2 EXPLODED VIEW OF TYPICAL 202 VALVES
12. System Inoperative Is the yellow CPU active LED blinking If no is the green power LED 051 Lit If no is the fuse OK If no replace the fuse If yes with a voltmeter verify power is applied to the power terminals L1 and L2 If power is applied to the power terminals and the above checks are OK the board is probably defective and should be replaced If no power is applied to the board check the power wiring to the system Display Blank Is the green power LED 051 lit If no refer to the system inoperative section If yes is the CPU active LED DS9 blinking If no replace the board If yes adjust the display contrast adjustment R3 Is the display still blank If yes replace the board Inlet Valve Will Not Operate Is the system in standby If no are any shut down conditions active If no is the inlet LED 058 lit If no replace the board If yes with a voltmeter verify if there is power on the inlet terminals Is there power If no replace the board If yes check the valve and wiring RO Pump Will Not Operate Is the system in standby If no are any shut down conditions active If no is the RO LED DS6 lit If no replace the board If yes with a voltmeter verify if there is power on the RO pump terminals Is there power If no replace the board If yes check the pump and wiring Unit Not Flushing or Not Flushing Correctly Verify that flush is enabled and what type of flush is selected Is flush enabled If no e
13. For other applications consult the factory INSTALLATION WARNING This valve is normally closed N C to flow when not powered Do not use in place of normally open N O valve Check valve specifications to be sure that the valve selected is the proper one for the application Installation must be performed only by a trained and experienced service person 1 Clear lines of all foreign matter 2 Valves are multipoised and may be mounted in any position 3 Thread seal should be applied sparingly and to the male threads only To tighten use a wrench on the body flats at the end being connected Do not use the solenoid housing as a lever to turn the valve 4 Provide a clearance for solenoid removal in case removal is subsequently necessary Unit 4C VALVES INSTALLATION SERVICE AND PARTS LIST TERMS AND CONDITIONS 211 SERIES PILOTED DIAPHRAGM 2 WAY SOLENOID VALVE SDI SDP 5211 1 Fig 1 Typical S211 5 Wire in accordance with applicable local and national electrical codes Loosen the hex nut Fig 3 No 1 to rotate the coil jacket Fig 3 No 4 Using a torque wrench tighten the hex nut to 20 25 inch pounds when installation is completed MAINTENANCE It is recommended that S211 Series Valves be cleaned on a routine basis by qualified personnel The customer or user should set up a sound maintenance schedule based on low media environment and frequency of use which s
14. 01 99 seconds 01 99 minutes 00 99 minutes DEFAULT 100 030 00 00000 00000 STANDARD SETPOINTS SETPOI DESCRIPTION 21 22 2 9 24 25 26 27 28 29 30 31 32 Pretreatment Lockout Delay The amount of time the pretreat lockout switch must be active before pretreat lockout is valid and the RO system shuts down Not Used Not Used Tank Full Delay The amount of time the tank full pump OFF switch input must be active before tank full is valid and the RO system shuts down Tank Full Restart Delay When Dipswitch 2 is OFF this delay is in minutes If ON the delay is in seconds Tank Full Override Tim When th Tank Full Override function is init iated Function 1 the tank full shutdown is overridden for the number of minutes in this setpoint Tank Low Delay The amount of time the tank low switch input must be active before tank low is valid and the Aux system shuts down Not Used embrane Flush Time The length of ime the membrane will flush when embrane flush has been activated embrane Flush Interval interval between flush operations Only valid for op hour elapsed time or off time flush Flush Mode Enables flush and selects the type of flush To disable flush set to 00 Not Used 15 RANGE DEFAULT 00 99 05 seconds 01 99 05 seconds 01 99 15 seconds minutes 0 9 3 minutes 01 99 05 seconds
15. 220mm Max gt 7 1 180mm SUCTION 4 1 2 HOLES 13mm 5 16 tommy 4 5 15 16 150mm Max CR IN 10 15 20 amp CR N X T 8 16 4 10 1 16 256mm Max gt 8 1 2 215mm SUCTION 4 1 2 HOLES 13mm DISCHARGE_ Ls ve 130mm gt 7 7 200mm Max CR N 32 11 3 4 298mm lt 9 7 16 240mm gt SUCTION 4 9 16 HOLES 14mm DISCHARGE ls Wher 4 8 7 8 226mm gt CR N 45 64 4 13 331mm 11 266mm gt SUCTION 4 9 16 HOLES 14mm f DISCHARGE_ le 7 4 9 7 8 251 CR N 90 13 3 4 348mm 1 280mm SUCTION 4 9 16 HOLES 14mm DISCHARGE k 7 1 somm 4 10 5 16 261mm gt Pipework NOTE The CR N pumps are shipped with covered suction and discharge The covers must be removed before the final pipe flange to pump connections are made Suction pipe The suction pipe should be adequately sized and run as straight and short as possible to keep friction losses to a minimum minimum of four pipe diameters straight run prior to the suction flange Avoid using unnecessary fittings valves or accessory items Butterfly or gate valves should only be used in the suction line when it is necessary to isolate a pump beca
16. 380v 194 psi 194 psi 192 psi 191 psi 188 psi R O ELEMENT 4 X 40 4 X 40 4 X 40 4 X 40 4 X 40 TAPE TAPE TAPE TAPE TAPE WRAPPED WRAPPED WRAPPED WRAPPED WRAPPED PREFILTER 4 5 X 9 75 4 5 X 9 75 4 5 X 9 75 4 5 X 9 75 4 5 X 9 75 CARTRIDGE 5 MICRON 5 MICRON 5 MICRON 5 MICRON 5 MICRON RECOVERY 5096 5096 5096 5096 5096 96 96 96 96 96 REQUIRED FEED FLOW RATE GPM 22 2 24 3 26 4 28 5 29 9 REQUIRED CLEANING FLOW 24 30 24 30 32 40 32 40 32 40 RATE GPM MINIMUM CLEANING SOLUTION MIX gt T 2 GAL BBRO 10 000 SERIES REVERSE OSMOSIS SYSTEMS SCHEMATIC AND PARTS LISTINGS oa DESCRIPTION BBRO 10 000 TO 17 500 BBRO 19 000 TO 21 500 PREFILTER 4 5 x 10 1 57 INLET ase 1 HOUSING Hino 4 5 X20 L5 INLET HPO07 2 PREFILTER 4 5 x 9 75 5 MICRON 4 5 x 9 75 5 MICRON CARTRIDGE PFCIO PFC10 INLET 125 NC BRASS 2 BRASS SOLENOID 220v GVC125B GCV125B 30455 15 STAGE 30455 9 STAGE RO PUMP AND 316SS 14 STAGE 31655 9 STAGE a MOTOR 60Hz 5 7 5 HP 5 7 5 HP RO PUMP AND 31655 22 STAGE 316SS 16 STAGE MOTOR 50Hz 5 7 5 HP 5 7 5 HP z PUMP THROTTLE 1 25 BRONZE 300 1 25 BRONZE 300 VALVE GLV03 GLV03 P PRESSURE 4 x 40 PVC 200 4 x 40 PVC 200 VESSEL HEO07 HEO07 REVERSE OSMOSIS TW30 4040 TAP WATER TW30 4040 TAP WATER MEMBRANE 11 11 CONCENTRATE 34 BRONZE 300 1 BRONZE 300 CONTROL VALVE G
17. Figure 2 50000 00060000006 ool TY Dum ule 0 o 1 Figure 3 S8000000 R33 1 R3 Doo 5 x 10 Ga Gs z Ka TDS COND oC Amo ari l CELL TANK FULL LOW SWITCH TANK FULL HIGH SWITCH PRETREAT SWITCH INLET PRESSURE SWITCH FLUSH VALVE RO PUMP L2 L1 GND 0 120 OR 240 POWER IN TANK LOW SWITCH Ll 120 240VAC VALVE POWER IN Figure 4 TDS CONDUCTIVITY SENSOR INSTALLATION 1 UP 4 FLOW PIPE TEE THE SENSOR FITTING IS 5 4 MALE SCREW THE SENSOR INTO THE END OF A PIPE TEE WITH THE FLUID FLOW IN THE DIRECTION INDICATED POSITION THE SENSOR IN A PLANE THAT WILL PREVENT AIR BEING TRAPPED IN THE AREA OF THE SENSOR Figure 5 11 STANDARD SETPOINTS SETPOINT TDS Cond Limit TDS Cond Delay RO Start Delay Press Fault Delay Auto Reset Alarm Silence TF Restart Delay TF Restart TFO Time Tank Lo Restart Flush Type Flush Time DESCRIPTION When this value is met or exceeded the alarm lamp will light and high TDS Cond will show on the display To disable set to 0 When the limit Setpoint is exceeded no alarm will be given until this time has expired The amount of time between the inlet valve opening and the RO pump start The time a
18. te C S eee ee 20 General Operation bites i vente ede eV S 20 Tank 1 Operate Onrar S uQ aa oa Sd SOS ee S 20 Tank Full OV 6rrid PS E 20 Low Feed High Pump Pressure 21 Low Bump Pressube lsu gGhile We ler E DUE D So TRUE SIND RU IRIS 21 Differential Pressure Alarms ie ced ee bee Pale Qu au wd We 21 High TDS Conductivity Alarm Shutdowns ceres 21 SoOROJgectronm we ve du susce ER eie 22 Shutdown Disables este eG Galea m re Remedy raus me 22 Iri RO System Shutdown eg eed 22 22 Membrane Q us seas STS RS 22 Auxi ltery RP Pump v Sus 23 Tank SHOW eet at ue ates eit a s MEINE MURIS S TERIS S 23 Operating Z wo sae bred wa Soe Soe w S ww 23 Temperature Alarm s sss ER uses ew uses 24 Sensor Unit otf Measures asus a 24 Alarm OUR DUE eter leds Sled Ei ar ated Pts Sed 24 Divert
19. AND 90 Example CR 32 2 1 U G A E KUHE Type range CR CRN Rated flow rate in m h x 5 Number of impellers Number of reduced diameter impellers Code for pump version Code for pipe connection Code for materials Code for rubber pump parts Code for shaft seal Type designation Model material number production code Gallons per minute at rated RPM Head in feet at nameplate flow o Pump horsepower Q Rated RPM Maximum psi Maximum fluid temperature 2 Production country Codes Example Pump version U FG A E HoQE A Basic version pump U version pump B Oversize motor 2 one flange size bigger F CR pump for high 21 temperatures Cool Top H Horizontal version HS High pressure pump with over synchronous speed and reversed direction of rotation I Different pressure rating K Low NPSH Magnetic drive Undersize motor R Horizontal version with bearing bracket SF High pressure pump with reversed chamber stack and direction of rotation T Oversize motor two flange sizes bigger X Special version Pipe connection A Oval flange B NPT thread C coupling CA FlexiClamp CX TriClamp F DIN flange G ANSI flange J JIS flange N Changed diameter of ports Externally threaded u
20. Average Concentration Over the Membrane 2 0 3 0 MOUNTING BBRO Reverse Osmosis systems are free standing and require no special mounting The BBRO series systems are shipped with adjustable leveling legs The machine should be mounted on a level surface Level adjustments can be made with the adjustable feet supporting the machine These machines run quiet and with very little vibration On occasion the machine may be installed on noise and vibration dampners with out affecting system performance INSTALLATION BBRO systems are easily installed The following guidelines will ensure a successful installation 3 1 Plumbing 3 1 1 system requires a continuous and smooth flow of water A constant non turbulent feed flow between 20 and 40 psi is recommended It is recommended that the incoming line be sized one size larger than the machine connection The following water flow is required to feed standard systems Refer to the specifications on pages 12 13 for the inlet pipe size BBRO 10 000 17 4 gpm BBRO 17 500 24 3 gpm 11 500 20 gpm BBRO 19 000 26 4 gpm BBRO 13 000 18 gpm BBRO 20 500 28 5 gpm 14 500 20 21 500 29 9 gpm BBRO 16 000 22 2 3 1 2 The concentrate outlet is labeled and located near the upper front left corner of the machine The tubing or piping used to discharge the concentrate should run to an open drain and be free of obstructions and
21. Full Flow 20 7 28 8 09 3 03 0275 X 21 25 21 65 24 0 X Depends on size ot pipe fitting selected Flowmatic Under Counter Filter Housings EYP M et Part Number Size Pipe Sump Case Part Number Size Pipe Sump Case 5 20 i FHSOOWW14 gt 14 While i FH7000DL12 20 12 Blue Black 6 FHSOOCW 14 T Clear While FH7000BL I2PR 20 127 Black PR 6 FH500CW12 5 1 Clear White 12 FH7000WW38 20 a White White 6 FHSOOWW12 12 White 12 riizovowwesrn ar 3 8 White PH 6 SS 44 j 3 4 uc at wae DUX ie 05960 Bue Black PR 6 FHA000WD20 Uc wr White Black 2 FH0000CBSMPR a Blag PN 8 FIM QUO WH12 10 12 While 12 FH6E000WW34PR 0o al White While PR 9 FH4000WD34 10 3 4 While Black 17 Full Flow Housings for 4 1 2 OD cartridges MOQQHI 14 1 4 Black 12 FH5000BL34Pn 10 3 4 Bhie Black PR 4 4000 4 10 aim Bluc Hlack 12 FH50008L1 10 1 Bluc 4 12 10 1 2 Blue Dlack 12 FHSQOOBLIPR 10 F 4 FH4000DL34 10 Blue Black 12 FH5000WW1PH 0 1 White White PR 4 14 w 1 4 Clear Black 12 FH5OQOWWISPR 10 1 5 While White PR 4 FH4000CD3B 10 3 8 Clear Black 12 FHSO00BL15 10 1 5 Black PR 4 I H4000CB 12 10 1 2 Clear 12 FHSQOOBLISPR 10 1
22. NOTE If the unit is off due to a pretreat lockout condition the RO will not flush START STOP The RO unit will flush each time the RO starts and stops The tank full flush can be combined with any of the 3 interval flush types A manual flush may be initiated at any time by selecting Function 2 Auxiliary Repressurization Pump Operation On power up the Aux RP system will start immediately if the Aux RP switch is on and the tank low input is not active Tank Low Operation If the tank low switch input is activated the Aux RP control relay will open after the delay programmed in setpoint 27 Tank Low Delay When the input becomes inactive the Aux RP control relay will operate after the delay programmed in setpoint 19 Aux Start Delay Operating Hours The counter that shows the current operating hours is displayed on screen 2 Figure 10 This is the number of hours that the RO pump has run This counter can be cleared or set to a specific number by programming Setpoint 16 Current Op Hours Setpoint 17 Maximum Op Hours can be programmed to give a warning when the unit has operated for the number of hours programmed in this setpoint If programmed to 00000 this warning is disabled 23 Temperature Alarm Setpoint 33 Temperature Limit can be programmed to shut down the unit if the measured temperature exceeds this setpoint A time delay for this limit is provided with Setpoint 34 Temp
23. el RS 25 SET FOR 12 PUMP PRESSURE SENSOR PREFILTER DIFF PRESS SENSOR Buck MEMBRANE DIFF e PRESS SENSOR RED COND TDS pe p SENSOR S ET SOLENOID BE COND TOS SENSOR al 05050505050 i 5 O TO TO TO P HNH jd EE LEGEND NON POWERED SWITCH INPUTS WIRE e WIRE CONNECTION NO CONNECTION LEVEL PRESS SWITCH S souenon varve ROTROL MOTOR RO II SAMPLE WIRING DIAGRAM 240 VAC MOTORS amp 12 VAC SOLENOIDS 11 TDS CONDUCTIVITY SENSOR INSTALLATION 1 PIPE TEE CONDUCTIVITY SENSOR MODEL T0S X 500 PSI MAX THE SENSOR FITTING IS A 3 4 MALE NPT SCREW THE SENSOR INTO THE END OF A PIPE TEE DOWN WITH THE FLUID FLOW IN THE DIRECTION INDICATED POSITION THE SENSOR IN A PLANE THAT WILL PREVENT 1 1 AIR BEING TRAPPED IN THE AREA THE SENSOR 8 20 96 12 STANDARD SETPOINTS SETPO NT DESCRIPTION 01 02 03 04 05 06 07 Low Feed Pressure Limit Sensor input lower than the programmed value will cause RO system shutdown To disable set to 00 Low Feed Pressure Delay The amount of time a low sensor input or a low Switch input must b
24. of measure setpoint 51 HRS 1734 The number of hours the RO pump has operated pH 6 2 If the optional pH sensor is installed the pH value is displayed 38PSI If the optional inlet pressure sensor is installed the inlet pressure is displayed If this sensor is not installed I will show on the display 31PS f the optional feed pressur sensor is installed the feed pressure is displayed If this sensor is not installed the display will show F OK or F LO depending on the status of the low pressure switch p 7PS f the optional inlet and feed sensors installed the differential pressure is shown Otherwise Np PSI is displayed P 196PSI If the optional pump pressure sensor is installed the current pump pressure is displayed If this sensor is not installed the display will show P OK or P HI depending on the status of the high pressure switch C 178PSI If the optional concentrate pressure sensor is installed the current concentrate pressure is displayed If this sensor is not installed C is displayed Np 18PS f the pump and concentrate sensors are installed the differential pressure across the membrane is shown Otherwise Np PSI is displayed 27 J SGPM ZRCV 51 5 1 7GPM 2448 D 1 6GPM TOTAL 1 8GPM 12846 Figure 11 Screen 3 If the optional f
25. 17 17 18 19 19 19 19 20 20 20 21 21 22 22 22 22 23 FIGURES AND TABLES Figure 1 Front Panel Controls and Indicators Figure 2 Terminal Strip Jumper Locations Figure 3 Sample Wiring Figure 4 Expander Board Terminal Strip Jumper Locations Figure 5 TDS Conductivity Cell Installation Table 1 Switch Select Programming Table 2 Expander Mode Programming Table 3 Flush Type Table 4 Flush Mode INTRODUCTION The R amp D Specialties Series 150 controller is a state of the art control system for commercial and industrial reverse osmosis systems The Series 150 combines features that have not previously been available in one compact unit The Series 150 is a microprocessor controlled system that can monitor pressure and level switches A TDS Conductivity monitor controller with programmable Setpoints is an integral part of the Series 150 The Series 150 displays system status and sensor and switch input status on an easy to read backlit display User programmable Setpoints are provided that allow fast and easy adjustment of system parameters SPECIFICATIONS Power 120 240 VAC 15 10 50 60Hz 25Watts Environment 22 F to 140 F 0 95 RH noncondensing Enclosure 8 X 6 X 4 208mm X 152mm X 102mm NEMA 4X Display 2 line X 20 character alphanumeric backlit LCD Front Panel Overlay with LCD window alarm lamp 7 key membrane switch Switch Inputs Dry Contact Pressure fault Pre
26. 2001 R amp D Specialties 9918 W 1 20 Midland Texas USA 79706 915 561 5707 Fax 915 561 5696 www rdspec com E mail rdspec rdspec com LIMITED WARRANTY R amp D Specialties warrants to the original purchaser that the products it manufactures will be free from defects in material and workmanship for a period of twelve months from the date of shipment on parts and ninety days on labor Some non R amp D Specialties manufactured resale items may have warranty periods less than twelve months R amp D Specialties obligation under this warranty is limited exclusively to the repair or replacement of any product that R amp D Specialties finds to be defective Items returned for warranty consideration must have a return authorization number and be properly packaged shipped prepaid and insured This warranty is valid only when the products are properly installed maintained and used for the purpose for which they were designed Misuse neglect damage accident improper repair or modification not authorized in writing by R amp D Specialties will void this warranty There are no warranties expressed or implied including the implied warranties for merchantability or fitness for a particular purpose that extend beyond the limited warranty expressly stated above R amp D Specialties liability to any purchaser of its products whether in contract or in tort and whether arising out of warranties representations instructions installati
27. 4 4 31 20 691 6268 JAPAN id ess e C 81 3 5460 2100 Australia 61 2 9776 3226 http www dow com liquidseps 5 Elements must be in use for at least six hours before formaldehyde is used as a biocide If the elements are exposed to formaldehyde before being in use for this period of time a loss in flux may result The membrane shows some resistance to short term attack by chlorine hypochlorite Continuous exposure however may damage the membrane and should be avoided The customer is fully responsible for the effects of incompatible chemicals on elements Their use will void the element limited warranty Notice The use of this product in and of itself does not necessarily guarantee the removal of cysts and pathogens from water Effective cyst and pathogen reduction is dependent on the complete system design and on the operation and maintenance of the system Notice No freedom from any patent owned by Seller or others is to be inferred Because use conditions and applicable laws may differ from one location to another and may change with time Customer is responsible for determining whether products and the information in this document are appropriate for Customer s use and for ensuring that Customer s workplace and disposal practices are in compliance with applicable laws and other governmental enactments Seller assumes no obligation or liability for the information in this document NO WARR
28. 5707 Phone support is only available from 8AM to 5PM Central Standard Time BUILT IN AIDS To help in locating any malfunctions all of the switch inputs have green LED lamps DS2 through DS7 that indicate when the switch for an input is closed The relays have red LED lamps DS11 through DS14 that indicate when a relay is energized Green LED DS1 indicates that power is applied to the board and amber LED DS8 blinks when the CPU chip is operating properly Make a note of which lamps are on what is indicated on the display and any actions that were performed prior to the problem occurring This information can be an aid in troubleshooting the unit Refer to Figure 3 for the location of terminal strips the fuse LEDs and adjustments TOOLS TEST EQUIPMENT Although most problems can be solved using the built in aids discussed above some problems can be solved faster using additional test equipment A digital voltmeter DVM one or more 1500 ohm 1 2 watt resistors a 10 000 ohm 1 2 watt resistor and a 33 000 ohm 1 2 watt resistor will greatly enhance your ability to pinpoint some problems quickly Refer to Figures 18 20 for further troubleshooting procedures SPECIFIC PROBLEMS System Inoperative Is the green 5V LED DS1 lit Is the amber CPU ACTIVE DS8 lamp blinking If no check the power source circuit breaker usually Then check the power wires connected to P3 L1 amp L2 either visually or measure betw
29. 60EC ncondensing 6 305mm X 254mm X 152mm NEMA 4X osures are provided when motor controls are character backlit SWITCH INPUTS Tank full pump ON switch Tank full pump OFF switch Tank low swi Low feed pre High pump pr Pretreatment tch ssure switch essure switch RO lockout switch SENSOR INPUTS Permeate TDS Optional Conductivity Standard 0 250 PPM uS 0 50 0 100 0 500 or 0 1000 PPM uS OPTIONAL SENSORS Feed TDS Conductivity 0 250 0 500 0 1000 0 2500 0 5000 PPM uS Feed pressur Pump pressur Prefilter di Membrane dif sensor 0 125 PSI e sensor 0 400 PSI or 0 1500 PSI fferential pressure sensor 0 125 PSI ferential pressure sensor 0 125 PSI SPECIFICATIONS Permeate flow meter Concentrate flow meter Recirculate flow meter Feed pH 0 12 pH RELAY OUTPUTS Inlet control 5A 120 240VAC SPDT RO pump control 20A max 120 240VAC Aux RP pump control 20A max 120 240VAC Flush control 5A 120 240VAC SPDT FRONT PANEL CONTROLS AND INDICATORS POWER SWITCH ALARM LAMP RO PUMP SW AUX SW BES 4 5 6 7 8 9 EDO POWER ALARM RO PUMP amp e amp AUX amp Controls power to the ROTrol electronics Flashes when a fault causes an RO system shutdown On steady when a setpoint is exceeded that does not cause a RO system shutdown
30. DAMAGE TO MOTOR BEARINGS GREASE MUST BE KEPT FREE OF DIRT FOR AN EXTREMELY DIRTY ENVIRONMENT CONTACT YOUR BALDOR DISTRIBUTOR OR AN AUTHORIZED BALDOR SERVICE CENTER FOR ADDITIONAL INFORMATION 1 Clean all grease fittings If the motor does not have grease fittings the bearing is sealed and cannot be greased externally 2 Ifthe motor is equipped with a grease outlet plug remove it This will allow the old grease to be displaced by the new grease 3 If the motor is stopped add the recommended amount of grease If the motor is to be greased while running a slightly greater quantity of grease will have to be added NOTE If new grease does not appear at the shaft hole or grease outlet plug the outlet passage may be blocked At the next service interval the bearings must be repacked Add grease SLOWLY until new grease appears at the shaft hole in the endplate or grease outlet plug Never add more than 1 1 2 times the amount of grease shown in the lubrication schedule 4 For motors equipped with a grease outlet plug let the motor run for 20 minutes before replacing the plug LCPTL003 CR I amp O 0104 1 26 2004 11 58 Page 10 F Preventative Maintenance At regular intervals depending on the conditions and time of operation the following checks should be made 1 Pump meets required performance and is operating smoothly and quietly 2 There are no leaks particularly at the shaft seal 3 The motor is not
31. LIGHT WITH THE SHORT ACROSS THE TERMINALS IF THE LED LIGHTS WITH THE WIRE SHORT AND GOES OUT WHEN THE WIRE IS REMOVED THE INPUT CIRCUIT IS WORKING CORRECTLY IF NOT THE ROTROL PC BOARD SHOULD BE REPLACED IF THE LED WORKS CORRECTLY THE DISPLAY SHOULD ALSO SHOW THE SWITCH CLOSURE I E LOW PRESSURE TANK FULL ETC IF THE LED WORKS CORRECTLY BUT THE LCD DOESN T INDICATE THE INPUT S STATUS WHEN THE INPUT IS SHORTED THE ROTROL II BOARD SHOULD BE REPLACED IF ALL THE ABOVE TESTS SHOW THE ROTROL II TO BE WORKING CORRECTLY BUT DOESN T SHOW A CONTACT CLOSURE WHEN THE MONITORED CONDITION TANK FULL ETC EXISTS THEN THE SWITCH IS BAD OR IMPROPERLY ADJUSTED OR THERE IS A PROBLEM WITH IT S WIRING PRESSURE AND TEMPERATURE TESTING THE ROTrol ANALOG INPUTS PRESSURE AND TEMPERATURE MAY BE EASILY AND QUICKLY TESTED USING RESISTORS TO SIMULATE THE SENSOR INPUTS ONE OR MORE 1500 OHM 1 2 WATT RESISTORS ARE RECOMMENDED FOR TESTING THE PRESSURE AND TEMP ERATURE INPUTS BEFORE ATTEMPTING TO TEST ANY INPUT DISCONNECT ALL RED SENSOR WIRES AS SHOWN THEN EACH INPUT MAY BE TESTED BY CONNECTING A RESISTOR TO EACH INPUT TERMINAL PAIR AS SHOWN AND OBSERVING THE DISPLAY READING FOR THE INPUT THE READINGS SHOULD BE TYPICALLY 70 80 PSI FOR 125 PSI PRESSURE SENSORS 140 160 PSI FOR 400 PSI PRESSURE SENSORS AND 70 89 DEG FOR TEMPERATURE INPUTS REMEMBER TO SELECT THE DESIRED TEMPERATURE SIGNAL WITH THE
32. MATERIALS DESCRIPTIONS Handwheel Nut Identification Plate Handwheel Stem i Packing Nut Packing Gland Packing Graphite Non Asbestos Bonnet Bonnet Ring Disc Locknut Horseshoe Ring Disc Body Seat Ring MATERIAL Brass Aluminum Maileable Iron Silicon Bronze Bronze Brass Cammercial Bronze Bronze Silicon Bronze Stainless Steel Bronze Bronze Silicon Bronze ASTM Spec Commercial Commercial A 47 Gr 32510 B 371 69400 B 62 B 16 B 61 B 61 B 371 C69400 582 Type 303 B 61 B 61 B 371 C69400 Sizes 1 4 through 3 Fig 180 1 2 to 1 size Silicon Bronze B 371 69400 Sizes 1 4 Io 17 incl 77 Sizes 1 4 to 2 incl 7 Sizes 1 4 1 1 4 incl Silicon Bronze 8 571 69400 E aJ SPECIFICATIONS MSS SP 80 U F FEATURES Plug type Dises are held by a locknut Fig 110 Disc and Stem are one piece in Needle valves Fig 180 Integral Seats have openings equal to nominal pipe size of the valve Needle valves have renewable Seat Rings in sizes 1 2 to 1 High Tensile Bronze Alloy Stems Valves can be reground without being removed from the line Fig 180 Globe Needl Threaded Sizes 1 4 through 1 DIMENSIONS Inches Size 1 4 3 8 1 2 3 4 1 114 11 2 2 2 1 2 3 A Fig 110 21 8 21A 2 1 2 3 3916 41 8 4 5 8 5 3 4 612 714 A Fig 180 2 2 1 8 21 2 3 39 16 G Fig 110 41 32 41 32 411 16 59 16 67 32 625 32 723 32 834 97 16 103 4 G Flg
33. Mode Setpoint Table 2 shows the values used to program the relay outputs EXPANDER MODE RELAY 1 RELAY 2 DIVERT ALARM TABLE 2 Auxiliary Pump If the Expander Mode Setpoint is programmed to 0 or 1 relay 1 operates as an auxiliary pump output This output always supplies the voltage applied to the power input and is energized when the tank low input is not active Divert Output If the Expander Mode Setpoint is programmed to 0 relay 2 operates as a divert relay and will supply power whenever the unit is in the divert mode If the Expander Mode Setpoint is programmed to 2 relay 1 operates as a divert relay and when in the divert mode will supply voltage or provide a contact closure based on the position of jumpers J1 J4 Alarm Output If the Expander Mode Setpoint is programmed to 1 or 2 relay 2 operates as an alarm relay When an alarm or warning is active this relay will supply voltage or provide a contact closure based on the position of jumpers J1 J4 Tank Low Switch A tank low switch input can be connected to the tank low input of P2 on the expander board This input will provide a tank low warning on the unit and if the expander is programmed to provide an auxiliary pump output will provide low tank level protection for this pump as Ino ha ba 00 sir ERE 00000000 0000000 amp 00000000 0000000 on Dresser oro 9000000 gt 6000000600 N SP1 u10 DE
34. Pipe valves and fittings must have a pressure rating equal to or greater than the maximum system pressure Before the pump is installed it is recommended that the discharge piping be pressure checked to at least the maximum pressure the pump is capable of generating or as required by codes or local regulations Whenever possible avoid high pressure loss fittings such as elbows or branch tees directly on either side of the pump The piping should be adequately supported to reduce thermal and mechanical stresses on the pump Good installation practice recommends the system be thoroughly cleaned and flushed of all foreign materials and sediment prior to pump installation Furthermore the pump should never be installed at the lowest point of the system due to the natural accumulation of dirt and sediment If there is excessive sediment or suspended particles present it is advised a strainer or filter be used Grundfos recommends that pressure gauges be installed on inlet and discharge flanges or in pipes to check pump and system performance NOTE To avoid problems with waterhammer fast closing valves must not be used in CRN SF applications LCPTLOO3_CR I amp O 0104 1 26 2004 11 58 AM Page 6 F ACCEPTADLE BY PASS b Conti Duty Flow Rates for CR I X N T ORIFICE PIPING ARRANGEMENTS inimum Continuous Duty Flow Rates for CR X N T RECOMMENDED Min Flow in GPM at Liquid Temperature min F to176 F at 210 F at 248 F 356
35. TROUBLESHOOTING Two of the most common problems experienced on these types of systems are low pressure conditions and poor quality quantity of permeate water 8 1 LOW PRESSURE CONDITIONS Low pressure conditions will result in low permeate flows and poor rejection The following items should be check if this condition occurs PUMP The pump is a mechanical device and on occasion may fail or wear out Pump problems can be detected without much difficulty All pumps have a performance curve This curve defines certain flow rates the pump can achieve at certain pressures If you know what the pump is discharging and at what pressure you can locate that point on the pump curve If this point does not fall near the pump curve then further investigation is required to determine the cause of this condition Low inlet conditions could be a contributing factor A blockage on the discharge of the pump could be hindering pump performance The pump s rotation could be reversed A pump can run backwards and produce some flow and pressure but it will not approach the performance indicated on the pump curve The pump impellers could be damaged or clogged with debris The mechanical coupling between the pump and motor can fail or slip All of these factors can be a possible cause for low pressure conditions associated with the pump PRE FILTER The system pre filter is in most cases the first and last line of defense against debris entering the system It i
36. Unit of Measure Program Setpoint 53 to 0 for GPM 1 for LPM or 2 for M3H NOTE The K factor for each flow sensor may need to be changed when the unit of measure is changed If the K factor for a meter is programmed to 0000 that meter is disabled and any reading based on that meter will show as dashes on the display 32 R amp D SPECIALTIES ROTROL RO2 D REV FLOW METER INTERFACE PERMEATE FLOW METER CONCENTRATE 2 FLOW METER ROTROL IID PC BOARD PARTIAL VIEW RECIRCULATE FLOW NOTES TERMINAL STRIP WIRING 1 J1 J3 PROGRAM THE CIRCUIT 2 EACH INPUT IS INDEPENDENTLY TO INTERFACE W METER SIGNALS PROGRAMMABLE ALLOWING METER LEFT JUMPER POS RIGHT JUMPER POS AS FOLLOWS TYPES TO BE MIXED 12v SIGNAL IN POSITION SIGNAL TYPE METER MFG 5 CALIBRATION REQUIRES STORING SIGNAL SIGNAL N FT E LEFT e HALE SENSOR THE CORRECT K FACTORS INTO common RIGHT PICKUP SETPOINTS 36 38 SEE TEXT FLOW METER INTERFACE MOUNTING amp WIRING Figure 13 33 Flow Factors Figure 14 lists the meter factors K FACTORS for many of the popular meters manufactured by the two manufacturers previously mentioned SIGNET MODEL 515 FLOW SENSOR PIPE FITTING PIPE KFACTOR KFACTOR SCH TYPE SIZE 05 GAL LITER 80 TEE 1 2 480 2 126 9 80 TEE 3 4 257 7 068 1 8e TEE 1 174 7 046 1 80 11 4 0854 022 0 80 11 2 9058
37. Way Solenoid Valves il T a K ipe K D OPI H 1 2 3 4 5 6 7 8 11 12 13 14 Operating Coil Applicable Orifice Series Mode Housing Insulation Voltage Material Seat Body Connection Size Option 21 1 Normally A Conduit F Class F K4 Viton Brass M Manual Closed P Open H Class H 60 Hz w S S Trim Override 2 Normally p 0 Me bsg Mounting Open X Erosion w S S Trim Bracket Proof T2 Teflon Brass p NEMA VII w S S Trim Neon S Junction N1 Buna N Brass Lamp with ig Suppressor NEMA IV 15 12V DC ain 2 Surge See the 16 24V DC 5 P R Bross Suppressor Valve Solec See the 1 7 Buna N SS Valve Selec L7 Viton S S N and Z apply housings tion Guide E7 EPR SS to housing for other with terminal voltages Compact Version only Notes 1 Indication above shows the standard products Model Frequency 150160 50 60 150 60 Inrush 26 22 35 30 56 51 14 11 19 14 23 Note 1 AC power consumption at 120V 60 Hz 110V 50 Hz data 2 Regarding body codes 5 and 7 with NPT the inrush apparent power is 41VA at 50Hz and 37VA at 60Hz respectively Normally Closed Normally Open De energized Energized e De energized Energized GC Valves 21 Series 2 Way Solenoid Valves External Dimensions Bra
38. ahead of the RO unit a pretreat lockout input is provided to shutdown the RO unit When a pretreat unit goes out of service due to regeneration or backwash and the pretreat lockout contact activates the RO unit will shutdown after the delay programmed setpoint 21 Pretreat Lockout Delay When the contact activation is removed the RO unit will automatically restart Membrane Flush Several modes of membrane flush are available In all modes the RO system will flush for the amount of time programmed in setpoint 29 Membrane Flush Time The flush mode is selected using Setpoint 31 Flush Mode The Flush Table Figure 8 shows the various types of flush modes and the value that must be programmed into Setpoint 31 to enable the selected flush mode The operation of each flush mode is described below 22 FLUSH TABLE LAPSED 13 OFF HOURS OFF HOURS TANK FULL Hoa RO START STOP 17 Figure 8 5 7 1 13 15 17 TANK FULL The RO unit will go into flush each time a tank full condition occurs OP HOURS A flush will occur each time the RO pump has operated the number of hours programmed in Setpoint 30 Flush Interval ELAPSED TIME A flush will occur each time the number of hours programmed in Setpoint 30 Flush Interval has passed OFF HOURS A flush will occur each time the RO pump has been off for the number of hours programmed in Setpoint 30 Flush Interval
39. and the alarm output at pin 14 01 An external 12VDC relay can be connected to this output by connecting 1 side of the relay coil to P4 pin 14 01 and the other side of the relay coil to pin 16 12 Divert Output The divert output is available at P4 pin 15 02 This output can be used to signal amp D Specialties RA series of remote alarm by using the common at P4 pin 13 C and the divert output at P4 pin 15 02 An external 12VDC relay can be connected to this output by connecting 1 side of the relay coil to 4 15 02 and the other side of the relay coil to P4 pin 16 12 MADE 1995 R amp D SPECIALTIES ROTROL l IN USA 1 5 4 5 6 7 8 a FEED pressure 2 7 MEI NE enam POWER IN mamas LE Eom esr LE P6 PERMEATE COND TDS SENSOR angi es tee ZERO E ub o cm 99 X uc CD Co s t E i eie EREEFEEEEEEEREE T Wd EN On Fae LLL TE 10O T leo 3 5 E 5 P db 28 de 3 25 e x B 22 5 J 85 ap 88 fe P Re mI ROTROL IID CIRCUIT BOARD LAYOUT LL D 83 RED FEED PRESSURE SENSOR BLACK PUMP PRESSURE SENSOR Buck RED PREFILTER DIFF 5 PRESS SENSOR erac o RED MEMBRANE DIFF PR
40. are installed correctly any all pressure readings are correct and the readings are simply off the sensors probe pins may need to be cleaned It may also be necessary to re calibrate the unit as explained in the ADJUSTMENTS section Keypad problems Ensure that the keypad ribbon cable is plugged into the PC board Then press a key and if no beep is heard and nothing changes on the LCD display the keypad is probably bad and should be replaced If a wrong indication on the LCD display or a long beep is heard when pressing most keys press 3 on the keypad If setpoint shows on the display turn the Power switch off unplug the ribbon cable from the keypad connector P1 rotate it 180 degrees and plug it back in Turn the power on and re check the keypad If the keypad still malfunctions ither the keypad or the PC board or both should be replaced Flow screen is not displayed Dipswitch 6 must be ON to enable flow metering No reading from any flow sensor Check all flow sensor wiring and verify that the jumpers on the flow interface board are in the correct positions for the sensors installed see Figure 13 If all is correct the flow interface is probably bad and should be replaced No reading from one flow sensor If the pulses are being received from a flow sensor the corresponding red LED on the flow board should be blinking Exchange wiring with a sensor that is working change jumper pos
41. be airtight Repair any leaks and retighten all loose fittings Install pressure gauge start pump gradually close the discharge valve and read pressure at shutoff Convert measured pressure in PSI to head in feet Measured PSI x 2 31 ft PSI ft Refer to the specific pump curve for shutoff head for that pump model If head is close to curve pump is probably OK If not remove pump and inspect Disassemble and inspect pump passageways Remove any foreign materials found 13 LCPTL003 CR I amp O 0104 1 26 2004 11 58 Page 14 F Diagnosing specific problems Problem Possible cause Remed The pump runs but at reduced capacity or does not deliver water continued Pump cycles too much 8 9 Incorrect drain plug installed Improper coupling setting Pressure switch is not properly adjusted or is defective Level control is not properly set or is defective Insufficient air charging or leaking tank or piping Tank is too small Pump is oversized If the proper drain plug is replaced with a standard plug water will recirculate internally Replace with proper plug Check reset the coupling see page 10 Check pressure setting on switch and operation Check voltage across closed contacts Readjust switch or replace if defective Check setting and operation Readjust setting refer to level control manufacturer s data Replace if defective Pump air into tank or d
42. cation Improper application can cause gauge failure and possible personal injury or property damage The informa tion contained in this catalog is offered as a guide to assist in making the proper selection of a pressure gauge Addi tional information is available from Dresser Instrument Division Consult ANSI B40 1 for guidance in gauge selection Gauges should be selected with a full scale pressure range of approximately twice the normal operating pressure The maximum operating pressure should not exceed approximately 7596 of the full scale range Failure to selecta gauge range within these criteria may ultimately result in fatigue of the Bour don tube The temperature to which a gauge will be subjected should not exceed 150 F Accuracy will be affected by approxi mately 0 2 psi per 10 F A pressure relief plug is supplied in all cases to relieve case pressure buildup in the eventa slow leak develops in the pres sure element Proper selection of the Bourdon system and socket material is dependent upon the process fluid to which the system will be subjected If a standard material is not suitable the use of a diaphragm seal may be necessary Gauges cleaned for gaseous oxygen or other strong oxidizing agents cannot be supplied with glycerine or silicone liquid fill Consult factory if liquid filling is required on strong oxidizing media B 2 5 hi 125 11 ACROSS i mo FLATS L Z PIA
43. condition occurs OPERATING HOURS A flush will occur when the RO pump has operated for the number of hours programmed in the Flush Interval Setpoint ELAPSED TIME A flush will occur after the number of hours programmed in the Flush Interval Setpoint has passed OFF HOURS A flush will occur when the RO has been shut down due to a tank full condition for the number of hours programmed in the Flush Interval Setpoint RO START STOP A flush will occur each time the RO starts or stops The tank full flush can be combined with any of the 3 interval flush types A manual flush can be initiated by pressing the Alarm Silence Reset key for 3 seconds 18 Flush Mode The Flush Mode Setpoint can be used to control the operation of the inlet valve and RO pump during flush Each can be independently programmed to operate during flush Table 4 shows the values to program into the Flush Mode Setpoint to control the operation of the inlet and RO outputs during flush FLUSH MODE RO PUMP INLET VALVE OFF CLOSED OPEN CLOSED OPEN TABLE 4 High TDS Conductivity If the TDS Conductivity reading exceeds the limit programmed the TDS Cond Limit Setpoint for the delay programmed in the TDS Cond Delay Setpoint the alarm lamp will light and the HI TDS COND warning message will show on the display This warning will clear when the TDS Conductivity drops below the Setpoint Operating Hours Exceeded If the current hours exceed the limit pro
44. defaulted to 00 which programs all switches as normally open Normally open means that a switch is open when not activated and closed when it is activated Normally closed switches operate opposite from normally open Sw FEED PRESSURE PUMP PRESSURE TANK FULL PUMP OFF TANK LOW Tank FUL PMP ON e e 32 PSST Sa Select the type of switch used for each input and put that value in the far right column Add the values and program this value in Setpoint 54 For example if the Low Pressure and Pretreat switches were normally closed and all others were normally open the value programmed in Setpoint 54 would be 1 32 33 WARNING DO NOT CONNECT POWERED SIGNALS TO THESE INPUTS Tank Full Pump OFF Switch The tank full level switch or in dual tank full switch systems the upper tank full switch connects to the P4 terminals labeled OFF When this switch activates the unit will shutdown for tank full Tank Full Pump ON Switch In dual tank full switch systems the lower tank full level switch connects to the P4 terminals T F P ON When dual tank full switches are selected and both the tank full pump OFF and the tank full pump ON switches are not activated the RO unit will operate Tank Low Switch The tank low switch connects to the P4 terminals TANK LOW Low Feed Pressure Switch
45. economy brand for residential and light commercial applications Specifications Filter media Polyester Temperature limit Up to 140 F 60 C depending on pressure End caps Plastisol pliable PVC and time under load Center tubes Rigid PVC with perforations pH 3 11 see compatibility charts Surface area Approximately 4 sq ft 0 37 Lengths 9 3 4 19 1 2 and 29 1 4 per 9 3 4 length Dimensions 2 3 4 70 mm OD 1 1 16 27 mm ID For housings and cartridges 9 3 4 248 mm For all Harmsco multi cartridge housings and most other single filter cartridge housings Micron Product Code Color End Caps No Case Ship Wt Ibs Ship Wt Kg Case Dimensions in 1 WB 1 Tan 24 10 4 5 12x17x11 5 WB 5 White 24 10 4 5 12x17x11 20 WB 20 Blue 24 10 4 5 12x17x11 50 WB 50 Yellow 24 10 4 5 12x17x11 3 4 248 mm Wrapped cartridges Individually shrink ovo in plastic outer wrap WB 1 W Tan 10 4 5 12x17x11 WB 5 W White gt 10 45 12x17x11 20 WB 20 W Blue 24 10 4 5 12x17x11 50 WB 50 W Yellow 24 10 4 5 12x17x11 1 2 495 mm Cartridges For Harmsco filter housings requiring double length cartridges WB 921 1 Tan 24 16 73 12x17x21 WB 921 5 White 24 16 7 3 12x17x21 20 WB 921 20 Blue 24 16 7 3 12x17x21 50 WB 921 50 Yellow 24 16 7 3 12x17x21 1 4 743 mm Cartridges For Harmsco filter housings requiring triple length cartridges WB 931 1 Tan 24 21 9 6 12x17x31 WB 931 5 White 24 21 9 6 12x17x31 20 WB 931 20 B
46. flow rate alarms are available for the permeate and concentrate flows When the setpoints for these alarms are programmed to a value other than 0 the alarm lamp will light and the active alarm is shown on the alarm screen when the setpoint is exceeded 35 MONITORING The optional pH monitoring allows the ROTrol II to monitor feed water pH Setpoints are provided to allow warnings or shutdowns for high and low pH conditions The pH interface board is mounted to the main board in the upper left corner of the board see Figure 15 or to the optional flow meter interface board The pH and or flow interface boards may be removed to allow easier wiring of the analog sensors to their terminal strip To remove the pH board remove the 2 screws holding the board and lift straight up on the board to unplug it from the connector If the optional flow meter interface board is installed remove th spacer and 2 screws holding the flow board in place and lift it from the connector After the analog sensors have been wired install the flow meter interface board if used and wire any flow sensors Install the pH board and wire the pH sensor to the terminal strip pH Sensor Mounting WARNING THE END OF THE pH SENSOR MUST BE WET ALL TIMES i e KEEP THE CAP ON THE SENSOR AND DO NOT INSTALL IN THE FLOW LINE UNTIL THE UNIT IS ACTUALLY PLACED INTO SERVICE The pH sensor must be mounted in the flow line an
47. overheating 4 Remove and clean all strainers or filters in the system 5 Verify the tripping of the motor overload protection 6 Check the operation of all controls Check unit control cycling twice and adjust if necessary 7 If the pump is not operated for unusually long periods the unit should be maintained in accordance with these instructions In addition if the pump is not drained the pump shaft should be manually rotated or run for short periods of time at monthly intervals 8 Toextend the pump life in severe duty applications consider performing one of the following actions Drain the pump after each use Flush the pump through system with water or other fluid that is compatible with the pump materials and process liquid Disassemble the pump liquid components and thoroughly rinse or wash them with water or other fluid dthat is compatible with the pump materials and process liquid If the pump fails to operate or there is a loss of performance refer to the Troubleshooting Section on pages 13 14 Motor Replacement If the motor is damaged due to bearing failure burning or electrical failure the following instructions detail how to remove the motor for replacement It must be emphasized that motors used on CR pumps are Figure 6 specifically selected to our rigid specifications Replacement motors must be of the same frame size should CR X N T 8 16 amp CRT 2 4 be equipped with the same or better bearings and h
48. pressure fault must be active before a pressure fault shut down occurs When a pressure fault shut down is active the system will attempt to restart after this delay If set to 0 system must be manually reset If the audible alarm is silenced after this delay the alarm will resound If set to 0 the alarm will remain silenced When a tank full condition clears the system will restart after this delay Selects whether the tank full restart delay is in seconds or minutes O seconds 1 minutes The amount of time that a tank full override lasts When a tank low condition clears the auxiliary pump will restart after this delay Selects the type of flush Set to 0 to disable flush The length of time a membrane flush cycle will last when flush is active RANGE 0 999 uS or PPM 0 999 seconds 0 99 seconds 0 99 seconds 0 99 minutes 0 99 minutes 0 99 sec min 0 1 0 9 minutes 0 99 Minutes 0 8 0 99 minutes DEFAULT 100 30 60 15 5 SETPOINT Flush Interval Flush Mode Maximum Hours Current Hours Expander Mode Temp Offset Temp UOM Switch Select TDS Cond UOM TDS Cond Range DESCRIPTION The interval between flush cycles Only valid with op hour elapsed time or off flush types Selects if the inlet and RO pump relays operate during flush If the current operating hours exceed this limit the operating hours warning will occur To disab
49. sized one size larger than the machine connection Avoid multiple turns or changes in elevation on the discharge line Any restrictions or blockage in the drain could cause backpressure which can hinder system performance Refer to the specifications on pages 11 12 for the concentrate pipe size 3 1 3 Permeate connections are typically made with a hose or pipe to the permeate discharge line located next to the concentrate connection Make sure there is minimal backpressure applied to the permeate line Too much pressure may affect the machine performance and possibly damage the Reverse Osmosis membranes Refer to specifications on page 11 12 for the permeate pipe size 3 2 Electrical All standard motors are totally enclosed fan cooled TEFC motors Three phase motors are supplied on standard systems Standard 60 hertz motors are wired for a 230 volt electrical supply Standard 50 hertz motors are wired for a 220 volt electrical supply All standard systems are equipped with an electrical control box with low level protection Incoming power is connected to this box from a customer supplied fused disconnect or similar power supply Connect power to the top of the fuse block located in the upper right hand corner of the control box Verify motor rotation before continuously running the system To check motor rotation turn the electrical supply on for a second and examine the rotation of the pump motor coupling remove guard to view shaft to ensur
50. trouble shooting the most common system problems Should a symptom occur that is not included in this matrix and assistance is need call your local representative or consult the factory TROUBLE SHOOTING MATRIX NO SYMPTOM PROBABLE ROOT CAUSE CORRECTIVE ACTION i BLOWN FUSE REPLACE FUSE SYSTEM CONTROL PANEL b NO POWER TO b CHECK P OWER 1 DOES NOT ILLUMINATE CONTROL PANEL DISTRIBUTION RUN LIGHT NOT LIT c LIGHT BULB BURNT PANEL OUT c INSTALL NEW BULB a OVERLOAD RELAY a RESET OVERLOAD SYSTEM ON BUT MOTOR TRIPPED THREE PHASE RELAYS CHECK 2 DOES NOT START ONLY CURRENT DRAW b EXTERNAL CONTROL THREE PHASE CONTACTS OPEN ONLY STORAGE TANK LEVEL b CHECK EXTERNAL CONTROL DEVICES AND INOPERATIVE REPAIR PER USERS d MOTOR BURNT UP MANUAL e PRETREATLOCK OUT CHECK FLOAT ACTIVATED SWITCHES AND REPLACE OR REPAIR d REPLACE MOTOR e CHECK PRETREATMENT a VERIFY INLET PRESSURE OF AT LEAST 20 PSI a LOW INLET PRESSURE b INSPECT INLET PIPE b AIR LEAK IN INLET FOR POSSIBLE PUMP DISCHARGE PIPING LEAKS PRESSURE WILL NOT c PUMP DAMAGED c REFER TO PUMP ACHIEVE d PUMP RUNNING MANUAL RECOMMENDED LEVEL BACKWARDS d CHECK PUMP e FAULTY SOLENOID ROTATION f DIRTY PREFILTER e INSPECT SOLENOID f INSPECT PREFILTER a ADJUST a CONCENTRATE CONCENTRATE CONTROL VALVE WIDE VALVE OPEN b CHECK HIGH LACK OF CONCENTRATE b LEAK IN PRESSURE PRESSURE PIPING PRESSURE PIPING FO
51. warnings can be displayed on the warnings screen by pushing the Display key on the keypad If no warnings are active or if the Display key is pushed again a second screen is shown that shows additional data If the optional flow sensing is enabled pushing the Display key again will show the flow data screen Pushing the Display key again returns the display to the main screen Tank Full Operation Two types of tank full operation are available If Dipswitch 2 is OFF single switch tank full operation is enabled In this mode if the tank full pump off switch input is activated after the time delay programmed in setpoint 24 Tank Full Delay the RO control relay will open shutting down the RO pump The display will now show TANK FULL When the tank full condition is removed the delay programmed in setpoint 25 Tank Full Restart Delay will be started This delay is in minutes When the delay times out the RO unit will restart The remaining delay time will be displayed during the delay period If Dipswitch 2 is ON the dual tank full switch operation is enabled In this mode 2 switches are used to provide pump off pump on operation When the upper switch is activated the RO control relay will open shutting down the RO pump Tank full will show on the display When the tank level drops and both the upper and lower switches are no longer activated the RO control relay will operate after the Tank Full Start Delay progr
52. 0 300 0 2000 1008S L only 0 400 0 400 0 2800 dry 1 Full Scale 0 4000 iquid Fill Accuracy 0 600 0 600 3lycerine Vacuum in Hg 30 0 in Hg 30 0 in Hg 100 0 kPa 100 100 100 200 100 400 100 700 100 1000 100 2000 kPa Outer Arc Compound in Hg psi 30 15 30 30 30 60 30 100 30 150 30 300 psi 0 1000 0 1500 0 2000 0 3000 0 5000 0 6000 0 7500 0 10000 in Hg psi 30 15 30 30 30 60 30 100 30 150 30 300 psi Inner Arc NPT Y NPT lower only 0 1000 0 1500 0 2000 0 3000 0 5000 0 6000 0 7500 0 10000 0 7000 0 10000 0 14000 0 20000 0 34000 0 40000 0 50000 0 70000 1008A LOWER CONNECT GAUGE SIZE B c K 0 15000 0 15000 0 100000 63 MM 63 31 69 10 55 MM f INCH 2 1 2 222 2 Dual Scale Ammonia Ranges Compound in Hg psi 0 Outer Arc 100 MM 100 35 105 5 13 5 86 inch 3 1 4 e 3 DIMENSIONS IN ARE INCHES S 30 150 40 84 SL 30 300 40 125 F Weightin grams ozs Dry 112g 4 oz 1824 6 5 oz 192g 6 9 oz NPT Liquid Fill 2054 7 5 oz 4349 15 oz 1 4 4444 16 V NPT Accessories For Panel Mounting 63mm U Clamp for panel mounting 63mm Bezel Ring for panel mounting 100mm U Clamp for panel mounting 100mm Bezel Ring for pa
53. 01 99 05 minutes 00 99 24 hours 00 99 00 STANDARD SETPOINTS SETPOINT DESCRIPTION RANGE 33 Temperature Limit When the 000 150 temperatur xceeds this limit after the temperature delay the RO system will shut down until reset To disable set to 000 34 Temperature Delay The amount of time 00 99 the temperature limit must b xceeded seconds before RO system shutdown occurs 35 Temp Offset Provides a plus or 0 9 minus offset to the temperature read ing When set to 5 the offset is 0 The displayed temperature is increased for each number above 5 and decreased for each number below 5 36 43 See flow section of manual 44 Not Used 45 49 pH section of manual 50 Not Used 51 Pressure Unit of Measur Selects PSI 0 1 or bar as unit of measure 52 Temperature Unit of Measur Selects 9 1 degrees EF or EC as unit of measure 53 Flow Unit of Measur Selects gallons 0 1 or liters as unit of measure If changed the K factor for each flow sensor may need to be changed 54 Switch Select Selects whether switch 0 255 inputs or normally open or normally closed 55 Pump Range Selects 500 or 1500 pump 0 1 pressure range NOTE Must have correct range sensor 56 Shutdown Disable Allows the low feed 0 9 pressure high pump pressure and high temperature shutdowns to be disabled configured for alarm only 57 64 Not Used 16 DEFAULT 120 000 TO DISPLAY OR CHANGE SETPOIN
54. 07 563 90007 656 76000 147 A 5 Fioatstopbotom 76001 085 76001 091 76001 091 76001 096 76001 3107 1 6 1i 7 zs W e Q EY Body 76100 118 76100 1 76100 120 76100 122 76100 124 76001 088 14 O ring valve body 90003 114 90003 08 90003 017 90003021 16001 0 76001 086 76001 093 76001 103 1 16 Retainercap 76001 084 76001 0900 76001 090 76001 095 76001 106 1 105 1 1 7 9000 8 Adapter 76001 079 91001 14 1 9 Locknut 91001 153 91001 1 19 inletAdapter 76001 153 91001173 91001 174 91001 175 91001 176 1 1i O ring inlet adapter 90003 034 90003 081 90003 081 90003 110 90003 082 1 oa Ong i 12 90003 004 90003 010 90003 010 90003 072 90003 113 1 O ring 76001 083 76001 089 76001 089 76001 097 76001 105 18 Setscrew 90011 056 90011 116 90011 146 90011 116 90011 116 Shading indicates item not sold separately L gt Web Site www bluwhite com Phone 714 893 8529 amp BLUE WHITE INDUSTRIES E mail sales biue white net Fax 714 894 0149 Nu Techsupport blue white net Flowmatic Under Counter Filter Housings High quality Competitive prices In stock Speedy shipments Flowmatic Single Cartridge Filter Housings Flowmatic under counter filter housings are manufactured from the highest quali
55. 180 3 13 16 3 13 16 45 8 51 2 65 32 H 21 2 21 2 234 314 358 41 16 434 51116 511 16 63 8 Diameter of Orifice Fig 180 1 8 V16 1 4 3 8 1 2 2 2 Fig 180 WEIGHTS Pounds Fig 110 0 9 0 9 Fig 180 0 9 0 9 H 22 34 49 7 7 123 16 3 24 1 Soidered g9 100 Socket S 5 Z MADE IN USA 2 z ER INSTRUMENT DIVISION 1008 Ashcroft s new Industrial Quality Type 1008 stainless steel gauge is designed to perform well even in applications where vibration pulsation and mechan ical shock are constant factors 1008 contains the unique spring sus pended movement which adds to dura bility and increased gauge life The movement is suspended between the Bourdon tube and socket reducing the load on precision moving parts This spring suspension helps the gauge resist mechanical shock and vibration Spring suspension provides long life through reduced gear wear with long term stability and greater reliability The helical Bourdon tube used in ranges 1 000 psi and over has high pressure capability with low internal volume and is designed for high cycle life All ranges are designed for maxi mum life under pulsating service conditions 1008 is available in 63mm or 100mm dial sizes stem or surface mounted with a stainless steel case and polished stainless steel crimped ring A standard polycarbonate window is offered wi
56. 20 34 Rod Hd 17 FH4200CWi4PH 10 Van Clear PR lz Ho l H4200CW36 am Clear White 12 Mounting brackets partial listing FHA4200CW38PH 10 E Clear White PR 12 10 Singla 10 plated with screws 150 FHA200CWI2 m uo Clear While 12 FM20AW Single 20 aluminum while 100 FH4200CWi2PH 0 V Clar While PR 12 TM3ORW Doubla 107 aluminum while FH4200CW94 10 3 4 Clear White 12 FMSOAW Triple to aluminum while 25 FIHA200C W34pH 10 3 4 Clear White PR 12 Single lor Full Flow housings 40 4200 14 10 1 4 Black 19 FMIOAW Single 10 aluminum white 150 FH42008B34 10 3 4 Black Black 12 Wrenches WR100 Wrench for standard 10 90 amp 7000 series 100 HD Series Heavy Duty Feely WR200 Wrench for Heavy Duly 107 20 amp 8000 serias 100 Wr 34 Blue lack 12 WH500 Wrench for Full Flow housings 9 HD4500BL3MPR 10 aya Blue flack 12 t 1045000834 10 9 4 Clear Black 12 Please sce our calalou lor completo listing of brackets amp parts HD4500CB34 PR 10 aa Clear Black 12 2000 Flowmatic Systems Inc Printed in U S A Toll free 800 461 4406 Distributed by Fax 352 465 2010 E Mail info flowmatic com In California Tel 909 272 4100 a Oly Fax 272 909 272 4111 Flowmatic Systems Inc 11611 S W 147 Court Dunnellon FL 34432 USA Tel 352 465 2000 www flowmatic com WaterBetter Cartridges
57. 4 months from date of installation but not more than 30 months from date of manufacture GRUNDFOS liability under this warranty shall be limited to repairing or replacing at GRUNDFOS option without charge GRUNDFOS factory or authorized service station any product of GRUNDFOS manufacture GRUNDFOS will not be liable for any costs of removal installation transportation or any other charges which may arise in connection with a warranty claim Products which are sold but not manufactured by GRUNDFOS are subject to the warranty provided by the manufacturer of said products and not by GRUNDFOS warranty GRUNDFOS will not be liable for damage or wear to products caused by abnormal operating conditions accident abuse misuse unauthorized alteration or repair or if the product was not installed in accordance with GRUNDFOS printed installation and operating instructions To obtain service under this warranty the defective product must be returned to the distributor or dealer of GRUNDFOS products from which it was purchased together with proof of purchase and installation date failure date and supporting installation data Unless otherwise provided the distributor or dealer will contact GRUNDFOS or an authorized service station for instructions Any defective product to be returned to GRUNDFOS or a service station must be sent freight prepaid documentation supporting the warranty claim and or a Return Material Authorization must be incl
58. 4 5 X 9 75 4 5 X 9 75 CARTRIDGE 5 MICRON 5 MICRON 5 MICRON 5 MICRON RECOVERY 40 40 50 50 SALT REJECTION MINIUM 96 96 96 96 REQUIRED FEED FLOW RATE GPM 17 4 20 0 18 0 20 0 REQUIRED CLEANING FLOW RATE GPM 16 20 24 30 16 20 MINIMUM CLEANING 20 25 25 25 SOLUTION MIX GAL SYSTEM SPECIFICATIONS BBRO 16 000 BBRO 17 500 BBRO 19 000 BBRO 20 500 BBRO 21 500 INLET 1 5 MPT 1 5 MPT 1 5 MPT 1 5 MPT 1 5 MPT PERMEATE 34 1 1 1 1 1 W 1 W 1 W 1 W 1 W FLOWMETER FLOWMETER FLOWMETER FLOWMETER FLOWMETER CONCENTRATE 34 1 MPT 1 MPT 1 MPT 1 MPT 1 W 1 W 1 W 1 W 1 W FLOWMETER FLOWMETER FLOWMETER FLOWMETER FLOWMETER HEIGHT 48 48 48 48 48 WIDTH 36 36 2 27 27 320 Ibs 335 165 350 165 365 Ibs 380 Ibs WEIGHT 145kg 152kg 159kg 166kg 172kg VOLTAGE 60Hz 220 380 460v 220 380 460v 220 380 460v 220 380 460v 220 380 460v 50Hz 220 380 415v 220 380 415v 220 380 415v 220 380 415v 220 380 415v MOTOR HP 60Hz 5 5 5 5 5 5 10 10 10 50Hz 5 5 5 5 1 5 7 5 7 5 PHASE 60Hz 1 1 3 3 PHASE ONLY 3 PHASE ONLY 3 PHASE ONLY 50Hz M 3 PHASE ONLY 3 PHASE ONLY 3 PHASE ONLY 3 PHASE ONLY RATED AMPS 60Hz 20 4 220v 20 4 220v 27 5 220v 27 5 220v 27 5 220v 50Hz 9 7 Q 380v 9 7 380v 12 4 380v 12 4 380v 12 4
59. 5 Blue Black PH 4 FH4000CH34 ur 3 4 Cleat Black 12 FH5000CB1PH Clear Black PR 4 4000 80 14 10 1 4 Black Black 12 FH10000DL34PR 20 3 4 Blue Black PH 4 MOQORB34 Uu 34 Black Black 2 FIRO0008L1 20 1 Black 4 FH4000TWH14 ur 1 4 While Black 2 FH10000DL1PH 20 1 Blue Black PR 4 FH4000TWW14 10 White While 12 FH10000WWIPR xov While White 4 TiMOQQWWiSPR ar 1 5 While PR 4 4200 Series Best FH10000BL15 20 1 5 Black 4 Fi14200WI314 wur 14 While Black 12 FH10000BLISPR 20 15 Blue Black PR 4 Mw 14 White 1 TH10000CB1PR 1 PR 4 4200 we White While 12 FH4200WW1 e 4 9 While White 12 High Purity Housings Pure Polypropylene with viton o ring FH4P00WW34 19 3 Whio 12 ME E PP f r DOE FHA20UDL14 10 14 Blue Rlack 12 150081 34 222 3 4 PP PP lor 222 12 FHA200BL IAPR 10 Blue Black PR 12 20 3 pr PP for DOF 2 38 Wr ver Hive Black 12 FIIRQOONP34 222 ad PP 222 lz FH4200DL3HPH 10 38 Blua Black PR 12 Valve In Hcad Housings FH4200BL 2 10 11 Blue Black 12 10 3 4 Clear White 12 H44200RI 1r 12 Blue Black PR 12 Io White White 12 FH42000L34 10 aa Black 12 High Temp Housings 200 F I 93 C FH42008L34PR 10 3 Black PH 12 HD4S00HT34 10 3 4 Red Ned 12 10 t Clear 12 HDR000HT34
60. 6 015 5 80 2 032 5 008 6 80 21 2 021 8 005 8 80 gt 015 5 005 6 80 4 007 6 002 0 BURKERT MODEL 8030 FLOW SENSOR SS BODY PVC BODY FACTOR K FACTOR FACTOR FACTOR US GAL LITER US GAL LITER 400 1 105 7 407 5 107 6 251 6 066 5 284 8 075 5 185 6 049 0 200 2 052 9 120 4 031 8 107 8 028 5 075 1 019 8 065 4 017 5 045 0 011 4 058 6 010 2 Figure 14 Meters manufactured by other companies may also work with this unit Contact R amp D Specialties for assistance Flow Setpoints REMEMBER TO MOVE JUMPER J5 TO OFF CHANGING A SETPOINT AND MOVE BACK TO THE ON POSITION WHEN COMPLETE SETPOINT DESCRIPTION RANGI D c Ei i 36 eter 1 Factor This setpoint is used 001 0 999 9 to calibrate the permeate flow meter 37 eter 2 Factor This setpoint is used 001 0 999 9 to calibrate the concentrate flow meter 38 eter 3 Factor This setpoint is used 001 0 999 9 SSS to calibrate the recirculate flow meter 34 39 Low Permeate Flow If the permeate 001 0 999 9 0000 flow drops below this value a low GPM LPM permeate flow alarm will be displayed If set to 0000 this alarm is disabled 40 High Permeate Flow If the permeate 001 0 999 9 0000 flow rises above this value a high GPM LPM permeate flow alarm will be displayed If se
61. ANTIES ARE GIVEN ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY EXCLUDED Published March 1998 gt Trademark of The Dow Chemical Company Form No 609 09040 398XQRP CH 172 031 E 398R Installation amp Maintenance Instructions TRIVPAOINT Pressure switches Miniature Size Fixed Deadband Pressure Switches With Field Adjustable Set Points DESCRIPTION The 5 are miniature size pressure switches having field adjustable set points fixed deadbands and diaphragm piston sensors These pressure switches are designed to provide long life and maintain set point accuracy Materials wetted by the fluid include brass or stainless steel pressure connections Internal elastomers are made of Buna N ethylene propylene fluorosilicone or VITON depending upon service requirements H Series pressure switches are available with Open Frame construction Type 1 General Purpose Enclosure Types 3 3S 4 Raintight Watertight Enclosure NOTE H Series Suffix L pressure switches are limited to Open Frame Construction H Series Suffix L Pressure Switch OPERATION The pressure switch controls electrical circuits in response to changes in pressure The set and reset points are adjustable over the full range of the switch As the deadband on off differential is adjusted both set point increasing pressure and set point on decre
62. AY TO DETERMINE THESE RNR ITIONS IF THE RELAY SHOULD BE ON BUT ISN T REPLACE THE PC BOARD IF A RELAY S LED IS ON BUT THE CONTROLLED DEVICE VALVE OR MOTOR IS NOT OPERATING MEASURE THE VOLTAGE ACROSS THE DEVICE WITH A DMM IF THE CORRECT VOLTAGE IS PRESENT THE DEVICE SHOULD BE REPLACED IF THE CORRECT VOLTAGE IS NOT PRESENT MEASURE BETWEEN THE DEVICES POWER COMMON AND THE PC BOARD TERMINAL STRIP IF THE VOLTAGE IS CORRECT BETWEEN THE TERMINAL AND COMMON BUT NOT BETWEEN THE TERMINAL FEEDING THE DEVICE REPLACE THE PC BOARD IF THE VOLTAGE IS NOT CORRECT BETWEEN THE HOT TERMINAL AND COMMON TRACE THE WIRE BACK TO ITS POWER SOURCE AND CORRECT THE PROBLEM TRIPPED BREAKER BLOWN FUSE OPEN WIRE ETC B R amp D SPECIALTIES R amp D SPECIALTIES SERIES 150 RO CONTROLLER USERS MANUAL 82001 by R amp D Specialties Inc All Rights Reserved No part of this document may be copied or reproduced in any form or by any means without the prior written permission of R amp D Specialties R amp D Specialties makes no warranties with respect to this documentation Information in this document is subject to change without notice R amp D Specialties shall not be held liable for technical or editorial errors or omissions that may appear in this document nor for incidental or consequential damages resulting from the furnishing performance or use of this document Document Series 150 V1 0 Released July
63. Boards s suy qata teas bade wen ete 40 re 18 Testing Chant eek SPS W 47 re 19 Ea eee E eU Sue 01 48 re 20 JG CHALE Ders w BAe tee a 49 INTRODUCTION The amp D Specialties ROTrol II is a state of the art control system for commercial and industria not previousl 1 reverse osmosis systems The ROTrol II combines features that have y been available in one compact unit The ROTrol is a microprocessor controlled system that can monitor multiple pressure sens ors and or pressure switches A TDS Conductivity monitor controller with programm displays syst able setpoints is an integral part of the ROTrol II The ROTrol II em status and all sensor and switch input status on an easy to read backlit display User programmable setpoints are provided that allow fast and easy adjustment of system parameters Plug in terminal strips allow easy wiring of all sensors and controls The ROTrol II contains relays for control of an inlet valve RO pump aux repressurization pump and a membrane flush valve SPECIFICATIONS POWER 120VAC Opti ENVIRONMENT 22 30EC 0 95 RH no ENCLOSURE T2 Larger encl incorporated DISPLAY 4 line X 20 onal 240VAC 24VAC 50 60 Hz 25 Watts to 140EF
64. CONTACTS ROTROL II INPUT CIRCUIT TESTING WITH A DIGITAL MULTIMETER DMM 47 ROTROL 10 PC BOARD SHOWN SWITCH INPUT VOLTAGE MEASUREMENT CONNECT A DMM TO THE INPUT TERMINAL PAIR OF THE INPUT BEING TESTED AS SHOWN IF THE SWITCH IS OPEN NORMAL STATE THE VOLTAGE WILL USUALLY BE BETWEEN 2 AND 3 VOLTS DC IF THE SWITCH IS CLOSED THE READING SHOULD BE APPROXIMATELY e NOTE IF THE SWITCH IS CLOSED DISCONNECT ONE SWITCH WIRE TO CHECK THE OPEN SWITCH VOLTAGE LEVEL IF THE VOLTAGE READING WITH THE SWITCH OPEN IS NOT CORRECT THE PC BOARD SHOULD BE RE PLACED IF THE READING DOES NOT DROP TO APPROXIMATELY ZERO WITH THE SWITCH CLOSED EITHER THE SWITCH IS BAD OR THERE IS A PROBLEM WITH THE WIRING IF THE DMM READING IS FLUCTUATING ELECTRICAL NOISE IS BEING PICKED UP IN THE WIRING WHICH MAY CAUSE ERRATIC PROBLEMS IN THE ROTROL II IF NOT CORRECTED OFTEN THE PROBLEM MAY BE SOLVED BY SIMPLY CONNECTING THE CABLE S SHIELD AND OR THE SWITCH S GROUND WIRE TO EARTH GROUND USUALLY POWER GROUND OFTEN RE ROUTING THE WIRE TO KEEP IT AWAY FROM MOTORS AND MOTOR WIRING WILL SOLVE THE NOISE PICKUP PROBLEM INPUT SWITCH TESTING TO TEST A SWITCH INPUT DISCONNECT ONE OF IT S WIRES FROM THE TERMINAL STRIP ENSURE THAT THE GREEN LED ABOVE THE TERMINAL STRIP AND ABOVE THE LEFT TERMINAL OF THE SWITCH INPUT PAIR IS NOT ON USE A SHORT WIRE LOOP AND SHORT BETWEEN THE SWITCH S TERMINAL PAIR THE GREEN LED SHOULD
65. EP ADAPTER PRESSURE VESSEL COMPONENTS BOTTOM END PLUG PVC 4 TOP END PLUG PVC 4 END PLUG O RING 4 PRODUCT TUBE O RING 4 RETAINING PINS 4 CHEVRON SEAL 4 DESAL ADAPTER HEOO7T PRESSURE VESSEL TUBE ONLY PVC 4 x 40 SYSTEM SPECIFICATIONS BBRO 10 000 BBRO 11 500 BBRO 13 000 BBRO 14 500 INLET 1 5 MPT 1 5 MPT 1 5 MPT 1 5 MPT 34 MPT 34 MPT 34 PW W 1 W FLOWMETER FLOWMETER FLOWMETER FLOWMETER 34 MPT 34 MPT 34 MPT CONCENTRATE PW 1 W 1 W FLOWMETER FLOWMETER FLOWMETER FLOWMETER HEIGHT 48 48 48 48 LENGTH 64 64 64 64 WIDTH 27 36 36 36 250155 265165 28016 295165 WEIGHIE 114kg 120kg 127kg 134kg VOLTAGE 60Hz 220 380 460v 220 380 460v 220 380 460v 220 380 460v 50Hz 220 380 415v 220 380 415v 220 380 415v 220 380 415v MOTOR HP 60Hz 5 5 5 5 5 5 5 5 5 5 5 5 50Hz 5 5 2 9 5 5 5 5 PHASE 60Hz 1 OR 3 1 OR 3 1 OR 3 1 3 50Hz 3 PHASE ONLY 3 PHASE ONLY 3 PHASE ONLY 3 PHASE ONLY RATED AMPS 60Hz 20 4 220v 20 4 e 220v 20 4 220v 20 4 220v 50Hz 9 7 380v 9 7 380v 9 7 380v 9 7 380 i PRESSURE 209 psi 206 psi 201 psi 196 psi 4 X 40 4 X 40 4 X 40 4 X 40 R O ELEMENT TAPE WRAPPED TAPE WRAPPED TAPE WRAPPED TAPE WRAPPED PREFILTER 4 5 X 9 75 4 5 X 9 75
66. ES OF THE SENSOR BEING TESTED WITH BOTH WIRES DISCONNECTED THE READING ON THE RO TROL II S DISPLAY SHOULD BE 8 FOR THE SENSOR BEING TESTED IF THE READING IS NOT EXACTLY ZERO ADJUST THE ZERO ADJUSTMENT SCREW TO GET A ZERO READING IF A 0 CAN NOT BE OBTAINED THE THE ROTROL PC BOARD SHOULD BE REPLACED IF A 9 READING CAN BE OBTAINED CONNECT A RESISTOR TO THE GREEN AND WHITE TERMINALS OF THE TERMINAL STRIP THE DISPLAY READING SHOULD INCREASE TO SOME VALUE ABOVE DEPENDING UPON THE RESISTOR S VALUE AND THE PROGRAMMED RANGE OF THE ROTROL II 22 000 OHM RESISTOR SHOULD GIVE A READING ABOVE 0 ON ANY UNIT IF NO INCREASE IN THE READING OCCURS WHEN THE RESISTOR IS CONNECTED THE PC BOARD IS PROBABLY BAD AND SHOULD BE REPLACED IF A READING IS OBTAINED BY CONNECTING THE RESISTOR THE PC BOARD IS PROBABLY WORKING PROPERLY RE CONNECT THE SENSOR AND SUBMERSE IT IN A CUP OF WATER OF A KNOWN QUALITY TDS OR uS AND IF A READING IS OBTAINED ADJUST IF NECESSARY THE COR RESPONDING SPAN ADJUSTMENT ON THE PC BOARD TO OBTAIN THE CORRECT READING IF NO READING IS OB TAINED WITH THE SENSOR IN WATER THE SENSOR OR CABLE IS BAD AND SHOULD BE REPLACED Figure 18 E N USA ama 1998 R3 T DISPLAY P2 EE DOODSEDOSQOOS HIGH TANK LEVEL HIGH PUMP PRESS on HIGH TANK LEVEL PUMP OFF LOW TANK LEVEL NON POWERED SWITCH INPUTS
67. ESS SENSOR BLACK 0 DOOG DOO RED Im COND TDS SENSOR tee SENSOR Ce n m 1575 rO rO rO F PuuP OFF LEGEND WIRE e WIRE CONNECTION 4 NO CONNECTION NON POWERED SWITCH INPUTS s LEVEL PRESS SWITCH SOLENOID VALVE ROTROL MOTOR RO II SAMPLE WIRING DIAGRAM 120 VAC MOTORS amp SOLENOIDS R amp D SPECIALTIES ROTROL II NUSA ama 0 1998 EES RO2 D rve lel P 4 ELLE 5 re SW m C2 gt PUMP PRESSURE 5M O O f SENSOR BLACK C n PREFILTER DIFF m Pg PRESS SENSOR RED MEMBRANE DIFF gt PRESS SENSOR BLACK RED Im COND TOS 2 SENSOR NA RO PUMP COND TDS M SENSOR P BARE gt int Ce He B TN nu 1575 TO amp Epor NEP E PUMP OFF LEGEND NON POWERED SWITCH INPUTS WIRE NO CONNECTION LEVEL PRESS SWITCH SOLENOID VALVE ROTROL MOTOR RO II SAMPLE WIRING DIAGRAM 240 VAC MOTORS amp SOLENOIDS WOE 1998 R amp D SPECIALTIES ROTROL II a
68. F min C to 80 C 99 C 120 C at 180 C CR CRI CRN10 5 5 5 CR CRI CRN 15 5 CR CRI CRN 20 s 1 _ 51 44 66 110 OPTIONAL FOR CR N 32 45 64 and CR 90 ONLY Type N Version e e CRN CRN 8 and 16 are only available in CRN S A CRN S is a CRN pump without staybolts All rubber parts are FXM Check valves A check valve may be required on the discharge side of the pump to prevent the pump s inlet pressure from being exceeded For example if a pump with no check valve is stopped because there is no demand on the system all valves are closed the high system pressure on the discharge side of the pump will find its way back to the inlet of the pump If the system pressure is greater than the pump s maximum inlet pressure rating the limits of the pump will be exceeded and a check valve needs to be fitted on the discharge side of the pump to prevent this condition This is especially critical for CRN SF applications because of the very high discharge pressures involved As a result most CRN SF installations require a check valve on the discharge piping Bypass A bypass should be installed in the discharge pipe if there is any possibility the pump may operate against a closed valve in the discharge line Flow through the pump is required to ensure adequate cooling and lubrication of the pump is maintained See Table A for minimum flow rates Elbows should be a minimum of 12 from the or
69. In systems with no feed pressure sensor or where a low pressure switch in addition to the feed pressure sensor is required the low feed pressure switch connects to the P4 terminals LOW PRESS High Pump Pressure Switch In systems with no pump pressure sensor or where a high pressure switch in addition to the pump pressure sensor is required the high pump pressure switch connects the P4 terminals HIGH PRESS Pretreat Lockout Switch In systems where it is desired to shutdown the RO unit when a pre treatment system is out of service a lockout switch can be wired to the P4 terminals P T L O The pretreatment equipment must provide a switch output when out of service Alarm Divert Outputs An alarm output and divert output are available on These outputs are open collector transistor outputs that pull to ground when active The maximum load limit for each output is 100mA These outputs can be used to signal a remote alarm unit such as R amp D Specialties RA series of remote alarms or can operate an external 12VDC relay An optional relay expander board is available that provides a SPDT relay output for each of these outputs Refer to the Alarm Divert Relay section for more information on this option Alarm Output The alarm output is available at pin 14 01 This output can be used to signal amp D Specialties RA series of remote alarm by using the common at P4 pin 13 C
70. LV10 GLVIO n PRESSURE 0 300 PSIN BRASS INTERNALS 0 300 PSIN BRASS INTERNALS GAUGE DGO02 DGO02 FLOWMETER 1 17 GPM ACRYLIC BLOCK 6 21 GPM ACRYLIC BLOCK OPTIONAL DFOO7 DFO08 RECYCLE VALVE 34 BRONZE 300 34 BRONZE 300 11 OPTIONAL NOT GEVIO SHOWN m BRASS SWITCH SET AT 8 PSI BRASS SWITCH SET AT 8 PSI DBO24 DBO24 STANDARD SYSTEM MEMBRANE SPECIFICATIONS MEMBRANE TYPE MAXIMUM OPERATING PRESSURE MAXIMUM OPERATING TEMPERATURE MAXIMUM FEED TURBITITY FREE CHLORINE TOLERANCE THIN FILM COMPOSITE 300 psi 2 1 M Pa 113 F 45 C 1 NTU lt 0 1 PPM PH RANGE CONTINUOUS OPERATION 2 11 SHORT TERM 30 MIN CLEANING 1 12 MAXIMUM FEED FLOW 10 GPM MAXIMUM FEED SILT DENSITY INDEX SDI 5 11 0 OPTIONAL EQUIPMENT The following equipment are offered as options XP System This option provides a complete water system The system includes an RO machine atmospheric storage tank with level controls and repressurization RP system The permeate water created by the RO machine is stored in the atmospheric storage tank The water in the atmospheric storage tank is then pump out of the tank via a repressurization pump The repressurization system may or may not have a bladder tank The purpose of the bladder tank is to provide initial pressure at the point of use until the repressurization pump is able to recover from being off A differential pressure switch controls the pump As the call for water is decreased at the point of
71. N THE POWER TERMINALS MEASURE THE VOLTAGE BETWEEN TERMINAL 1 OF THE TERMINAL STRIP AND TERMINAL 3 TERMINAL 4 AND EACH END OF THE FUSE IF THE VOLTAGE IS CORRECT ON TERMINAL 3 AND NOT ON TERMINAL 4 EITHER THE POWER SWITCH OR ITS WIRING IS BAD CORRECT THE PROBLEM BY REPLACING THE SWITCH OR BROKEN WIRE IF THE VOLTAGE IS CORRECT ON TERMINAL 4 BUT BOTH ENDS OF THE FUSE REPLACE THE IF THE VOLTAGE IS CORRECT ON BOTH ENDS OF THE FUSE UNPLUG THE DISPLAY S RIBBON CABLE IF THE POWER LED LIGHTS THE DISPLAY ASSEMBLY SHOULD BE REPLACED IF THE LED STILL DOES NOT LIGHT THE PC BOARD SHOULD BE REPLACED TROUBLESHOOTING OUTPUT CIRCUITS WARNING DANGEROUS VOLTAGES PRESENT PROCEED WITH CAUTION THE OUTPUT CIRCUITRY OF THE ROTrol II IS DESIGNED TO TURN THE OPERATING POWER FOR THE RO UNIT S VALVES AND MOTORS ON AND OFF THE ROTrol DOES NOT SUPPLY POWER IT SIMPLY SWITCHES THE POWER FEEDING EACH OUTPUT CIRCUIT EACH OUTPUT CIRCUIT RELAY CONTACT IS UNIQUELY INDEPENDENT FROM ALL OTHERS THIS ALLOWS THE CONTROLLED DEVICES VALVES MOTORS ETC TO BE OPERATED AT DIFFERENT VOLTAGES i e THE VALVES MAY BE OPERATED FROM ONE POWER SOURCE AND THE MOTORS MAY BE OPERATED FROM A DIFFERENT POWER SOURCE AS AN EXAMPLE IT IS NOT UNUSUAL TO OPERATE THE VALVES AND AUX RP PUMP FROM 12 V AND THE RO PUMP FROM 240 THIS INDEPENDENT ARRANGEMENT ALLOWS A LOT OF FLEXIBILITY IN SELECTING THE VALVES AND MOTORS FOR AN RO UNI
72. N5EGS5 S211AFO2L7EGS 11 AFO2N1FG9 Ho2T2FG9 11AF02N5FG9 S211AFO2L7FG9 S211AFO2E7FG9 11SF02N1GJ5 S211SHO2T2GJ5 TH AFO2N5GJ2 S211AF02L7GJ2 TI AFO2C5GJ2 S211AFO2E7GJ2 Va afojn a o M eg eeleleeeelee sees eelee eese e gt 5 5 8 BBBBBB 1AFO2N5HJ2 5211 AFO2L7HJ2 1AFO2C5HJ2 S211 AFO2E7HJ2 11SF02N1JJ5 11SH02T2JJ5 11 AFO2N5JJ2 S211AF02L7JJ2 11 AFO2C5JJ2 S211AF02E7JJ2 Energized S212AF02K4CG1 S212AH02T4CG1 2AFO2N5CGA4 S212AF02L7CG4 S212AF02K4DG1 S212AHO2T4DG1 S212AF02N5DG4 S212AFO2L7DG4 S212AFO2K4EG5 S212AH02T4EG5 S212AF02N5EG5 S212AF02L7EG5 S212AF02N1FG9 S212AHO2T2FG9 S212AF02N5FG9 S212AFO2L7FG9 S212AF02C5FG9 S212AF02E7FG9 S212SFO2N1GJ5 S212SHO2T2GI5 S212AFO2N5GJ2 S212AF02L7GJ2 S212AFO2C5GJ2 S212AF02E7GJ2 S212SF02N1HJ5 212SHO02T2HJ5 l 2 6 fal lefi 9 ofo 9 9 8 09608 8 HM a 5 x S212AF02L7HJ2 S212AFO02C5HJ2 S212AF02E7HJ2 2SF02N1JJ5 212SH02T12JJ5 S212AF02N5JJ2 S212AF02L7JJ2 2AF02C5JJ2 S212AF02E7JJ2 N J j 1 gt 1 4 3 1 j L I 0808000808 gt GC Valves 521 Series 2
73. NTACTS INLET SOLENOID TO RO MOTOR POWER COMMON TROUBLESHOOTING NOISE PROBLEMS VALVES AND MOTORS ARE ELECTROMAGNETIC EVICES THAT GENERATE ELECTRICAL NOISE OLTAGE SAGS OR SURGES WHEN THEY PERATE THIS ELECTRICAL NOISE CAN CAUSE MOMENTARY MALFUNCTIONS IN ELECTRONICS EQUIPMENT IF THE NOISE FINDS ITS WAY INTO THE ELECTRONICS CIRCUITRY IF ELECTRICAL NOISE PROBLEMS ARE ENCOUNT ERED THE ROTrol Il MAY MOMENTARILY MAL FUNCTION IN A VARIETY OF WAYS USUALLY A MICROPROCESSOR RESET WILL OCCUR WHEN THE NOISE IS ENCOUNTERED IF THE UNIT IS SHUTTING DOWN A PUMP OR CLOSING A VALVE IT MAY RESTART THE PUMP OR OPEN THE VALVE SEVERAL TIMES BEFORE FINALLY OPERATING PROPERLY ALSO THIS REACTION WILL USUALLY BE VERY ERRATIC OCCURING ONLY OCCASSIONALLY ALSO IT MAY OPERATE OTHER DEVICES DURING THIS REACTION ALTHOUGH CIRCUITS IN THE ROTrol ARE DESIGNED TO REJECT MOST ELECTRICAL NOISE DUE TO THE WIRING AND OR DEVICES OPERATED BY THE ROTrol II SOME NOISE MIGHT OCCAS SIONALLY GET INTO THE CIRCUITRY FORTUNATELY NOISE PROBLEMS CAN USUALLY BE PREVENTED OR SOLVED USING INEXPENSIVE NOISE FILTERS CONNECTED ACROSS THE VALVE OR MOTOR GENERATING THE NOISE IT IS ALWAYS ADVISABLE TO EMPLOY NOISE FILTERS WHEN OPERATING ELECTROMAGNETIC DEVICES WITH ELECTRONIC CONTROLLERS IF R amp D SPECIALTIES SUPPLIES THE ROTrol WITH AN OVERSIZED ENCLOSURE AND WITH PRE WIRED POWER DISTRIBUTION TERMINAL STRIPS NOISE FILTERS WILL BE SUP
74. OPERATION AND MAINTENANCE MANUAL FOR BBRO 10 000 21 500 SERIES REVERSE OSMOSIS SYSTEMS Manufactured By Big Brand Water Filter 7745 Alabama Ave 11 Canoga Park CA 91304 U S A PHONE 818 340 7258 TABLE OF CONTENTS Page 1 0 Introduction 1 2 0 Mounting 2 3 0 Installation 2 3 1 Plumbing 3 2 Electrical 4 0 Pre filtration 3 5 0 Pump 3 6 0 Start up 3 7 0 Membrane Cleaning 4 8 0 Troubleshooting 6 8 1 Low Pressure Conditions 8 2 Abnormal Permeate Production 8 3 Trouble Shooting Matrix 9 0 Pressure Vessel Breakdown 10 10 0 System Specifications 11 11 0 Optional Equipment 15 Appendix Electronic Control Box Appendix Major Component Cutsheets Pump Membranes 1 0 INTRODUCTION Big Brand Water Filter BBRO Systems incorporate the highest quality Reverse Osmosis components The system design emphasizes reliability affordability ease of operation and system expandability Reverse Osmosis systems manufactured by Big Brand Water Filter produce high quality permeate water from municipal and well water The basic BBRO unit is designed to produce fresh water at the capacity indicated by the suffix in the model number For example an BBRO 10 000 will produce 10 000 gallons of Reverse Osmosis permeate per day This production rate is based on feed water at 77 F 25 with turbidity of less than 1 NTU slit density index SDI of less than 5 and total dissolved solids TDS of 500 mg l The production rate is accurate plu
75. OT ONLY BY THE RESISTOR VALUE BUT ALSO BY THE CALIBRATION OF THE ROTrol Il BEING TESTED A RESISTOR ASSORTMENT OF 1000 4700 10 000 22 000 AND 47 000 OHMS SHOULD BE ADEQUATE FOR TESTING ANY ROTROL CALIBRATED FOR ANY OF THE STANDARD RANGES OFFERED TYPICALLY THESE RESISTORS COST 10 TO 20 CENTS EACH EACH SO THE MONETARY INVESTMENT IS MINIMAL FOR SUCH AN ASSORTMENT TO TEST A TOS CONDUCTIVITY CIRCUIT SIMPLY CONNECT A RESISTOR TO THE GREEN AND WHITE TERMINALS OF THE TERMINAL STRIP AND OBSERVE THE READING USE THE LOWER VALUE RESISTORS TO TEST THE HIGHER RANGES OF TDS OR CONDUCTMITY AND VISE VERSA REGARD LESS OF THE CALIBRATED RANGE ANY OF THE HIGH VALUE RESISTORS SHOULD GIVE A READING OTHER THAN 9 Figure 19 Oc ES C CPU SOCKET PUMP PRESSURE SENSOR ROTROL 10 PC BOARD SHOWN PERMEATE COND TDS SENSOR FEED COND TDS SENSOR i fac 0 00 09590 0 006095 Ir NOTE ALL COND TDS SENSORS HAVE TEMPERATURE OUTPUTS O rO 9 OFF HIGH TANK LEVEL Peor HIGH TANK LEVEL PUMP LOW TANK LEVEL NON POWERED SWITCH INPUTS CONTACTS ROTROL II ANALOG CIRCUIT TESTING WITH TEST RESISTORS 48 R amp D SPECIALTIES ROTROL I D RO2 D LED INDICATOR TO POWER SWITCH POWER WIRES TO WALL PLUG BREAKER ETC NOTE ALL OUTPUTS ARE UNPOWERED N O RELAY CO
76. P F JUMPER IF EACH READING IS CORRECT WITH THE RESISTOR CONNECTED RECONNECT THE SENSORS ONE AT A TIME AND OBSERVE THE READINGS ON THE DISPLAY IF THE READING FOR A PARTICULAR INPUT IS CORRECT WITH THE RESISTOR CONNECTED BUT NOT WITH THE SENSOR CONNECTED THE SENSOR SHOULD BE REPLACED IF THE READING WITH THE RESISTOR IS NOT CORRECT REMOVE THE SENSOR S BLACK WIRE AND RE TEST IF THE READING IS CORRECT WITH THE WIRE REMOVED THE PC BOARD IS GOOD CONNECT THE SENSOR BOTH WIRES AND CHECK THE DISPLAY READING IF THE READING IS CORRECT THE SENSOR IS GOOD IF NOT REPLACE THE SENSOR IF THE READINGS ON ALL CONNECTED SENSORS GO BAD WHEN ONE SENSOR IS CONNECTED THAT SENSOR SHOULD BE REPLACED THE 15VDC POWER FOR THE SENSORS CAN BE PULLED DOWN BY A SINGLE BAD SENSOR AND CAUSE ALL READINGS TO BE BAD TOS CONDUCTIVITY TESTING THE TDS CONDUCTIVITY CIRCUITS MAY BE TESTED BY CONNECTING RESISTORS TO THE GREEN AND WHITE INPUT TERM INALS OF THE SENSORS CORRESPONDING TERMINAL STRIPS THE VALUES OF THE RESISTORS USED WILL DETERMINE THE READINGS THAT WILL BE SHOWN ON THE LCD DISPLAY BUT THE RELATIONSHIP BETWEEN THE RESISTOR VALUE AND THE READING IS NOT AS SIMPLE AS THE RELATIONSHIP BETWEEN THE 1500 OHM RESISTOR AND THE TEMPERATURE AND PRESSURE READINGS ABOVE THERE ARE SEVERAL DIFFERENT RANGES OF TDS AND OR CONDUCTIVITY OFFERED FOR THE ROTrol AND THE READING OBTAINED FROM A RESISTOR WILL BE DETERMINED N
77. PLIED IF THE ROTrol II IS SUPPLIED IN ITS GENERIC FORM STANDARD ENCLOSURE IT IS THE CUSTOMER S ESPONSIBILITY TO PROVIDE ALL POWER WIRING AND ANY NOISE FILTERING IT IS ADVISABLE TO INSTALL FILTERS IN ALL CASES SIMPLY TO AVOID POSSIBLE PROBLEMS FILTERS MAY BE PURCHASED FROM ELECTRONIC SUPPLY HOUSES OR R amp D SPECIALTIES OR CONSTRUCTED FROM COMMONLY AVAILABLE ELECTRONIC PARTS A SUGGESTED FILTER IS SHOWN BELOW CONNER TO INLET SOLENOID CONNECT TO SWITCHED HOT PC BOARD POWER COM SAMPLE FILTER CAPACITOR 1uF 400 OR HIGHER RESISTOR 47 OHM 1 2 WATT CONNECT FILTER ACROSS DEVICE AS SHOWN ROTrol Il POWER AND OUTPUT TESTING WITH A DIGITAL MULTIMETER Figure 20 DMM 49 TROUBLESHOOTING POWER PROBLEMS WARNING DANGEROUS VOLTAGES PRESENT PROCEED WITH CAUTION WHEN THE CORRECT AC POWER IS APPLIED TO THE ROTrol AND THE POWER SWITCH IS SWITCHED ON THE GREEN POWER LED ON THE ROTrol II PC BOARD SHOULD LIGHT IF THE LED DOES NOT LIGHT THE VOLTAGE SELECT JUMPERS FOR THE CORRECT SETTING 12 V SHOWN IN PICTURE IF THE JUMPER SETTING IS CORRECT MEASURE THE VOLTAGE ON THE POWER TERMINALS WITH A DMM AS SHOWN IF THE VOLTAGE IS NOT PRESENT OR CORRECT ENSURE THAT THE POWER WIRES ARE INTACT BY TRACING THEM BACK THE POWER SOURCE WALL PLUG BREAKER BOX ETC AND ENSURE THE PLUG OR BREAKER IS CORRECT ANY PROBLEMS FOUND IF THE VOLTAGE READING IS CORRECT O
78. R LEAKS c MEMBRANE FOULED c CLEAN REPLACE d PRESSURE GAUGE MEMBRANE INACCURATE d CALIBRATE PRESSURE GAUGE a INSUFFICIENT FEED FLOW OR PRESSURE CHECK FEED HOSES 2 NOISY FEED WATER STREAM PIPES AND PREFILTERS INCREASED INTERRUPTED OR FOR LEAKS LOW FLOW TURBULENT OR BLOCKAGE c AIRIN SYSTEM a CHECK FEED CONNECTIONS AND REPAIR AS NEEDED a INSUFFICIENT FEED b VERIFY SOLENOID PRESSURE OPERATION b INLET SOLENOID c CHECK PUMP INDICATOR LIT INOPERATIVE DISCHARGE VALVE c PUMP PULLING TOO AND THROTTLE MUCH WATER VALVE POSITION VERIFY TOTAL SYSTEM FLOW RATE INSUFFICIENT PERMEATE PRODUCTION OR EXCESSIVE PERMEATE TDS a b MEMBRANE FOULING FEED WATER EXCEEDS DESIGN GUIDELINES DAMAGED O RINGS a CHECK MEMBRANE PERFORMANCE b PERFORM WATER ANALYSIS ON FEED WATER c PULL MEMBRANE AND CHECK ORING CONDITION REFER TO SECTION 8 OF THE MANUAL FOR ADDITIONAL INFORMATION HEA02 HEA04 06 07 09 11 CMF02 TCA04 RETAINING PINS 7 BOTTOM PLUG PLUG O RING O RING FOR PRODUCT TUBE ELEMENT HOUSING T 9 CHEVRON 6 n5 PRESSURE VESSEL BREAKDOWN N aS 7 4 y f f 509 PLUS PRODUCT TUBE OR X PRODUCT TUBE ADAPTER 1 J y SEAL ELEMENT 7 7 7 BBRO SERIES REVERSE OSMOSIS SYSTEMS R O HOUSING AND ELEMENT PARTS LIST TRIS
79. ROUGHLY BLACK JACKET IS IMPREGNATED WITH GRAPHITE WHICH WILL THE READING PARTICLES CONTAMINATE THE SURFACE OF THE CLEAR 6 CONNECT THE CENTER CONDUCTOR AND e 2 THE TERMINAL STRIP ON THE pH BOARD AS SHOWN ABOVE pH BOARD MOUNTING amp WIRING NOTE IF A FLOW BOARD INST THE pH BOARD MOUNT ON TOP OF THE FLOW BOARD CABLE PREPARATION BLACK JACKET WIRE BRAID LEAR JACKET pH SENSOR CABLE CENTER CONDUCTOR SHIELD 1 USING A SHARP CAREFULLY REMOVE APPROXIMATELY 1 1 2 OF THE OUTER JACKET 2 CAREFULLY UNWEAVE APPROX 1 1 4 OF THE WIRE BRAID AND TWIST TIGHTLY AS SHOWN Figure 16 39 ALARM DIVERT RELAY BOARD An optional PC board is available to provide relay outputs for operating additional devices or equipment when alarms are detected by the ROTrol or the TDS Conductivity Setpoint is exceeded The optional relay board attaches to the ROTrol terminal strip P4 as shown in Figure 17 The relay outputs do not supply power but will switch power routed through them to the controlled devices 1 phase Each relay is capable of switching loads up to 5A at voltages up to 240V he alarm output activates whenever any warning or shutdown is active The divert utput can be used to operate a divert valve or can be used as a high DS Conductivity alarm output The divert output is active any time the DS Conductivity is above the value programmed in Setpoint 10
80. T BUT IT ALSO COMPLICATES THE TROUBLESHOOTING OF THIS CIRCUITRY AS THE WIRING FOR THESE DEVICES MAY VARY CONSIDERABLY BETWEEN RO UNITS THE FIRST STEP IN TROUBLESHOOTING THE OUTPUT CIRCUITRY IS TO DETERMINE EXACTLY HOW THE VALVES MOTORS PC BOARD AND POWER SOURCE S ARE WIRED TURN OFF ALL POWER FEEDING THE RO UNIT AND PHYSICALLY TRACE OUT ALL POWER AND CONTROL WIRING PAY PARTICULAR ATTENTION TO ANY WIRE NUTS OR OTHER CONNECTORS USED AND ENSURE THAT ALL CONNECTIONS ARE CLEAN AND TIGHT OFTEN THE PROBLEMS ARE CORRECTED DURING THIS INSPECTION AFTER DETERMINING HOW THE VALVES AND MOTORS ARE WIRED THE UNIT MAY BE POWERED UP AND TROUBLESHOOTING OF ANY PROBLEMS MAY BEGIN IT WOULD BE HELPFUL TO READ THE SYSTEM OPERATION SECTION OF THE ROTrol II MANUAL APPROX 3 PAGES TO ENSURE THAT THE FUNCTIONAL OPERATION OF THE OUTPUT CONTROL CIRCUITRY IS THOROUGHLY UNDER STOOD i e WHEN SHOULD EACH CONTROL RELAY OPERATE AND WHEN SHOULD IT NOT OPERATE EACH RELAY WHICH OPERATES A VALVE OR MOTOR HAS A RED LED ON THE PC BOARD THAT LIGHTS WHEN THE RELAY OPERATES IF A VALVE OR A MOTOR IS NOT TURNING ON CHECK THE COR RESPONDING LED ON THE PC BOARD TO ENSURE THAT THE RELAY IS OPERATING IF THE LED IS OFF CHECK FOR ANY ERROR CONDITIONS Low PRESSURE HIGH PRESSURE ETC OR NORMAL SHUT DOWN CONDITIONS PRE TREAT LOCKOUT TANK FULL ETC THAT WOULD PRE VENT THE RELAY FROM OPERATING USE THE GREEN INPUT LED INDICATORS AND THE LCD DISPL
81. TCH DISPLAY KEYBOARD DISPLAY KE 11 SETPOINT KEY FUNCTION KEY RESET KEY CANCEL TCH Enables or disables RO pump control Enables or disables Aux RP pump control Shows status of ROTrol system Used to input changes to the ROTrol system Toggles display to show other status displays Allows setpoints to be displayed or changed Allows function operations to be initiated Push once for alarm silence and twice to reset system after a shutdown has occurred Confirms entry of a new setpoint value or activates function Aborts entry or display of a setpoint or function NSTALLATION Physical Installation Mount the ROTrol II in a convenient location on the RO equipment using either the four mounting ears provided with the unit or the optional panel mounting brackets Note All terminal strips plug in and all terminals are labeled Terminal Strip Jumper and Adjustment Locations Refer to Figure 3 for the location of all terminal strips and connectors Figure 3 also shows all jumper and adjustment locations Figures 4 6 show sample wiring diagrams for various power pump and valve voltages Power Wiring Refer to Figures 3 6 for terminal strip locations and wiring options AC power for the unit is connected to terminal strip P3 The unit is configured for 120VAC oper
82. TS 0 Refer to Figure 3 for location of J5 Move the shorting block J5 WRITE PROT to the OFF position center and left pins If J5 is in the write protected position and an attempt is made to change a setpoint WRITE PROTECTED will show on the display and the long error beep will be heard CAUTION J5 must be returned to the ON position to secure the memory from inadvertent changes Press the Setpoint key Enter the 2 digit setpoint number The setpoint will be displayed Press the cancel key to return to the main screen or To change the setpoint enter the new value for the setpoint and then press the Enter key The ROTrol II will beep twice if the change is accepted or one long beep if an error is made The setpoint value entered must have the correct number of digits For example the value entered for maximum operating hours must have 5 digits Precede your entry by zeros if needed When finished with all setpoint entries move the write protect jumper J5 back to the ON position center and right pins 17 STANDARD FUNCTIONS Tank Full Override Allows the RO unit to be turned when it is shut down due to a tank full condition When the override is initiated the RO unit will operate for the amount of time programmed in setpoint 26 Manual Flush Manually initiates a flush cycle Startup Screen Enables special screen that shows all the number of the
83. The maximum temperature and pressure is shown on the following page Although the meter may be suitable for other chemicals Blue White meters are tested with water and air only If you are unsure of the meters compatibility with your chemical consult the factory Blue White guarantees the meter is suitable with air and water only STEP 2 Choose a suitable location for the flowmeter Never allow the flowmeter to support the weight of related pipe or tubing Flowmeter must be installed in plumbing which is free of vibration Flowmeter must be installed in an exact vertical plane to ensure accuracy Valves Avoid a system that will impose a sudden burst of flow water hammer to the meter Such a burst will cause the float to impact the float stop with destructive force Magnetic solenoid ball or other quick opening valves cannot be used unless the meter is protected against sudden bursts of flow Do not exceed maximum working pressure see Temperature vs Pressure chart on next page STEP 3 Connecting the flowmeter to the plumbing Use an appropriate amount of Teflon or similar tape on external pipe threads before making connections Acrylic and other exotic plastics cannot tolerate PVC Glue and or pipe dope Even fumes can cause crazing If you are installing your flowmeter to a glued pipe configura tion install flowmeter after all glued fittings are dried and lines are purged of all fumes Neve
84. UE shaft seals can be operated down to 40 F 40 C where x is the seal type LCPTL003 CR I amp O_Rev0104 qxd 1 26 2004 11 58 AM Page 4 Pre installation Checklist continued Minimum Inlet Pressures Maximum Operating Pressures All CR CRI CRX CRN NPSHR 2 feet at 250 F 194 F for CRN SF CRN SF 29 psi 2 bar Pump type 50 Hz 60 Hz Max Maximum Inlet Pressures Type 11036 11027 362 25 CRN 1s 2 to 36 2 to 25 145 10 CRNA 145 10 1to 36 1to 27 362 25 145 10 1to17 232 16 1to 27 362 25 CRN 5 145 10 11678 1to 24 362 25 CRN 15 116 8 145 10 CRN 20 116 8 232 16 E 145 10 145 10 217 15 232 16 362 25 a 79 a lt w N 79 a 2 n 145 10 217 15 145 10 58 4 232 16 145 10 362 25 217 15 232 16 58 4 362 25 145 10 580 40 217 15 232 16 145 10 362 25 m a 145 10 RTS rie CR CRX CRN 8 87 6 CR CRX CRN 16 87 6 CRN SF 72 5 362 25 2 a a 79 a 2 o o N while pump is off or during start up Consult Grundfos for other working conditions during operation Select pump location The pump should be located in a dry well ventilated area which is not subject to freezing or extreme variation in temperature Care must be taken to ensure the pump is mounted at least 6 inches 150 mm clear of any obstruction or hot surfaces Th
85. ada Inc Mississauga Service Centre 6688 Kitimat Road Mississauga Ontario L5N 1 8 Canada Tel 416 826 8411 FAX 416 826 9106 Germany Dresser Europe S A Instrument Division European Operations Postfach 11 20 Max Planck Str 1 D 5112 Baesweiler Germany Tel 49 2401 808 0 FAX 49 2401 808 25 England Dresser U K Ltd 29 31 Rufford Court Hardwick Grange Warrington Cheshire England WA1 4RF Tel 44 925 814545 FAX 44 925 816378 _ r ram s Saudi Arabia DARVICO P O Box 10145 Jubail Industrial City Saudi Arabia 31961 Tel 966 3 341 0278 FAX 966 3 341 7624 Japan Niigata Ashcroft Keiki Co Ltd 9 3 Kamata Honcho 1 Chome Ohta Ku Tokyo 144 Japan Tel 81 3 3739 4924 FAX 81 3 3739 4975 South East Asia Dresser Singapore Instrument Division 152 Paya Lebar Road 04 06 Citipoint Industrial Complex Singapore 1440 Tel 65 825 4783 FAX 65 447 1448 Korea Dresser International S A Korea Office 2015 Kuk Dong Bldg 60 1 3 KA Choongmu Ro Chung ku Seoul Korea Tel 82 2 274 0792 FAX 82 2 274 0794 China Dresser Trading Division Dresser Industries Inc Room 3 24th Floor China International Trust amp Investment Corp Bldg Jianguo Menwai Dajie Beijing People s Republic of China Tel 86 1 500 3139 FAX 86 1 512 0030 India indfos Industries Limited 706 707 Surya Kiran 19 Kasturba Gandh
86. adjustment pressure setting a pressure gauge within suitable range is required If electrical hookup to line of final application to the switch is not desirable a battery powered test lamp or Ohmmeter may be used The markings on the pressure switch calibration scale in PSIG or BAR are for an approximate pressure setting The adjustment wheel in center of the pressure switch is turned clockwise or counterclockwise to change pressure setting For an exact pressure setting proceed as follows Adjust Set Point On Increasing Pressure 1 If the pressure switch is in the line of final application when set point adjustment is made be sure switch can be test operated without affecting other equipment 2 Turn adjustment wheel clockwise until indicator is full down toward pressure connection or well beyond desired pressure setting set point 3 Follow the steps in the chart below to make the pressure setting Form No P7079R4 50 00 Hanover Road Florham Park New Jersey 07932 zero pressure connect test lamp to common 4 For exact pressure setting cycle pressure switch and make fine adjustments with wheel 5 After setting has been made make permanent electrical connections WARNING To prevent the possibility of personal injury or property damage be sure electrical power is off when making permanent electrical connections To Adjust Set Point On Decreasing Pressure 1 If the pressure switch is in the line o
87. ale biological matter colloidal particles and insoluble organic substances can foul the reverse osmosis membranes Deposits of these foulants on the membrane can result in a reduced product water quantity and quality Periodic cleaning of the reverse osmosis membranes can improve performance of the system Cleaning chemicals are dangerous and can cause personal injury and damage to the environment Read and comply with all safety and disposal precautions listed on the Material Safety Data Sheets MSDS Big Brand Water Filter makes a complete line of membrane cleaning stations which can be used to clean your membranes 7 1 Inorganic Foulant Cleaning An acid cleaning solution can be used to remove inorganic salts such as CaCO3 4 BaSO4 and metal oxides i e iron from reverse osmosis membranes Sulfuric acid should not be used for cleaning because it may cause calcium sulfate to precipitate on the membranes Acceptable acid cleaning solutions are 1 asolution of 0 2 by weight hydrochloric acid HCD 2 asolution of 0 5 by weight phosphoric acid H3PO4 3 asolution of 0 2 by weight sulfamic acid NH2SO3H or 4 asolution of 1 0 by weight sodium hydrosulfite Na2S204 5 Big Brand Water Filter cleaner 1 may also be used A cleaning station should be used to clean membranes in the BBRO Series Systems First the cleaning solution should be prepared Use a polypropylene or fiberglass reinforced plastic tank The ta
88. alve Use a small probing object or blow through The vaive must be free from dirt to ensure tight shutoff Buzzing or chattering can be caused by low voltage or dirt or chips between top of plunger and tube head Check voltage Clean the plunger and the interior of the tube and base assembly UNIVERSAL KIT UNIVERSAL KIT CHART 211 SERIES UNIVERSAL KIT 13TH amp 5TH DIGIT 10TH TH DIGIT OF DIGIT OF WoLTAGE CAT NO NO TYPE STANDARD KS211AF02N1FGSBA 5 KS211AF16N1FG8BA SW _KS211AF02N1GJ5BA KS211AFI6N1GJSBA KS211AF02C1FG9BA Ci _KS211AF16CiFG9BA KS211AF02C1GJ5BA KS211AF16C1GJ5BA KS211AF02K4CG1AA KS211AF16K4CG1AA KS211AF02K4EGSAA KS211AFT6KAEGSAA KS211AF02T4CG1AA KS211AF16TACGIAA KS211AF02T4EGSAA KS 11AFIGTAEGSAA KS211AF02T2CGTBA KS211AF16T2CG1BA KS211AFO2T2EGSBA KS211AF16T2EG5BA KS211AFO02T2FGSBA KS211AFT6T2FGOBA T KS211AF02T2GJ5BA 5211 16720 5 1 KS211XF02NTFG9BB KS211XF16N1FG9BB KS211XF02N1GJ5BB KS211XF16N1GJ5BB KS211AF02C1FG9BB KS211AF16C1FG9BB KS211AF02C1GJ5BB KS211AF16C1GJ5BB KS211XF02K4CG1AB KS211XF16K4CG1AB KS211XF02K4EG5AB KS211XF16K4EG5AB KS211XF02T4CG1AB KS211XF16T4CG1AB KS211XF02T4EGSAB KS211XF16T4EG5AB KS211XFO2T2CG1BB DC KS211XF16T2CG1BB AC KS211XF02T2EG5BB T2 DC KS211XF16T2EG5BB AG KS21iXFO2T2FG9BB KS211XF16T2FG9BB KS211XF02T2GJ5BB TKS211XF16T2GJ5BB T4 EXPL PROOF
89. ammed in setpoint 25 This time delay is in seconds and will be shown on the display during the delay period Tank Full Override Function 1 Tank Full Override allows the RO unit to be operated when it has shut down due to a tank full condition When this function is initiated the RO unit will operate for the number of minutes programmed in setpoint 26 Tank Full Override Time At the end of this time the RO unit will then shut down if the tank full condition is still active This feature allows the RO unit performance to be checked or samples to be taken when the RO unit is not operating due to a full tank 20 Low Feed High Pump Pressure Operation If dipswitch 1 is OFF only the pressure switch inputs are active If it is ON the switch inputs and the analog pressure sensor inputs are enabled If the low feed pressure switch input becomes active or if the analog inputs are enabled and the feed pressure sensor input drops below the value programmed in setpoint 01 Low Feed Pressure the low feed pressure shutdown will occur after the time delay programmed in setpoint 02 Low Feed Delay NOTE The low feed pressur alarm generated by the pressur sensor can be disabled by programming Setpoint 01 to 00 The RO Pump control relay will open shutting down the RO pump and the alarm will begin to sound LOW FEED PRESSURE will show on the display and the alarm lamp will flash The RO system will remain shutdown until reset
90. and open the suction Discharge priming plug on the pump head See Figures 5A and 5B Gradually open the pain Plug Plug isolation valve in the suction line until a steady stream of airless water runs m Opposite side out the priming port Close the plug and securely tighten Completely open the isolation valves Suction UL e Discharge In open systems where the water level is below the pump inlet the Drain Plugs G 1 2 A suction pipe and pump must be filled and vented of air before starting the pump Close the discharge isolation valve and remove the priming plug Pour water through the priming hole until the suction pipe and pump are completely filled with water If the suction pipe does not slope downward from the pump toward the water level the air must be purged while being filled Replace the priming plug and securely tighten 1 Switch power off Check to make sure the pump has been filled and vented Remove the coupling guard and rotate the pump shaft by hand to be certain it turns freely Verify that the electrical connections are in accordance with the wiring diagram on the motor Switch the power on and observe the direction of rotation When viewed from the top the pump should rotate counter clockwise clockwise for CRN SF 6 reverse the direction of rotation first switch OFF the supply power On three phase motors interchange any two power leads at the load side of the starter On sin
91. ane Differential are provided If the sensors record a pressure drop across the prefilter or the membrane that exceeds the setpoints the alarm lamp will light and the alarm display will show the setpoint that was exceeded Programming these 2 setpoints to 00 will disable these alarms High TDS Conductivity Alarm Shutdown If Dipswitch 3 is OFF and the permeate TDS Conductivity reading exceeds the value programmed in setpoint 10 High TDS Conductivity Limit the delay programmed in Setpoint 11 TDS Cond Alarm Delay is started When this time delay times out the alarm lamp will flash the audible alarm will sound and high TDS Conductivity will show on the alarm display If Dipswitch 3 is ON and the high permeate TDS Conductivity limit is exceeded for the delay programmed in setpoint 12 High TDS Conductivity Shutdown Delay the RO system will shut down until reset Programming Setpoint 10 to 000 will disable the high TDS Conductivity alarm When the unit is in flush or when the RO unit is off due to any shut down condition the TDS Conductivity alarm is disabled 21 Rejection Limit If the optional feed TDS Conductivity monitor is installed feed TDS Conductivity and membrane rejection are displayed If the membrane rejection drops below the value programmed in setpoint 13 Reject Limit the alarm lamp will light and LOW PERCENT REJECTION will show on the alarm screen Programming Setpoint 13 to 00 will disable the percent rejec
92. anently installing the switch You want the switch to shut down the RO without the tank overflowing The blue float will let the RP run if it is in the up position It will shut the RP pump off when it drops to the down position Be sure that the switch is adjusted so it shuts the RP pump off before the level in the tank drops below the RP pump inlet suction line If the float ball drops below the inlet suction line of the pump the pump will continue to run without water and burn the pump up Please refer to the attached figure for typical system installation APPENDIX ELECTRONIC CONTROL BOX Big Brand Water Filter utilizes a UL CUL listed Industrial Control Panel to control and operate the BBRO line of machines The control box is offered in all common voltages in both single and three phases and 50 and 60 HZ In most cases the box will consist of a motor contactor and overload incoming fuses secondary control power fuses and or transformer and an electronic control board mounted in a Nema 4 enclosure One of two electronic control board is standard in all boxes and voltages The difference is whether auto flush was ordered as an option The functions of the board are described in detail in the accompanying pages Included within these pages is a board diagram showing where to make the field connections of various devices All inputs are closed to run Crane will wire devices on the machine to the control board other external connection
93. asing pressure are changed The difference between these points is fixed and is not adjustable Pressure setting adjustments are made by turning the adjustment wheel at the center of the switch On H Series Suffix S pressure switches the snap switch has ar adjustment knob to vary the deadband range To increase deadband range turn knob counterclockwise to decrease range turn knob clockwise NOTE The maximum proof pressure for H Series pressure switches is 250 psig Proof pressure is the pressure which a device can be subjected to for extended periods of time without changes in its operating characteristics DuPont s Registered Trademark Automatic Switch MCMXCIII All Rights Reserved ASCO Valves H SERIES Form No P7079R4 INSTALLATION Check the nameplate for correct catalog number electrical rating and pressure range Never apply incompatible fluids or exceed pressure rating of the switch IMPORTANT All internal adjustments have been made at the factory Any adjustment alteration or repair to the parts of the switch other than stated herein voids all warranties Temperature Limitations Ambient Temperature Standard amp Suffix Switch 4 to 140 F e Suffix U Switch 4 F to 122 F Check catalog number on nameplate to determine fluid temperature limitations The seventh 7th digit in the catalog indicates diaphragm material and fluid temperature limitations See chart provi
94. ation standard Optionally 240VAC and 24VAC units are available Wire th correct voltage for the unit to P3 terminals 11 and 12 Pump and Valve Relay Outputs The ROTrol II provides a contact closure to control the pumps and valves that are controlled by the unit These contact closures DO NOT supply power on their own The power to operate the pump or pump contactor and the power for the valves must be supplied to the relays This configuration allows the pumps and valves to be operated with different voltages if required One wire of the incoming power for a pump being controlled should be connected to the odd terminal for that pump P6 One wire of the pump will be connected to the even terminal The other wire from the pump will connect to the other wire of the incoming power for that pump For pumps and valves operated from 120 or 240VAC the ground wires should be tied to the ground of the incoming power The remaining pump and valves can be connected in the same manner S Figures 3 4 5 amp 6 for sample wiring diagrams Pump Motor Wiring The RO and auxiliary repressurization pump motors are connected to the terminal strip P6 The control relays for these pumps can control up to 20A directly or larger pump motors through appropriate motor starters The control relays provide a contact closure and do not supply power The RO pump motor connections are to P6 terminals RO PUMP The Aux RP pump motor connection
95. ave the same service factor Failure to follow these recommendations may result in premature motor failure Disassembly 1 Turn off and lock out power supply The power supply wiring can not be safely disconnected from the motor wires 2 Remove the coupling guards 3 Using the proper metric Allen wrench loosen the four cap screws in the coupling Completely Note the clearance remove coupling halves On CR1s CR20 the shaft pin can be left in the pump shaft CR N 32 45 below the coupling Raise the coupling 64 and 90 do not have a shaft pin higher as far as it will go CR 1s 1 3 5 10 15 and 20 do not loosen the three shaft seal securing allen screws 9 Lower it halfway back down 1 2 the distance 4 With the correct size wrench loosen and remove the four bolts which hold the motor to the 12 you just raised it Y Tighten screws pump end see torque specifica Zale tions below 5 Lift the motor straight up until the shaft has cleared the motor stool Assembly 1 Remove key from motor shaft if present and discard 2 Thoroughly clean the surfaces of the motor and pump end mounting flange The motor and shaft must be clean of all oil grease and other contaminants where the coupling attaches Set the motor on the pump end 3 Place the terminal box in the desired position by rotating the motor 4 Insert the mounting bolts then diagonally and evenly tighten For 3 8 bolts torque to 17
96. cted If the voltage constantly remains high or low the motor should be changed to the correct supply voltage Current measurement How to Measure Use an ammeter set on the proper scale to measure the current on each power lead at the terminal box or starter See the motor nameplate for amp draw information Current should be measured when the pump is operating at constant discharge pressure What it Means If the amp draw exceeds the listed service factor amps SFA or if the current imbal ance is greater than 5 between each leg on three phase units check the following 1 Burned contacts on motor starter 2 Loose terminals in starter or terminal box or possible wire defect 3 Toohigh or too low supply voltage 4 Motor windings are shorted or grounded Check winding and insula tion resistances 5 Pump is damaged causing a motor overload Insulation Resistance How to Measure Turn off power and disconnect the supply power leads in the pump terminal box Using an ohm or mega ohm meter set the scale selector to Rx 100K and zero adjust the meter Measure and record the resistance between each of the terminals and ground What it Means Motors of all HP voltage phase and cycle duties have the same value of insulation resistance Resistance values for new motors must exceed 1 000 000 ohms If they do not motor should be repaired or replaced 12
97. d The system may shut down repeatedly on low pressure or pump damage may occur DO NOT run the machine with the pre filter removed This will void the warranty This can also cause irreversible damage to the membranes PUMP The BBRO 10 000 to 21 500 Reverse Osmosis systems are supplied with multi stage centrifugal pumps The following guidelines will ensure trouble free operation e The pump must never run dry Operating the pump without sufficient feed water will damage the pump seals and void the warranty e Always feed the pump with filtered water Sediment and debris in the feed water can damage the pump and membranes e Prime the pump during initial start up Refer to the pump manufacturer s directions on priming START UP 6 1 Plumbing connections should be made as recommended in section 3 1 State and local plumbing codes shall be followed For more information on state and local codes contact your local plumbing inspector or a licensed plumber in your area 6 2 Follow the recommended electrical connections in section 3 2 State and local electrical codes shall be followed For more information on state and local codes contact your local electrical inspector or a licensed electrician in your area 6 3 Check pump rotation by bumping the on switch momentarily and observing pump shaft rotation removal of shaft guard is required If rotation is backwards on a three phase system switch any two incoming power leads On a single pha
98. d oriented to allow physical contact with the fluid being measured and not allow air to be trapped around the sensor i e the pH sensor should be side or bottom mounted in horizontal pipe runs Also the output from the pH sensor is a low level voltage which may be affected by any static charges and or stray currents flowing in the fluid stream It is recommended that the pH sensor be installed in a grounded metal fitting to prevent possible stray voltages from affecting the reading See Figure 15 for one suggested mounting configuration pH Sensor Wiring Connect the shield wire to and the signal wire or center conductor to t The shorting jumper must be removed from J10 on the main PC board to enable pH readings Refer to Figure 16 for pH wiring information and Figure 3 for J10 location pH Calibration The pH sensor is calibrated at the factory but periodic recalibration should be done to maintain sensor accuracy Refer to Figure 16 for adjustment locations To calibrate the pH monitor insert the pH sensor in a pH 4 0 standard solution and adjust the zero control for a reading of 4 0 Remove the pH sensor rinse with distilled water and shake dry Then insert the probe in a pH 10 0 standard solution and adjust the span control for a reading of 10 0 These steps should be repeated several times as there is some interaction between the 2 adjustment controls Also most pH sensors respond to changes very slowly allow ad
99. ded Seventh 7th Dig Diaphragm Fluid Temperature it in Catalog Num Material Limitations ber VITON 4 F to 250 F Ethylene Propylene 4 F to 250 F Fluorositicone 40 F to 250 F EXAMPLE For Catalog Number HB46A278 the seventh digit of the catalog number is 7 This indicates that the diaphragm material is Fluorosilicone and the fluid temperature limitations are 40 F to 250 F Positioning The pressure switch may be mounted in any position Mounting For mounting bracket optional feature or mounting dimensions of general purpose enclosure see Figures 1 2 and 3 Partial View of Mounting Bracket Optional Feature 28 Diameter 97 1 2 Mounting Holes INCHES Figure 1 Optional mounting bracket 44 5 Printed in U S A Page 1 of 4 Switch 50 60 Hanover Road Florham Park New Jersey 07932 1 750 44 5 4 223 dia 105 9 223 5 6 Hole and siot are for mounting with 190 dia screws or 5 196 screws Figure 2 General purpose enclosure Piping Tubing Adequate support of piping and proper mounting of pressure switch should be made to avoid excessive shock or vibration To minimize the effect of vibration on a switch mount perpendicular to vibration Connect piping or tubing at base of pressure switch CAUTION Do not use 1 2 pipe thread on pressure switch body as a p
100. dings INCOLrECE we eed pH Sensor Not Reading or Incorrect pusu x VY TROUBLESHOOTING CHART Se ofc eue eite Ene Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig ILLUSTRATIONS re 1 Front Panel Controls and Indicators 3 re 2 owiteh Select ewe 6 re 3 ROZO POB Tay Ol yU ee eee 8 re 4 Sample TZ0VAC Z eee Se we Ww Se 9 re 95 Sample 240VAC WITING 2 49 mcm ee ee we re 6 Sample 1207240 VAC WEEPING wk wet eta ea wee re 7 TDS Conductivity Sensor Installation 12 re 8 den Sieh Seer be ads TERCERA 23 y 9 Screen Drees ense SRE Se SESS SL 25 re 10 SST SST Zech 3t tes oh Sissy ns eso Yaseen arte 27 re 11 SOLOS Soc MEI e Da EIQUE 28 re 12 Startup SCTECN sy 34 ww Seed Bead 30 re 13 Flow Mounting and Wiring ss 4b y ua ae ars 33 re 14 K Factor ey iB uka us ua 34 re 15 pH sensor Installatioles uyu oe De eee 37 re 16 pH Mounting and Wale UN wn ee do eae e 39 re 17 Alarm Brvert Relay
101. display and the position of the RO PUMP switch If conditions indicate that the inlet valve should be open LED DS11 should be on If DS11 does not light the RO PUMP is operating and the unit is not engaged in a membrane flush cycle the PC board should be replaced If LED DS11 is on and the valve does not operate check the wiring between the valve s power source and the valve If all wiring appears intact and correctly wired see Figure 4 5 or 6 check for the correct voltage on the valve with a DVM If voltage is present on the valve it is probably bad and should be replaced If voltage is not present on the valve check between the valve s unswitched directly wired to valve power lead the P6 terminals labeled INLET V Between the unswitched wire and the P6 terminal COM the supply voltage 120 240 should be present If the voltage is not correct the problem is either a break in the wiring between the P6 terminal COM and the power source or the power source proper It will probably be connected to several other wires with a wire nut or splice of some kind which may be loose If the correct voltage is present at P6 COM it should also be present at the terminal N O when DS11 is on and at the terminal N C when DS11 is off If DS11 is on and no voltage is present on N O the PC board should be replaced 42 Aux RP pump will not operate The Aux RP pump will not operate if the AUX switch front panel is
102. e Size 1 2 9 5 8 9 4 1 114 11 Body Brass Stainless Steel 2 Sealing Seat Buna N Teflon Viton Ethylene Propylene 5 Standard Conduit NEMA1 Housing Explosion proof NEMA VII Grommet Open frame Junction box Watertight NEMA IV Etc AC24V 60Hz DC 12 Available Voltages AC110V 50Hz AC120V 60Hz AC220V 50Hz AC240V 60Hz DC 24V Voltage Tolerance 10 to 15 of applicable voltage Coil Class F and H Lead Length 24 Inch Temperature Ratings athe HO F Coil 175 F max with Class Coil Mounting position Mounts in any position Best position is Solenoid vertical and upright direction Agency Listings UL Listed CSA Certified Consult factory for further details Options Manual Override Mounting Bracket Neon Lamp Surge Suppressor Consult the factory for specifications other than those listed above GC Valves 21 Series 2 Way Solenoid Valves Valve Selection List Check the Operating Pressure Range carefully when selecting a valve Power Voltage Consumption V Model Code Pipe Connection Stainless Steel Body Brass Body z Orifice Size 2 5 Normally Closed Energized TIAFO2K4CG1 MAHO2T4CG1 1T1AHO2T2CG1 _ 11 AFO2N5CG4 S211AFO2L7CG4 5 8 11AH02T4DG1 11AH02T2DG1 s 11AF02N5DG4 S211AFO2L7DG4 11 2 4 5 q11AHO2T4EGS 11AHO2T2EGS5 TI AFO2
103. e active before RO system shutdown occurs High Pump Pressure Limit Sensor input higher than the programmed value will cause RO system shutdown To disable set to 0000 High Pump Pressure Delay The amount of time a high pressure sensor input or a high pressure switch input must be active before an RO system shutdown occurs Low Pump Pressure Limit When the pump pressure drops below this limit with the RO unit operating the alarm lamp will light and low pump pressure will show on the alarm screen To disable set to 000 Maximum Prefilter Differential PSI When the prefilter sensor pressure minus the low feed sensor pressure exceeds this value the alarm lamp will light and high prefilter differential pressure will show on the alarm screen To disable set to 00 Maximum Membrane Differential PSI When the pump pressure sensor pressure minus the membrane pressure sensor exceeds this value the alarm lamp will light and high membrane differen tial pressure will show on display To disable set to 00 08 Not Used 09 Not Used 13 RANGE DEFAULT 01 99 20 PSI BAR 00 99 05 seconds 001 9999 0220 PSI BAR 01 99 05 seconds 000 999 150 PSI BAR 01 99 20 PSI BAR 01 99 20 PSI BAR STANDARD SETPOINTS SETPOINT DESCRIPTION 10 11 12 13 14 DS 16 17 18 T9 20 High TDS Cond Limit When this value is met or exceeded the alarm lamp will light and hi
104. e at a time Move J13 to select the connected sensor and check the reading If the reading is good that sensor and the PC board are good Whether the reading was good or bad disconnect that sensor s black wire reconnect the second sensor s black wire move 44 J13 s shorting block and check the LCD reading If at least one sensor gives a good reading that sensor and the PC board are good If any pressure sensor s was disconnected reconnect the wire s and ensure that the temperature reading remains good Replace all bad sensors found If no good reading was obtained the PC board should be replaced A 1500 OHM RESISTOR MAY BE CONNECTED IN PLACE OF THE RED AND BLACK WIRES OF THE SELECTED SENSOR TO GIVE APPROXIMATELY A 75 EF READING AND THE 10000 AND 33000 OHM RESISTORS CAN BE CONNECTED IN PLACE OF THE WHITE AND GREEN WIRES TO GIVE TDS CONDUCTIVITY READINGS TDS Conductivity sensor reading s inaccurate Verify that each sensor is wired correctly and the temperature reading is correct The sensor readings are temperature compensated and if the temperature reading is not correct the TDS Conductivity readings will not be correct Also each sensor must have a good fluid flow around the sensing element pins to yield an accurate reading See Figure 7 for correct sensor installation If the temperature reading is good the sensors
105. e motor requires an adequate air supply to prevent overheating and adequate vertical space to remove the motor for repair For open systems requiring suction lift the pump should be located as close to the water source as possible to reduce piping losses Foundation Concrete or similar foundation material should be used to provide a secure stable mounting base for the pump Bolt hole center line dimensions for the various pump types are given in Figure 1 Secure the pump to the foundation using all four bolts and shim pump base to assure the pump is vertical and all four pads on the base are proper ly supported Uneven surfaces can result in pump base breakage when mounting bolts are tightened The pump can be installed vertically or horizontally see drawing at right Ensure that an adequate supply of cool air reaches the motor cooling fan The motor must never fall below the horizontal plane Arrows on the pump base show the direction of flow of liquid through the pump To minimize possible noise from the pump it is advisable to fit expansion joints on either side of the pump and anti vibration mountings between the foundation and the pump Isolating valves should be fitted either side of the pump to avoid draining the system if the pump needs to be cleaned repaired or replaced 4 LCPTL003 CR I amp O_Rev0104 qxd 1 26 2004 11 58 AM Page 5 Figure 1 Bolt Hole Centers CR I N 1s 1 3 5 amp CRT 2 4 lt 8 11 16
106. e pump version is X X also indicates special pump versions not listed above GRUNDFOS H FEET 6 RPM LO Lok F max Model Key 12345678 1 01 41 Designates Matt produerion ABCD Last two digits of production year Production week number 01 52 LCPTLOO3_CR I amp O Rev0104 qxd 1 26 2004 11 58 AM Page 3 Pre installation Checklist 1 3 Confirm you have the right pump Read the pump nameplate to make sure it is the one you ordered CR Centrifugal pump with standard cast iron and 304 stainless steel construction CRIorCRX Centrifugal pump all parts in contact with water are 304 stainless steel construction CRN Centrifugal pump all parts in contact with water are 316 stainless steel construction CRT Centrifugal pump all parts in contact with water are titanium construction CRE Centrifugal pump with a Grundfos MLE VFD motor attached Check the condition of the pump The shipping carton your pump came in is specially designed around your pump during production to prevent damage As a precaution the pump should remain in the carton until you are ready to install it Examine the pump for any damage that may have occurred during shipping Examine any other parts of the shipment as well for any visible damage If the pump is shipped as a complete unit motor attached to pump end the position of the coupling that connects the p
107. e that the motor turns in the direction indicated by the arrow on the motor pump adapter base 4 0 5 0 6 0 Ensure that the electrical circuit supplying the system matches the power requirements of your machine Consult a qualified electrician or your Big Brand Water Filter dealer if you have any questions Refer also to the electrical schematic for a standard BBRO machine Additional features supplied with each control panel are pre treat lockout point of use level control two switch level control or single switch level control and auto flush if so equipped and low pressure protection All inputs are dry contact and closed to run If the option is not in use a wire jumper needs to be installed on the board where this connection is made Please see controller specifications for addition information PRE FILTRATION All BBRO Reverse Osmosis systems include a cartridge type pre filter with a nominal 5 micron sediment cartridge which will remove most particles greater than 5 microns in size The sediment cartridge must be checked periodically and changed when dirty The sediment filter should be changed when the pressure drop across the filter exceeds 10 psi or at a minimum once a month It is recommended that pre filter and post filter pressure gauges be installed to facilitate in determining pre filter performance If the prefilter becomes clogged and water flow to the pump is reduced or interrupted system performance will be affecte
108. ect sunlight These situations and others tend to reduce the strength of the materials from which the meters are manufactured Flowmeters are tested and calibrated for water or air only Although meters may be suitable for other chemicals Blue White cannot guarantee their suitability QUAL amp BLUE WHITE INDUSTRIES AXES Exploded View and Parts List Standard Meters Option x L liquid G gas F 55005L DESCRIPTION F 55250x x 55500 F 55750L F 55100L F 55376x F 55017L 1 Cao 76001 080 910014032 91001 032 91001 033 91001 160 2 2 90003 072 9000341 900032081 90003 082 90003 079 76000 039 90007 534 90007 534 90007 535 76000 046 76001 170 qe 76000 129 90007 522 90007 563 90007 565 1 76000 147 8 Adapter 76001 079 91001 141 91001 142 91001 143 91001 44 2 9 tocknut 91001 153 910014153 91001 154 91001 171 91001 172 2 Shading indicates item not sold separately gt Adjustable Meters Option x L liquid or G gas F 55005LA ITEM DESCRIPTION F 55750LA F 55100LA x F 55017LA 1 7 76001 080 91001 032 91001 032 91001 033 91001 160 2 O ringcap 90003 072 90003 081 90003 081 90003 082 90003 079 76001 108 76001 108 76001 109 76001 110 76000 111 76001170 Float 76000 129 90007 47 90007 522 900
109. ed If rigid conduit is used do not consider it or use it as a means of supporting mounting the pressure switch The raintight watertight enclosure has a 1 2 conduit hub When replacing housing cover torque screws in a crisscross manner to 10 in Ibs 1 1 Nm to ensure even gasket compression Page 2 of 4 ASCO Valves Automatic Switch Co A CAUTION Electrical load must be within range stated on nameplate Failure to stay within the electrical range of the switch rating may result in damage or premature failure of the electrical switch A CAUTION Do not overtighten screw type terminal connections When connections are made be sure there is no stress on the wire leads Excess of either condition may cause malfunction of switch Standard amp Suffix L Switches 15 amps resistive 125 volts AC 10 amps resistive 250 volts AC 1 8 HP 125 volts AC 1 4 HP 250 volts AC 1 2 amp resistive 125 volts DC 1 4 amp resistive 250 volts DC Suffix U Switch 5 amps resistive 125 and 250 volts AC 1 8 HP 125 volts AC 1 4 HP 250 volts AC 1 2 amp resistive 125 volts DC 1 4 amp resistive 250 volts DC SPDT NO N E NC A IMPORTANT H Series pressure switches are available with optional snap switches which have different electrical ratings than listed above Check nameplate on housing cover or frame to verify electrical ratings Set Point Adjustment Pressure Setting of Fixed Deadband Pressure Switch When making
110. ed and to the power source feeding the motor with a DVM If voltage is measured between the power wire feeding the motor directly and both RO pump terminals of P6 either the wire from P6 to the motor is broken or loose or the pump motor is bad If voltage is present on 1 terminal of P6 from the power source but not the other and DS14 is on the relay is may be bad requiring the circuit board to be replaced Reference Figure 4 5 or 6 for correct wiring If DS14 is off and the RO pump switch is on check the green LEDs above P4 DS2 7 check the alarm lamp on the front panel and note all readings on the LCD display Remember these indicators and LCD readings and read through the section SYSTEM OPERATION in this manual Using both the knowledge of how the unit operates and the indications shown by the LEDs and LCD you should be able to determine whether the problem is on or off the PC board malfunctioning level switch pressure switch etc If the unit is not responding correctly to the signals feeding the unit input switches etc the PC board should be replaced Inlet valve will not operate The inlet valve will not operate unless the RO PUMP switch is on Also there must be no shutdown alarms present the unit must not be in any restart time delay period and it must not have a tank full or pre treat lockout signal present Check for all normal shutdown conditions by observing the LEDs DS2 DS7 the LCD
111. een them with a DVM If they are tight in the terminals or the DVM shows the correct voltage at P3 L1 amp L2 check the fuse next to P3 and the front panel power switch and wiring to P3 If checking visually look for loose wires a broken switch or a blown fuse located to the left of P3 If using a DVM measure the voltage between L1 and the top terminal of P3 and between L1 and both ends of the fuse clip Correct any problem s found If no problems are found the PC board is probably defective and should be replaced 41 Display Blank Turn the power off and back on If the POWER ON LED DS1 and CPU ACTIVE LED DS8 are not on see System Inoperative above If DS1 is on and DS8 is blinking ensure that the display cable is plugged into the display connector P2 and inspect the ribbon cable solder connections on the display board for broken wires If the cable appears intact try adjusting the display contrast control If none of these checks reveal a problem the display should be replaced RO Pump Will Not Operate The RO pump will not operate if the RO pump switch is off an RO pump restart time delay is active the tank full input is present a low or high pressure shutdown has occurred or the pre treat lockout signal is present First turn the RO pump switch on then check to see if the relay LED DS14 is on If it is and the pump will not run check all the wiring from P6 to the RO pump or motor starter if equipp
112. eference BE THINK gt INNOVATE gt GRUNDFOS LCPTLOO3_CR I amp O_Rev0104 qxd 1 26 2004 11 58 AM Page 2 SAFETY WARNING Electrical Work All electrical work should be performed by a qualified electrician in accordance with the latest edition of the National Electrical Code local codes and regulations Shock Hazard A faulty motor or wiring can cause electrical shock that could be fatal whether touched directly or conducted through standing water For this reason proper grounding of the pump to the power supply s grounding terminal is required for safe installation and operation In all installations the above ground metal plumbing should be connected to the power supply ground as described in Article 250 80 of the National Electrical Code Nameplate Data Type key CR CRI CRN 1s 1 3 5 10 15 and 20 Example CR 3 10 A FGJ E HQQE Type range CR CRI Rated flow rate m3 h x 5 GPM Number of impellers Code for pump version Code for pipe connection Code for materials Code for rubber parts Code for shaft seal CR CRX CRN 8 and 16 Example CR 16 30 2 U G A AUUE Type range CR CRN Rated flow rate m h x 5 GPM Number of stages x 10 Number of impellers used only if the pump has fewer impellers than stages Code for pump version Code for pipe connection Code for materials Code for shaft seal and rubber parts CR CRN 32 45 64
113. embrane differential pressure setpoint has been exceeded LO PUMP PRESS The RO pump discharge pressure has dropped below the low pump pressure setpoint LO 5 REJECTION The RO system percent rejection has dropped below the rejection setpoint HI PERM FLOW The permeate flow has exceeded the high permeate flow setpoint LO PERM FLOW The permeate flow has dropped below the low permeate flow setpoint HI CNC FLOW The concentrate flow has exceeded the high concentrate flow setpoint LO CNC FLOW The concentrate flow has dropped below the low concentrate flow setpoint LO pH The pH has dropped below the low pH alarm setpoint HI pH The pH has exceeded the high pH alarm setpoint NOTE Warnings can be cleared by correcting the source of the warning or by changing the setpoint associated with the warning 29 Startup Screen FEED 1580 32 INLET 57 PUMP 194 FEED 51 CONC 178 1 7 1 6 1 6 Figure 12 The startup screen can be utilized during initial system startup to display all of the sensor readings on 1 screen Pressing the Display key exits the startup screen show a sensor is not installed the display for that sensor will Line 1 of the display shows the TDS Conductivity values Hy PERM 32 Th ED 1380 The feed water PPM uS permeate water PPM uS Line 2 of the display shows the inlet and pump discharge pr
114. ement instructions on page 10 LCPTLOO3_CR I amp O_Rev0104 qxd 1 26 2004 11 58 AM Page 7 F Electrical WARNING THE SAFE OPERATION OF THIS PUMP REQUIRES THAT IT BE GROUNDED IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE AND LOCAL GOVERNING CODES OR REGULATIONS CONNECT THE GROUND WIRE TO THE GROUNDING SCREW IN THE TERMINAL BOX AND THEN TO THE ACCEPTABLE GROUNDING POINT All electrical work should be performed by a qualified electrician in accordance with the latest edition of the National Electrical Code local codes and regulations Motor Grundfos CR pumps are supplied with heavy duty 2 pole 3600 RPM nominal ODP or TEFC NEMA C frame motors selected to our rigid specifications Motors with other enclosure types and for other voltages and frequencies are available on a special order basis CRN SF pumps are supplied with an IEC metric type motor with a reverse thrust bearing If you are replacing the pumping unit but are using a motor previously used on another CR pump be sure to read the Motor Replacement section on page 10 for proper adjustment of the coupling height Position of Terminal Box The motor terminal box can be turned to any of four positions in 90 steps To rotate the terminal box remove the four bolts securing the motor to the pump but do not remove the shaft coupling turn the motor to the desired location replace and securely tighten the four bolts See Figure 4 a Motor Terminal Box Positions Top Vie
115. en and readjust if necessary 7 Be certain the pump shaft can be rotated by hand If the shaft cannot be rotated or it binds disassemble and check for misalignment S 8 Prime the pump 9 Follow the wiring diagram on the motor label for the correct motor wiring combina tion which matches your supply voltage Once this has been confirmed reconnect the 9 power supply wiring to the motor 10 Check the direction of rotation by bump starting the motor Rotation must be left to CORRECT NOT CORRECT right counter clockwise when looking directly at the coupling 11 Shut off the power then re install the coupling guards After the coupling guards have been installed the power can be turned back on Figure 7 CR N 32 45 64 90 Parts List For each CR pump model Grundfos offers an extensive Parts List and diagram of part used in that pump and is recommended to have on hand for future maintenance In addition the listings also provide information about prepackaged Service Kits for those pump components most likely to exhibit wear over time as well as the complete Impeller Stack needed to replace the guts of each model These Parts Lists are available separately from the Grundfos literature warehouse or as a set with extensive service instructions in the Grundfos CR Service Manuals for a small charge Left prepackaged impeller stacks ready for immediate installation right prepackaged flange kits
116. equate time for the reading to stabilize each time the sensor is moved into a different solution before making any adjustments 36 ELECTRICAL GROUND CLAMP M TEE WIRE 7 coses um _ 3 4 FITTING T x COAXIAL SIGNAL CABLE Figure 15 pH Setpoints REMEMBER TO CHANGE JUMPER J5 TO OFF IF CHANGING A SETPOINT AND MOVE J5 BACK TO THE ON POSITION WHEN COMPLETE SETPOINT DESCRIPTION RANGE DEFAULT 45 LOW pH ALARM If the pH reading drops to or 01 0 13 0 06 0 below this value a low pH alarm will be displayed Set to 000 to disable alarm 46 HI pH ALARM If the pH reading rises to 01 0 13 0 08 0 or above this value a high pH alarm will be displayed Set to 000 to disable alarm 37 SETPOINT DESCRIPTION RANGE DEFAULT 47 LOW pH SHUTDOWN If the pH reading 01 0 13 0 05 0 drops to or below this value a low pH shutdown will occur after the pH delay has timed out Set to 000 to disable shutdown 48 HIGH pH SHUTDOWN If the pH reading 01 0 13 0 10 0 rises to or above this value high pH shutdown will occur after the pH delay has timed out Set to 000 to disable shutdown 49 pH DELAY This is the time the pH 00 99 10 value must meet the shutdown setpoint seconds before a pH shutdown will occur pH Operation The pH is displayed by pushing the display key until the screen 2 is shown Pushing the display key again wi
117. erature Delay If Setpoint 33 is programmed to 000 this alarm is disabled Sensor Unit of Measure Setpoints 51 PSI BAR 52 F C and 53 GPM LPM M3H allow the pressure temperature and flow unit of measure to be changed to meet customer requirements NOTE If the flow unit of measure is changed the K factor for each flow sensor must also be changed Alarm Output The alarm output available at pin 14 O1 is active whenever any alarm or shut down condition is active DS9 is lit whenever this output is active Divert Output The divert output available at P4 Pin 15 02 is active whenever th TDS Conductivity reading has exceeded Setpoint 10 The RO unit does not need to be running for this output to be active DS10 is lit whenever this output is active 24 SCREEN DESCRIPTIONS RO OPERATING F 1590PPM F 31PSI P 52 P 196PSI 97 7 68 Figure 9 Screen 1 Screen 1 shows the standard operating conditions for the RO unit The first line of screen 1 shows the status of the RO unit The following is a list of status messages with explanations RO OPERATING The RO unit is on and operating properly RO ON DELAY 10 The inlet solenoid is open and the number is the remaining delay in seconds before the RO pump starts RO OFF The RO pump is turned off with the RO pump switch TANK FULL 15 The RO pump is shutdown due t
118. erminals on the board are labeled Terminal Strip Jumper and Adjustment Locations Refer to figure 2 for the location of all terminal strips and connectors Figure 2 also shows all jumper and adjustment locations Figure 3 shows a sample wiring diagram Power Wiring Refer to figure 2 3 for terminal strip and jumper locations Before applying power to the unit verify that the voltage jumpers are configured correctly for the voltage that will power the unit The voltage jumpers are located below the transformer For 120VAC operation there should be a wire jumper installed between P2 and and a second wire jumper installed between P4 and P5 For 240VAC operation a single wire jumper should be installed between P3 and P4 AC power for the unit is connected to terminal strip P1 Connect the ground wire of the AC power to the terminal labeled GND For AC power with a neutral and hot wire the hot wire connects to L1 and the neutral wire connects to L2 For AC power with 2 hot wires either wire can connect to L1 and L2 On AC power with 2 hot wires the wire jumper between P6 and P7 should be removed and a fuse GMA 1 4A installed in F2 Pump and Valve Relay Outputs The Series 150 supplies relay outputs to control the RO pump and solenoid valves NOTE The relays output the same voltage as the AC power to the board If the pump and solenoids operate on different voltages a contactor will need to be supplied to operate the pump RO Pump Wir
119. essures NLET 37 Th inlet pressur PUMP 194 The pump discharge pressure Line 3 of the display shows the pump feed and concentrate pressures FEED 31 The pump feed pressur CONC 178 The concentrate pressure Line 4 of the display shows the system flow rates 1 7 The permeate flow 1 6 The concentrate flow 1 6 The recirculate flow 30 ADJUSTMENTS TDS Conductivity Calibration To calibrate the permeate TDS Conductivity adjust the permeate TDS Conductivity zero PERM ZERO control for a reading of zero on the display with the cell clean and dry Refer to Figure 3 for the location of the adjustments Immerse the cell in a test solution with a known TDS or conductivity value and adjust the permeate TDS Conductivity span P SPAN control so the display reads the correct TDS or conductivity for the solution The optional feed TDS Conductivity is calibrated in the same manner using FEED ZERO and F SPAN If the unit is in service cells installed each cell may be calibrated by disconnecting the green wire of the cell from the terminal strip and adjusting the corresponding ZERO control to obtain a zero reading on the RO II s display Reconnect the green wire and start up the RO unit Collect a sample of the water circulating through each cell measure the TDS Conductivity of the sample with a calibrated TDS Conductivity meter then adjust the appropriate SPAN control to ge
120. f final application when set point adjustment is made be sure switch can be test operated without affecting other equipment 2 Turn adjustment wheel counterclockwise until indicator is full up toward snap switch 3 Follow the steps in the chart below to make the pressure settings Normally Closed Adjustment Switch Procedure Terminal 1 Starting with initial pressure above desired pressure set point connect test lamp to common 2 Decrease pressure to desired Switch Some Terminal Lamp set point pressure On On Closed NC Open pes Then turn adjust Off Closed Circuit 3 Raise pressure Of until switch returns Open On Closed on increasing Circuit pressure Circuit 4 For exact pressure setting cycle pressure switch and make fine adjustments with wheel 5 After setting has been made make permanent electrical connections WARNING To prevent the possibility of personal injury or property damage be sure electrical power is off when making permanent electrical connections Form No P7079R4 ASCO Valves Testing of Installation _If the adjustment of the switch has been made outside of the line of final application the switch should be re tested when installed in the line of final application Follow adjustment instructions Be sure switch can be test operated without affecting other equipment MAINTENANCE WARNING To prevent
121. f terminals labeled F COND Connect each wire to its corresponding color designated terminal as noted in Figure 3 Each TDS Conductivity cell generates a temperature output which may be displayed on the LCD display Jumper J13 selects the temperature sensor in either the permeate or feed cell If jumper J13 is in the position labeled P the permeate temperature will be displayed If it is in position F the feed temperature will be displayed Analog Pressure Sensors The analog pressure sensors are connected to P5 Dip Switch 1 should be moved to the ON position to enable reading of the analog pressure sensors and the jumper for each sensor J6 J9 should be removed for each sensor installed The switches and jumpers are pre configured by the factory if the sensors are ordered with the unit If the optional flow metering is installed the flow meter interface board may be removed to allow easier wiring of the analog sensors The plug in terminal strip Pb may also be unplugged for the same reason Feed Pressure Sensor The feed pressure sensor should be installed downstream from the pre filters and inlet valve and before the inlet side of the RO pump The feed pressure sensor wires connect to the P5 terminals labeled Al The red wire connects to RD and the black wire to BK Jumper J6 should be removed to enable this sensor Pump Pressure Sensor The pump pressure sensor is instal
122. ft Ibs for 1 2 bolts torque to 30 ft Ibs and for 5 8 bolts torque to 59 ft Ibs 5 CR1s 1 3 and 5 Insert shaft pin into shaft hole Reinstall the coupling halves onto shaft and shaft pin Reinstall the coupling screws and leave loose Check that the gaps on either side of the coupling are even and that the motor shaft keyway is centered in the coupling half as shown in Figure 6a page 11 Tighten the screws to the correct torque CR 10 15 and 20 Insert shaft pin into shaft hole Insert plastic shaft seal spacer beneath shaft seal collar Reinstall the coupling halves onto shaft and shaft pin Reinstall the coupling screws and leave loose Check that the gaps on either side of the coupling are even and that the motor shaft key way is centered in the coupling half as shown in Figure 6a page 11 Tighten the screws to the correct torque Remove plastic shaft seal spacer and hang it on inside of coupling guard CR 2 4 8 and 16 Reinstall coupling halves Make sure the shaft pin is located in the pump shaft Put the cap screws loosely back into the coupling halves Using a large screwdriver raise the pump shaft by placing the tip of the screwdriver under the coupling and carefully elevating the coupling to its highest point see Figure 6 Note the shaft can only be raised approximately 0 20 inches 5mm Now lower the shaft halfway back down the distance you just raised it and tighten the coupling screws finger tight while keeping t
123. function you want to select 1 9 FUNCTION DESCRIPTION 2 3 sensor readings FUNCTION OPERATION 1 Press the Function key 2 Press 3 Press the Enter key to activate the function or Cancel to abort the function 18 DIPSWITCH SETTINGS Switch 1 Off Analog pressure inputs disabled Single tank full switch Long restart time Alarm lamp on high TDS Conductivity RO pump on during flush Inlet valve open during flush Flow metering disabled Not used Not used On Analog pressure inputs enabled Dual tank full switches Pump ON Pump OFF short restart RO system shutdown on high TDS Conductivity RO pump off during flush Inlet valve closed during flush Flow metering enabled 19 SYSTEM OPERATION General Operation On power up if the RO pump switch is ON the inlet control relay will activate and the RO start delay programmed in Setpoint 18 RO Start Delay will begin If no alarms are active the RO pump control relay will operate when the delay times out and the display will show the status of the RO system Refer to the SCREEN DESCRIPTIONS section of the manual for a description of the various display screens Shutdown conditions are indicated by a flashing red alarm lamp and audible warning beeper The cause of the shutdown is shown on the first line of the display Warnings that do not shut down the system are indicated by a steady red alarm lamp The status of any
124. g 3 for an exploded view of a typical S211 Model A and Fig 4 for an exploded view of a typical S211 Model Explosion proof operator assembly NOTE A GROUNDING PROVISION IS SUPPLIED FOR CSA CERTIFIED VALVES COIL CHART IDENTIFYING CATALOG DIGITS QUICK CONNECT TERMINALS S21 VF uy Sixth digit of Catalog Number represents coil class as shown G Seventh and eighth digits of Catalog Number represent voltages shown in coil class chart These digits must be transterred into the coil part number 3 Recommended spare part NOTE Type A coil is replaced by Type M coit For coil part number CS3AA 24 use CS3AM A24 COIL CLASS CHART 24V 60Hz 12V 60Hz amp 110V 50Hz x 208V 60Hz 240V 60Hz amp 22CV 50Hz 480V 60Hz CATALOG AVAILABLE WITH COIL CLASS DIGITS REPLACED BY REPLACED BY F TROUBLE SHOOTING If valve fails to open 1 Check voltage against rating on nameplate Check voltage at solenoid lead connections Check control circuit and solenoid coil for burnout Check operating pressures Clean all passageways and check condition of dia phragm 6 Replace coil a Pron If valve fails to close 1 Check for bent or nicked plunger tube 2 Check for damaged springs 3 Clean pilot valve and main valve seats 4 Check condition of plunger seat disc and main valve diaphragm 5 Clean passageways in pilot valve and main v
125. g is replaced with gt Warning Messages Warning messages are also shown on the second line If any warnings are active the active warnings will alternate with the normal displays for the bottom line The following lists the warning messages HI TDS COND The TDS Conductivity reading has exceeded the programmed limit TANK LOW The tank low input is active TANK LOW 99 The tank low input has cleared but the tank low restart delay is active The number is the minutes left in the delay OP HOURS EXCEEDED The current operating hours have exceeded the programmed limit Tank Full Operation The unit can be operated with 1 or 2 level switches With 1 level switch the switch is connected to the tank full high input When this switch has been active for 5 seconds the unit will shut down on tank full TANK FULL will show on the display When the tank full condition clears the display will show TANK FULL 99 The number is the tank full restart time and the unit will restart when this delay times out For 2 level switch operation the upper switch is connected to the tank full high input and the lower switch is connected to the tank full low input When both switches are clear the RO unit will run The RO unit will continue to run when the water level rises and the lower switch becomes active When the upper switch becomes active after the 5 second delay the RO unit will shut down TANK FULL will show on the display When the tank level d
126. gh TDS Cond will show on alarm screen after the delay pro grammed in setpoint 11 has expired To disable set to 000 TDS Cond Alarm Delay When setpoint 10 has been exceeded no alarm will be given until this time has expired High TDS Cond Shutdown Delay If the TDS Cond shutdown is enabled with dipswitch 3 the shutdown will occur after this delay Reject Limit If the membrane rejection drops to or below this value the alarm lamp will light and low rejection will show on the alarm screen To disable set to 00 Not Used Not Used Current Operating Hours current number of hours of RO system operation aximum Operating Hours When the RO system operating hours exceed this value the alarm lamp will light and max operating hours exceeded will show on the alarm screen To disable set to 00000 RO Start Delay The amount of time before the RO pump starts when any RO system shut down is cleared Aux Start Delay The amount of time before the Aux relay starts when the tank low input clears Automatic Reset Timer If the RO system is shutdown due to high pump pressure or low feed pressure after the programmed amount of time the RO system is automatically reset and the RO system will attempt to re start after the RO start delay To disable auto matic reset set to 00 14 RANGE 001 999 PPM uS 001 999 seconds 01 99 minutes 00 99 00000 99999 hours 00001 99999 hours
127. gle phase motors see connection diagram on nameplate Change wiring as required 8 Switch on the power and again check for proper motor rotation Once rotation has been verified switch off power again Do not attempt to reinstall the coupling guards with the motor energized Replace the coupling guard if the rotation is correct After guards are in place the power can be reapplied NOTE Motors should not be run unloaded or uncoupled from the pump at any time damage to the motor bearings will occur to vent pump REMINDER Do not start the pump before priming or venting the pump Never operate the pump dry Vent plug Operating Parameters CR multi stage centrifugal pumps installed in accordance with these instructions and sized for correct performance will operate efficiently and provide years of service The pumps are water lubricated and do not require any external lubrication or inspection The motors will require periodic lubrication as noted in the following Maintenance Section Under no circumstances should the pump be operated for any prolonged periods of time without flow through the pump This can result in motor and pump damage due to overheating A properly sized relief valve should be installed to allow sufficient water to circulate through the pump to provide adequate cooling and lubricaton of the pump bearings and seals Pump cycling Pump cycling should be checked to ensure the pump is not starting
128. grammed in the Maximum Hours Setpoint the alarm lamp will light and the OP HOURS EXCEEDED warning message will be shown This warning can be cleared by programming the current hours to 0 or by increasing the maximum hours limit T O Expander The I O Expander board adds 2 relays and 1 switch input The operation and programming of the 2 relays is described in the installation section Auxiliary Output Relay 1 can be used to control a repressurization pump when relay 1 of the expander board is configured to operate an aux relay In this mode this relay will be energized as long as the tank low input is not active When energized the relay supplies power to the repressurization pump 19 Tank Low When the tank low input has been active for 5 seconds the auxiliary output will turn off The alarm lamp will light and the TANK LOW warning message will show on the display When the tank low condition clears the TANK LOW 99 warning message is displayed The number is the delay in minutes before the auxiliary relay will energize Divert Output When relay 1 or relay 2 has been programmed to operate as a divert relay the relay will energize when the TDS Conductivity exceeds the TDS Cond Limit Setpoint This will occur as soon as the reading exceeds the limit there is no delay When the reading drops below the limit and stays below the limit continuously for 5 seconds the divert relay will turn off Alarm Output When relay 2 has been prog
129. he coupling separation equal on both sides When the screws are tight enough to keep the couplings in place then torque the screws evenly in a criss cross pattern 10 LCPTLOO3_CR I amp O_Rev0104 qxd 1 26 2004 11 58 AM Page 11 F CR N 32 45 64 amp CR90 Torque Specifications Place the plastic adjustment fork under the cartridge seal collar see Figure 7 CR I N 1s 1 3 5 10 15 and 20 CR N X T 2 4 8 and 16 Fit the coupling on the shaft so that the top of the pump shaft is flush with the bottom of the clearance chamber in the coupling see Figure 8 Coupling Min Torque m Bolt Size Specifications Lubricate the coupling screws with an anti seize and lubricating compound Tighten the coupling screws finger tight while keeping the coupling separation equal on both sides and the motor shaft keyway centered in the coupling half as shown Figure When 8 23 ft lbs the screws are tight enough to keep the couplings in place then 10 46 ft lbs torque the screws evenly in a crisscross pattern CORRECT Torque coupling screws to 62 ft Ibs Remove the adjustment fork NM Figure 6a from under the cartridge seal collar and replace it to the storage View All CR I N X T location see Figure 9 Keyway Keyway 6 Check to see that the gaps between the coupling halves are equal Gap between coupling Loos
130. hould be performed at each inspection WARNING DO NOT TOUCH ELECTRICAL CONNECTIONS BEFORE YOU FIRST ENSURE THAT POWER HAS BEEN DISCONNECTED ELECTRICAL SHOCK CAN CAUSE SERIOUS OR FATAL INJURY ONLY QUALIFED PERSONNEL SHOULD ATTEMPT INSTALLATION OPERATION AND MAINTENANCE OF THIS EQUIPMENT 1 Check that the motor is clean Check that the interior and exterior of the motor is free of dirt oil grease water etc Oily vapor paper pulp textile lint etc can accumulate and block motor ventilation If the motor is not properly ventilated overheating can occur and cause early motor failure 2 Use an Ohmmeter Megger periodically to ensure that the integrity of the winding insulation has been maintained Record the Ohmmeter readings Immediately investigate any significant drop in insulation resistance 3 Check all electrical connectors to be sure that they are tight Motor Lubrication Electric motors are pre lubricated at the factory and do not require additional lubrication at start up Motors without external grease fittings have sealed bearings that cannot be re lubricated Motors with grease fittings should only be lubricated with approved types of grease Do not over grease the bearings Over greasing will cause increased bearing heat and can result in bearing motor failure Do not mix petroleum grease and silicon grease in motor bearings Bearing grease will lose its lubricating ability over time not suddenly The lubricating abilit
131. hould begin with checking for leakage Cor rect voltage must be applied when the valve is tested If excessive leakage based on the application occurs or if operation is sluggish the unit must be cleaned The Cleaning fluid must be compatible with the valve s mate rials of construction SERVICE Disassembly and Reassembly See Fig 3 WARNING During reassembly be certain that the plunger is free of scratches or burrs These imperfections could cause the valve to stick in an open or closed position resulting in a potential hazard If the valve has any tendency to stick during a test return the whole Universal Kit for a new one Dissassembly and reassembly should be performed only by properly trained and experienced personnel Turn off flow media and electrical power supply to the valve REPLACE ALL PARTS with the new parts contained in the Universal Kit only see Universal Kit section Use only the correct Universal Kit use the chart to match Catalog Number with Kit Number and never attempt to interchange parts from different numbered kits All products of the company are sold and all services of the company are offered subject to the company s terms and conditions ot sale copes of which wilt be furnished upon request When ordering parts kits specify Catalog Number Serial Number and Part Name If your valve s Catalog Number is not listed obtain the complete Serial Number and consult the factory See Fi
132. i Marg New Delhi 110 001 India Tel 91 11 331 6196 FAX 91 11 332 5993 The Instrument Division is represented in other locations by factory trained distributors and representatives Please contact Domestic and International Headquarters for your nearest representative DRESSER DRESSER INDUSTRIES INSTRUMENT DIVISION MOUNTING INSTRUCTIONS FOR ASHCROFT TYPES 1009 1008 amp 3005 U CLAMP XUC U CLAMP KIT 101A164 01 212 63mm amp 101A164 02 3 2 100mm Assemble the 2 1 inch long set screws to the rear of the case Tighten finger tight Slip gauge into panel and assemble U clamp over the set screws Secure the U clamp with lockwasher nuts using a 146 wrench 16 20in Ibs torque Panel Hole a Max 22542 101A164 01 25 gon 71mm 31 6 63 3005 2172 2916 101 164 01 63 65mm 4 101A164 02 10 1008 aa 102mm FORM 83A213 01 REV D DRESSER CRANE ENVIRONMENTAL PRESSURE VESSEL 4 x ELEMENT SCHEDULE 80 PVC 105 _ 4 DOS COSTRUCTEN TRANG CRANE ENVIRONMENTAL 4 x40 PVC VESSEL 200 1 CRANE Co Company misc 2 ELEMENT 08 ENVIR NNENTAL PRODUCTS n CUCHRANE CHICAGO HEATER WESTINGHOUSE CONDENSERS syn awe Product Information FILMTEC Membranes FILMTEC 4 Tapwater RO Elements Product Specifications S
133. iaphragm chamber Check diaphragm for leak Check tank and piping for leaks with soap and water solution Check air to water volume Repair as necessary Check tank size and air volume in tank Tank volume should be approximately 10 gallons for each gpm of pump capacity The normal air volume is 2 3 of the total tank volume at the pump cut in pressure Replace tank with one of correct size Install pressure gauges on or near pump suction and discharge ports Start and run pump under normal conditions record gauge readings Convert PSI to feet Measured PSI x 2 31 ft PSI ft Refer to the spe cific pump curve for that model ensure that total head is sufficient to limit pump delivery within its design flow range Throttle pump discharge flow if necessary Fuses blow or circuit breakers or overload relays trip 14 Low voltage Motor overloads are set too low Three phase current is imbalanced Motor is shorted or grounded Wiring or connections are faulty Pump is bound Defective capacitor single phase motors Motor overloads at higher ambient temperature than motor Check voltage at starter panel and motor If voltage varies more than 10 contact power company Check wire sizing Cycle pump and measure amperage Increase heater size or adjust trip setting to a maximum of motor nameplate full load current Check current draw on each lead to the motor Must be within 5 If not check mot
134. ifice discharge to prevent erosion Temperature rise It may sometimes be necessary to stop the flow through a pump during operation At Pump Tine fof shut off the power to the pump is transferred to the pumped liquid as head causing Type 225 nun Seconds Minutes temperature rise in the liquid The result is risk of excess heating of and consequent damage to the pump The risk depends on the temperature of the pumped liquid and CR 15 1 3 210 3 5 for how long the pump is operating without flow See temperature rise chart 5 240 40 CR 10 210 3 5 Conditions Reservations 150 25 The listed times are subject to the following conditions reservations CR 20 120 2 0 e No exchange of heat with the surroundings nay ae 62 00 28 10 e pumped liquid is water with a specific heat of 1 0 pe 4 18 c Pump parts chambers impellers and shaft have the same thermal capacity as water The water in the base and the pump head is not included These reservations should give sufficient safety margin against excessive temperature rise The maximum temperature must not exceeed the pump maximum rating For Pump Ends With Bellows Seals Only CR 2 4 8 16 Remove shaft seal protectors before installing motor see diagram at below Remove coupling guards Remove coupling halves Remove shaft seal protectors Jd Uu ges Follow motor replac
135. il manually reset If the Auto Reset Setpoint is programmed to a value greater than 0 the unit will automatically clear the pressure fault and attempt to restart after this delay times out Alarm Silence When a shut down occurs that causes the audible alarm to sound the alarm can be silenced by pressing the Alarm Silence Reset key once The alarm will remain silenced if the Alarm Silence Setpoint is programmed to 0 If the Alarm Silence Setpoint is programmed to a value greater than 0 the alarm will resound after this delay times out Pressing the Alarm Silence Reset key will silence the alarm and reset this delay Pretreat If the pretreat input becomes active and stays active for 2 seconds the unit will shut down in a pretreat lockout condition PRETREAT will show on the display and the unit will remain shut down as long as the pretreat input is active 17 Membrane Flush If the Flush Type Setpoint is programmed to 0 flush is disabled If membrane flush is desired several types of flush are available When the unit enters a flush cycle the flush relay will activate The flush cycle will last for the time programmed in the Flush Time Setpoint Table 3 shows the value that must be programmed in the Flush Type Setpoint for each type of flush OPERATING HOURS AND TANK FULL ELAPSED TIME OFF HOURS OFF HOURS AND TANK FULL ELAPSED TIME AND TANK FULL RO START STOP TABLE 3 TANK FULL The RO unit will flush each time a tank full
136. ing The RO pump connects to the 11 and 12 RO pump terminals of P1 This output can operate 120 240VAC motors up to 1HP directly For motors larger than 1HP or 3 phase motors this output can be used to operate a contactor Inlet and Flush Valve Wiring The inlet and flush valves must operate at the same voltage as supplied to the board These outputs can supply 5A maximum and are not designed to operate pump motors directly If these outputs are to be used to operate a boost or flush pump the output should be used to operate a contactor The inlet valve connects to the L1 and L2 inlet terminals of P1 The flush valve connects to the L1 and L2 flush terminals of P1 TDS Conductivity Cell Wiring For accurate TDS Conductivity readings the cell should be installed in a tee fitting where a continuous flow of water passes over the cell and no air can be trapped around the cell Refer to figure 5 for example installation The cell is connected with 5 wires to terminal strip P10 Connect each colored wire to the terminal labeled with the same color Switch Inputs Switch inputs are connected to P9 The connections for these inputs are not polarity sensitive and can be connected to either terminal The switch inputs should be dry contact closures only NOTE Applying voltage to these terminals will damage the controller The switches can be either normally open or normally closed in any combination The switch connected to an input that is configured a
137. ition if necessary If the LED now blinks and a reading is now shown replace the bad sensor If a reading is not shown replace the flow interface board Flow sensor readings inaccurate The meter factor for each sensor installed may need to be adjusted If the reading is higher than the actual flow increase the meter factor If the reading is lower decreas the meter factor see Figure 14 Also verify that each sensor is installed in the proper location and wired to the correct terminal strip pH sensor not reading or inaccurate Slow response or large errors can be caused by coated or dirty electrodes If the electrode is coated with a soft substance the electrode may be cleaned by rinsing under running water If this is not successful try wiping with a soft wet cloth 45 For hard coatings such as scale soaking the electrode in a 5 solution of HCl may work For some hard coatings alternate between a 5 HCl solution and a 10 NaOH solution for 10 minutes each Greasy or oily coatings can be removed by using a detergent solution or isopropyl alcohol After treating the electrode with these solutions be sure to rinse well with clean water If the LCD display shows no reading for pH ensure that the shorting block on J10 is off or on only 1 pin Also check the pH sensor wiring as shown in figure 16 If these checks do not reveal the problem either the pH sensor or the pH PC board may be defective Inspect the pH senso
138. key is pressed If the key is pressed and held for 1 second the Setpoint value will change at a fast rate When the key is released the fast rate will be reset Pressing both the Up and Down arrow keys together will reset the Setpoint value to 0 Pressing the Alarm Silence Reset key at any time will cancel the operation and return the display to the main screen To accept the new Setpoint value press the Enter key The unit will beep twice if the change is accepted If the write protect jumper is on the unit will show WRITE PROTECTED on the display and one long beep will sound When finished changing Setpoints the write protect jumper should be placed in the on position center and right pins 14 SYSTEM OPERATION General Operation The unit has 2 modes of operation a standby mode and an operating mode In the standby mode the unit is effectively off All outputs are turned off and the display shows STANDBY In the operating mode the unit operates automatically All inputs are monitored and the outputs are controlled accordingly Pressing the Power key will toggle the unit from standby to operate or from operate to standby If power is removed from the unit when power is reapplied the unit will restart in the mode it was in when power was removed Display The display is a 2 line x 20 character backlit liquid crystal display System operating status and sensor readings are shown on this display Setpoint information is also show
139. le set to 0 Current number of hours of RO system operation Selects how the relays on the I O expander board operate Allows adjustment of temperature reading by 5 degrees Selects display of temperature in F or C Selects if switch inputs are normally open or normally closed Selects display of water quality in uS or PPM NOTE If this Setpoint is changed the unit must be recalibrated Selects range of TDS Conductivity monitor 0 50 1 100 2 250 3 500 4 1000 5 2500 6 5000 NOTE If this Setpoint is changed the unit must be recalibrated RANGE 0 99 hours 0 3 0 65000 hours 0 65000 0 2 5 50 0 1 0 32 0 1 0 6 DEFAULT 24 TO DISPLAY OR CHANGE SETPOINTS 1 Refer to figure 1 for the location of the keys used to display or change the Setpoints and figure 2 for the location of the write protect jumper J3 For the unit to be able to accepta change ina Setpoint the shorting jumper must be in the off position center and left pins NOTE Setpoints cannot be changed if the write protect jumper is in the ON position Use the Left and Right arrow keys to display the Setpoints Each press of an arrow key will advance the display to the next Setpoint The Left arrow key starts with the beginning Setpoint and the Right arrow key starts with the last Setpoint The Up and Down arrow keys are used to increment or decrement the Setpoint value The value will change by 1 count each time a
140. led on the discharge side of the RO pump The pump pressure sensor wires connect to the P5 terminals labeled A2 The red wire connects to RD and the black wire to BK Jumper J7 should be removed to enable this sensor Prefilter Differential Pressure Sensor The prefilter differential pressure sensor is installed upstream of the prefilters The prefilter pressure sensor wires connect to P5 A3 The red wire connects to RD and the black wire to BK Jumper J8 should be removed to enable this sensor Membrane Differential Pressure Sensor The membrane differential pressure sensor is installed in the concentrate line of the membrane array The membrane differential pressure sensor wires connect to P5 A4 The red wire connects to RD and the black wire to BK Jumper J9 should be removed to enable this sensor Switch Inputs Switch inputs are connected to P4 The connections for these inputs are not polarity sensitive and can be connected to either terminal The switch inputs should be contact closures only NOTE Applying voltage to these terminals will damage the ROTrol The Switches can be either normally open or normally closed in any combination Setpoint 54 selects whether an input looks for a normally closed or normally open switch to activate the input The following table lists the values used to program Setpoint 54 to select which switches are normally open N O or normally closed N C Setpoint 54 is
141. lity to use such h e information or 3 any errors inaccuracies or omissions in suc information even if R amp D Specialties has been advised of th possibility of such damages II TABLE OF CONTENTS TENTRODUCT ELON u ede de dhe eie SPECTEICATIONS dad uu Set Sd wa be al FRONT PANEL CONTROLS AND INDICATORS e win 3 INS PAT TAT DA S ORAS BGT GAG 4 Physical Installaatio Sasa 4 Terminal Strip Jumper and Adjustment Locations 4 PONET C WANG mM exei eps eis ee 4 Pump ana Valve oses a a was sua mo hse m 4 Pump Motor Wiring i e ye eu wee eee ee ewe SUE Se eas 4 Telet ane Flush Valys eee tees EUER 4 TDSyConducErvrby Win Gis Sie tee erie ee ee 4 Analog Pressure 5 Feed Pressure SENSO ss w s lS SU Sel GR SUS S WS S 5 Pump Pressure sedan
142. ll advance the display to the next screen If the pH value has reached one of the warning levels the alarm light will light and low or high pH will be shown on the alarm display If the pH value reaches on of the shutdown levels and is maintained for the time programmed in setpoint 49 pH Delay the ROTrol II will shutdown the RO pump flash the alarm lamp and sound the audible alarm The display will show the pH shutdown message on the display The unit will remain shutdown until the reset key is pressed NOTE pH electrodes age with time and eventually become desensitized and must be replaced The actual service life of a pH electrode is extremely variable and is dependant on many factors Exposure to extremely pure water will accelerate electrode aging and cause a shorter service lif pH Electrode Warranty The manufacturer warrants that at the time of shipment the pH electrode shall be free from defects in material and workmanship and shall perform within stated specifications upon initial installation If the electrode proves to be defective within the above warranty the manufacturer will replace th lectrode with a similar model or product 38 ROTROL IID PC BOARD PARTIAL VIEW 3 A SHARP KNIFE VERY CAREFULLY REMOVE APPROX 1 OF BLACK INNER JACKET 4 pes A SHARP KNIFE CAREFULLY REMOVE APPROX 1 4 OF THE CLEAR JACKET 5 CLEAN THE CLEAR JACKET WITH ALCOHOL OR VERY CLEAN WATER AND DRY THO
143. low metering is installed screen 3 shows the system flow data Readings can be displayed for 3 flow meters If a flow sensor is not used the reading for that sensor and any readings based on that sensor will read 0 0 The readings will be in gallons or liters based on the flow unit of measure setpoint F 3 3GPM The feed flow rate This reading is the sum of the permeate and concentrate flows P lh LGR The permeate flow rate C 1 6GPM The concentrate flow rate R 1 8GPM The recirculate flow rate RCV 51 5 The calculated percent recovery based on the current flow rates 2448 D The estimated permeate flow per day based on the current flow rate TOTAL A totalizer of the permeate flow 12846 Warning Screen If the red alarm lamp is on steady a non shutdown warning is active To determine which warning is indicated push the display key The warning will be shown on the first line of the display If multiple warnings are active each warning condition will be displayed with a pause between each warning The warnings and descriptions are HIGH TDS COND The high TDS Conductivity setpoint has been exceeded OP HOURS EXCEEDED The RO operating hours setpoint has been exceeded HI PREFIL DIFF PRESS The prefilter differential pressure setpoint has been exceeded TANK LO The tank low switch input is active 28 MEMBR DIFF PRESS The m
144. lue 24 21 9 6 12 17 31 50 WB 931 50 Yellow 24 21 9 6 12x17x31 Applications Low pressure drop Here are typical applications for Harmsco filter cartridges Pressure drop with Harmsco cartridges is exceptionally low due to our pleated design and increased filter area Initial pressure Drinking water Asbestos abatement drop for 9 3 4 Harmsco cartridge in clean water is shown below Bottled water Plating baths Initial pressure drop in clean water Drinking fountains Heating loops Whole house Chill water Ground water Desalination prefilters Surface water Ultrafiltration prefilters R O prefiltration Spray nozzle protection Process water Well water Waste water Municipal water Rinse water Water vending equipment Environmental Ground water remediation Harmsco High Temp Cartridges with approx 6 sq ft of media per cartridge Pressure Drop PSI Product Code bes H Case Ship Wt Dimensions 801 1 HT 11 Ibs 12x17x11 801 5 HT gt 11 Ibs 12x17x11 801 20 HT 20 24 11 Ibs 12x17x11 801 50 HT 50 24 11 Ibs 12x17x11 Rated up to 200 F depending on pressure and time under load s Flow Rate GPM 11 LCPTLOO3_CR I amp O_Rev0104 qxd 1 26 2004 11 58 AM Page 1 GRUNDFOS INSTRUCTIONS Installation and Operation CR CRI CRX CRN CRT Vertical Multistage Centrifugal Pumps Please leave these instructions with the pump for future r
145. may see a build up of scale or deteriorate due to the aggressiveness of the water This may affect the operation of the valve Debris could prevent the valve from being properly adjusted The valve may require occasional cleaning If cleaning does not correct the problem replace the valve 8 2 ABNORMAL PERMEATE PRODUCTION Abnormal permeate flow is often an indication of a problem with the reverse osmosis membrane LOW PERMEATE FLOW High organic or inorganic concentrations will often lead to scaling or fouling of the membrane surface causing poor rejection of impurities and low permeate flow Cleaning the membranes will often improve system performance Cleaning instruction can be found in Section 7 Membranes left too long with this condition may have irreversible damage and require a membrane change out HIGH PERMEATE FLOW High permeate flow is often a symptom of membrane or o ring damage A product o ring or membrane brine seal may have shifted due to normal operation or have suffered some damage Damage includes cuts nicks or even lack of lubrication The reverse osmosis membrane may be channeling This can be caused by exposure to chlorine If a membrane has been exposed to chlorine the permeate flow will be high and the water quality reduced The membrane may have freeze damage Steps need to be taken to protect the machine from freezing temperatures 8 3 TROUBLE SHOOTING MATRIX The following matrix is included in this manual to aid in
146. more than 20 times per hour on 1 3 to 5 HP models 15 times per hour on 7 1 2 to 15 HP models 10 times per hour on 20 to 60 HP models Rapid cycling is a major cause of premature motor failure due to increased heat build up in the motor If necessary adjust controls to reduce the frequency of starts and stops Boiler feed installations If the pump is being used as a boiler feed pump make sure the pump is capable of supplying sufficient water throughout its entire evaporation and pressure ranges Where modulating control valves are used a bypass around the pump must be installed to ensure pump lubrication see Minimum Continuous Duty Flow Rates Freeze Protection If the pump is installed in an area where freezing could occur the pump and system should be drained during freezing temperatures to avoid damage To drain the pump close the isolation valves remove the priming plug and drain plug at the base of the pump Do not replace the plugs until the pump is to be used again Always replace the drain plug with the original or exact replacement Do not replace with a standard plug Internal recir culation will occur reducing the output pressure and flow LCPTLOO3_CR I amp O_Rev0104 qxd 1 26 2004 11 58 AM Page 9 F Motor Inspection Inspect the motor at regular intervals approximately every 500 hours of operation or every three months whichever occurs first Keep the motor clean and the ventilation openings clear The following steps s
147. n on this display Operating Status Messages The operating status of the unit is shown on the top line of the display The following list describes the items shown for the operating status STANDBY The unit is in the standby mode DELAY 99 The unit is in the RO start delay The number is the seconds remaining before the RO pump starts OPERATING The RO unit is operating TANK FULL The unit is shut down due to a tank full condition TANK FULL 99 The unit is shut down due to a tank full condition If the number is blinking the tank full high switch has cleared but the tank full low switch is still active If the number is on steady both tank level switches have cleared and the delay is counting down PRETREAT The unit is shut down due to a pretreat lockout condition PRESS FAULT The unit is shut down due to a pressure fault condition MEMB FLUSH 99 Membrane flush is active The number is the minutes remaining in the flush cycle TDS Conductivity The TDS Conductivity is shown on the top line after the unit operating status When the unit is offline because of a shut down condition the reading is replaced with gt f the reading is over range the reading is shown as BAM 15 Operating Hours The current operating hours are shown on the bottom line Temperature The current water temperature is shown on the bottom line after the operating hours When the unit is offline because of a shut down condition the readin
148. nable flush If yes press the Alarm Silence Reset key for 3 seconds Does the unit show flush on the display If no replace the board If yes is the flush LED DS10 lit If no replace the board If yes with a voltmeter verify if there is power on the flush terminals Is there power If no replace the board If yes check the valve and wiring 22 or Incorrect TDS Conductivity Reading Is sensor wired correctly If no correct wiring If yes is sensor installed as described in the installation section If no install correctly If yes verify correct TDS Conductivity range Range correct If no correct range If yes calibrate unit Does unit calibrate OK If no disconnect green and white wires of sensor Does reading show 0 If no replace board If yes reconnect wires and remove sensor from piping and dry Does reading show 0 If no replace cell If yes short pins of cell together Does reading show gt If no replace board 23 INSTALLATION INSTRUCTIONS E F 550 SPECIFICATIONS Meter Body Acrylic clear Floats 316 Stainless Steel Adapters Polypropylene O Rings Viton Lock Nut Polypropylene Scale Permanent Silkscreen Max Pressure See Temperature vs Pressure chart Max Temperature See Temperature vs Pressure chart Standard Meter Adjustable Meter Your Blue White F 550 Series Panel Mount Flowmeter Your Blue White flowmeter was designed to be easy to install Please read the Instruction Guideline
149. nel mounting 63mm Three Hole Front Mounting Flange 100mm Three Hole Front Mounting Flange 63mm Front Mounting Flange 3529 MM NCH 2u V 28 100 MM 100 325 106 7 50 INCH 35 1 4 135 Domestic Headquarters Stratford Connecticut 250 E Main Street Stratford CT 06497 Tel 203 378 8281 FAX 203 385 0499 Sales Offices Chicago Illinois 400 W Lake Street Suite 318 Roselle IL 60172 3392 Tel 708 980 9030 FAX 708 980 9440 Houston Texas 3838 North Sam Houston Parkway East Suite 120 Houston TX 77032 Tel 713 590 1092 FAX 713 590 7100 Los Angeles California 3450 East Spring Street Long Beach CA 90806 Tel 213 595 4691 FAX 213 427 0537 Philadelphia Pennsylvania Computer Road and Maryland Ave Suite A 8 Willow Grove PA 19090 Tel 215 657 2886 FAX 215 657 7962 International Headquarters Stratford Connecticut 250 E Main Street Stratford CT 06497 Tel 203 378 8281 475 001 7ITT FAX 203 385 0357 Instrument Division Sales and Customer Service Locations International Operations Brazil Dresser Industria e Comercio Ltda Divisao Manometros Willy Caixa Postal 212 09601 Sao Caetano do Sul Sao Paulo Brazil Tel 55 11 453 5477 FAX 55 11 453 6778 Venezuela Manufacturas Petroleras Venezolanas S A Apartado Postal 617 Maracaibo Venezuela Tel 58 61 412 120 FAX 58 61 413 954 Canada Dresser Can
150. nion P X Specialversion Materials A Basic version D Carbon graphite filled PTFE bearings G Stainless steel parts of 316 SS GI Base plate and flanges of 316 SS I Stainless steel parts of 304 SS Base plate and flange of 304 SS K Bronze bearings 5 SiC bearing ring PTFE neck ring only CR CRN 32 to 90 T Titanium X Special version Code for rubber parts E EPDM F FXM Flouraz K FFKM Kalrez V FKM Viton Shaft seal HQQE A O ring seal with fixed driver B X Rubber bellows seal D O ring seal balanced E Cartridge seal with O ring H Balanced cartridge seal with O ring K Cartridge shaft seal with metal bellows Double seal back to back Double seal tandem R seal with reduced face X Special version B Carbon synthetic resin impregnated H Cemented tungsten carbide embedded hybrid Q Silicon carbide U Cemented tungsten carbide E EPDM F FXM Flouraz K FFKM Kalrez V FKM Viton In August 2003 the NEMA pump code was discontinued for all material numbers created by GRUNDFOS manufacturing companies in North America The NEMA version pump code will still remain in effect for existing material numbers NEMA version pumps built in North America after this change will have either an A or U as the pump version code depending on the date the material number was created If a pump incorporates more than two pump versions the code for th
151. nk should have a removable cover and a temperature gauge Next dissolve the cleaning chemical into the amount of water called for in the system specifications It is preferable to use R O water The pH should be around two Check the instructions on the chemical being used as some chemical suppliers may recommend a different pH range This will take approximately five ounces of Big Brand Water Filter cleaning solution 1 for every 15 gallon of water Acid cleaning is more effective when the solution is maintained at 95 F 35 C The cleaning pump should be sized to pump between 8 10 per pressure vessel on the first array at pressure rating from 20 60 psi DO NOT EXCEED 60 PSI The pump should be constructed of 316SS or other corrosion resistant material Plumb the concentrate and permeate lines to the cleaning solution tank during cleaning so the solution may recirculate First pump the solution through the system at a flow of between 4 5 gpm per pressure vessel on the first array and at low pressure Check to ensure that the cleaning solution does not become diluted Recycle the cleaning solution until the temperature stabilizes For more effective cleaning soak the membranes for a period of one hour longer up to overnight for heavy fouling Check the pH during acid cleaning Add additional chemical if the pH increases above 2 5 Next feed the cleaning chemical at a higher rate between 8 10 gpm pressure vessel on the first array fo
152. nt readings at maximum pump loads on each leg of a three wire hookup You must make calculations for all three hookups To begin add up all three readings for hookup number 1 2 and 3 1 51 Amps T2 46 Amps T3 53 Amps TOTAL 150 Amps Divide the total by three to obtain the average 50 Amps 3 150 Amps Calculate the greatest current difference from the average Divide this difference by the average to obtain the percentage of unbalance In this case the current unblanace for hookup number 1 is 8 L to T4 Amps Ly to T5 Amps L3 to T5 Amps TOTAL Amps FIGURE HERE Hookup 2 Lj toT3 _ Amps 2 0 5 LytoT 5 TOTAL Amps 50 Amps 46 Amps 4 Amps Hookup 1 08 or 8 50 4 00 Amps Ly to T5 5 15 to T3 Amps L3 to T1 Amps TOTAL Amps Amps 3 Amps Hookup 2 Amps 3 Amps Amps 3 Amps Hookup 1 Amps Amps Amps Hookup 2 Amps Amps Amps Hookup 3 Amps B Amps Amps or 26 _ amps 15 LCPTLOO3_CR I amp O_Rev0104 qxd 1 26 2004 11 58 AM Page 16 BEING RESPONSIBLE IS OUR FOUNDATION BE gt THINK gt INNOVATE gt THINKING AHEAD MAKES IT POSSIBLE INNOVATION IS THE ESSENCE LIMITED WARRANTY Products manufactured by GRUNDFOS PUMPS CORPORATION GRUNDFOS are warranted to the original user only to be free of defects in material and workmanship for a period of 2
153. o a tank full condition The number after tank full is the delay in minutes before the RO starts after the tank full condition clears HIGH PUMP PRESS 60 The RO pump is shutdown due to a high pump discharge pressure condition The number is the amount of time in minutes before the unit attempts to restart LOW FEED PRESS 60 The RO pump is shutdown due to a low feed pressure condition The number is the amount of time in minutes before the unit attempts to restart EM FLUSH TIMER 5 The RO unit is in the membrane flush mode and the number of minutes remaining in the flush mode HIGH TDS COND The RO unit has shutdown due to a high TDS Conductivity condition PRETREAT LOCKOUT The RO unit is shutdown because the pretreat system is out of service HI FEED TEMP The RO unit has shutdown due to a high feed water temperature condition LO FEED pH The RO unit has shutdown due to a low feed pH condition HI FEED pH The RO unit has shutdown due to a high feed Ph condition 25 Screen 1 also displays 6 other RO operating conditions F 1390PPM If the optional feed sensor is installed the feed water quality PPM will be displayed If the unit of measure is microsiemens the PPM will be replaced with uS If the feed sensor is not installed the display will show If the feed reading is out of range the display will show
154. off the Aux Start Time Delay is active or the Tank Low input is present Turn the AUX Switch on if off and check the LED DS13 If DS13 is on check the pump motor wiring as explained above in the RO pump section If DS13 does not light check DS5 If DS5 is on the Tank Low input is present and the pump should not start If necessary correct the Tank Low condition and then re check the unit for correct operation If the Tank Low LED DS5 is off the AUX Switch is on and DS13 does not light check Setpoint 15 If the unit has shut down the AUX output because the Tank Low input had been present the unit will not restart until the time set into Setpoint 15 has expired Allow the amount of time selected by Setpoint 15 to elapse and if the AUX output still does not occur the PC board is bad and should be replaced RO unit not flushing or not flushing correctly NOTICE If your CPU version ends with S see Figure 3 for location of CPU you have a custom chip and should have a manual addendum explaining the correct flush operation if different from the standard variations explained in the section SYSTEM OPERATION First determine when and exactly what the correct operation should be when flush occurs The correct operation is explained in the section SYSTEM OPERATION for the different dipswitch settings and related Setpoint values If flush has been initiated DS12 should be on and the flush valve sho
155. on the next page before installing your flowmeter This flowmeter is an instrument and special care should be taken when installing VN Dimensional Drawing English System 5 58 6 12 Maximum Recommended nel Thickness Panel Cutout T max inches hole inches Pa i 1 2 1 2 1 2 DIMENSION L Eee e Rm raso ne 558 rss s Frss ven e 23 S4Z x 13 16 1 21 64 Foa ra 2 Ursa taa 4 2 Metric System DIMENSION L METERS mm 5 of no 325 2030 700 so 60 10 5 5 13 16 1 21 64 13 16 1 21 64 5 5 6 6 1 2 Maximum Recommended Panel Thickness Panel Cutout T max mm hole mm 2190 so s io ao 445 2805 1015 sto 260 29 80000 349 4 6 2000 BLUE WHITE INDUSTRIES Rev A 5300 Business Drive Huntington Beach CA 92649 USA Installation Guideline Please use the following steps to guide you through the installation Ca Caution Follow these tips to avoid failure F 550 Lock Nut x 2 F 550 Adapter x 2 Danger Wear eye protection when installing or removing flowmeter STEP 1 Unpack the flowmeter Check for damage while unpacking the flowmeter Be sure the meter is suitable for your application
156. onnection Cover screw mounting bracket x housing cover General Purpose Open Frame Switch Enciosure Construction Torque cover screws in a crisscross manner 1 4 wide spade 1 2 conduit hub to 10 inch pounds terminal connection 1 1 Newton Meters housing pressure switch housing gasket cover gasket housing cover 1 8 or 1 4 NPT external or 1 8 NPT internal process connection Open Frame Suffix L Construction Figure 3 H Series pressure switches Cover screw Raintight Watertight Switch Enclosure Page 4 of 4 Form No P7079R4 ASCO Valves Switch Co 50 60 Hanover Road Florham Park Now Jersey 07932 gt GC Valves 21 Series 2 Way Pilot Operated Diaphragm Solenoid Valves 5211 Normally Closed 212 Normally Open The S21 Series 2 way general purpose solenoid valves are of piloted diaphragm construction and are available in normally closed and normally open operating modes They are available in a variety of pipe connections from NPT 36 to 2 there is an extensive range of options This series is widely used in various industrial applications For special applications contact your GC Valves customer service representative Specifications Normally Closed Closed when de energized open when energized Operating Mode Open when de energized closed when energized NPT Pipe Size 4 4 41 414 419 2 Orific
157. ons Inches mm Product Permeate Flow to Feed Flow TW30 4014 0 05 14 0 356 1 05 27 0 75 19 3 913 99 4 TW30 4021 0 08 21 0 533 1 05 27 0 75 19 3 913 99 4 TW30 4040 0 15 40 0 1016 1 05 27 0 75 19 3 913 99 4 TW30HP 4040 0 15 40 0 1016 1 05 27 0 75 19 3 913 99 4 4 Consult most recent DESIGN GUIDELINES for multiple element applications and 1 inch 25 4 mm recommended element recovery rates for various feed sources 5 Element to fit 4 00 inch 1 0 pressure vessel tMaximum feed flow for TW30HP 4040 is 18 gpm 4 1 m3 h Trademark of The Dow Chemical Company FILMTEC Membranes FilmTec Corporation is a wholly owned subsidiary of The Dow Chemical Company Important Operating Information 1 Keep elements moist at all times after initial wetting 2 If operating specifications given in this Product Information bulletin are not strictly followed the limited warranty will be null and void 3 Permeate obtained from first hour of operation should be discarded 4 To prevent biological growth during storage shipping or system shutdowns it is recommended that FILMTEC elements be immersed in a protective solution The standard storage solution contains 1 5 percent by weight sodium metabisulfite food grade FILMTEC Membranes For more information about FILMTEC membranes call Dow Liquid Separations North America 1 800 447 4369 Latin America 455 11 5188 9345 Europe
158. ons or defects from any cause will be limited exclusively to repairing or replacing the product or any part thereof under the conditions set out above 5 INTRODUCTION SPECIFICATIONS FRONT PANEL CONTROLS AND INDICATORS INSTALLATION Physical Installation Terminal Strip Jumper and Adjustment Locations Power Wiring Pump and Valve Relay Outputs RO Pump Wiring Inlet and Flush Valve Wiring TDS Conductivity Cell Wiring Switch Inputs Pressure Fault Switch Pretreat Switch Tank Full Switch I O Expander Board Auxiliary Pump Divert Output Alarm Output Tank Low Switch SETPOINTS Standard Setpoints Displaying or Changing Setpoints SYSTEM OPERATION General Operation Display Operating Status Messages TDS Conductivity Operating Hours Temperature Warning Messages N O O O O1 C1 C1 C1 O1 14 15 15 15 15 16 16 Tank Full Operation Tank Full Restart Tank Full Override Pressure Fault Auto Reset Alarm Silence Pretreat Membrane Flush Flush Mode High TDS Conductivity Operating Hours Exceeded I O Expander Auxiliary Output Tank Low Divert Output Alarm Output ADJUSTMENTS TDS Conductivity Calibration Display Adjustment TROUBLESHOOTING System Inoperative Display Blank Inlet Valve Will Not Operate RO Pump Will Not Operate Unit Not Flushing or Not Flushing Correctly No or Incorrect TDS Conductivity Reading 16 16 17 17
159. or and wiring Rotating all leads may eliminate this problem Turn off power and disconnect wiring Measure the lead to lead resistance with an ohmmeter RX 1 Measure lead to ground values with an ohmmeter RX 100K or a megaohm meter Record values If an open or grounded winding is found remove the motor repair and or replace Check proper wiring and loose terminals Tighten loose terminals Replace damaged wire Turn off power and manually rotate pump shaft If shaft does not rotate easily check coupling setting and adjust as necessary If shaft rotation is still tight remove pump and inspect Disassemble and repair Turn off power and discharge capacitor Check with ohm meter RX 100K When the meter is connected to the capacitor the needle should jump towards ohms and slowly drift back to infinity Replace if defective Use a thermometer to check the ambient temperature near the overloads and motor Record these values If ambient temperature at motor is lower than at overloads especially where temperature at overloads is above 104 F 40 C ambient compensated heaters should replace standard heaters LCPTL003 CR I amp O_Rev0104 qxd 1 26 2004 11 58 AM Page 15 F Three Phase Motors Below is a worksheet for calculating current unbalance on a three phase hookup and selecting the proper wiring Use the calculations in the left hand column as a guide EXPLANATION amp EXAMPLES Here is an example of curre
160. or encountered If no good reading is obtained with any sensor the PC board is probably bad and should be replaced If all pressure sensors read OK one or both of the TDS Conductivity sensors may be bad A 1500 OHM RESISTOR CONNECTED TO ANY PRESSURE INPUT IN PLACE OF THE SENSOR SHOULD GIVE APPROXIMATELY A MID SCALE READING EXAMPLE A 400 PSI SENSOR SHOULD READ APPROXIMATELY 200 PSI Method 2 DVM available With power applied and a DVM setting range of 20VDC or better measure the voltage between the bottom and top terminals of P5 TDS SENSOR SH and A 1 RD If the reading is less than 14VDC disconnect the red wire of each pressure sensor one at a time while observing the DVM If the reading jumps to approximately 15VDC after a wire is disconnected that sensor or its cable is bad With the bad sensor disconnected all other pressure readings should read correctly If all pressure Sensors are disconnected and the 15VDC is still not correct disconnect the red wires on the TDS Conductivity sensors one at a time and if the 15VDC returns the sensor disconnected at the time the 15VDC appeared is bad and should be replaced If the 15VDC reading is correct with all sensors connected measure between each pressure sensor s BK terminal and the bottom terminal of P5 The valid voltage range is 1 5VDC for these readings If any sensor black wire is outside this range it i
161. r 30 60 minutes to flush out any foulants removed from the system by cleaning Last flush out the cleaning solution using prefiltered raw water Increase the pressure to reach the operating pressure and recheck the permeate Total Dissolved Solids TDS and flow rates Do not use the permeate water until the system has been sufficiently flushed 7 2 Organic Foulant Cleaning An alkaline cleaning solution is used to clean silica biofilms and organics from reverse osmosis membranes Alkaline cleaners should be mixed to a pH of approximately 12 and should not exceed 86 F 30 C Acceptable alkaline cleaning chemicals are 1 A solution of 0 1 by weight sodium hydroxide NaHO and 0 1 by weight of the tetra sodium salt of ethylene diamine tetraacetic acid Na EDTA 2 A solution of 0 1 by weight sodium hydroxide NaHO and 0 05 by weight sodium salt of dodecylsulfate Na DSS 3 A solution of 1 0 by weight sodium truphosphate STP 1 0 by weight trisodium phosphate TSP and 1 0 by weight Na EDTA 4 Big Brand Water Filter cleaning solution 2 can also be used Follow the cleaning procedure described in section 7 1 above To mix the alkaline cleaning solution you can use approximately eight ounces of Big Brand Water Filter cleaning solution 2 for every 15 gallons of R O water Mix the solution until a pH of approximately 11 12 has been reached The alkaline cleaning solution is most effective at a temperature 86 F 36 C 8 0
162. r and ensure that it still has fluid inside the glass bulb If the bulb is dry either re fill the sensor with fluid if re fillable or replace it If the sensor bulb appears to have fluid inside and the wiring appears intact try adjusting the ZERO ADJ Figure 16 adjustment screw to see if any reading appears on the LCD display If after turning the adjustment screw several turns from its original position both directions no reading appears the pH board should be replaced If there is some reading on the LCD display but it is incorrect and does not change with a known change in the pH of the solution surrounding the sensor the pH sensor is probably bad Inspect it and its wiring as explained above and correct any problems found or replace it If the sensor is repaired or replaced and the reading does not change the pH board should be replaced If the LCD reading appears incorrect but changes as the pH of the measured solution changes it may be necessary to calibrate the pH board Refer to the pH section for calibration instructions Erratic readings can be caused by electrical currents in the fluid stream If the pH lectrode is removed from the piping calibrates correctly and the reading is stable until the electrode is installed into the piping this could be the problem The electrode should be installed in a metal tee that is grounded to a good earth ground 5 recommended installation shown in Figure 15 46
163. r hold the meter with pliers or like tools F 550 Metel T max see Dimensional Drawing on first page for maximum panel thickness Cleaning The flowmeter body and all other parts can be cleaned by washing in a mild soap and water solution A soft bristle bottle brush will simplify cleaning inside the meter body Note the floats up position for re assembly t BLUE WHITE INDUSTRIES Temperature vs Pressure Temperature 200 F 93 3 C 190 F 87 8 C 180 F 82 2 C 170 F 76 7 160 F 71 1 C 150 F 65 6 C 140 F 60 C 130 F 54 4 C 120 F 48 9 C 110 43 3 C 100 F 37 8 C 90 F 32 2 C 80 F 26 7 C 70 F 21 1 C 0 0 50 3 5 100 6 9 150 10 3 200 13 8 250 17 2 PSIg BAR see n z s models F 55750xx F 55100xx F 55017xx models F 55250xx F 55375xx F 55376xx F 55500xx Pressure and Temperature Pressure and temperature limits are inversely proportional At the maximum suggested pressure the temperature should approach 70 F 21 1 C at the maximum suggested temperature the pressure should approach zero psi We cannot guarantee our flowmeters will not be damaged either at or below the suggested limits simply because of many factors which influence meter integrity stress resulting from meter misalignment damage due to excessive vibration and or deterioration caused by contact with certain chemicals as well as dir
164. rammed to operate as an alarm relay the relay will energize whenever a warning or alarm condition occurs The relay will remain energized as long as the warning alarm condition is active 20 ADJUSTMENTS TDS Conductivity Calibration Refer to figure 2 for adjustment location To calibrate the TDS Conductivity place the cell in a known standard solution Adjust the span adjustment for the correct reading If the cell is installed the unit can be calibrated by taking a sample of the permeate water and testing it with a known good meter Adjust the span control until the reading matches the meter Display Adjustment The display contrast can be adjusted for best viewing by adjusting control R3 This control is located toward the upper right corner of the board just to the left of the cell connector 21 TROUBLESHOOTING CAUTION Hazardous voltages are present when power is applied to the unit Care should be taken when troubleshooting any of the input power or output circuits When disconnecting or connecting any board or accessory be sure power is turned off at the disconnect Before contacting R amp D Specialties for technical help verify the programming of all Setpoints check the display and check the status of all lights and indicators The more information available when you contact us the easier it will be to determine the source of the problem NOTE Phone support is only available from 8AM to 5PM Central Standard Time 6 GMT
165. ressure connection This thread is provided for mounting the pressure switch in a panel enclosure or mounting bracket through a 7 8 diameter hole CAUTION Pressure switches with the seventh 7th digit in the catalog number being a six 6 are provided with ethylene propylene diaphragm material which can be attacked by oils and greases Wipe the pipe threads clean of cutting oils Apply pipe compound sparingly to male pipe threads only If applied to internal threads the compound may enter the sensor and cause operational difficulty Avoid pipe strain on pressure switch by properly supporting and aligning piping When tightening pipe do not use the pressure switch as a lever Locate wrenches applied to pressure switch body on wrenching flats only A CAUTION For steam service install a condensate loop pigtail or steam siphon tube between the steam line and the pressure switch Wiring Wiring must comply with local codes and the National Electric Code Use No 14 AWG copper wire rated for 60 C minimum Switch is marked NO for normally open NC for normally closed and C for common 5 Suffix L switches are provided with 1 4 spade terminal connections The general purpose switch enclosure is provided with two 7 8 diameter knockouts to accommodate 1 2 electrical hub or connector For extra support leave switch housing assembled when driving out 7 8 diameter knockout It is recommended that flexible conduit be us
166. ressure in system with suitable pressure gauge Pressure must be within rangc specified on nameplate e Incorrect Adjustment Check pressure scale to see approximate setting Refer to section on Set Point Adjustment of Fixed Deadband Pressure Switch External Leakage or Snap Switch Failure Replace pressure switch see ORDERING INFORMATION e Excessive Vibration or Surges Causing Switch to Operat Undesirably Check for pressure fluctuations in system and install pressure surge suppressor Check switch mounting and be sure there is no excessive vibration If the operation of the pressure switch cannot be corrected by the above means it should be replaced FOR SERVICE REPLACEMENT OR INFORMATION Consult Factory or Authorized Factory Representative or Distributors ORDERING INFORMATION When Ordering Specify Catalog Number Fluid and Pressure Range Page 3 of 4 Automatic Switch CO so so Hanover Road Park New Jersey 07932 Torque Chart Part Name Torque Value Inch Pounds Torque Value Newton Meters Cover screws indicates Parts Supplied In Mounting Bracket Kit No 5 screw terminal connection 7 8 diameter knockouts 2 housing pressure switch adjustment ea wee i indicator 1 2 pipe thread for i N wrenching panel or bracket i flats mounting in 7 8 i Wee A diameter hole i 1 8 1 4 internal process c
167. rops and the upper level switch clears the display will show TANK FULL 99 and the RO unit will remain off The number is the tank full restart time and the number will blink until the lower level switch clears When the lower level switch clears the number will remain steady and the RO will restart when the delay times out Tank Full Restart The tank full restart is the delay before the RO unit starts when a tank full condition clears This delay can be in minutes or in seconds The TF Restart Setpoint selects seconds or minutes 16 Tank Full Override A timed tank full override can be initiated when the RO unit is shut down due to a tank full condition Pressing the Alarm Silence Reset key for 3 seconds during a tank full condition will enable the tank full override The RO will start and TF OVERRIDE 9 will show on the display The number is the minutes remaining in the override timer When the override times out the unit will return to the tank full shut down condition Pressure Fault If the pressure fault input becomes active and stays active for the delay programmed in the PF Delay Setpoint the unit will shut down for a pressure fault The display will show PRESS FAULT the alarm lamp will flash and the audible alarm will sound The pressure fault can be cleared by pressing the Alarm Silence Reset key twice Auto Reset If a pressure fault shut down occurs and the Auto Reset Setpoint is programmed to 0 the unit will remain shut down unt
168. s normally open must be open for the unit to run The switch connected to an input that is configured as normally closed must be closed for the unit to run The Switch Select Setpoint allows each input to be configured as normally open or normally closed The Switch Select Setpoint is defaulted to 0 which programs all inputs as normally open Table 1 lists the values used to program the Setpoint to configure the inputs pressuneraut 0 pretacaT o 2 o a TMKFULLOW o fos mom TABLE 1 Select the type of switch used for each input and put that number in the value column Add the values and program the total in the Switch Select Setpoint For example if the pressure fault and tank low inputs were normally closed and all others normally open the value programmed in the Switch Select Setpoint would be 17 1 16 Pressure Fault Switch On systems where a low feed pressure shut down is required a feed pressure switch can be connected to the pressure fault input of P9 If a high pump pressure shut down is required a high pressure switch can be connected to this input If both low feed pressure and high pump pressure shut down are required both switches can be connected to this input Both switches must be either normally open or normally closed to operate properly Pretreat Switch In systems with pretreatment a pretreat lockout switch can be connected
169. s are then installed to secure the board Flow Sensor Wiring A maximum of three flow sensors may be installed Each sensor is wired to its corresponding terminal strip on the flow interface board For Signet type flow sensors the wires connect as follows The red wire to the top terminal the black wire to the middle terminal and the shield wire to the bottom terminal see Figure 13 The jumper above each terminal block should be connected to the middle and right pins for most Signet sensors For Burkert flow sensors connect the red wire to the top terminal the black wire to the middle terminal and the shield wire to the bottom terminal The jumpers should be connected to the middle and left pins for Burkert sensors Consult R amp D Specialties for wiring instructions for other types of flow sensors Flow Meter Calibration For each flow sensor installed the corresponding meter factor setpoints should be programmed The meter factor is determined by the pipe size type of fitting the sensor is mounted in and whether the flow is in GPM LPM or M3H The meter factors may need to be adjusted to compensate for flow differences under actual conditions The K factor is entered as a 4 digit number If the flow rate indicated is too low the meter factor should be lowered If the rate is too high the meter factor should be raised Refer to Figure 14 The displayed flow can be in GPM LPM or M3H as selected by Setpoint 53 Flow
170. s are to P6 terminals AUX PUMP Inlet and Flush Valve Wiring An inlet valve relay is provided to control the inlet valve A flush valve relay is provided to allow a flush operation to be controlled by a tank full condition or by a periodic time function These relays provide both normally open and normally closed contacts to operat ither solenoid or motor driven valves Each relay can be connected to whatever voltage is required for its corresponding valve The inlet valve connections are to P6 terminals INLET V The flush valve connections are to P6 terminals FLUSH V The inlet relay can also be used to operate a motor starter for a booster pump in addition to an inlet valve TDS Conductivity Cell Wiring For accurate TDS Conductivity readings the cell should be installed in a tee fitting where a continuous flow of water passes over the cell and no air can be trapped around the cell Refer to Figure 7 for example installation The permeate TDS Conductivity cell is connected with five wires to the plug in terminal strip P5 The color coded wires are connected to the group of terminals labeled P COND Each wire must connect to the terminal labeled with its color s notation i e connect the red wire to the terminal labeled RD black to BK etc see Figure 3 The optional feed TDS Conductivity cell is connected with five wires to the plug in terminal strip P7 The color coded wires are connected to the group o
171. s of utmost importance that it is changed cleaned on a regular basis A clogged dirty pre filter will cause a poor inlet condition to the pump This may cause the pump to cavitate air in water source or trip the low pressure switch Never run the system without the pre filter installed FEED WATER FLOW RATE Each machine requires a minimum amount of water to run properly Refer to the system requirements following this section Be sure that the feed line is properly sized to deliver the required flow and pressure It is highly recommended that the inlet line be sized one size larger that he machine connection INLET SOLENOID There is an inlet solenoid installed on every machine The solenoid is normally closed and requires an electrical signal from the control panel to operate it On occasion debris may hinder the proper performance of the solenoid diaphragm and plunger The solenoid may need to be cleaned to remove this debris The electrical coil may fail and not allow the solenoid to open PRESSURE GAUGE The first array feed pressure gauge may not be reading correctly The sensing port may be blocked with debris or scale Remove the gauge and inspect the sensing port for any type of blockage CONCENTRATE CONTROL VALVE A globe valve controls the concentrate flow This valve sets the pressure that the system operates at and also controls the amount of permeate generated It is very important that this valve operates properly This valve
172. s or minus 15 The BBRO 10 000 can be expanded to a capacity of 17 500 gallons per day GPD by adding membranes Similarly an BBRO 19 000 can be expanded to produce 21 500 GPD The Reverse Osmosis process uses semi permeable spiral wound membranes to separate and remove dissolved solids organics pyrogens submicron colloidal matter and bacteria from water Feed water is delivered under a pressure of approximately 200 psi through Reverse Osmosis membranes Water permeates the minute pores of the membrane and is delivered as purified water Impurities in the water are concentrated in the reject stream and flushed to drain Reverse Osmosis is capable of removing 90 99 of all bacteria in feed water This figure illustrates how impurities are concentrated as the feed water passes through the BBRO system and flows over the membrane Impurities removed from the feed water are concentrated in the concentrate or reject stream As impurities concentrate they may reach saturation and precipitate The operator must be certain that impurities in the feed water are not concentrated enough in the BBRO equipment to cause precipitation because precipitation can damage membranes avg Cc CONCENTRATE FEED wass Co PERMEATE MEMBRANE POROUS P BACK UP MATERIAL Concentration of feed Qf Feed Flow Rate Cc Concentration of Concentrate Qc Concentrate Flow Rate Cp Concentration of Permeate Permeate Flow Rate C avg
173. s probably bad If the reading is extremely high 7VDC or better it may over drive the analog circuitry on the PC board and cause all readings to be bad Disconnect any bad sensor s and the other sensors should read correctly If all readings appear to be wrong one or more sensors may be bad or mis wired or the PC board may be bad Check for bad sensors and wiring errors as explained in the previous section Also ensure that each sensor is of the correct range and installed in the correct location No TDS Conductivity or temperature readings Check the wiring for each sensor Also if the feed sensor is not reading verify that jumper J12 is removed Both TDS Conductivity sensors have temperatur outputs but only one will be monitored and displayed J13 selects the temperature sensor to be monitored If the shorting block is plugged into the top 2 pins of J13 it will monitor the PERMEATE temperature sensor output If it is plugged into the bottom 2 pins it will monitor the FEED temperature sensor output If the temperature reading is bad and both sensors are present moving the shorting block to select the alternate sensor may yield a good reading on the LCD If so the sensor originally selected is bad and should be replaced If neither sensor reads correctly try removing the red wires from all pressure sensors at terminal strip P5 If neither sensor reads correctly now disconnect each TDS sensor s red wire at terminal strip P5 and P7 on
174. s will have to be made in the field i e Pretreat lockout level controls All inputs are non powered Please pay close attention to the control board input voltage It may be 120 or 240 volt This will affect the inlet and flush solenoids and the contactor coil voltage selection Several wiring diagrams are included in this appendix to cover the many variations that we offer The motor overload and incoming fuses are based on actual system horsepower A chart has been provided to distinguish the various combinations of fuses and overloads Due to the numerous combinations that can be offered the following wire diagrams may cover more than one scenario The horsepower rating indicated on the drawings are the maximum that the panel will support smaller horsepower may be used with the same panels A troubleshooting section is also included within this documentation Should Big Brand Water Filter build an electro mechanical box for a custom application a copy of the schematic will be located in the control panel APPENDIX CUTSHEETS ALT ES R amp D SPECIALTIES ROTrol II Version D USER S MANUAL R amp D Specialties Inc Midland TX 79706 1999 by R amp D Specialties Inc All Rights Reserved No part of this document may be copied or reproduced in any form or by any means without the prior written permission of R amp D Specialties R amp D Specialties makes no warranties with respect
175. se system switch wires number 5 and 8 BE SURE POWER IS OFF when making these changes Allow the system to run for about three minutes with the concentrate valve fully open and the recycle valve if present fully closed to purge air from the system 7 0 6 4 Turn the concentrate control valve until the correct pressure is displayed on the concentrate pressure gauge Refer to the System Specifications Table for the correct concentrate pressure for your system Alternately adjust the pump throttle valve and the concentrate control valve until the proper pressure and feed flow is achieved 6 5 Discard the permeate water from the first 30 minutes of operation to ensure that all bactericide and preservative has been fully flushed from the membrane Slowly open the recycle valve Never exceed 75 recovery or you will damage the membrane Permanent element fouling is likely to occur at excessively high recovery rates Note As the recycle valve is opened pressure will drop Adjust the concentrate control valve to bring the pressure back up to operating pressure 6 6 Feed water should not flow through the system when the system is turned off because such flow may cause premature fouling of the reverse osmosis membranes All standard BBRO systems are equipped with a normally closed solenoid valve which closes when the system is not operating and prevents water flow through the system MEMBRANE CLEANING INSTRUCTIONS In normal operations mineral sc
176. ss Body Conduit coil housing Type A units inch Pipe Conn po B 39 366 382 oss 28 25 38 468 06 38 33 4 25 49 425 469 ji i 1 2 4 e S GC Valves Toll Free 1 800 582 4232 Western Region Eastern Region 4525 E Industrial Street 456 Crompton St Unit 4C G C P 0 Box 7066 Simi Valley CA 93063 Charlotte NC 28241 Phone 805 582 0065 VALVES Phone 704 588 3300 Fax 805 582 0210 Fax 704 588 5831 DISTRIBUTOR 4525 E industrial Street Simi Valley CA 93063 Phone 805 582 0065 Fax 805 582 0210 DESCRIPTION 5211 Solenoid Valves are normally closed 2 way pilot operated diaphragm type which are designed for on off control of air steam and liquids Available options include Manual Opening Device and UL Class F and H coils OPERATION 5211 Valves are normally closed opening when ener gized and closing when de energized SPECIFICATIONS Use the valve within the specified operating ranges as indicated on the valve nameplate min max psi volt age cycle maximum media temperature at F ambient Cv factor etc OPERATING TEMPERATURES MAXIMUM TEMPERATURE SEAT AM BIENT MATERIAL GAS M 105 C TA AA BUNA LIQUIDS F 155 C OIL M 105 C F 155 C VITON H 220 C H 220 C TEFLON H 220 C RULON H 220 C TEFLON STEAM d4 RULON HOT WATER STEAM
177. t the correct reading on the RO II display for each cell Display Adjustment The DISPLAY CONTRAST control can be used to adjust the display contrast for the clearest display for the viewing conditions in which the ROTrol II is mounted Refer to Figure 3 for the contrast control s location 31 FLOW METERING The optional flow metering allows permeate concentrate and recirculate flows to be monitored and displayed by the ROTrol II Setpoints are provided for calibration for various pipe sizes and flow conditions Setpoints are also provided to program high and low flow limit warnings for permeate and concentrate flow The flow meter interface PC board is mounted to the main board in the upper left corner of the board see Figure 13 The flow meter interface board and the optional pH board may be removed to facilitate the wiring of the analog sensors to their terminal strip To remove the pH board remove the 2 mounting screws holding the board Lift straight up on the pH board to remove it from the connector To remove the flow board remove the thr screws or if the pH board was removed the 2 screws and 1 spacer holding the flow meter interface board and then lift straight up on the board to unplug it from the connector After wiring the analog sensors the board is reinstalled by aligning the pins of the connector with the holes in the bottom of the meter interface board and pushing the board into place The mounting screw
178. t to 0000 this alarm is disabled 41 Low Concentrate Flow If the concen 001 0 999 9 0000 trate flow drops below this value GPM LPM a low concentrate flow alarm will be displayed If set to 0000 this alarm is disabled 42 High Concentrate Flow If the concen 001 0 999 9 0000 trate flow rises above this value GPM LPM a high concentrate flow alarm will be displayed If set to 0000 this alarm is disabled 43 Flow Totalizer The permeate flow 000000 totalizer can be reset to 0 by pro GAL LTR gramming this setpoint to 000000 The number shown when this setpoint is displayed may not match the current total This is normal as this setpoint is only used to clear the total Flow Operation Dipswitch 6 see Figure 3 must be ON for the flow metering screen to be displayed The flow rate display is shown by pressing the display key on the keyboard until the flow display is reached Permeate concentrate and recirculate flows are displayed If sensor is not installed for one of the flow rates that display will read 0 0 If the permeate flow sensor is installed the total permeate flow per day and the current permeat total will be shown in addition to the permeate flow per minute If the permeate and concentrate sensors are both installed the system feed flow rate and also the system percent recovery are calculated and displayed Press the display key to return to the main display Flow Alarms Low and high
179. tabilized Salt Rejection Minimum Salt Rejection Product Water Flow Rate Product gpd m3 d TW30 4014 475 TW30 4021 900 3 41 142 98 0 99 0 TW30 4040 2200 8 33 347 TW30HP 4040 2800 10 60 442 98 0 99 0 1 Permeate flow and salt rejection based on the following test conditions 2000 ppm NaCl 225 psi 1 6 MPa 77 F 25 C pH 8 and recovery as indicated below 2 Flow rates for individual elements may vary 15 25 for TW30 4014 TW30 4021 and TW30 4040 and 15 NUL NUL No Upper Limit for TW30HP 4040 3 Sales specification of TW30 4014 and TW30 4021 may vary slightly as design revisions take place D DIA Outer Wrap Feed U Cup Brine Seal End Cap Brine Product Operating Limits Membrane Type u uuu etes Thin Film Composite Maximum Operating Pressure 300 psi 2 1 MPa Maximum Feed Flow Rate aaa 17 3 9 m3 h t pH Range Continuous 2 to 11 pH Range Cleaning Cycle 80 min 1 to 12 Maximum Operating Temperature 113 F 45 Maximum Feed TUDIA 1 Maximum Feed Silt Density Index seen SDI 5 Free Chlorine Tolerance tote ene n e e e ea 0 1 ppm Single Element Recovery Dimensi
180. th pins The absence of a shorting block or the shorting block plugged into 1 pin only will enable the reading If no pressure readings are present on the LCD display either Dipswitch 1 is OFF one or more pressur sensors or cable is bad or mis wired a TDS Conductivity sensor is bad or the PC board is bad Assuming Dipswitch 1 is ON the problem may be isolated to a failed sensor or PC board by one of the following methods 43 Method 1 no DVM available Turn off the Power switch on the front panel and disconnect the red wires for both TDS Conductivity sensors and every pressure sensor except 1 at the terminal strips P5 and P7 Then place the shorting blocks across both pins of the corresponding enable jumpers J6 J9 for the disconnected sensors to disable the alarms for those sensors Turn the Power switch on and check the LCD display for a pressure reading from the sensor still connected to the terminal strip If a good reading is obtained that sensor is good If the reading is bad either the sensor is bad or the PC board is bad If the reading is good leave the good sensor connected Then one at a time connect each disconnected sensor and remove its jumper to enable a reading If the reading is correct leave th Sensor connected and check the remaining sensors one at a time in the same fashion If any good readings are obtained the PC board is probably good and each sensor giving a good reading is OK Replace any bad sens
181. th temperature compensating design The gauge utilizes a u clamp for panel mounting Type 1008A has a bronze tube and brass socket with soft soldered pres sure containing joints The gauge has an RTV seal on the lower connection and an O ring seal on the back con nection Vacuum through 600 psi ranges are available Type 10085 has a stainless steel tube and socket with welded pressure con taining joints In addition the socket is welded to the case This joint protects against corrosion and provides a perma nent case seal for liquid fill applications Ranges available from vacuum to 15 000 psi All liquid filled pressure gauges 300 psi and over are supplied with a throttle device as standard Throttle Devices All liquid filled 1008 gauges 300 psi and above are supplied with a throttle device in the gauge socket If requested these devices will be supplied on dry gauges or on liquid filled units below 300 psi Accuracy 3 2 3 ANSI Grade B All gauges made in U S A The 1008AL bronze socket is equipped with a push in brass throttle plug with a 0 013 diameter orifice 100851 stainless steel socket is equipped with the Ashcroft annular ori fice device with an orifice equivalent to 0 013 by 2 4 length This device will attenuate up to 7096 of excess pulsation Product Selection Information All gauge components should be selected considering media and operat ing conditions to prevent mis appli
182. the overloads be set to a higher value than the full load current shown on the motor nameplate This will void the warranty Overloads for auto transformers and resistant starters should be sized in accordance with the recommendations of the manufacturer Three phase MLE motors CRE Pumps require only fuses as a circuit breaker They do not require a motor starter Check for phase imbalance worksheet is provided on page 15 NOTE Standard allowable phase imbalance difference is 5 3 5 The CRN SF is typically operated in series with a feed pump Because the maximum allowable inlet pressure of the CRN SF increases from 73 psi when pump is off and during start up to 365 psi during operation a control device must be used to start the CRN SF pump one second before the feed pump starts Similarly the CRN SF must stop one second after the feed pump stops CRN SF Feed Pump Feed Pump CRN SF tart tart TIME gt s 5 5 5 uin 1lormore y 4 Both Pumps Operating gt 4 1 or more seconds seconds LCPTLOO3_CR I amp O_Rev0104 qxd 1 26 2004 11 58 AM Page 8 F Starting the Pump Figure 5a Figure 5b CRIN 32 45 the First Time 64 amp 90 Priming Vent Plug CR I N 15 1 3 5 10 15 20 Priming CR X N T 2 4 8 16 Il To prime the pump closed system an open system where the water f source is above the pump close the pump isolation valve s
183. the possibility of personal injury or property damage turn off electrical power depressurize switch and vent fluid to a safe area before removal or inspection IMPORTANT Pressure switch is not field repairable In case of damage replace the entire pressure switch Address all service inquiries to Automatic Switch Company 50 60 Hanover Road Florham Park New Jersey 07932 Valve Service Department Preventive Maintenance e While in service operate the fixed deadband pressure switch periodically cycle between two set points to ensure proper operation If necessary electrical wiring and pipe connections should be made so that switch can be test operated without affecting other equipment Periodic inspection of the pressure switch external surfaces only should be carried out Switch should be kept clean and free from paint foreign matter corrosion icing or freeing conditions Keep the medium entering the pressure switch as free from dirt and foreign material as possible Causes of Improper Operation e Incorrect Electrical Connection Check leads to switch Be sure they are properly connected Switch is marked NO for normally open NC for normally closed and C for common Faulty Control Circuit Check the electrical power supply to switch Check for loose or blown fuses circuited or grounded wires loose connections at switch See nameplate for electrical rating and range e Incorrect Pressure Check p
184. the terminal box cover If voltage variations are larger than 10 do not operate the pump Is the application correct for this pump Compare the pump s nameplate data or its performance curve with the application in which you plan to install it Will it perform the way you want it to perform Also make sure the application falls within the following limits Type Designed to pump CR Hot and chilled water boiler feed condensate return glycols and solar thermal fluids CRI CRN CRX Deionized demineralized and distilled water Brackish water and other liquids unsuitable for contact with iron or copper alloys Consult manufacturer for specific liquid compatibilities CRN SF High pressure washdown reverse osmosis or other high pressure applications CRT Salt water chloride based fluids and fluids approved for titanium Operating Conditions Pump Fluid Temperatures CR I N 1s 3 5 10 15 and 20 4 to 248 F 20 to 120 C CR N 32 45 64 and 90 22 TO 248 F 30 TO 120 C CR N X T 2 4 8 16 4 to 248 F 20 to 120 C CRN SF 4 to 221 F 15 to 105 C with Cool Top up to 356 F 180 C All motors are designed for continuous duty in 104 F 40 C ambient air conditions For higher ambient temperature conditions consult Grundfos xUBE Shaft Seals are recommended for temperatures above 200 F Pumps with hybrid shaft seals can only operate up to 200 F 90 C Pumps with xU
185. tion alarm Shutdown Disable The low feed pressure high pump pressure and high temperature shutdowns can be disabled and configured for alarm only by programming Setpoint 56 Shutdown Disable with the correct value The default for this setpoint is 0 which enables all 3 shutdowns Each shutdown has a factor The factor for low feed pressure is 1 the high pump pressure factor is 2 and the high temperature factor is 4 Add the factors for the shutdowns that are to be disabled and program this value in Setpoint 56 For example to disable the shutdowns for high pump pressure and high temperature the value programmed in Setpoint 56 would be 2 4 6 RO System Shutdown Reset Low feed or high pump pressure shutdowns can be reset ither manually or automatically The high TDS conductivity shutdown and the high feed temp shutdown can only be reset manually For manual reset push the RESET key on the front panel twice Automatic reset is controlled by setpoint 20 Automatic Reset Timer If programmed to 00 automatic reset is disabled and all shutdowns must be reset manually If a time is programmed into this setpoint when the RO system is shutdown due to low feed or high pump pressure the automatic reset timer is activated When the timer times out the RO system is reset and the RO system will operate if the fault causing the shutdown has cleared Pretreatment Lockout In systems where softeners or filters are used
186. to the pretreat input of P9 This switch should operate when the pretreatment device is out of service NOTE The output from the pretreatment device must be a dry contact and must not supply voltage Tank Full Switch In systems with a single tank level switch for controlling the RO pump the level switch connects to the tank full high input of P9 If dual level switches are used for controlling the RO pump the upper level switch connects to the tank full high input of P9 and the lower level switch connects to the tank full low input of P9 Expander Board If the optional expander board is installed 2 additional relay outputs and 1 additional switch input are provided Refer to figure 4 for the location of terminal strips jumpers and wiring for this board AC power for the relays is connected to the L1 and L2 power terminals of P1 Relay 1 is connected to this power input and will supply the same voltage This relay is rated for 120 240VAC at 1HP maximum Relay 2 can be selected to supply voltage 120 240 5A maximum or as a dry contact output Jumpers J1 J4 are used to select the relay 2 output type To output voltage a wire jumper is installed between J1 and J4 and a second wire jumper is installed between J2 and J3 For a contact closure output a single wire jumper is installed between J3 and J4 The 2 relay outputs can be selected to operate as an auxiliary pump output a divert output or an alarm output by programming the Expander
187. to this documentation Information in this document is subject to change without notice R amp D Specialties shall not be liable for technical or editorial errors or omissions that may appear in this document nor for incidental or consequential damages resulting from the furnishing performance or use of this document Document RO2D V5 02 Released August 1999 R amp D Specialties Inc 9918 W I 20 Midland TX USA 79706 915 561 5707 Fax 915 561 5696 www rdspec com email rdspec rdspec com LIMITED WARRANTY R amp D Specialties warrants to the original purchaser that the products it manufactures will be free from defects in material and workmanship for a period of twelve months from the date of shipment on parts and ninety days on labor Some non R amp D Specialties manufactured resale items may have warranty periods less than twelve months R amp D Specialties obligation under this warranty is limited exclusively to the repair or replacement of any product that R amp D Specialties finds to be defective Items returned for warranty consideration must have a return authorization number and be properly packaged shipped prepaid and insured This warranty is valid only when the products are properly installed maintained and used for the purpose for which they were designed Misuse neglect damage accident improper repair or modification not authorized in writing by R amp D Specialties will
188. treat lockout Tank full high Tank full low Relay Outputs RO pump relay 120 240VAC 1HP Inlet valve relay 120 240VAC 5A Flush valve relay 120 240VAC 5A Relays supply same output voltage as board power 120 or 240 VAC Cell Tds Conductivity cell with digital display standard range 0 250PPM or uS Other ranges available 0 50 0 100 0 500 0 1000 Wetted parts ABS and 316SS 3 4 NPT 300 PSI Optional I O expander Auxiliary divert relay 120 240VAC 1HP Divert alarm relay 120 240VAC 5A Tank low switch input dry contact FRONT PANEL CONTROLS AND INDICATORS Figure 1 DISPLAY Shows status of system ALARM LAMP Flashes when fault causes an RO system shut down On steady when a Setpoint is exceeded that does not cause an RO system shut down POWER KEY Places controller in operating or standby mode LEFT ARROW KEY Scrolls through Setpoints starting with first Setpoint RIGHT ARROW KEY Scrolls through Setpoints starting with last Setpoint UP ARROW KEY Increases value of Setpoint DOWN ARROW KEY Decreases value of Setpoint ENTER KEY Confirms entry of new Setpoint value ALARM SILENCE RESET KEY Push once for alarm silence and twice to reset system after a shut down has occurred INSTALLATION Physical Installation Mount the Series 150 in a convenient location on the RO equipment using the four mounting ears provided with the unit or the optional panel mounting bracket NOTE All t
189. ty FDA grade 100 polypropylene and acrylic styrene Leak proof sealing is accomplished by compression against a top seated EPDM o ring located in the housing s sump Thick wall and added ribs make the housings ideal for a wide range of applications Polypropylene construction provides excellent chemical resistance with most acids alcohol arnmonia oils plating solutions and many aggressive chemicals Housings sup plied with and without pressure release valves Rated for temperatures lo 125 F 52 C and pressures to 125 psid 8 75 bar Full product line EE We offer a complete line of under counter filler housings for virtually every application where single cartridge filler housings are typically used Select from slandard heavy duty full flow high purity high temp and valve in head models Standard amp HD models Full Flow High Purity High Temp Valve In Head 4000 4200 HD serias Clear or opaque Virgin polypropylene For 200 I 93 Clear or opaque Dimensions A ee ae a E _ d 500 Series 5 4 28 1 57 1 18 016 X ST 70 4000 Series 10 472 157 1 18 0 18 X 10 5 11 0 11 8 oS 4200 Series 10 4 72 1 57 1 18 0 18 X 105 110 11 8 Tr 8000 Series 20 5 35 2 22 228 02 X 20 47 21 26 22 8 HD Series 10 536 299 926 X 10 49 11 49 12 5 Full Flow 10 7 28 30 30 0 278 X 11 33 11 57 14 0
190. uded if so instructed GRUNDFOS WILL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES LOSSES OR EXPENSES ARISING FROM INSTALLATION USE OR ANY OTHER CAUSES THERE ARE NO EXPRESS OR IMPLIED WARRANTIES INCLUDING MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXTEND BEYOND THOSE WARRANTIES DESCRIBED OR REFERRED TO ABOVE Some jurisdictions do not allow the exclusion or limitation of incidental or consequential damages and some jurisdictions do not allow limitations on how long implied warranties may last Therefore the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from jurisdiction to jurisdiction L CP TL 003 Rev 1 04 PRINTED IN USA Grundfos Pumps Corporation Grundfos Canada Inc Bombas Grundfos de Mexico S A de C V 17100 W 118th Terrace 2941 Brighton Road Boulevard TLC 15 Olathe KS 66061 Oakville Ontario L6H 6C9 Canada Parque Stiva Aeropuerto Telephone 913 227 3400 Telephone 905 829 9533 Apodaca N L 66600 Mexico Fax 913 227 3500 Fax 905 829 9512 Telephone 52 81 8144 4000 Fax 52 81 8144 4010 QC www grundfos com GRUNDFOS 2 BRONZ GI GLOBE Fig 110 Globe Threaded E REGRINDING IEEDLE VALVES MODEL STAR CLASS 200 UNION BONNET THREADED ENDS PRESSURE TEMPERATURE RATINGS 200 psi Steam at 550 F 400 psi Non Shock Cold water Cil or Gas
191. ues If an open or grounded winding is found remove motor and repair or replace Turn off power and discharge capacitor Check with ohmmeter RX 100K When the meter is connected to the capacitor the needle should jump towards ohms and slowly drift back to infinity Replace if defective Turn off power and manually rotate pump shaft If shaft does not rotate easily check coupling setting and adjust as necessary If shaft rotation is still tight remove pump and inspect Disassemble and repair The pump runs but at reduced capacity or does not deliver water Wrong rotation Pump is not primed or is airbound Strainers check or foot valves are clogged Suction lift too large Suction and or discharge piping leaks Pump worn Pump impeller or guide vane is clogged Check wiring for proper connections Correct wiring Turn pump off close isolation valve s remove priming plug Check fluid level Refill the pump replace plug and start the pump Long suction lines must be filled before starting the pump Remove strainer screen or valve and inspect Clean and replace Reprime pump Install compound pressure gauge at the suction side of the pump Start pump and compare reading to performance data Reduce suction lift by lowering pump increase suction line size or removing high friction loss devices Pump runs backwards when turned off Air in suction pipe Suction pipe valves and fittings must
192. uld open If DS12 is on and the valve does not switch check the wiring between the valve s power source and the valve If all wiring appears intact and correctly wired see Figure 4 5 or 6 check for the correct voltage on the valve with a DVM If voltage is present on the valve it is probably bad and should be replaced If voltage is not present on the valve check between the valve s unswitched directly wired to valve power lead and the P6 terminals labeled FLUSH V Between the unswitched wire and the P6 terminal COM the supply voltage 120 240 should be present If the voltage is not correct the problem is either a break in the wiring between the P6 terminal COM and the power source or the power source proper It will probably be connected to several other wires with a wire nut or splice of some kind which may be loose If the correct voltage is present at P6 COM it should also be present at the terminal N O when DS12 is on and at the terminal N C when DS12 is off If DS12 is on and no voltage is present on N O the PC board should be replaced Pressure sensor readings incorrect or not reading All pressure sensor readings require Dipswitch 1 to be turned ON up With Dipswitch 1 ON each sensor reading may be enabled disabled with its corresponding jumper J6 97 J8 or 99 FEED PUMP PREFILTER DIFF and MEMBRANE DIFF respectively A sensor reading is disabled by plugging a shorting block onto bo
193. ump shaft to the motor shaft is set at factory specifications No adjustment is required If the unit is delivered as a pump end only follow the adjustment procedures on pages 10 11 Pump without Motor CR I N 1s 1 3 5 10 15 and 20 Only If you purchased a pump without a motor the shaft seal has been set by the factory Do not loosen the three set screws on the shaft seal when attaching the motor Pump without Motor CR N 32 45 64 amp 90 Only If you purchased a pump without a motor you must install the seal The seal is pro tected in its own sub boxing within the pump packaging crate To protect the shaft and bearings during shipment a shaft holder pro tective device is used This device must be removed prior to installation of the seal Read the seal installation instructions which are included in the pump package Verify electrical requirements Verification of the electrical supply should be made to be certain the voltage phase and frequency match that of the pump motor The proper operating voltage and other electrical information can be found on the motor nameplate These motors are designed to run on 10 of the nameplate rated voltage For dual voltage motors the motor should be internally connected to operate on the voltage closest to the 10 rating i e 208 voltage motor wired per the 208 volt connection diagram The wiring connection diagram can be found on either a plate attached to the motor or on a diagram inside
194. use the RP pump is building up pressure in the discharge piping until the pressure switch is activated and shuts the pump off When water is called for the stored water in the bladder tank which is under pressure is released to the point of use When the pressure in the line drops below the low side of the differential pressure switch the RP pump energizes and builds up pressure again The float switches that are provided with the atmospheric storage tanks are color coded One is red and the other blue Each switch has a different function The red switch is closed when down and open when up It is used to control the RO portion of the system The blue switch is closed when up and open when down It is used to run the RP pump There are several ways to install the float switches in the tank The two most common ways are to use a piece of PVC pipe installed in the atmospheric tank to anchor the float switches to or penetrate the side wall of the tank with two bulkhead fittings with chord grips and install the float switches through the side of the tanks A third way is to hang the float switches from the top of the tank and install zinc weights where you want the float ball to pivot Either way is acceptable The red float ball will turn the RO on when it is in the down position and off when it is in the up position The float ball will need to swing in an arc to operate the switch contacts Be sure to test the switch operation before perm
195. use of a flooded suction condition This would occur if the water source is above the pump See Figures 2 and 3 Flush piping prior to pump installation to remove loose debris Flooded Suction Suction Lift Figure 2 Figure 3 Eccentric Butterfly Valve Expansion Joint CRN SF pumps cannot be used for suction lift The suction pipe should have a fitting on it for priming Minimum suction pipe sizes The following recommended suction pipe sizes are the smallest sizes which should be used with any specific CR pump type The suction pipe size should be verified with each installation to ensure good pipe practices are being observed and excess friction losses are not encountered High temperatures may require larger diameter pipes to reduce friction and improve NPHSA CR I N 1s 1 3 CRT 2 1 Nominal diameter sch 40 pipe CR I N 5 CRT 4 11 4 Nominal diameter sch 40 pipe CR I N X 10 15 20 8 16 2 Nominal diameter sch 40 pipe CR N 32 21 2 Nominal diameter sch 40 pipe CR N 45 3 Nominal diameter sch 40 pipe CR N 64 4 Nominal diameter sch 40 pipe CR N 90 4 Nominal diameter sch 40 pipe Discharge piping It is suggested that a check valve and isolation valve be installed in the discharge pipe Pipe valves and fittings should be at least the same diameter as the discharge pipe or sized in accordance with good piping practices to reduce excessive fluid velocities and pipe friction losses
196. void this warranty There are no warranties expressed or implied including the implied warranties for merchantability or fitness for a particular purpose that extend beyond the limited warranty expressly stated above R amp D Specialties liability to any purchaser of its products whether in contract or in tort and whether arising out of warranties representations instructions installations or defects from any cause will be limited exclusively to repairing or replacing the product or any part thereof under the conditions set out above YEAR 2000 COMPLIANCE All products manufactured and supplied by R amp D Specialties have been tested for Year 2000 compliance All products are certified as being Year 2000 compliant or do not have functions that require Year 2000 compliance No information or statement in this document modifies or extends the terms of service or warranty of any product or service of R amp D Specialties The Year 2000 compliance information contained in this document is provided AS IS without any express or implied warranty of any kind including warranties of merchantability or fitness for any particular purpose In no event shall R amp D Specialties be liable for any damages whatsoever including without limitation damages for loss of profits business interruption or loss of information arising out of 1 the use of such information 2 any inabi
197. w Terminal Field Wiring 12 00 Position Wire sizes should be based on the current carrying properties of a conductor as required by the Terminal Box cw Terminal Box latest edition of the National Electrical Code or local regulations Direct on line D O L starting is 9 00 Position 3 00 Position approved due to the extremely fast run up time of the motor and the low moment of inertia of gua pump and motor If D O L starting is not acceptable and reduced starting current is required an auto transformer resistant starter or soft start should be used It is suggested that a fused 6 00 Position disconnect be used for each pump where service and standby pumps are installed Figure 4 Suction Motor Protection 1 Single Phase Motors With the exception of 7 1 2 and 10 HP motors which require external protection single phase CR pumps are equipped with multi voltage squirrel cage induction motors with built in thermal protection 2 Three Phase Motors CR pumps with three phase motors must be used with the proper size and type of motor starter to ensure the motor is protected against damage from low voltage phase failure current imbalance and overloads A properly sized starter with manual reset and ambient compensated extra quick trip in all three legs should be used The overload should be sized and adjusted to the full load current rating of the motor Under no circumstances should
198. y of a grease over time depends primarily on the type of grease the size of the bearings the speed at which the bearings operate and the severity of the operating conditions Good results can be obtained if the following recommendations are used in your maintenance program Ambient Severity Temperature Approved Types of Service Maximum of Grease Standard 104 F 40 C Clean little corrosion See motor nameplate for Severe 122 F 50 C Moderate dirt corrosion grease type or compatible Extreme gt 122 F 50 C Severe dirt abrasive equivalent type of grease or Class H insulation dust corrosion If pump is fitted with a bearing flange that requires grease see the stickers on either the bearing flange or coupling guards for proper grease type and greasing schedule Motor Lubrication Schedule Standard Severe Extreme Weight of Volume of Service Service Service Grease to Add Grease to Add Frame Size Interval Interval Interval Oz Grams In Teaspoons Up through 210 132 5500 hrs 2750 hrs 550 hrs 0 30 8 4 0 6 2 Over 210 through 280 180 3600 hrs 1800 hrs 360 hrs 0 61 17 4 1 2 3 9 Over 280 up through 360 225 2200 hrs 1100 hrs 220 hrs 0 81 23 1 1 5 5 2 Over 360 225 2200 hrs 1100hrs 220hrs 212 60 0 41 13 4 grease outlet plug MUST be removed before adding new grease Procedure CAUTION TO AVOID

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