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1. CRYSTAL QUESTO Thunder Reverse Osmosis Introduction Your Thunder commercial reverse osmosis system is a durable piece of equipment which with proper care will last for many years This User s Manual outlines installation operating maintenance and troubleshooting details vital to the sustained performance of your system The test results which are included with this User s Manual indicate your systems permeate product and rejection test results Your system is designed to operate at a pressure of 150 psi unless otherwise stated The recovery set for your system is between 3396 5096 If your system is altered at the site of operation or if the feed water conditions change please contact your local dealer or distributor to determine the proper recovery for your application NOTE In order to maintain warranty an operating log must be maintained Copies must be sent to your local dealer or distributor for review NOTE Prior to operating or servicing the Thunder commercial reverse osmosis system this User s Manual must be read and fully understood Keep it and other associated information for future reference and for new operators or qualified personnel near the system Safety The Safety section of this User s Manual outlines the various safety headings used throughout this manual s text and are enhanced and defined below NOTE Indicates statements that provide further information and clarification CAUTION Indicates statem2. Permeate flow and salt rejection based on 550 TDS 150 psi 77 F 25 C pH 7 and recovery as indicated NOTE Higher TDS and or lower temperatures will reduce the system s production Start Up Unless otherwise indicated these instructions cover the Thunder 10000 15000 amp 20000 reverse osmosis systems Please refer to the flow diagrams and exploded view diagrams found in this User s Manual for additional information Installation These Thunder reverse osmosis systems are mounted onto a station which is on caster wheels These wheels must be securely locked or fastened and placed on an even floor so that the system will not vibrate or move If this occurs place the system on a rubber mat to reduce the vibrations and movement If you remove the caster wheels from the system s frame then properly mount the system to the ground Carefully inspect your system before start up Check all plumbing and electrical connections Connections may have come loose during shipment A User s Manual Test Results and Filter Housing Wrench will accompany your Thunder reverse osmosis system Start Up 1 2 10 11 Locate the 2 FNPT feed water inlet on the 18 FSI bag filter housing Attach the inlet piping to the 2 FNPT feed water inlet Always maintain a smooth and sufficient flow of feed water during operation Locate the 1 FNPT permeate outlet Attach the permeate piping to the permeate outlet Make sure that the perme
3. and low pressure to displace the process water Use only enough pressure to compensate for the pressure drop from feed to concentrate The pressure should be low enough that essentially no permeate is produced approx 60 psi A low pressure minimizes redeposition of dirt on the membrane Dump the concentrate as necessary to prevent dilution of the cleaning solution Table 2 Recommended Feed Flow Rate Per Housing During High Flow Rate Re Circulation Element Diameter PSI GPM 2 5 Inches 20 60 3 5 4 Inches 20 60 8 10 e Dependent on number of elements in pressure vessel 4 Inch full fit elements should be cleaned at 12 14 gpm 2 7 3 2 m3 hr 3 Re circulate After the process water is displaced cleaning solution will be present in the concentrate stream that can be recycled to the cleaning solution tank Recycle the cleaning solution for 10 minutes or until there is no visible color change If at anytime during the circulation process there is a change in pH or a color change dispose of the solution and prepare a new solution as described in step 2 A pH of 2 must be maintained for the cleaning to be effective 14 4 Soak Turn the pump off and allow the elements to soak Soak the elements for 1 15 hours soaking overnight will give best results To maintain temperature during an extended soak period use a slow recirculation rate about 10 percent of that shown in Table 2 Soak time will vary depending on the severity of the scaling
4. For lightly scaled systems a soak time of 1 2 hours is sufficient 5 High flow pumping Feed the cleaning solution at the rates shown in Table 2 for 10 minutes The high flow rate flushes out the foulants removed from the membrane surface by the cleaning If the elements are heavily fouled using a flow rate that is 50 percent higher than shown in Table 2 may aid cleaning At higher flow rates excessive pressure drop may be a problem The maximum recommended pressure drops are 15 psi per element or 50 psi per multi element vessel whichever value is more limiting 6 Flush out Prefiltered raw water can be used for flushing out the cleaning solution unless there will be corrosion problems e g stagnant seawater will corrode stainless steel piping To prevent precipitation the minimum flush out temperature is 20 C The system should be flushed for one hour 7 The system should be restarted Elements and the system need to stabilize before taking any data The stabilization period will vary depending on the severity of the fouling To regain optimum performance it may take several cleaning and soak cycles NOTE Recommendations made here are specifically designed for the membrane elements inserted in the Titan reverse osmosis and nanofiltration elements These recommendations such as cleaning procedures and chemicals employed may not be compatible with other brands of membrane elements It is your responsibility to ensure the suitabilit
5. Water Specifications Free Chlorine 1 ppm Manganese 0 05 ppm Total Dissolved Solids 2000 ppm Organics 1 ppm Turbidity SDI 5 Temperature 40 F 105 F pH 3 11 Silica lt 1 ppm Hardness 15gpg Iron 2 ppm in Concentrate The manufacturer has provided you with operation specifications These specifications should be met in order to have the reverse osmosis system perform optimally All operation specifications are based on the test conditions listed below Operation Specifications Minimum Feed Pressure 35 psi Minimum NaCl Rejection 96 Nominal 96 Rejection 98 596 Maximum Hardness 15000 Maximum TDS 2000 ppm Operating Pressure 150 psi pH Range 3 11 Maximum Temperature 110F Test Conditions Permeate flow and salt rejection based on 550 TDS 150 psi 77 F 25 C pH 7 and recovery as indicated NOTE Higher TDS and or lower temperatures will reduce the system s production Rejection Recovery amp Flow Rates Thunder reverse osmosis systems are designed to produce purified water at the capacities indicated by the suffix in the system s name under the conditions listed above For example the Thunder 10000 produces 10000 gallons per day of purified water 77 F The amount of total dissolved solids TDS rejected by the membrane is expressed as a percentage For example a 99 rejection rate means that 99 of total dissolved solids do not pass through the membrane To calculate the 96 rejection use the following formula
6. any bacteria or biofilm in the system Please refer to separate instructions on methods for sanitizing membrane systems i e Sanitization with DBNPA Tech Facts If the only choice for a sanitizing agent is an oxidant such as hydrogen peroxide the system must be cleaned before sanitization Inorganic Foulant Cleaning The following cleaning procedures are designed specifically for membranes that have been fouled with organic matter Review the general cleaning instructions for information that is common to all types of cleaning such as suggested equipment pH and temperature limits and recommended flow rates Safety Precautions 1 When using any chemical indicated here in subsequent sections follow accepted safety practices Consult the chemical manufacturer for detailed information about safety handling and disposal 2 When preparing cleaning solutions ensure that all chemicals are dissolved and well mixed before circulating the solutions through the membrane elements 3 Itis recommended the membrane elements be flushed with good quality chlorine free water after cleaning Permeate water is recommended but a de chlorinated potable supply or pre filtered feed water may be used provided that there are no corrosion problems in the piping system Operate initially at reduced flow and pressure to flush the bulk of the cleaning solution from the elements before resuming normal operating pressures and flows Despite this precaution cl
7. liquid level switch is to be used install it at this time and turn the power to the Titan system on Otherwise turn the system on by plugging in the power cord Allow the system to run for about three to five minutes with the concentrate control valve fully open to purge air from the system Make sure that the concentrate re circulate valve is closed The Thunder systems permeate or product water should be discarded for the first hour of operation This will flush out any impurities which are in the system Turn the concentrate control valve to the desired recovery rate Follow any specified system projections in supplied Flush the system at 50 psi for 15 minutes to remove the impurities from the system Check for leaks and cracked fittings which may have occurred during shipment Connect the permeate line to the storage tank or point of use application Make sure that no backpressure exists on the permeate line 12 Locate the concentrate control valve and the concentrate pressure gauge 13 Turn the concentrate control valve until the designated recovery is acquired The concentrate pressure will increase as the concentrate control valve is closed The exact operating pressure may vary depending on the temperature and TDS of your feed water It may be necessary to re adjust the system if there is a major change in feed water temperature and or TDS 14 Turn the pump bypass valve until the correct pump pressure is achieved For example a Tit
8. of flow from bottom to top the brine seal should be located on the end of the membrane element at the bottom of the housing 3 Lubricate the brine seal with a food grade lubricant 4 Ata slight angle insert membrane while slightly rotating element being careful not to tear or flip the brine seal Re lube the brine seal if necessary 5 With a smooth and constant motion push the membrane element into the housing so that the brine seal enters the housing without coming out of the brine seal groove A slow twisting motion should be used to insert the membrane element to ensure that the brine seal stays in place 9 Re install the end caps by gently twisting the end cap while pushing it onto the housing Ensure that you do not pinch or fatigue any O rings while pushing the end plug on Push the end plug on until the outer diameter of the plug is flush with the outer diameter of the membrane housing Insert nylon snap ring until fully seated Snap ring must be able to be spun in place if fully seated If you are using a stainless steel housing Install the clamps halves and tighten bolts until the clamp halves meet Reconnect any fittings that may have been disconnected when the membrane element housings were disassembled To Start Up the system refer to Start Up CAUTION New or factory cleaned membranes are shipped in a preservative solution New or cleaned membranes must be flushed for at least 1 hour to remove the preservative from
9. s warranty for their systems and terms and conditions please contact your local dealer and distributor 23 OPTIONAL OPTIONAL Thunder 10 000 CHAMP 4 X 40 HOUSING PART 200530 THIN FILM COMPOSITE MEMBRANE TFC 4 X 40 LP PART 200379 END PLUC 4 PART 200596 SNAP RING 4 PART 200597 4 O RING KIT PART 200599 0 300 P S I PRESSURE GAUGE PART 200904 COMPUTER CONTROL S 150 PART 200859 120 VAC 200860 220VAC CONTROL VALVE RECYCLE VALVE 1 SS PART 200995 0 160 P S I PRESSURE GAUGE PART 200901 20 BIG GRAY PRE FILTER HOUSING PART 200731 5 MICRON SEDIMENT FILTER PART 200650 3 HP GOULDS PUMP 110 220 VOLT PART 200790 SOLENOID VALVE 110 220 VOLT PART 200914 120VAC 200915 220VAC LOW PRESSURE SWITCH PART 200905 POWDER COATED EPOXY FRAME PART N A RECYCLE FLOW METER 10 GPM PART 200899 FILTER HOUSING FSI PART 200739 18 FSI BAG FILTER 10MICRON PART 200710 AUTO FLUSH PART 200042 EI I SA GE 19 js CRYSTAL QUESTO Thunder Reverse Osmosis Thunder 15 000 g crane x 40 HOUSING PART 200530 THIN FILM COMPOSITE MEMBRANE TFC 4 X 40 LP PARTE 200379 END PLUG 4 PART 200596 SNAP RING 4 PART 200597 4 O RING KIT PART 200599 0 300 P S I PRESSURE GAUGE PART 200904 COMPUTER CONTROL S 150 PART 200859 120 VAC 200860 220VAC CONTROL VALVE RECYCLE VALVE 1 55 PART 2009
10. 0899 FILTER HOUSING FSI PART 200739 18 FSI BAG FILTER 10MICRON PART 200710 AUTO FLUSH PART 200042 A TDS PRDBE TANK LOW LVL TANK HI LVL PRE TREAT LPS fare CAUTION DISCONNECT AND BRANCH PROTECTION IS REQUIRED UN THE POWER FEEDING THIS PANEL 9 8 7 6 9 4 3 e 1 ERY ora ex J s der te ters Thunder 10 000 20 000 and 20 000 Do not scale drawing FLUSH L1 INLET L1 RO PUMP L1 240V GND 2 9 8 7 6 5 4 3 2 1 TDS PROBE MDA 10 Xe d i TANK LDW LVL TANK HI LVL PRE TREAT LPS 1 5 Li Le L1 Le INLET FLUSH VALVE VALVE L220 vac 55 19 GROUND LUG 220V 3PH POWER IN L1 Le L3 RO PUMP 3HP CAUTION DISCONNECT AND BRANCH PROTECTION IS REQUIRED ON THE POWER FEEDING THIS PANEL L 8 11 2 8 A QUEST pm Water Filters Thunder 10 000 20 000 and 20 000 Do not scale drawing FLUSH L1 INLE RU pump b L1 L1 1200V H GND MAIN POWER CONNECT TO APPROVED NEC DISCONNECT CAUTION DISCONNECT AND BRANCH PROTECTION IS REQUIRED ON THE POWER FEEDING THIS PANEL 10 000 20 000 and 20 000 Do not scale drawing
11. 2 54 1 391 1 588 13 55 1 355 1 530 14 57 1 320 1 475 15 59 1 286 1 422 16 61 1 253 1371 17 62 1 221 1 323 18 64 1 190 1 276 19 66 1 160 1 232 20 68 1 132 1 189 21 70 L104 1 148 22 72 1 076 1 109 23 73 1 050 1 071 24 75 1 025 1 035 25 A 1 000 1 000 26 79 0 988 0 971 27 81 0 976 0 943 28 82 0 964 0 915 29 84 0 953 0 889 30 86 0 942 0 863 To use Simply multiply the actual flux to obtain temperature corrected flax 21 Service Assistance If service assistance is required take the following steps 1 Call your distributor a Priorto making the call have the following information available i Machine installation date ii Serial number found on left hand side of front panel iii Daily Log Sheets iv Current operating parameters i e flow operating pressures pH etc v Detailed description of problem Warranty amp Guarantee The manufacturer of your Thunder reverse osmosis system guarantees that the proposed product is to be free from defects in material or workmanship when operated in accordance with written instructions for a period of one year from start up or fifteen months from receipt whichever is shorter Parts that are not manufactured directly by the manufacturer of your reverse osmosis system will be covered by their manufacturer s warranties which are normally for one year The manufacturers membrane elements are guaranteed to operate within sp
12. 95 0 160 P S I PRESSURE GAUGE PART 200901 20 BIG GRAY PRE FILTER HOUSING PART 200731 5 MICRON SEDIMENT FILTER PART 200650 3 HP GOULDS PUMP 110 220 VOLT PART 200792 SOLENOID VALVE 110 220 VOLT PART 20091 4 120VAC 2009 15 220VAC LOW PRESSURE SWITCH PART 200905 POWDER COATED EPOXY FRAME PART N A FLOW METER 20 CPM 7 PARTE 200900 RECYCLE FLOW METER 10 GPM PART 200899 FILTER HOUSING FSI PART 200739 18 FSI BAG FILTER 10MICRON PART 200710 AUTO FLUSH OPTIONAL 2 oagt 200042 Se OPTIONAL IO OPTIONAL OPTIONAL Thunder 20 000 10 CHAMP 4 X 40 HOUSING PART 200530 20 THIN FILM COMPOSITE MEMBRANE TFC 4 X 40 LP PART 200379 END PLUG 4 PART 200596 20 SNAP RING 4 PART 200597 20 4 O RING KIT PART 200599 0 300 P S I PRESSURE GAUGE PART 200904 COMPUTER CONTROL S 150 PART 200859 120 VAC 200860 220VAC CONTROL VALVE RECYCLE VALVE 1 SS PART 200995 Ro M 0 160 P S I PRESSURE GAUGE PART 200901 20 BIG GRAY PRE FILTER HOUSING PART 200731 5 MICRON SEDIMENT FILTER PART 200650 5 HP GRUNDFOS PUMP 220 460 VOLT PART N A SOLENOID VALVE 110 220 VOLT PART 20091 4 1 20VAC 200915 220VAC LOW PRESSURE SWITCH PART 200905 POWDER COATED EPOXY FRAME PARTE N A FLOW METER 20 GPM PART 200900 RECYCLE FLOW METER 10 GPM PART 20
13. 96 Rejection z Feed TDS Product TDS Feed TDS x 100 NOTE All TDS figures must be expressed in the same units usually parts per million ppm or milligrams per liter mg l Thunder commercial reverse osmosis systems are designed to reject up to 98 596 NaCl unless computer projections have been run and provide a different rejection percentage The amount of purified water recovered for use is expressed as a percentage recovery To calculate recovery use the following formula 96 Recovery z Product Water Flow Rate Feed Water Flow Rate x 100 NOTE All Flow Rates must be expressed in the same units usually gallons per minute gpm Thunder commercial reverse osmosis systems are designed to have a minimum recovery of 5096 and up to 7096 when computer projections have been run System Requirements amp Operation Guidelines Plumbing The membranes and high pressure pumps used on Thunder systems require a continuous and non turbulent flow of water to the system with a minimum feed pressure of 35 psi which does not exceed 105 F The piping used for the inlet of the concentrate is 1 FNPT The piping used for the discharge of the concentrate is 1 FNPT and should be run to an open drain in a free and unrestricted manner The tubing or piping used for the permeate is 1 FNPT and can be transported to the holding tank or directly to the point of use through a PVC pipe or other FDA accepted materials Material must not precipitate
14. ag containing the membrane element from the shipping box 3 Cutthe bag open as close as possible to the seal at the end of the bag so the bag may be re used if necessary 4 Remove the membrane element from the bag and remove the black core tube protectors from each end of the membrane 5 Remove parts from the parts container if included and inspect Make sure that all parts are clean and free from dirt Examine the brine seal and permeate tube for nicks or cuts Replace the O rings or brine seal if damaged 6 Flow directions should be observed for installation of each element in each housing As time progresses the efficiency of the membrane will be reduced In general the salt rejection does not change significantly until two or three years after installation when operated on properly pretreated feed water The permeate flow rate will begin to decline slightly after one year of operation but can be extended with diligent flushing and cleaning of the system A high pH and or precipitation of hardness can cause premature loss in rejection of membrane elements in the system To replace the membrane elements 1 Remove all of the membrane element s from the membrane element housings from the top of the housing Heavy duty pliers and channel lock pliers may be necessary to pull the old membrane element out of the membrane element housing 2 Install the brine seal side of the membrane elements first When the housings have a direction
15. an 10000 should be adjusted until it produces about 10000 GPD or 6 94 GPM of permeate or product water GPM GPD 1440 WARNING Never exceed the maximum pressure rating of your pressure vessels Operation amp Maintenance The reverse osmosis process causes the concentration of impurities The impurities may precipitate come out of solution when their concentration reaches saturation levels NOTE Precipitation can scale or foul membranes and must be prevented Check your feed water chemistry Pre treat the water and or reduce the system recovery as required If necessary consult with your local dealer or distributor Pre Filter Pressure Gauges These gauges measure the feed water pressure when it enters and exits the pre filter housing A pressure differential of 1596 or more on the two pressure readings indicates that the pre filter needs to be replaced For example if the inlet pressure is 40 psi the filter should be changed when the outlet pressure is 34 psi or below Product Permeate Flow Meter amp Waste Concentrate Flow Meter These flow meters indicate the flow rates of permeate and concentrate water The measurements when added together also indicate the feed water flow rate if the system is not equipped with a waste recycle Waste Recycle Valve This valve allows you to recycle some of the concentrate water back to the feed of the pump This will increase the recovery of the Thunder system An optional waste recy
16. an those which come with your system NOTE 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 WARRANTIES ARE GIVEN ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY EXCLUDED Additional Information By experience the cleaning solution of Na4EDTA with caustic has been found to be slightly less effective than a standard caustic solution or a solution of caustic and Na DSS For any solution contact time is critical Several overnight soaks may be necessary to restore the system performance After the elements are clean it is very beneficial to clean one additional time in order to clean off the last remaining biofilm layer on the surface of the membrane Any remaining biofilm will tend to attract and trap dirt so an extra cleaning will increase the time between cleanings For industrial systems where the permeate or product water is not used for drinking a non oxidizing biocide can be used prior to step 1 of the cleaning procedure to kill
17. ate water can flow freely and that there is no backpressure Backpressure can cause damage to the membrane elements CAUTION The plumbing in the permeate line can contaminate the high quality water produced by the system ensure that the components are compatible with the application The pH of the reverse osmosis permeate will normally be 1 2 points lower than the feed water pH A low pH can be very aggressive to some plumbing materials such as copper piping Locate the concentrate waste outlet Locate the concentrate outlet on the drain side of the concentrate control valve Attach the drain line to the concentrate outlet Run the concentrate line to the drain Water must be allowed to run freely without any restrictions or blockage in the drain line Make sure that no backpressure exists on the concentrate line Ensure that the electrical power requirements of the Thunder system match your electrical power supply Thunder systems are typically controlled with a liquid level switch in a storage tank The liquid level switch turns the system on when the water level in the tank drops and off when the tank is full If your reverse osmosis system is equipped with an electrical control box the level control is connected to the level control connections in the control box The level control connections are dry contacts and never apply power to these connections Liquid level switches can be obtained by your local dealer or distributor If a
18. cle flow meter allows you to measure how much concentrate is recycled The amount of waste water recycled is limited by the TDS of the feed water The drawback of using concentrate recirculate is an increase of total dissolved solids in the permeate water CAUTION Excessive recycling may cause premature fouling or scaling of the membrane elements Low Pressure Switch The low pressure switch shuts off the system and sounds an alarm when the feed water pressure drops too low for the system to function properly This prevents damage to the pump The system restarts automatically when the pressure is restored If you notice the pressure fluctuating and the system cycling off and on turn the system off and ensure that proper feed flow and pressure are available to the system For further information please review the computer controller s manual Low Pressure Shut Off Switch The low pressure protection circuit can be located on the back panel of your Thunder system The low pressure shut off switch monitors the system s feed water pressure and will shut off the system and sound alarm if pressure loss is detected Auto Flush The auto flush option bypasses the concentrate control valve reducing the concentrate pressure and increasing the flow of feed water across the membrane The auto flush removes foulants that may have attached to the surface of the membrane By removing these foulants before they crystallize on the surface of the membrane t
19. eaning chemicals will be present on the permeate side following cleaning Therefore permeate must be diverted to drain for at least 10 minutes or until the water is clear when starting up after cleaning 13 4 During recirculation of cleaning solutions the temperatures must not exceed 50 C at pH 2 10 35 CatpH 1 11 and30 CatpH 1 12 5 For membrane elements greater than six inches in diameter the flow direction during cleaning must be the same as during normal operation to prevent element telescoping because the housing thrust ring is installed only on the reject end of the housing This is also recommended for smaller elements Cleaning Procedures There are seven steps in cleaning membrane elements with Inorganics 1 Make up the cleaning solution listed from Table 1 Table 1 Inorganic Cleaning Solution e Preferred 2 0 wt Citric Acid PH 2 45 C maximum Alternate Muriatic Acid Notes 1 wt denotes weight percent of active ingredient 2Cleaning chemical symbols in order used HCI is hydrochloric acid Muriatic Acid Cleaning the Inorganics from Membrane Elements e Alternative 1 0 N32S204 Alternative 0 5 HsPCM Form No 609 00301 1202XQRP Notes 1 wt denotes weight percent of active ingredient 2Cleaning chemical symbols in order used HCI is hydrochloric acid Muriatic Acid 2 Low flow pumping Pump mixed preheated cleaning solution to the vessel at conditions of low flow rate about half of that shown in Table 2
20. ecifications when used for general water treatment for a period of 12 months from receipt providing the membrane elements have not been abused by operating at high temperatures high or low pH s on un disinfected water or on solutions which tend to precipitate For applications or water conditions other than those specified in the original purchase order for the reverse osmosis system the User should consult with their local dealer or distributor to access the suitability of the solution to be run in the membrane elements Limitations on pH and temperature can vary with membrane element type and the application of the equipment For special applications or for pH or temperature ranges outside the stated limits the manufacturer may reduce the warranty period at their discretion A membrane element which fails to perform satisfactorily within the first 90 days after receipt has not been mishandled and is returned to the factory will be replaced free of charge except for freight and local labor If a membrane element fails to perform satisfactorily during the balance of the warranty period and with the return of the membrane element to the factory the manufacturer will replace the membrane element with a new membrane element and will charge the User for the portion of the 12 months that the membrane element was used plus incoming freight and local labor Such pro rated charges will be based on the list price prevailing at the time of warranty consid
21. ed Normal to Moderate Increase Normal to Moderate Increase Any Stage Decreased or Slightly Increased Most Severe in First M vere in Fir Increased Increased Decreased ost Severe st Stage Increased Increased Normal to Low Decreased Normal to Increased 19 MIT At Random Possible Causes Metal Oxide Fouling Colloidal Fouling Scaling CaS04 CaSOS BaSO4 SiO2 Biological Fouling Organic Fouling Chlorine Oxidation Abrasion of membrane by Crystalline Material O Ring Leaks End or Side Seal Leaks Recovery Too High Verification Analysis of Metal lons in Cleaning Solution SDI Measurement of Feed Walter Analysis of metal ions in cleaning solution by checking LSI of reject Calculate max solubility of CaS04 BaS04 SiO2 in reject Bacteria count in permeate and reject Slime in pipes and pressure vessels Destructive Element Testing Chlorine Analysis of feed water Destructive element test Microscopic solids analysis of feed Destructive element test Probe test Vacuum test Colloidal material test Check Flows and Pressure Against Design Guidelines Corrective Action Improve pretreatment to remove metals Clean with Acid Cleaners Optimize pretreatment for colloid removal Clean with high pH anionic cleaners Increase acid addition and antiscalant dosage for CaVOS and CaCO4 Reduce recovery Clean with Acid Cleaners Shock dosa
22. ed the cleaning solution at the rates shown in Table 2 for 45 minutes The high flow rate flushes out the foulants removed from the membrane surface by the cleaning If the elements are heavily fouled using a flow rate that is 50 percent higher than shown in Table 2 may aid cleaning At higher flow rates excessive pressure drop may be a problem The maximum recommended pressure drops are 15 psi per element or 50 psi per multi element vessel whichever value is more limiting 6 Flush out Prefiltered raw water can be used for flushing out the cleaning solution unless there will be corrosion problems e g stagnant seawater will corrode stainless steel piping To prevent precipitation the minimum flush out temperature is 20 C The system should be flushed for 1 hour 12 7 The system should be restarted Elements and the system need to stabilize before taking any data The stabilization period will vary depending on the severity of the fouling To regain optimum performance it may take several cleaning and soak cycles NOTE Recommendations made here are specifically designed for the membrane elements inserted in the Titan reverse osmosis and nanofiltration elements These recommendations such as cleaning procedures and chemicals employed may not be compatible with other brands of membrane elements It is your responsibility to ensure the suitability of these recommendations and procedures if they are applied to membrane elements other th
23. electrical connections are secure Use a voltmeter to verify that the motor is getting sufficient power 6 Pressure Gauge Check for foreign matter on the gauge fitting Remove any visible matter and replace the fitting Verify that the tube is not pushed too far inside the fitting This could restrict flow and cause an inaccurate display If the fitting and tube are fine and the pressure gauge is still malfunctioning the gauge should be replaced 7 Concentrate Control Valve The concentrate control valve may have a tear in the diaphragm Remove the valve inspect the diaphragm and replace if necessary 8 Motor The motor may not be drawing the correct current Use a clamp on amp meter to check the current draw 9 Leaks Check the system for leaks as this can result in low pressure Abnormal Permeate Flow Permeate flow should be within 1596 of the rated production after correcting the feed water temperatures above or below 77 F Check your permeate flow meter to determine the permeate flow rate If the system does not have a permeate flow meter measure the time it takes to fill a 1 gallon container then calculate the permeate flow rate at gallons per minute or gallons per day 17 osis System Troubleshooting s Permeate Flow L Salt Passag ocation Normal to Increased Predominately First Stage Predominately First iil Predominately First B i Decreased Normal to Increased Decreased Normal to Increas
24. ents that are used to identify conditions or practices that could result in equipment or other property damage WARNING Indicates statements that are used to identify conditions or practices that could result in injury or loss of life FAILURE TO FOLLOW WARNINGS COULD RESULT IN SERIOUS INJURY OR EVEN DEATH Labeling Do not under any circumstance remove any Caution Warning or other descriptive label from the system System Specifications Gallons Per Day 10000 15000 20000 Dimensions approx 49 x 31 x 54 56 5 x 31 x 54 64 x 31 x 54 Weight approx 385 Ibs 400 Ibs 415 Ibs Recycle Line Optional Optional Optional Auto Flush Optional Optional Optional Element Size in 4040 TFC HF 1 4040 TFC HF 1 4040 TFC HF 1 Elements qty 6 8 10 MotorHP 3 3 5 Voltage 220 1 Phase 220 1 Phase 220 3 Phase Hertz 60 60 60 Feed Connection 2 2 2 Product Connection 1 4 E Waste Connection 1 4 x Minimum Feed gpm 14 50 Recovery 21 50 Recovery 30 50 Recovery Maximum Feed gpm 30 30 50 Feed Water amp Operation Specifications Nothing has a greater effect on a reverse osmosis system than the feed water quality For lasting performance it is important to supply the system with the feed water quality shown below It is also important to feed the system the required amount of feed water NOTE It is very important to meet the feed water requirements Failure to do so will cause the membranes to foul and void the warranty Feed
25. eration A new membrane element supplied under warranty terms will carry the standard 12 month new membrane element warranty If a membrane element is to be returned for warranty inspection the User must obtain a Return Good Authorization RGA number from their dealer or distributor before returning the membrane elements Completely fill out a Return Merchandise Form which will accompany the returned good Membrane elements are to be returned freight prepaid to the manufacturer The manufacturer will return any warranty replacement membrane elements to the customer prepaid Membrane elements must be kept damp at all times and must be clean and bagged in a watertight bag before returning Only the manufactured approved cleaners biocides dispersants or other chemicals may be used with the membrane elements Use of other chemicals may void the warranty The User is responsible for knowing the membrane element material and for ensuring that chemicals harmful to the membrane element are never in contact with the membrane elements 22 It is the obligation of the User to maintain frequent operating data records The manufacturer may request these records in the warranty evaluation The User must notify their dealer or distributor at the very first sign of changes in operation of the system or membrane elements Such notification should be in writing and should include all data requested on the operating log sheets To obtain a copy of the manufacturer
26. flow for the permeate storage tank is recommended Pump Bypass Valve This valve is installed as a standard feature on the Thunder 10000 15000 amp 20000 reverse osmosis systems It provides an adjustment for pump pressure which will vary as the required system pressure changes Note that with a multi stage pump the pump flow decreases as the operating pressure increases As the feed water temperature decreases and or the feed water TDS increases the system will require a higher operating pressure to produce the specified permeate flow A Thunder system installed in Florida may provide the specified permeate flow of 3 47 gpm at 150 psi however the same system installed in Maine much colder feed water may require 190 psi to produce the same amount of permeate The system in Florida would have a higher concentrate flow to the drain because of the lower operating pressure which would result in poor system recovery 5 Rejection Feed IDS Product TDS Feed IDS x 100 Membrane Removal amp Replacement Changing membranes in pressure vessels is an easy process if you have the proper information and tools at hand Please refer to the following instructions when removing and replacing membrane elements 1 Remove the end caps from the top of the membrane housings This is done by removing the white Nylon snap ring of the Champ housing or unscrewing the bolts of the PuroTech housing which holds on the clamp 2 Remove the membrane b
27. ge of Sodium Bi Sulfate Continuous feed of Sodium Bi Sulfate at reduced pH Formaldehyde disinfection Chlorination and de chlorination Replace cartridge filters Activated Carbon or other pretreatment Clean with high pH cleaner Check Chlorine feed equipment and de chlorination System Improve pretreatment Check all filters for media leakage Replace 0 Rings Repair or replace elements Reduce the recovery rate Calibrate and or add sensors Operation Log Company Date of Start Up Location Date of Last Cleaning Week Of Cleaning Formulation System Serial Date __ j j O Time y Hours of Operation Oo O Cartridge Filter Inlet Pressure ps GE ential Pressure o Peririeato Pressure psi Po Feed Pressure psi Concentrate Pressure psi Differential Pressure psi Pump Discharge Pressure psi Permeate Flow GPM O _ O oa Flow GPM y ad Flow GPM O es y O Recovery Feed Temperature Feed Conductivity mg L Permeate Conductivity mg L Rejection 96 FeedpH Scale Inhibitor Feed ppm Acid Feed ppm Sodium Bisulfite Feed ppm Feed Water Iron mg L Free Chlorine mg L Hardness m E Notes 20 Temperature Correction Factors For Membrane Flux TEMPERATURE CA TF ec ep Cellulose Acetate Thin Film Composite 10 50 1 468 1 71 11 52 1 429 1 648 1
28. he system can operate longer without cleaning and or replacing the membrane elements The following are instances in which the auto flush should be utilized 1 When injecting antiscalant chemicals These chemicals keep scaling ions in solution up to a higher concentration so the ions don t precipitate and scale the membrane elements If the solubility concentration is exceeded the ions may precipitate and scale the membrane 2 Forfeed water with a high scaling potential hard water in addition to the auto flush pre treat the water with an antiscalant or a water softener Do not use the automatic fast flush instead of pretreatment 3 Where minimal maintenance is important auto flush can increase the time between membranes cleaning 4 Forhigh TDS total dissolved solids applications where the TDS exceeds 500 ppm consider upgrading system to auto flush 5 Forhigher recovery applications that use a recycle valve consider using auto flush 6 For systems that may remain inoperative for long periods of time auto flush should be installed The auto flush will not operate if the electrical power is removed from the system The auto flush feature includes an adjustable setting that regulates its operation In the auto flush mode the water will flush across the membrane in the same direction as the water flows in normal operation this is not a backwash flow NOTE Some permeate will be produced during the auto flush therefore an over
29. in the system Be certain that all of the components of the feed water are soluble at the concentrations attained in the system A system operating at 5096 recovery concentrates all impurities by twice the amount If the feed water contains a slightly soluble material such as calcium sulfate silica or colloidal clay an anti sealant should be used CAUTION Any restrictions or blockage in the drain can cause backpressure which will increase the system s operating pressure This can result in damage to the system s components Electrical The motors used on Thunder 10000 15000 amp 20000 systems are pump and motor combinations The Titan 10000 and 150000 are available in 1 phase 220 volt at 60 hertz or 220 volt at 50 hertz at an additional charge The Thunder 20000 is available in 3 phase 220 volt at 60 hertz Please ensure that the electrical circuit supplying the system is compatible with the requirements of the specific Thunder model NOTE We recommend that a licensed electrician install your system in accordance with local and national electrical codes WARNING To reduce the risk of electrical shock the incoming power supply must include a protective earth ground Each Thunder system is equipped with a 5 foot electrical cord Pre Filtration These Thunder systems are supplied with a 10 Micron FSI Bag Filter which filters sediment to a level of 10 microns The 4 5 x 20 5 Micron polypropylene filter removes particles over 5 mic
30. int If the system is not equipped with this gauge disconnect the hose that runs from the pump to the pressure vessel Install a pressure gauge The pressure of the pump must reach at least 190 psi when the flow is restricted 2 Pre Filter Check the differential in the pre filter gauges to determine if the filter needs to be replaced If the system is not equipped with these gauges examine the pre filter cartridge to make sure that it is not clogged and does not restrict feed flow to the pump Replace if necessary 3 Low Feed Water Flow Rate Determine that the system is getting a sufficient volume of feed water Disconnect the feed water hose from the system and place it in a one gallon bucket Measure the time it takes to fill the bucket to determine the feed flow Feed flow is measured in gallons per minute so divide 1 gallon by the time in minutes to obtain the flow rate Refer to the System Specifications for the required feed flow 4 Inlet Solenoid Valve Feed water enters the system through an automatic solenoid shut off valve which is normally closed Ensure that the solenoid opens when the reverse osmosis pump starts The system can be operated without the solenoid for troubleshooting Remove the solenoid to see if it is contributing to the problem Normally cleaning the solenoid diaphragm will correct any malfunction of the solenoid 5 Electric Check to ensure that there are no electrical fuses blown and that all
31. reheated cleaning solution to the vessel at conditions of low flow rate about half of that shown in Table 2 and low pressure to displace the process water Use only enough pressure to compensate for the pressure drop from feed to concentrate The pressure should be low enough that essentially no permeate is produced A low pressure minimizes re deposition of dirt on the membrane Dump the concentrate as necessary to prevent dilution of the cleaning solution Table 2 Recommended Feed Flow Rate Per Housing During High Flow Rate Re Circulation e Dependent on number of elements in pressure vessel 4 full fit elements should be cleaned at 12 14 gpm 2 7 3 2 m3 hr 3 Re circulate After the process water is displaced cleaning solution will be present in the concentrate stream that can be recycled to the cleaning solution tank Recycle the cleaning solution for 15 minutes or until there is no visible color change If a color change occurs dispose of the cleaning solution and prepare a new solution as described in step 2 4 Soak Turn the pump off and allow the elements to soak Soak the elements for 1 15 hours soaking overnight will give best results To maintain temperature during an extended soak period use a slow recirculation rate about 10 percent of that shown in Table 2 Soak time will vary depending on the severity of the fouling For lightly fouled systems a soak time of 1 2 hours is sufficient 5 High flow pumping Fe
32. rons Change the cartridge at least every month or whenever needed A chlorine removal system must be installed before the system Ask your local dealer or distributor about Water Softeners and or Filtration systems NOTE The system must be operated on filtered water only Do not attempt to clean used filter cartridges CAUTION If the pre filter becomes clogged and the water flow to the pump is reduced or interrupted cavitation will occur This will damage the pump Pump The pumps used on Thunder 10000 15000 amp 20000 systems are pump and motor combinations They are multi stage centrifugal pumps Follow these guidelines to ensure proper operation of the pump The pump must NEVER be run dry Operating the pump without sufficient feed water will damage the pump ALWAYS feed the pump with filtered water The pump is susceptible to damage from sediment and debris Mounting The free standing system should be bolted down in compliance to local regulation standards or securely fastened Membrane Elements Thunder reverse osmosis systems come preloaded with Thin Film Composite High Flow membranes unless otherwise specified General membrane element performance characteristics are listed below Membrane Element Characteristics Operating Pressure 150651 Maximum Pressure 400 psi Nominal Rejection 98 5 Chlorine Tolerance 1 ppm Maximum Temperature HOF Turbidity 1NTU Silt Density Index 5 SDI pH Range 3 11 Test Conditions
33. stems which have biological fouling It is however easier to handle than HCI and is included as an the primary cleaner for that reason Flushing the System The system should be flushed weekly to remove sediment from the surface of the membranes To manually flush the system following the preceding steps 1 The system must be running during the flushing procedure 15 2 Openthe concentrate valve until the pressure gauge reads approximately 50 psi 3 5 bar NOTE If pressure will not drop to approximately 50 psi 3 5 bar pressure during flushing the concentrate valve must be cleaned 3 Allow the system to run for 10 to 20 minutes 4 After 10 to 20 minutes close the concentrate valve to its previous position raising the operating pressure to 150 psi Ensure the proper concentrate flow rate is going to the drain 5 The system is now ready to operate Draining the System for Shipment Prior to shipping or storing your system the system should be cleaned with an appropriate cleaner flushed with water and protected from biological attack with an appropriate solution for membrane elements The membrane housing s and plumbing lines of the system must be completely drained Any water remaining in the plumbing of a system may freeze causing serious damage The party shipping or storing the system is responsible for any damage resulting from freezing To drain the system 1 Disconnect the inlet concentrate pre filter and permea
34. table supply or pre filtered feed water may be used provided that there are no corrosion problems in the piping system Operate initially at reduced flow and pressure to flush the bulk of the cleaning solution from the elements before resuming normal operating pressures and flows Despite this precaution cleaning chemicals will be present on the permeate side following cleaning Therefore permeate must be diverted to drain for at least 10 minutes or until the water is clear when starting up after cleaning During recirculation of cleaning solutions the temperatures must not exceed 50 C at pH 2 10 35 CatpH 1 11 and30 CatpH 1 12 For membrane elements greater than six inches in diameter the flow direction during cleaning must be the same as during normal operation to prevent element telescoping because the 11 housing thrust ring is installed only on the reject end of the housing This is also recommended for smaller elements Cleaning Procedures There are seven steps in cleaning membrane elements with organics 1 Make up the cleaning solution listed from Table 1 Table 1 Organic Cleaning Solution Preferred 0 1 96 wt Soda Ash PH 12 30 C maximum e Preferred 0 1 wt NaOH 0 025 wt PH 12 30 C maximum Notes 1 wt Denotes weight percent of active ingredient 2 Cleaning chemical symbols in order used NaOH is sodium hydroxide Cleaning the Organics from Membrane Elements 2 Low flow pumping Pump mixed p
35. te plumbing 2 Drain all water from the pre filter cartridge housings by unscrewing the housings removing the pre filter cartridges and drain the water from the housings 3 Disconnect the tubing from the connector on the permeate and concentrate inlets and outlets 4 Fully open the concentrate valve 5 Drain the flow meters by disconnecting the tubing from the bottom fitting of each meter 6 Allow the system to drain for a minimum of eight hours or until the opened ports quit dripping 7 After draining is complete reconnect all of the plumbing Troubleshooting If the system production declines or the system stops working check the mechanical components for any visual problems Listed below are the items to check for any visual problems Listed below are the items to check for two of the most commonly encountered problem conditions Low system pressure and abnormal permeate flow Also refer to the reverse osmosis troubleshooting matrix on the next page Low System Pressure Low system pressure occurs when sufficient feed water pressure and flow are not obtained This causes the high pressure reverse osmosis pump to cavitate Failure to provide the proper feed will result in lower system pressure that may result in low production and poor rejection Check the following components 1 Pump Isolate the pump and determine how much pressure can be achieved This can be determined by checking the pump discharge pressure gauge at this po
36. the membrane Discard all of the permeate and concentrate which is produced during the flush Membrane Cleaning Periodic cleaning of the membrane s can improve system performance In normal operation mineral scale biological matter colloidal particles and organic substances can foul the membranes WARNING Cleaning chemicals are dangerous and can cause injury and damage to the environment Read and comply with all safety and disposal precautions listed on the Material Safety Data Sheets MSDS s It is the user s responsibility to comply with all applicable federal state and local regulations Organic Foulant Cleaning The following cleaning procedures are designed specifically tor membranes that have been fouled with organic matter Review the general cleaning instructions for information that is common to all types of cleaning such as suggested equipment pH and temperature limits and recommended flow rates Safely Precautions 1 When using any chemical indicated here in subsequent sections follow accepted safety practices Consult the chemical manufacturer for detailed information about safety handling and disposal When preparing cleaning solutions ensure that all chemicals are dissolved and well mixed before circulating the solutions through the membrane elements It is recommended the membrane elements be flushed with good quality chlorine free water after cleaning Permeate water is recommended but a de chlorinated po
37. y of these recommendations and procedures if they are applied to membrane elements other than those which come with your system NOTE 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 WARRANTIES ARE GIVEN ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY EXCLUDED Additional Information Never recirculate the cleaning solution for longer than 20 minutes With longer recirculation the carbonate scale can reprecipitate and end up back on the membrane surface making it more difficult to clean Carbonate scale reacts with HCI releasing carbon dioxide gas Depending on the severity of the fouling it may take repeated cleanings to remove all the scale Cleaning severe scale may not be economical and element replacement may be the best choice Citric acid was originally used as a cleaner for cellulose acetate membranes and is not as effective with thin film composite chemistry Further it has a disadvantage of being a nutrient source for sy
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