Freshpoint U440 Service (4002816)
Contents
1. Board Number DIP Switch Positions Master 1 2 amp 3 ON UA 01 1 OFF 2 amp 3 ON UA 02 2 OFF 1 amp 3 ON UA 03 1 amp 2 OFF 3 ON SLAVE 1 CONTROL O O TO SLAVE 2 RS 485 1 i RSS 7 Meter RS 485 2 z gt ad To Solenoid Terminal Block Ed ad ai To Solenoid Terminal Block O Figure 13 Circuit Board Diagram The preset flush program selected in the master unit will also be used by the slave unit s in series NOTE For each module the inlet and drain solenoids will be actuated simultaneously NOTE If backflush kits have not been included there will be no inlet solenoids NOTE Apply power to slave unit s before powering the master control FreshPoint U440 e 17 BASIC PROGRAMMING QUICK REFERENCE GUIDE Parameter Data Display Display Error Diagnostics Icon E i Flow Indicator Service ee Icon 4 x1000 Indicator Programming Icon f Extra Cycle Up Down Button Button Button J Figure 14 Plug in the system 2 The display will read U440 If something other than U440 is displayed upon power up see TROUBLESHOOTING 3 Press and hold the Up and Down buttons for five seconds to enter User Programming DV will be shown in the upper left of the display window 4 Once in User Programming use the Up and Down buttons to adjust the values for ea2. General Test Information e The test requires that the membrane be fully wet out all pores full of water e The membrane assembly should be drained of all excess water e This test does not require the visual detection of a bubble Instead it measures the loss of pressure or vacuum over time via a gauge e certain amount of pressure loss will occur in an intact system from diffusion of air through the trapped water in the membrane pores baseline decay But a higher pressure loss will occur from membrane flaws or broken seals e To prevent contamination use a clean air source preferably filtered through a 0 2 micron filter on the air source Equipment See Figure 16 FreshPoint Flow Vs Pressure Drop e Pressurized air source 20 psig 3 scfm capacity 138 kPa 1 4 Lps with pressure regulator a small portable air tank or a portable compressor e Pressure gauge 0 20 or 0 30 psi 0 138 kPa or 0 207 kPa with accuracy to 0 1 psi 0 7 kPa e Positive shut off valve a bubble tight ball valve to isolate the FreshPoint membrane inlet and one to isolate the air source e Stopwatch or watch with a second hand FreshPoint U440 e 15 SYSTEM START UP continued Integrity Test Procedure 1 Ensure that the membrane is fully wet out by operating the system at its maximum flow rate for at least 20 minutes by opening the nearest tap downstream 2 Isolate the system by closing the inlet valve of th
3. PERFORMANCE MONITORING The consistency of performance of the ultrafilter membrane can be assessed by measuring the transmembrane pressure TMP filtrate flow rate and water temperature and comparing the results to the unit s previous performance Most beneficial is to have the data from when the membrane was first installed for comparison Establishing Initial Conditions 1 If a flush tank has been installed isolate it by closing the ball valve Open the faucet closest to the FreshPoint system Record the filtrate flow rate as reported by the FreshPoint controller as Finitial 4 Record the pressure at the UF module inlet as Pinitial Record the known or estimated water temperature as Tinitial Assess the current performance of the ultrafilter membrane by normalizing its current performance to its initial performance as follows 6 If a flush tank has been installed isolate it by closing the ball valve 7 Open the faucet closest to the FreshPoint system This should be the same faucet used during the initial testing 8 Record the filtrate flow rate as reported by the FreshPoint controller as Fcurrent unit 9 Record the pressure at the UF module inlet as Pcurrent 10 Record the known or estimated water temperature as Tcurrent If the water temperature is assumed to not have changed this term of the equation will reduce to 1 11 Calculate the current flow rate normalized to the initial performance by the
4. NOTE Installations without a pressure tank may experience drops in pressure flow to the home during a flush cycle Drain Flow Control Note flow direction Noto few direction Outlet Valve Outlet 1 2 Drain Shut Off Valve Inlet Bypass Valve Inlet Valve Pre Filter Recommended Drain Piping must include code compliant air gap 3 4 Backflush Inlet Shut Off Valve 61504 U440 FF Rev B Figure 3 Tankless Installation FreshPoint U440 e 9 INSTALLATION INSTRUCTIONS continued Additional Water Treatment Devices e When multiple devices for water treatment equipment are involved the most effective order of installation must be determined for the specific water source and the treatment objective This can best be accomplished by a local water treatment professional e The FreshPoint system is designed to remove particles much smaller than conventional filtration devices The FreshPoint system is not designed to be used as a roughing filter and as such should be installed after conventional filters iron filters multimedia filters etc which are used to remove larger suspended solids This will permit the smallest particles which pass through a conventional filter to be removed by the FreshPoint system without fouling the FreshPoint membrane e The small particle removal and turbidity reduction achieved by the FreshPoint system can be beneficial to achieving maximum perf
5. an unpleasant Unit has not been flushed sufficiently at Open all faucets in the house and let water flow for 20 taste and or suds when startup minutes starting at the faucet closest to the system being drawn Water splashes at drain Drain line not positioned properly Reposition the end of the drain line during flush Backflush flow stops High flush tank precharge pressure flush tank precharge pressure Adjust flush tank precharge pressure to 20 psi 138 kPa flush tank precharge pressure to 20 psi 138 kPa betore end ell EE Backflush tank is too small for flush and Install a larger backflush tank service usage Water leaks at the end of Seal missing or damaged Replace seal the membrane housing 22 e FreshPoint U440 TROUBLESHOOTING continued Error Messages Press the Extra Cycle button to clear The service volume and days will be reset ERR1 Service Volume or Service Days has expired Communication error Check dip switches and communication cable connections and cycle power to controller If a multi unit system turn off power to all units correct cable or switch issues and restore power first to slave unit s then to master FLOW RATE VS DRIVING PRESSURE Flow Rate f Temp F Figure 16 FreshPoint Flow Vs Pressure Drop NOTE Curves are shown for a clean membrane at various water temperatures NOTE Flow decreases 3 for each 1 8F 1C decrease in feed water temperature APPENDIX A
6. connections for any possible leaks System Sanitizing With Prefilter Installed The unit should be sanitized disinfected after the initial start up rinsing procedure or in the case of biological fouling The system should be disinfected after flushing but prior to use Disinfect after the integrity test if performed A Sodium hypochlorite bleach is used for disinfection The user should acquaint themselves with the appropriate safety precautions for storage and handling of the chemicals being used USE ONLY SODIUM HYPOCHLORITE DO NOT USE BLEACHES CONTAINING ANY OTHER COMPOUNDS 1 Close the inlet valve of the bypass plumbing arrangement If installing with backflush kit disconnect the wiring harness from the inlet solenoid valve 2 If the FreshPoint system is equipped with a backflush or product tank initiate a sufficiently long flush by pressing and holding the Extra Cycle button on the control for five seconds to empty the flush tank Isolate the backflush tank by closing the tank isolation valve ie Any product or backflush tank needs to be isolated during disinfection The chemicals use in disinfection are at a higher concentration than recommended for these tanks and are likely to cause damage to the tanks if exposed 3 Opena faucet near the FreshPoint system to ensure that the plumbing system is depressurized 4 Remove the prefilter sump Remove the filter cartridge 6 Add unscented bleach to the sanitation
7. differential pressure switch or other remote switch a backflush will be started FRESHPOINT ASSEMBLY 61653Q Rev B Item No QTY Part No Description QTY Part No Description lens lasse 35710 issue Vessel Assy Stainless Steel 4 ds el EE EN Fitting Kit Inlet U440 Diameter Be eee 60700 10 voeseeeeseees DLFC F x 3 4 F NPT 10 gpm Part of 357707 Body Vessel Stainless Steel 4 de 1 220020 Fitting Kit Drain U440 ae Part of 357707 End Cap Assy TD Vie 4002607 n Solenoid Assy U440 DC w Cable oa 2 Part of 3577071 0 ring 342 EPDM NE N 60699 70 asasan DLFC F x 4 F NPT 7 0 gpm ee 2 Part of 357707 0 ring 210 EPDM N Te 002792 cnrs Fitting Kit Outlet U440 TE en 2 Part of 3577071 0 ring 118 18e 1e 182B ee Kit 1 Turbine w NPT i esse 2 Part of 357707 U Pin Stainless Steel 2 35 Not Shown PRES ES asses 61595 03 357708 Membrane Element 4 A3BAD Power Supply 24V DC 2 5A is 357719 4002947 Adapter Kit UF Filter 1 42047 01 Harness Solenoid U440 72 ele a Bracket Mounting UF Filtar AR eee Fitting Kit BSP Conversion anes 41976 css Clamp Assy UF Filter ABO Silicone Packet RS 1 4002607 oeecceesssee Timer Assy UF U440 24VDC eN Ee Ri FreshPoint U440 e 13 SYSTEM START UP Electrical Follow the instructions in the programming section of this service manual to se
8. gt PENTAIR FRESHPOINT U440 ULTRAFILTRATION SYSTEM SERVICE MANUAL 2013 Pentair Residential Filtration LLC www pentairaqua com pro TABLE OF CONTENTS INSTALLATION AND START UP CHECKLIST www see ese see ee 3 PRODUCT SPECIFICATIONS AND IMPORTANT INFORMATION eee eens 4 IMPORTANTEREAD THIS FIRST vies sees ees esse seek Be dee ke eb ee geed 4 SAFETY CAUTIONS AND WARNINGS ees ee 5 DIMENSIONAL DRAWIND assie ve en ve as sg As ae ee BEE ges Ee ve RE SEGE EER 5 FLUSHING SCHEDULE scenic veg see ges iaoiae 6 INSTALLATION INSTRUCTIONS ee ee ee ee ee ee ee 6 FRESHPOINT ASSEMBLY SYSTEM START UP ses eeue esse Reg sd ese Ene E eie ERG es Ee ER Reed MULTI UNIT FRESHPOINT INSTALLATION 17 BASIC PROGRAMMING QUICK REFERENCE GUIDE 18 MASTER RESET scr sasacaacescrsssuscicecstenmnaantessasetaesssasiancecscavananchade 20 SERVICE AND MAINTENANCE cece ee eek ee ee ee ee 21 TROUBLES HOOUING eseis resani ves sfeer ro Ee eed Ee ekke Vee eer enk eke dee 22 FLOW RATE VS DRIVING PRESSURE 23 APPENDIX A PERFORMANCE MONITORING 23 SERVICE ASSEMBLIES sisi eek Ged ede ee Be eeue Re Eed ee ees 23 2 e FreshPoint U440 PORTANT PLEASE READ The information specifications and illustrations in this manual are based on the latest information available at the time of printing The manufacturer reserves the right to make changes at any time without notice This manual is intended as a guide for serv
9. should be replaced 10 Turn on the air compressor 11 With the drain solenoid valve closed carefully pressurize the feed side the inside of the fiber lumens to 15 1 psi 1 04 bar or 104 kPa to 15 4 psi 1 06 bar or 106 kPa by pressing the air compressor hose chuck onto the air supply valve on the Technician s Decay Test Components Figure 16 FreshPoint Flow Vs Pressure Drop DO NOT PERMIT THE MODULE TO BE PRESSURIZED TO GREATER THAN 16 PSI 1 1 bar or 110 kPa 12 Turn off the air compressor 13 Begin timing the pressure decay when the pressure falls to 15 0 psi 1 03 bar or 103 kPa 14 Record the pressures at 30 60 90 and 120 seconds 15 Once the plumbing has passed the test test the membrane and membrane seals by opening the nearest downstream faucet to allow air to escape during the test or crack open the outlet union NOTE A membrane that is not properly wet out or has been sitting for some time may cause a false failure Ensure that the membrane has been flushed properly before performing the Integrity Test Acceptance Criteria After two minutes the system should not have decayed from 15 0 psi 1 03 bar or 103 kPa to less than 14 5 psi 0 99 bar or 100 kPa 16 If the system fails to hold pressure verify the integrity of the inlet and drain plumbing by closing the outlet valve of the bypass plumbing arrangement and repeating steps 10 through 14 16 e FreshPoint U440 NOTE Pressure decay with o
10. water quality in the entire home It uses ultrafiltration membrane technology to provide a physical barrier to suspended solids large molecules most colloids and microbes down to 0 025 um in size The FreshPoint is not designed to remove ions or other elemental forms such as hardness and heavy metals or small organic molecules such as pesticides The FreshPoint system should only be installed by a qualified professional The installation must comply with all local codes and state or provincial laws and regulations In addition to meeting codes laws and regulations the home owner should understand the care and maintenance of the FreshPoint system Please read the information found in this service manual SAFETY NOTICE Read all safety precautions before installing operating or servicing the FreshPoint Product Specifications Technical Data and Specifications pH Range During Operation 3 10 Free Chlorine Max 200 mg L for cleaning 4 mg L for service Maximum Continuous Flow Recommended 1 2 gpm surface waters to 3 0 gpm well water Maximum Intermittent Flow 10 gpm up to 60 psi 413 kPa Recommended Operating Pressure Maximum Operating Pressure 120 psi 827 kPa 34 F Do Not Freeze Minimum Operating Temperature Maximum Operating 104 F Temperature Contaminant Removal Size 150 000 daltons molecular weight cut off 0 025 um nominal pore size Multibore Capillar
11. 30 seconds e Downtime Over 15 days Automatic flushing Systems that are equipped with automatic time based flush systems and feed water is available can continue to flush automatically provided the flush cycle occurs at least every 24 hours for a minimum of 60 seconds Downtime gt 7 days No Automatic flushing Membranes stored in place Membranes should be cleaned and disinfected The system should be put in bypass Then fill with a 0 1 sodium bisulfite solution Leave membranes installed in the system DO NOT FREEZE Take precautions to ensure the FreshPoint system is not exposed to freezing temperatures In all cases the membranes must be stored hydraulically filled CN Any time a storage solution is used the membranes must be flushed and sanitized prior to use See Membrane Flushing amp Disinfection guidelines An integrity test is recommended To replace the Membrane Element 1 Use the bypass valve to bypass the system Isolate the backflush tank if applicable 2 Run a manual flush by pressing and holding the Extra Cycle button for five seconds until water no longer comes out of the drain port 3 If installed use the integrity test port to drain the system It may be useful to open the drain by running a manual flush to help draining 4 Unplug the power cord leading to the system and gently disconnect the cord leading to the flow meter and the wire harnessles leading to the solenoid valvels 5
12. G System controller does not The system is not plugged in Plug the system controller in have power Display shows HS or Control set for wrong system Power up control while holding the Extra Cycle button SC upon power up to reset control Use the Up or Down buttons to select U440 and press Extra Cycle button to accept Single unit display shows Control has been set as a multi unit Set all control DIP switches to ON and cycle power to UA Ox upon power up slave control See MULTI UNIT FRESHPOINT INSTALLATION There is no product water Bypass valves are not in the correct Restore supply flow to the system flow to the house positions to allow water flow to the house or supply water is unavailable Cartridge in prefilter is plugged Replace or clean the filter cartridge FreshPoint membrane is fouled Contact your FreshPoint dealer for service There is low flow or FreshPoint is flushing Wait for flush to end If desired have a pressure tank pressure available installed after system to maintain pressure during flush If flushing continuously see System is flushing continuously below Unit is not flushing frequently enough Decrease the volume between flushes and or increase the flush time Inlet water pressure is too low Boost the inlet water pressure Cartridge in prefilter is plugged Replace or clean the filter cartridge FreshPoint membrane is fouled Contact your FreshPoint dealer for service
13. Incoming water temperature is too low Contact your FreshPoint dealer for options to compensate for low water temperature System is flushing Drain solenoid valve is stuck open Replace the drain solenoid valve continuously System controller circuit board is sending Contact your FreshPoint dealer for service flush signal continuously System is not flushing The system is not plugged in Plug the system controller in Drain solenoid valve is stuck closed Replace the solenoid valve Meter is not reading flow Check the connection of meter cable to meter secure if necessary System controller circuit board is not Contact your FreshPoint dealer for service sending flush signal Meter is not reading flow Meter cable is not secured to meter body Check the connection of meter cable to meter and secure if necessary Meter or controller are malfunctioning Contact your FreshPoint dealer for service Water leaks at the end of Cartridge end connections are not tight Tighten with wrench if necessary the filter cartridge after enough changing cartridge O rings are not properly lubricated Lubricate O rings O EEN are cut or deformed Replace 0 EE SEEK System controller display The system controller is not The system controller is not plugged in in Plug the system controller in the system controller in is blarik System controller circuit board is Contact your FreshPoint dealer for service malfunctioning Water has
14. Slowly disconnect the inlet fitting union located closest to the floor This will allow any remaining water to drain from the system 6 Slowly disconnect one end of the PEX tubing from the drain solenoid valve by pushing in the connector collar and pulling out the tubing 7 Slowly disconnect one end of the meter assembly from the outlet assembly 8 Loosen the four mounting bolts that fasten the FreshPoint to the wall Lift the system up slightly and pull away from the wall 9 Remove the end caps and slide the membrane element out of the membrane housing both end caps may need to be removed so the element can be pushed out of the housing 10 Lubricate the O rings sparingly with silicone Replace the end cap on the bottom of the vessel 11 Install the spacer spring 12 Gently slide the new membrane element into the housing NOTE The open distributor tube of the membrane should be oriented up dYU TT DO NOT DROP THE MEMBRANE ELEMENT INTO HOUSING THIS COULD DAMAGE THE MEMBRANE ELEMENT 13 Gently and firmly slide the top adaptor with O rings into the membrane elements center tube and secure the end cap 14 Remount the FreshPoint and reattach plumbing Reconnect the meter cable and wire harnessles 15 Put the unit back into service with the bypass valve Before using system perform flushing and sanitizing procedures as listed in the Installation section of this service manual FreshPoint U440 e 21 TROUBLESHOOTIN
15. TALLATION Parallel arrangements of FreshPoint modules should be considered to provide service flow rates greater than that available from a single module while lowering the cost and simplifying the system by programming the units together only once Controls can be wired and programmed to sequentially backflush up to four modules thus minimizing the demand on the Backflush Tank and the impact on the service flow rate Equipment Required Two Membrane System Item Qty Description PN 1 2 FreshPoint System with Control 61788 01 2 1 Backflush Kit with Tank 61667 11 3 1 Multi Unit System Kit 4002815 4 1 Inlet Solenoid Kit 4002788 Recommended Plumbing Schematic FLOWMETER N SERVICE DRAIN SOLENOID VALVE 10 GPM FLOW r MANUAL VALVE CONTROL UR UF if DRAIN DRAIN 1 7GPM A ja 7GPM FLUSH TANK FLOW CONTROL ROMATE 40 INLET 20 PSI 138 kPa asia SOLENOID PRECHARGE VALVE Parallel Ultrafilters L1380277 Figure 12 Parallel Ultrafilter Schematic To assure the proper hydraulic challenge to each module each module should be equipped with the proper inlet and drain flow controls MASTER CONTROL OR FINAL SLAVE CONTROL MULTI UNIT SHUNT RS 485 1 Fi RSS sl Meter RS 485 2 pg ae l Wiring To connect a multi unit system first connect the shunt included in the Multi Uni
16. USHING SCHEDULE Flushing Schedule The FreshPoint system is flushed on a schedule dependent on the quality of water being treated Default Factory Settings Flush Frequency 100 gallons 378 L Flush Duration 0 5 minutes Day Override 1 day These settings may need to be adjusted based on the analysis for the water treated and practical experience with fouling The FreshPoint system will automatically initiate a flush if 24 hours for each 1 day of the Day Override setting has elapsed since the last flow initiated flush This setting is adjusted in the day override setting in master programming A post ultrafilter pressure tank is recommended to ensure sufficient flow and pressure to the home during a flush cycle The backflush surge tank where installed will perform the same function Refer to the table below for initial set up Water Source Typical Water Quality Recommended Backflush Kit Scheduled to Filter Pretreatment Flush and with recommended Duration pretreatment Surface Water Chlorine lt 4 0 mg l e 200 micron Recommended Every 100 Municipally Turbidi prefilter gal 378 L ty lt 5 0 NTU Treated DT for 30 sec e TOC lt 2 0 mg L e SDI15 lt 6 67 e Metals Fe Mn Cu etc lt 1 mg l Surface Water Chlorine gt 2mg l e In Line Recommended Every 50 Private lt 4 0 mg l coagulation and gal 189 L Multi Barrier Turbidity lt 5 0 NTU iltration w
17. ailure to do so may damage the system If the FreshPoint system is drained or out of service for an extended period of time the installer dealer should put a preservative into the system to keep the membrane wetted and prevent microbial growth A 0 1 sodium bisulfite solution is recommended A 0 1 sodium bisulfite solution would be 1 gram of sodium bisulfite added to one liter of water approximately ten liters are required Prior to putting the FreshPoint back into service the system should be flushed and sanitized per the instructions in the Installation section of this service manual Membrane Cleaning Membrane cleaning is required when the surface of the membrane and membrane pores become fouled This is most often detected by a loss of flow rate The FreshPoint membranes should be maintained in a clean condition unfouled by particulate matter precipitates or biological growth Contact your FreshPoint Distributor for cleaning Membrane Storage After Use After initial use the membranes need to be kept wet at all times To avoid biological growth during shutdowns or storage wet membranes should be treated with a compatible biocide e Downtime up to 24 hours no measures required e Downtime 1 to 15 days Automatic flushing Systems that are equipped with automatic time based flush systems and feed water is available can continue to flush automatically provided the flush cycle occurs at least every 24 hours for a minimum of
18. ater to flow until a chlorine smell is detected in the water flowing from the open faucet 10 Close the open faucet and allow the system to soak for one hour 11 Manually initiate a 30 second flush by pressing the Extra Cycle button on the control 12 Open the service faucet and allow the water to flow until the chlorine smell is not detected 13 Use a test kit to confirm that the chlorine level is below 4 ppm ideally below 1 ppm 14 Close the faucet Open the tank isolation valve and reconnect the inlet solenoid valve to the wiring harness if applicable Add Sanitizing Solution 61504 U440 Rev B Figure 9 Adding Sanitizing Solution Membrane Integrity Test Recommended All membrane elements are factory tested and pass integrity tests before they are shipped However a full system integrity test should be done upon startup and then routinely once per year minimum thereafter The integrity is used to check for e Internal leaks such as cut or misaligned O rings e Damaged membranes The preferred integrity test is the pressure decay test Air pressure is applied to the membrane when it is fully wet out the pores are full of water which is the membrane s condition when it has been properly flushed after start up The amount of pressure loss is measured over a set period of time If the pressure declines too fast it indicates that there is a seal leak in the system or membrane fiber damage
19. bracket has been designed to mount the FreshPoint system sufficiently off the wall to accommodate installation of a pre post filter inline with the water inlet and or water outlet of the system e Remember to allow for visual and physical access to the meter programming controls e Do not mount the FreshPoint system above any electrical eguipment or above items that may become damaged if they get wet e Install the FreshPoint in a location that will allow for easy service access Service and maintenance requires access to the unit and removal and replacement of the membrane element e Mount the FreshPoint system to a wall in a vertical orientation using appropriate mounting hardware not included capable of supporting 51 pounds 23 1 kilograms e The FreshPoint system s footprint is 12 x 12 30 x 30 cm exclusive of plumbing connections The FreshPoint system requires 85 2 1 m of vertical room to allow for removal of the membrane unless plumbing accommodations are made e g unions See Figure 1 for a typical installation with dimensions e The backflush surge tank in the backflush kit requires an additional 16 x 16 41 x 41 cm of level floor space Plumbing Options There are two options for plumbing in the FreshPoint system 1 Backflush Surge Tank Installation 2 Installation Forward Flush Backflush Surge Tank Installation Installations with high fouling potential will require plumbing in a pres
20. ch programming option listed below and press the Extra Cycle button to accept the displayed value and move to the next option 5 After cycling through each available option the control will return to the In Service display NOTE In typical applications only the Time Override Volume Between Flushes and Program Select would need adjustment User Programming Options Abbreviation Programming Values Option In Service Flow Rate units per Display minute Volume Remaining units Time Remaining before next flush HH MM Scroll through all three displays Between 1 Units defined by meter 999 900 constant Flushes Time Override 1 99 Hours between flush OFF cycles Program PrG1 Preset programs 1 4 Select PrG5 or custom program 5 If PrG5 is selected F1 through F9 are enabled F1 F9 Flush Step 1 600 Time can be selected in OFF seconds or step can be turned off Note Program 5 unavailable in multi unit configurations Note F1 through F9 are only available if PrG5 is selected Volume DV VF TO PS 18 e FreshPoint U440 Controller Operation During Service 1 In normal operation the display scrolls through current flow rate volume remaining until the next flush cycle and time remaining until next flush if enabled 2 Without any water usage the flow indicator should be either off or on but not changing Open a tap The flow indicator should begin flashing at a rate t
21. d valve between union and flow control see Figure 2 3 Install male half of union Item 3B onto second 3 4 NPT nipple Item 2B 4 Install 34 NPT tee Item 6 on open end of nipple Tee will now have one port open on the side and one open on top Install reducing bushing Item 5 into top port of tee Install 2 NPT 1 long nipple Item 4 in reducing bushing Install 34 NPT plug Item 8 in open side port of tee Pre On Install 2 NPT plug Item 7 in center port of second end cap not shown If installing recommended integrity test fittings see Figure 11 install these fittings in this location instead of the plug 9 Install full assembly just created in off center port of end cap not shown next to 2 NPT plug just installed 10 Place end cap and fitting assembly to side for now Outlet Fittings NOTE Apply thread sealant to all threaded joints unless otherwise noted Figure 6 Outlet Fitting Assembly 1 Install 3 NPT turbine assembly Item 1 in Figure 6 above on NPT tee Item 5 Tee will now have one port open on the side and one open on bottom 2 Install to 1 2 reducing bushing Item 3 on open port on bottom of tee 3 Install 2 NPT 4 long nipple Item 4 on reducing bushing If not using backflush kit insert 34 NPT plug Item 2 on open port on side of tee 5 Install full assembly on open port in center of same end cap with drain assembly Outlet assembly should extend
22. e bypass plumbing arrangement 3 If the system is installed with the optional flush tank close the valve to the flush tank 4 If installed with a backflush kit disconnect the wiring harness from the inlet solenoid valve 5 Depressurize the system by pressing and holding the Extra Cycle button for five seconds 6 Open the nearest downstream faucet to allow air to escape during the test or crack open the outlet union 7 Drain the module by opening the ball valve at the bottom of the module and pressing and holding the Extra Cycle button on the control for five seconds to open the drain solenoid valve 8 The drain solenoid valve will need to be opened repeatedly using the Extra Cycle button until there is no further evidence of water draining from the module 9 Connect the Technician s Decay Test Components Figure 16 FreshPoint Flow Vs Pressure Drop with the quick connect fitting to the valve at the bottom of the module see Figure 16 FreshPoint Flow Vs Pressure Drop NOTE Test the system first for plumbing leaks by closing the downstream faucet and or connecting the outlet union and performing steps 11 through 13 Pressure decay with outlet plumbing closed indicates a leak in the plumbing or valves and the plumbing connections should be tightened or replaced and the system retested until the plumbing passes In the event a drain solenoid is leaking actuating a flush a few times may cause it to seat If not it
23. e control for five seconds Rinse Cycle 1 1 Open the service water faucet closest to the FreshPoint system installation to permit a flow of up to 5 gpm 19 Lpm Allow the system to flow for twenty minutes 2 Manually initiate a flush to drain by pressing and holding the Extra Cycle button on the control for five seconds 3 If a backflush tank is installed and not isolated ensure that it is emptied by initiating a sufficiently long flush by allowing the control to complete the manual flush cycle Rinse Cycle 2 1 Allow the service water to continue to flow at up to 5 gpm 19 Lpm Permit the system to flush for an additional twenty minutes 2 Manually initiate a flush to drain by pressing and holding the Extra Cycle button on the control for five seconds 3 If a backflush tank is installed and not isolated ensure that it is emptied by initiating a sufficiently long flush by allowing the control to complete the manual flush cycle Rinse Cycle 3 1 Allow the service water to continue to flow at up to 5 gpm 19 Lpm Permit the system to flow for an additional twenty minutes 2 Manually initiate a flush to drain by pressing and holding the Extra Cycle button on the control for five seconds 3 If a flush tank is installed ensure that it is emptied by initiating a sufficiently long flush by allowing the control to complete the manual flush cycle 14 e FreshPoint U440 4 While the system is flushing check all plumbing
24. e port of one end cap not shown 2 Install 2 NPT tee Item 2 on open end of nipple Tee will now have one port open on the side and one open on top 3 Insert 2 NPT plug Item 4 in open top port of tee Insert 2 NPT to PEX fitting Item 8 in open side port of tee 5 Insert open end of 2 PEX tubing Item 7 into 2 NPT to PEX fitting 6 Install inlet port of drain solenoid valve Item 6 on PEX tubing The valve s flow direction is indicated on the valve 7 Install outlet port of the drain solenoid valve to other Va PEX tubing Item 7 8 Insert open end of PEX tubing to other 1 2 NPT to PEX fitting Item 8 9 Install 2 NPT to PEX fitting to reducer Item 1 10 Install reducer to outlet port of flow control assembly Item 3 The flow control s flow direction is indicated on flow control assembly 11 Place end cap and fitting assembly to side for now INSTALLATION INSTRUCTIONS continued Inlet Fittings NOTE Apply thread sealant to all threaded joints unless otherwise noted Do not apply sealant to these threads 42571 Rev C Figure 5 Inlet Fitting Assembly 1 Install NPT 2 long nipple Item 2A in Figure 5 above into outlet of 10 gpm 37 8 Lpm flow control Item 1 The flow direction is indicated on the body of the flow control 2 Install female half of union Item 3A onto nipple extending from the flow control If installing with backflush kit insert backflush kit inlet solenoi
25. er draw The standard single element FreshPoint system is sized for 10 gpm 37 8 Lpm peak capacity flow Water draw in the house that exceeds peak capacity will have the effect of reduced pressure and volume delivery at the open taps e Maximum recommended continuous flow for the FreshPoint system is 1 2 gpm 4 5 Lpm for surface water and 3 0 gpm 11 Lpm for well water INSTALLATION INSTRUCTIONS Plumbing e The system and installation piping should be cleaned before the system is started so that no impurities abrasive materials or oily materials are washed into the membranes The piping must be purged of air to prevent water hammer which can damage the system e A bypass system is strongly recommended to permit the most efficient service of the FreshPoint system over its life Additionally some local plumbing codes may require a bypass e The connections to the FreshPoint housing ports on the system are 1 2 NPT connections for outlet and drain and 34 NPT connection for inlet e A 10 gpm 37 8 Lpm flow control is included to be installed on the inlet of the FreshPoint system to ensure the membrane operates in an efficient manner e A7gpm 26 5 Lpm flow control is included to be installed on the drain line to maximize water efficiency and ensure proper flushing rates are achieved Ensure the drain selected has the capacity for this flow rate e Private wells often have higher levels of turbidity or suspended solids t
26. following equation Fnormalized Fcurrent Pinitial Pcurrent 1 TinitialeF Tcurrent F 0 017 TMP will be approximated by the inlet pressure measured at the center Va NPT port in the bottom head when a faucet near the UF system is opened SERVICE ASSEMBLIES EA Stainless Steel Vessel Assy U440 61595 03 357708 UF Filter Element Assy 4 GSAS Sse EER ESE Bracket Mounting UF Filter ONO T o etiese GE seas Clamp Assy UF Filter 2002963 nes Timer Service U440 24VDC 9577 AE N Fitting Kit Inlet U440 60700 10 5 DLFC F x F NPT 10 gpm 4002792 Fitting Kit Outlet U440 ed Ee RE N Kit 1 Turbine w 3 4 NPT 40027938 Fitting Kit Drain U440 TA oo ARE EE TE Solenoid Assy U440 DC Drain NC 60699 70 ee DLFC F NPT 7 0 gom 357719 4002947 000 UF Adapter Kit 357707 61595 AOD2788 sus Inlet Solenoid Kit DC lo N Outlet Solenoid Kit DC See FreshPoint Pricing Guide for complete list of service parts assemblies and pricing FreshPoint U440 e 23 For Pentair Product Warranties visit Pentair para las garantias de los productos visite www pentairaqua com Pour Pentair garanties produit visitez le site gt PENTAIR FILTRATION amp PROCESS 5730 NORTH GLEN PARK ROAD MILWAUKEE WI 53209 P 262 238 4400 800 279 9404 www pentairaqua com tech supportdpentair com All Pentair trademarks and logos are owned by Pentair Inc All other brand or product names are trademarks or
27. ged 2 Open the Plumbing Kit bags and verify that all of the components listed on the parts lists found in the plumbing kit bags are present and undamaged 3 The membrane is packed in a preservative solution and should not be opened until it is to be installed in the housing 10 e FreshPoint U440 Hardware Assembly 1 Assembly is most easily done on a horizontal surface 2 Position a mounting bracket Item 4 of FRESHPOINT ASSEMBLY pg 13 a saddle Item 5 and a saddle clamp Item 5 about 10 from the top of the vessel Item 1 Leave the bolts loose Note The smaller diameter portion of the mounting bolt holes in the mounting bracket must be positioned toward the top of the vessel 3 Position the bracket of the control Item 6 between the mounting bracket and the saddle clamp Ensure control is oriented correctly 4 Install the remaining mounting bracket saddle and saddle clamp at a convenient location near the bottom of the vessel and tighten the saddle clamp bolts with a Va wrench Vessel Head Removal 1 Remove the top and bottom end caps Item 1B and bag of parts U pins and O rings from the vessel Item 1A Note that the top and bottom end caps are identical Drain Fittings NOTE Apply thread sealant to all threaded joints unless otherwise noted Do not apply sealant to these threads Figure 4 Drain Fitting Assembly 1 Install 2 NPT 1 long nipple Item 5 in Figure 4 above into sid
28. gramming Volume since system serviced A Reset with system service reminder TF VL TL V2 T2 SD SV or by changing SV value in Master W Programming S Software version FreshPoint U440 e 19 PROGRAMMING continued Flush Cycle Steps NOTE The preset flush programs 1 4 can be set froma master unit in a multi unit configuration Custom program 5 is available for single unit configuration only The flush cycle steps for each preset flush cycle are shown below Custom program 5 can have up to 9 steps of fill pressurize flush and forward flush Flush Cycle Steps PrG1 Fill and Pressurize PrG2 Fill and Pressurize PrG3 Fill and Pressurize N A PrG4 Fill and i Pressurize Flush Fill and Flush N A N A N A Pressurize Flush Forward N A N A N A Flush A Flush Pressurize Pressurize Flush Pressurize Flush Pressurize Flush Program Fi ra ra m rs e a e P ree o o o o o o m mm wa Defined Defined Defined Defined Defined Defined Defined Defined Defined Flush Drain Open Inlet amp Outlet Closed Forward Flush Inlet amp Drain Open Outlet Closed MASTER RESET Turn off power to the unit Power up control while holding the Extra Cycle button to reset the control Use the Up or Down buttons to select U440 and press the Extra Cycle button to accept Reprogram the c ontrol 20 e FreshPoint U440 SERVICE AND MAINTENANCE When to call the Dealer If pr
29. hat can shorten membrane life without adequate flushing If fouling potential is high a backflush kit should be installed The installation of a pressure tank and solenoid valve switches the system from forward flushing to backflushing thereby extending the membrane life in high fouling potential waters e For standard installations a post ultrafilter pressure tank is recommended to maintain pressure during a flush cycle e The system must be protected from possible back contamination by the installation of an air gap between the FreshPoint drain connection and the drain line Electrical Reguirements The FreshPoint controller reguires a constant electrical supply to flush correctly 120 or 220VAC The system controller and solenoid valvels operate on 24 VDC Pretreatment Pretreatment of the FreshPoint system with a 200 um filter is recommended Some installations may require additional pretreatment Reference the Flushing Schedule Table 1 or the FreshPoint Ultrafiltration Systems Applications Guide for more information FreshPoint Location e Note the location of the water supply and drain when choosing a mounting location The FreshPoint system is a point of entry POE device designed to treat water distributed throughout the entire plumbing system The installation should be located near the point of entry but ahead of where plumbing splits for distribution INSTALLATION INSTRUCTIONS continued e The system mounting
30. hat varies with flow rate Close the tap after 3 5 gallons of water flow Control Operation During a Flush Cycle 1 Manually initiate a flush cycle and allow water to run to the drain To initiate a flush press and hold the Extra Cycle button for five seconds The system will go into flush mode immediately A During Flushing The the system will display the time remaining for each flush step F1 through F9 B Pushing the Extra Cycle button during the flush cycle will immediately move the flush cycle to the next cycle step NOTE On Multi Unit installations the Extra Cycle button will not advance to the next cycle step C After the flush cycle the system returns to in service and will resume normal operation On Multi Unit installations each unit will flush in series immediately following completion of the previous unit flush Control Operation During Programming The system will only enter Program Mode when it is in service and operating on line power While in Program Mode the system will continue to operate normally monitoring water usage and keeping all displays up to date System programming is stored in memory permanently with or without power Button Operation f f f Extra Cycle Up Down Button Button Button Figure 15 Extra Cycle Button Pushing and holding this button for five seconds will initiate a flush cycle immediately independent of the actual system conditions The Extra Cycle button is also u
31. ice of the controller only System installation requires information from a number of suppliers not known at the time of manufacture This product should be installed by a plumbing professional This unit is designed to be installed on potable water systems only This product must be installed in compliance with all state and municipal plumbing and electrical codes Permits may be required at the time of installation If daytime operating pressure exceeds 80 psi 552 kPa nighttime pressures may exceed pressure limits A pressure reducing valve must be installed Do not install the unit where temperatures may drop below 34 F 1 C or above 110 F 43 C Do not place the unit in direct sunlight Black units will absorb radiant heat increasing internal temperatures Do not strike the controller or any of the components Warranty of this product extends to manufacturing defects Misapplication of this product may result in failure to properly condition water or damage to product A prefilter should be used on installations in which free solids are present Correct and constant voltage must be supplied to the controller to maintain proper function INSTALLATION AND START UP CHECKLIST e Use this form to record initial system hardware site conditions and controller programming information e Retain a copy for future reference e Fill in the appropriate data if available e Checklist data should be collected and logged o
32. ies Capillaries per Fiber 7 Outer Diameter 0 17 inch Inner Diameter 0 04 inch Material PESM Molecular Weight Cutoff MWCO 100 150 k daltons Active Membrane Surface 48 50 ft 4e FreshPoint U440 IMPORTANT READ THIS FIRST Read this service manual thoroughly before first use All plumbing and electrical codes must be complied with when installing this product Only qualified personnel should install this product Check the FreshPoint system periodically to ensure proper operation i e flushing flow rate pressure drop etc Do not allow the FreshPoint system to be exposed to freezing temperatures Freezing may damage the system Ensure the membrane does not dry out Opened membranes should be preserved with a 0 1 sodium bisulfite solution The FreshPoint system will continue to operate as a filter during power loss However when power returns after an extended outage the control may need reprogramming Keep this service manual near the FreshPoint system for future reference The FreshPoint system is intended to treat only potable quality water It is not intended as the permanent primary treatment of water from a source that is contaminated such as from radon pesticides insecticides sewage or wastewater Use lubricants such as silicone sparingly SAFETY CAUTIONS AND WARNINGS Safety The FreshPoint system must be wired according to local electrical codes to preven
33. inlet of the filter sump as follows Filter Size Teaspoons ml of Unscented Bleach 10 x 2 5 3 4 tsp 3 7 ml 20 x 2 5 1 1 2 tsp 7 4 ml 10 x 4 1 1 2 tsp 7 4 ml 20 x 4 3 tsp 14 8 ml 7 Open the inlet valve purge air from the cartridge filter sumps and allow the water to flow until a chlorine smell can be detected in the water flowing from the open service faucet 8 Close the service faucet and allow the system to soak for one hour 9 Manually initiate a system flush by pressing and holding the Extra Cycle button on the control for five seconds 10 Open the service faucet and allow the water to flow until the chlorine smell is not detected 11 Use a test kit to confirm that the chlorine level is below 4 ppm ideally below 1 ppm 12 Close the inlet valve depressurize the plumbing and replace the filter cartridge 13 Repressurize the system by opening the closest faucet and slowly opening the inlet valve of the bypass plumbing arrangement Expel air from the feed side by manually initiating a manual flush by pressing and holding the Extra Cycle button for five seconds 14 Close the faucet Open the tank isolation valve and reconnect the inlet solenoid valve to the wiring harness if applicable SYSTEM START UP continued System Sanitizing No Prefilter Installed Sodium hypochlorite bleach is used for disinfection The user should acquaint themselves w
34. ith for 60 sec Treatment multimedia e TOC lt 10 0 mg L ilter e SDI15 lt 20 e Disinfection with e Metals Fe Mn Cu chlorine etc lt 1 mg l 200 micron prefilter Well e Chlorine lt 4 0 mg l e Iron removal Recommended Every 200 Municipally Turbidi iltration with high gal 757 L ty lt 5 0 NTU Treated MEN if iron over 1 turbidity for 30 sec e TOC lt 2 0 mg L mg l suspended e SDI15 lt 6 67 200 micron solids colloids Metals Fe Mn Cu prefilter di etc lt 1 mg l Well Private e Chlorine lt 4 0 mg l e Iron removal Recommended Every 100 N filtration if iron with high gal 378 L e Turbidity lt 1 0 NTU EN i over 1 mg l turbidity for 30 sec e TOC lt 2 0 a lt mg e Disinfection suspended f e SDI15 lt 6 67 optional solids colloids Ferri e Metals Fe Mn Cu e 200 micron Oe etc lt 1 mg l prefilter In all cases a disposable pre filter cartridge is recommended to protect the FreshPoint system from large particles plumbing debris etc 2 Some shallow wells may have serious contamination problems hazy water high TOC color and high bacterial loads The backflush kit is recommended to avoid fouling in these installations NOTE It is important to understand the water quality and fouling potential to determine the type of flushing required when installing the FreshPoint system 6e FreshPoint U440 Flow Capacity e Assess the household water use especially peak wat
35. ith the appropriate safety precautions for storage and handling of the chemicals being used USE ONLY SODIUM HYPOCHLORITE DO NOT USE BLEACHES CONTAINING ANY OTHER COMPOUNDS 1 Close the inlet valve of the bypass plumbing arrangement If installing with backflush kit disconnect the wiring harness from the inlet solenoid valve 2 If the FreshPoint system is equipped with a backflush tank manually initiate a sufficiently long flush to empty the tank by pressing and holding the Extra Cycle button for five seconds Isolate the backflush tank by closing the tank isolation valve CN Any product or backflush tank needs to be isolated during disinfection The chemicals used in disinfection are at a higher concentration than recommended for these tanks and are likely to cause damage to the tanks if exposed 3 Opena faucet near the FreshPoint system to ensure that the plumbing system is depressurized Remove 1 2 NPT sanitizing plug from top of drain fitting Drain the FreshPoint housing into a bucket by loosening the supply port union or using the recommended integrity test port 6 Tighten the supply port or close integrity test valve 7 Through the sanitizing port fill the FreshPoint housing with a solution containing chlorine at 100 mg L 1 2 teaspoons of unscented bleach in 1 gallon of clean water See Figure 9 Adding Sanitizing Solution Reinsert sanitizing plug Open the inlet valve of the bypass valve arrangement and allow w
36. ivering the surge tank will be unable to store water for subsequent flushing or service In this case extra measures must be taken to provide flow restrictions or service line closures to permit surge tank filling FreshPoint U440 e 7 INSTALLATION INSTRUCTIONS continued Drain Flow Control Note flow direction Flow Meter Note flow direction Outlet Valve Outlet 4 2 Drain Shut Off Valve 3 4 NPT Threaded Union Inlet not supplied Bypass Valve Tank Isolation Valve Inlet Valve gt Pre Filter Recommended Drain Piping must include code compliant air gap N 3 4 Backflush Inlet Shut Off Valve Inlet Flow Control Note flow direction 61504 U440 BF Rev B Figure 2 Backflush Surge Tank Installation 8e FreshPoint U440 INSTALLATION INSTRUCTIONS continued Installation Forward Flush This installation approach cleans the membrane periodically by opening the drain valve and allowing the feed stream to remove the suspended solids that have been retained in the fiber lumens and flushed to drain Connect the FreshPoint system to the household plumbing supply as shown in Figure 3 Tankless Installation It is recommended that the plumbing include a system bypass for future service A 200 um sediment pre filter is recommended For ease of membrane element replacement unions are recommended as indicated on Figure 3 Tankless Installation
37. n this form for each system installed Start Up Data Installation Date __ Installer Application System Model Serial Number _ _ Water Source Pretreatment Installed Backflush Kit Installed Yes No Set Flushing Program _____ Water Analysis Turbidity Total Iron Chlorine Water Temperature System Inlet Pressure if available __ System Outlet Pressure if available Initial Product Water Flow Rate with flush tank isolated Other Program Details General Notes Checklist of Installation Start Up Steps Installation location allows access to membrane ___ Mounting provision accommodates system weight ___ Listed components fittings present Loose components assembled to system System securely mounted __ Solenoid valve flow meter signal connections ___ Plumbing connections completed __ Initial flush w o leaks ___ 30 o N O OTe N Electrical power connected ___ System sanitized ___ 11 Controller display okay ___ 12 Al programming steps completed ___ 13 Proper operation verified 14 Installation Set Up information entered onto form Specific Installation Notes Problems Suggestions Comments FreshPoint U440 3 PRODUCT SPECIFICATIONS AND IMPORTANT INFORMATION Introduction to the FreshPoint Ultrafiltration System The FreshPoint ultrafiltration system is an advanced Point of Entry POE water treatment device designed to improve the
38. oblems are experienced with the installation or operation of the FreshPoint system refer to the troubleshooting guide in this service manual or contact your FreshPoint Distributor for assistance Monitoring If changes to the flow rate or pressure are noticed contact the installer to get recommendations on changing flushing settings and or have the system evaluated by the installer Many factors can cause a change in pressure As water temperature decreases the flow available from the FreshPoint system will also decrease for the same inlet pressure The flow rate will drop or rise approximately 3 for a corresponding 1 8F 1C drop or rise in water temperature Prefilter plugging will cause a decrease in available pressure Additionally if a noticeable loss of pressure is detected over time the current flushing schedule may not be sufficient to prevent fouling and additional flushing will be required Refer to the Troubleshooting section in this service manual to address this and other issues Prefilter Changes The prefilter should be changed as recommended by the manufacturer Generally change the cartridge when a decrease in pressure is noted or after six months installed Membrane Maintenance The FreshPoint membrane must be kept in a wetted condition Once installed or during service and maintenance activities do not allow the FreshPoint membrane to sit completely drained for extended periods greater than 12 hours F
39. ormance from devices that are installed after the ultrafilter e Ferrous dissolved iron is not removed by the FreshPoint Ferric precipitated iron is removed by the FreshPoint system Note that ferric iron may foul the membrane if present at greater than 1 ppm We recommend that the FreshPoint system be installed after an iron filter or conditioner when iron is present e The presence of a low level of chlorine in the supply water will help prevent biofouling of the FreshPoint system but continuous exposure to more than 4 ppm of chlorine may shorten the life of the membrane The membrane must not be exposed to ozone Exposing the membrane to ozone voids the membrane warranty FreshPoint Installation Instructions Tools and Supplies Needed 1 Plumber tape or paste for leak free assembly of the pipe thread connections TN Ensure that the paste is compatible with PVC fittings 2 Lubricant for seals a packet of silicone is supplied NOTE Silicone should be applied sparingly to avoid fouling the membrane Four 1 4 bolts to mount the system to the wall 12 open end wrench to tighten saddle clamp 7 16 open end wrench to tighten wall mount bolts Oe ON Crescent wrench that can open to 1 1 2 to grip flow control Unpacking Refer to FRESHPOINT ASSEMBLY pg 13 1 Open the box with the hardware and verify that all of the components pictured on the FreshPoint Assembly pg 13 are present and undama
40. over drain assembly in same direction Insert Vessel End Caps 1 Lightly lubricate O rings Items 1C 1D and 1E on FRESHPOINT ASSEMBLY pg 13 and place on each end cap 2 Insert adapter Item 3 into the bottom of end cap with outlet and drain fittings already installed 3 Carefully insert top end cap with outlet and drain fittings into vessel lining up holes on the vessel with slots on the cap Insert U pin Item 1F to secure the cap in place Installing the Membrane 1 Lay the assembled vessel and fittings on a horizontal surface 2 Cut open the sealed bag of the filter element Item 2 at the end where the center tube is open Lightly lubricate the center tube with the supplied silicone 3 Insert the filter element into the bottom of the vessel with the open end of the center tube first and remove the plastic bag as it goes in A slight resistance will be felt at the last inch of insertion as the seals on the adapter are compressed into the center tube of the element NOTE The open distributor tube of the membrane should be oriented up YT DO NOT DROP THE MEMBRANE ELEMENT INTO HOUSING THIS COULD DAMAGE THE MEMBRANE ELEMENT 4 Insert the spacer spring Item 3 5 Install the bottom cap O ring Item 1C on the bottom end cap Item 1B Lightly lubricate 6 Carefully insert the bottom end cap with inlet fittings into the vessel Item 1A Attach with the U pin Item 1F then secure with the cot
41. r elements The outlet used for power to the FreshPoint system should be an unswitched outlet This appliance is not intended for use by persons including children with reduced physical sensory or mental capabilities or lack of experience and knowledge unless thye have been given supervision or instruction concerning use of the appliance by a person responsible for their safety Children shall not play with the appliance Cleaning shall not be made by children without supervision NOTE This product should be installed by a qualified professional Comply with all plumbing and electrical codes when installing this product TT Minimum water pressure 20 psi 138 kPa Maximum water pressure 120 psi 827 kPa YT Minimum water temperature 3 F 1 C Maximum water temperature 104 F 40 C TEI Ambient temperature 34 F to 104 F 1 C to 40 C AMI Disconnect all power sources before servicing TT Always operate the controller with the cover in place 7 EVAN The system MUST be depressurized before removing any connections for servicing DIMENSIONAL DRAWING 5 p A TT 220 03 _ Le 441 64 53486 mg 187 96 X2 7 400 gi Ho l 1 el gt ED EE Ps Figure 1 Dimensional Drawing for the FreshPoint Ultrafiltration System FreshPoint U440 e 5 FL
42. registered marks of their respective owners Because we are continuously improving our products and services Pentair reserves the right to change specifications without prior notice Pentair is an equal opportunity employer 4002816 Rev E JA15 2013 Pentair Residential Filtration LLC All Rights Reserved
43. rness to the solenoid valve If installing with the backflush kit A Install inlet solenoid s wiring harness backflush kit to the control board terminal block Connect the other end of the wire harness to the inlet solenoid valve Drain Inlet Outlet Figure 7 Solenoid Electrical Connection Diagram Meter Connection Refer to Figure 8 Circuit Board Diagram 1 O O O To Solenoid Terminal Block Insert the flow meter cable into the socket on the flow meter Connect other end of flow meter cable to circuit board in location shown RS 485 1 Lederle Figure 8 Circuit Board Diagram 3 Plug the power supply into a 120V or 220V GFI outlet 12 e FreshPoint U440 Remote Flush Connection Multi Unit System Kit P N 4002815 Required 1 Cut one end of Multi Unit wire harness included in Multi Unit System Kit exposing two bare wires Plug other end of wire harness into port labeled RSS on back of control circuit board Disassembly of controller casing may be reguired to access port Thread wire harness through controller assembly backplate and secure with supplied bushing Connect differential pressure switch or other remote switch to loose wires and secure No power is to be supplied into switch When there is continuous contact closure between the loose wires for the specified interval 1 999 seconds default 60 seconds see Master Programming on page 19 as supplied by
44. sed to go to the next cycle step during a flush cycle and to go to the next programming option while in Programming mode PROGRAMMING continued Up Down Buttons These buttons are used to enter into Programming mode and to adjust programming options Master Programming 1 To enter Master Programming A Enter into User Programming by pressing and holding the Up and Down buttons for five seconds Release when DV is shown in the upper left of the displayed B Use the Up and Down buttons to change the value of DV to AU C Press and hold the Up and Down buttons for an additional five seconds until NU is shown in the upper left corner of the display 2 Once in Master Programming use the Up and Down buttons to adjust the values for each programming option listed below and press the Extra Cycle button to accept the displayed value and move to the next option 3 After cycling through each available option the control will return to the In Service display Master Programming Options Abbreviation Programming Values Option NU Number of 1 4 Default is 1 up to 4 Units C total units in series M Meter 1 0 Default is 65 0 pulses Constant 999 9 per unit volume of flow meter Default is OFF days until system service reminder ERR 1 System Service Interval Days Default is 0 units of volume until system service reminder ERR 1 Default is 60 seconds of continuous contact closure to start fl
45. surized surge tank and inlet solenoid valve See Flushing Schedule Table 1 In the backflush mode the filtered water from a pressure tank flows backward through the membrane from the filtrate side during the flushing cycle This removes the foulant from the membrane surface as well as material that may have entered into the porous structure Connect the FreshPoint system to the plumbing supply as shown in Figure 2 Backflush Surge Tank Installation It is recommended that the plumbing include a system bypass for future servicing etc A 200 um sediment pre filter is recommended For ease of membrane element replacement unions are recommended as indicated on Figure 2 Backflush Surge Tank Installation The backflush tank should be installed on a tee before the flow meter The backflush tank precharge pressure should be set to 20 psi 1 3 bar 138 kPa NOTE Installation of the backflush tank after the meter will cause reverse flow through the meter and could have a detrimental effect on meter performance NOTE Consider that in a typical residential installation that there is a considerable time frame in which the service flow rate is far below the maximum delivery capability of the FreshPoint unit Therefore the surge tank will be permitted to store a sufficient quantity of water to satisfy subsequent flushing and service requirements Alternatively if the service requirement is continuous and demanding all that the FreshPoint unit is del
46. t System Kit P N 4002815 to the port on the back of the master control circuit board labeled RS 485 1 see Figure 13 Circuit Board Diagram Next connect the Multi Unit wire harness from the port on the master control labeled RS 485 2 to the port labeled RS 485 2 on the first slave control To connect additional units daisy chain the connection cables from each additional slave unit to the port with the same label Connect an additional shunt to the open RS port on the final slave unit in the series NOTE The two RS ports on the back of the controller circuit board are not directly accessible To access the ports you must remove the circuit board from the controller casing After connecting a wire harness to one or both of the RS ports thread the wiring through an available window in the controller casing backplate before reassembling the controller casing Each slave control will have a board number from UA 01 up to UA 03 for a four unit system The slave board numbers can be adjusted using the DIP switches on the front on the control board The switches are labeled 1 2 and 3 respectively with the ON position to the left and the OFF position to the right To set each slave board to the correct board number slide the DIP switches to the appropriate position as shown in the table below and reset the control The board number will display on the control and programming will be disabled
47. t the possibility of electrical shock Do not modify the power supply cord The FreshPoint system must be installed in compliance with local plumbing codes and any other applicable codes The FreshPoint system has been designed and tested to offer reliable service when installed by a qualified professional and operated and maintained according to the instructions in this service manual For safety reasons the FreshPoint system is furnished with a low voltage power supply to plug into the electrical outlet Do not replace this power supply with another power supply except as supplied by the manufacturer Install the FreshPoint system only for its intended use as described in this service manual Do not use corrosive chemicals in the FreshPoint system Do not install the FreshPoint system if it has a damaged cord or plug if it is not working properly or if it has been damaged or dropped Do not immerse the cord or plug in water Keep the cord away from heated surfaces Disconnect the FreshPoint system from the power source before performing any service or maintenance on the solenoid valves Do not plug in the controller power supply if there is water on the electrical wiring or the power supply Always shut off the water flow and release water pressure before cleaning or maintaining the FreshPoint system The FreshPoint system is intended for indoor use only The power supply and controller must not be exposed to weathe
48. t up the control Check the FreshPoint System For Leaks e Ensure that all new plumbing connections the three ports from the housing and the two end cap perimeters have no leaks Correct if needed e Manually initiate a flush cycle by pressing and holding the Extra Cycle button for five seconds Ensure the drain solenoid valve opens and a robust flow goes to the drain and that the drain can handle the flow Flushing Flush the membranes prior to placing the system in service to remove the membrane storage solution NOTE If installed the backflush surge tank isolation valve should be closed If there is a tank and no isolation valve ensure that each flush cycle fills and empties the backflush tank NOTE If installed with the backflush kit the inlet solenoid valve should not be connected to the wiring harness for flushing at this time as it will not permit supply water to enter the FreshPoint system Connect the inlet solenoid after the backflush tank fills with water Rinse the preservative solution from the membrane as follows 1 Close the bypass valve of the bypass plumbing arrangement Open the outlet valve of the bypass plumbing arrangement 3 Slowly open the inlet valve of the bypass plumbing arrangement This will fill the module with water without creating a water hammer effect 4 To expel air from the feed side of the membrane manually initiate a flushing by pressing and holding the Extra Cycle button on th
49. ter pin Item 1J and put on the U pin cap Item 1K Mounting the Assembly on the Wall 1 Position the hardware assembly and vessel against the wall and mark the four mounting bolt locations 2 Install four 1 4 bolts at the positions previously marked Leave enough clearance between the wall and the bolt heads to permit the mounting brackets to be slid into place NOTE Bolts larger than may not fit through the keyhole openings in the mounting brackets 3 Place the mounting brackets over the bolts and slide unit into place 4 Tighten the four wall mounting bolts Plumbing Connections 1 Connect the supply water to the inlet flow control Item 8 and complete the supply plumbing Tighten the inlet union 2 Connect the drain line plumbing to the drain line flow control Item 11 and complete the drain plumbing Tighten the drain union 3 Connect the meter adapter to the outlet plumbing and complete the outlet plumbing Tighten the outlet union NOTE If installing with the backflush kit complete the plumbing between the outlet tee and the backflush tank see Figure 2 The backflush tank pre charge should be adjusted to 20 psi 1 3 bar 138 kPa If installed the backflush tank isolation valve should be closed FreshPoint U440 e 11 INSTALLATION INSTRUCTIONS continued Solenoid Electrical Connection Refer to Figure 7 Solenoid Electrical Connection Diagram i 2 Connect the drain solenoid wire ha
50. ush NOTE The default meter constant value is 65 0 pulses per unit volume which is ideal for measuring flow in gallons To measure flow in liters the meter constant value should be changed to 17 2 System Service Interval Volume Remote Flush Diagnostic Display The Diagnostic Display shows read only diagnostic data that may be useful when servicing the system Diagnostic data is indicated by a icon in the lower left corner of the display 1 To view the Diagnostic Display press and hold the Extra Cycle and Up buttons for five seconds while in service The icon will appear in the lower left corner of the display 2 Use the Up and Down buttons to scroll through the diagnostic options listed below 3 Press the Extra Cycle button to exit the Diagnostic Display and return to service Diagnostic Display Options Abbreviation Diagnostic Values Option Totalizer 0 999 9 Water used since x1000 reset Volume since User Units definted by last flush specified meter constant Time since User Hours since last last flush specified flush Units definted by meter constant Volume used User between last specified two flushes Time between User Defined in hours last two specified flushes Set in Master Programming Days since Defined in days system serviced Reset with system service reminder or by changing SD value in Master Programming Units defined by meter constant Set in Master Pro
51. utlet plumbing closed indicates a leak in the plumbing or valves and the plumbing connections should be tightened or replaced and the system retested until the plumbing passes In the event a drain solenoid is leaking actuating a flush a few times may cause it to seat If not it should be replaced Air Compressor Quick Disconnect Fitting Air Fill Valve 0 2 Micron Air Filter Shut Off Valve Tee 42613 RevA Pressure Gauge Figure 10 Technician s Decay Test Assembly 17 When the testing is complete depressurize the modules by pressing the valve core in the air supply valve on the Technician s Decay Test Components and by pressing and holding the Extra Cycle button 18 Close the 1 4 valve at the bottom of the module 19 Remove the Technician s Decay Test Components 20 Repressurize the module with water by slowly opening the inlet valve of the bypass plumbing arrangement 21 Close the downstream faucet was opened for the test or reconnect the outlet union when air is no longer being expelled Open the outlet valve of the bypass arrangement if closed 22 Press and hold the Extra Cycle button on the control to flush trapped air from the feed side of the module 23 Open the flush tank valve if present 24 Reconnect the inlet solenoid valve wiring harness if applicable 4 ei 61504 U440 BF Rev B Figure 11 Integrity Test Simplified Diagram MULTI UNIT FRESHPOINT INS
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