GE E2 Series Water System User Manual
Contents
1. A 1 micron pre filter cartridge is factory installed to protect the membrane elements and valves from particles which may be in the feed water To order replacements see the Spare Parts List Technote 109 A pressure drop across the filter of 8 psi 0 55 bar or more during operation indicates that the pre filter cartridge s need changeing Use only GE approved filters rated at 2 microns or less Refer to Technote 109 Spare Parts List for pre filter cartridge replacements Do not attempt to clean used pre filter cartridges NOTE Failure to perform normal preventative maintenance procedures will void machine warranty Daily Flushing A manually flush of the E2 EZ2 Series must be done machine daily To flush the machine NOTE During flushing procedure the machine must be running STEPS 1 With the machine running open the concentrate valve 1 2 3 4 of a turn Figure 2 1 Flow Control Center 2 15 2 Allow the machine to operate with the concentrate valve open 1 2 3 4 of a turn Step 1 for 10 15 minutes 3 After 10 15 minutes return the concentrate valve to its previous setting and return to normal operation CAUTION When opening the concentrate valve never allow the machine s primary pressure to drop more than 10 below normal operating pressure Table 2 3 E2 EZ2 Series Primary Pressure Range Membrane Element Cleaning Periodic cleaning of the machine with appropriate membrane element cleaners will pr2. NOTE External control contacts are normally closed dry contacts 2 6 2 Deluxe Model To remotely control the Deluxe Model DLX with float switches and or pre treatment lockout remove the jumper between terminals 2 and 3 and wire in the float switches and pretreatment in series After all field wiring is complete and complies with local and national electrical codes move onto Section 2 10 Pretreatment for Water Purification NOTE External control contacts are normally closed dry contacts Single Phase Electrical Always check voltage tag on the machine to ensure the correct voltage and amperage is available The E2 EZ2 Series machines are shipped as either 120 Volt 60 Hertz or 220 Volt 50 Hertz from the factory Machines should always be connected to a 15 Amp single phase dedicated circuit The circuit provided should be a separately fused disconnect with the proper protection for the Hp and Amp draws of the machine Reverse osmosis RO machines with 115 Volt circuit include an 8 foot 2 4 m electrical cord which plugs into a single phase outlet All machines shipped with a 220 VAC single phase power require ment are shipped with an 8 foot 2 4 m electrical cord but customers must provide electrical plug All field wiring must comply with applicable local and national electrical codes Machine Start Up Preparations 2 8 1 Pretreatment for Water Purification A water analysis of your feed water should have been performed as
3. 2 0 barg 40 psig 2 7 barg 50 psig 3 4 barg 60 psig 4 1 barg WARNING IF PERMEATE BACK PRESSURE EXCEEDS 60 PSI 4 1 BAR MACHINE DAMAGE MAY OCCUR WARNING INSTALLING A CHECK VALVE WILL PREVENT REVERSE FLOW THROUGH THE MEMBRANE ELEMENT WHEN THE MACHINE IS NOT IN OPERATION REVERSE FLOW WHEN THE MACHINE IS NOT IN OPERATION CAN SEVERELY DAMAGE THE MEMBRANE ELEMENTS 2 12 2 13 2 14 Operation and Maintenance The operation and maintenance of an E2 EZ2 Series RO machine requires regular data recording and routine preventative maintenance It cannot be emphasized enough the importance of filling out the Daily Log Sheet Technote 106 during each operating shift A Start Up Data Sheet Technote 101 should have been completed at start up The Start Up Data Sheet contains pertinent facts on the operation of your machine These two records are invaluable in diagnosing the performance of the equipment and must be kept for reference If you have questions concerning the operation of your machine or the method of data recording contact the manufacturer Three preventative maintenance procedures which must be done on a regular basis are as follows 1 Change the pre filter cartridges as needed 2 The machine needs to run and flush for at least 10 minutes every 72 hours clock time 3 Clean the RO membrane elements with approved cleaners at least quarterly depending on feed water quality Pre filter Cartridge
4. Figure 2 4 Membrane Element Direction for Installation 14 2 17 Troubleshooting This troubleshooting guide can assist you in identifying common operating problems you may experience with your machine The operator can easily correct may of these problems however for those that persist or are not understood you should contact the GE Customer Support Center Have the following information available when calling the Customer Support Center Machine installation date Model number Serial number Aw NS Detailed description of problem TROUBLESHOOTING GUIDE Low operating pressure Insufficient feed water pressure Open feed water valve Check feed water valve for restrictions in feed plumbing Clogged pre filter cartridge Replace pre filter cartridge Dirty or fouled membrane Flush and or clean machine elements Inlet solenoid valve not Verify valve receiving power opening when machine is ON Clean or replace solenoid valve Insufficient electrical power Verify proper voltage is present Check fuses and circuit breakers Pump or motor not operating Contact your distributor for correctly replacement or repair of pump or motor TROUBLESHOOTING GUIDE PROBLEM POSSIBLE CAUSES REMEDIES Low operating pressure Concentrate or recycle valve to Refer to Section 2 9 for proper continued far open ly setting concentrate and recycle valves Low permeate production Low operating pressure See above Machine operati
5. cali brated container Flush and or clean machine Replace the O rings check the sealing surfaces on the O ring groove and end caps Replace damaged parts Replace with new membrane elements See Spare Parts List Section 2 20 Calibrate the meter with a DS standard solution or check the readings with another conduc tivity meter Replace or clean the probe Check the connec tions between the probe and monitor Refer to Section 2 16 2 Deluxe Model Ensure machine is plugged in TROUBLESHOOTING GUIDE Pressurized storage switch or storage tank float switch cut power to machine ON OFF switch ON machine not running continued Thermal overload of motor Pump motor failure Pressure does not drop when Dirty concentrate valve concentrate valve opened Restricted flow after pump outlet Excessive pressure drop acrosse membrane element s over 50 psi 3 5 bar Telescoped membrane element covering membrane element housing Fouled or dirty membrane elements 18 The storage tank may be full The switch control may require adjustment Allow the machine to cool Check the Amp draw to the machine Check the fuses or circuit breakers measure the volt age Contact your distributor for service Disconnect and clean the concentrate valve Check for blockage of the concentrate flow at the inlets and outlets of membrane element housings Ensure that the anti telescop ing device A
6. 50 psi Range 114 17 2 bar Primary pressure temperature for normal operation is 77 F 25 C CAUTION The E2 EZ2 Series must not operate outside the ranges listed above NOTE Optimum recovery will vary according to feed water quality The concentrate valve is drilled and when completely closed the machine is run ning at the correct concentrate flow for a 75 recovery Table 2 4 Flow Specifications for E2 EZ2 Series Machines If the temperature of the inlet feed water is not 77 F 25 C use the Temperature Correction Factor Table Technote 113 The proper adjustment of the recycle and concentrate valves are critical to the correct operation of the machine Complete the Start Up Data Sheet Technote 101 The Start Up Data Sheet and the Daily Log Sheet Technote 106 are invaluable in diagnosing the performance of the equipment and must be be kept for reference If you have questions con cerning the operation of your machine or the method of data recording contact your distributor or the manufacturer Feed Water Inlet Pressure Gauge Recycle Valve CAUTION CAUTION CAUTION Concentrate Valve Figure 2 1 Flow Control Center Once the machine is running with orifices adjust pressures and flows to the correct measure flush machine to drain for 30 45 minutes The E2 EZ2 Series machines are designed to run at 50 recov ery To confirm flows are correct check Tabl
7. OSMONICS E2 EZ2 SERIES WATER PURIFICATION MACHINES INSTALLATION OPERATION AND MAINTENANCE MANUAL GE Infrastructure Water amp Process Technologies Distributor Information Distributor Contact Phone Fax Email Machine Information Installation Date Model Number Serial Number Service Assistance Consult the Troubleshooting Section of this manual Section 2 19 If the problem cannot be identified and correct ed contact your distributor Prior to making the call have the following information available Model Number Daily Log Sheets Serial Number Operating Parameters Installation Date Description of Problem Spare Parts Contact your distributor to order spare parts Refer to the Spare Parts List Technote 109 2 0 INSTALLATION OPERATION AND MAINTENANCE MANUAL E2 EZ2 SERIES WATER PURIFICATION MACHINES TABLE OF CONTENTS Page INSTALLATION seenuererieseanesaezeonereoteseeneeneeseseenesneseoneseezaesaneeeneseotereonesaeeseseenesaesenneseosesseneoneese0teneeneseeneseeseoseaseonese0teneoneseeenee 1 24 Mounting the Une ne en ee acer ree mene ee eT 1 22 Plumbing l 2 3 Plumbing Connections 1 24 Feed Water Requirements lat 2 5 Transporting Pure Water Permeate to Point of Use l 2 2 6 Machine Control TAI ran eeee rere eeeeeee reer errr eee reer eee reer eee eerie 3 2 6 1 Economy Model Lana 3 2 6 2 Deluxe Model TA rr ee eee eee eee eee eee eee eee eee eee eee eee eee ee
8. TD is intact Flush and or clean the machine TROUBLESHOOTING GUIDE Flow through machine while Inlet solenoid valve not fully Ensure valve is not getting any power is OFF closed power when machine is OFF Replace inlet solenoid valve For more information call 952 933 2277 or 800 848 1750 in the U S or visit www gewater com GE Infrastructure Water amp Process Technologies North American Sales Euro Africa Sales 5951 Clearwater Drive 230 rue Robert Schurman Minnetonka MN ZA des Uselles 55343 8995 77350 Le M e sur Seine USA FRANCE 952 933 2277 Phone 33 1 64 10 2000 Phone 952 933 0141 Fax 33 1 64 10 3747 Fax 2004 General Electric Company All rights reserved P N 1227273 Rev C Asia Pacific Sales 1044 8 SOI 44 2 Sukhumvit Road Parkanog Bangkok 10110 THAILAND 66 2 38 14213 Phone 66 2 39 18183 Fax
9. ave been removed for the machine If cleaning with an organic cleaner return to Step and repeat Steps 1 11 After completing cleaning normal and organic and flushing to the drain recon nect permeate to the point of use concentrate to the drain and reconnect feed to the RO unit WARNING LOSS OF PRIME DURING SUCTION CLEANING MAY RESULT IN SERIOUS DAMAGE TO THE PUMP NOTE As previously mentioned the manufacturer recommends use of a CIP or booster pump to circulate the cleaning solution during membrane element cleaning Membrane Element Replacement STEPS CAUTION Replacement membrane elements are shipped from the factory in a plas tic bag with a small amount of bactericide solution to prevent biological growth When installing the membrane elements always provide ade quate ventilation and wear gloves while handling the membrane elements as recommended The membrane elements must be kept moist at all times to prevent possible damage to the membrane element material Remove the top end caps and clamps from the membrane element housings Figure 2 4 Membrane Element Installation Lubricate all O rings and brine seals and the polyvinyl chloride PVC membrane element stems stingers with a non petroleum based lubricate i e glycerin or poly water Load the down flow membrane elements first by inserting the membrane element into the membrane element housing with the brine seal end of the membrane ele ment up Slowly t
10. e 2 4 Flow Specifications for E2 EZ2 Series Machines To correct any temperature variations check Table 2 4 If your E2 EZ2 Series machine is operating under permeate back pressure to point of use refer to Table 2 5 E2 EZ2 Series Permeate Back Pressure Correction Factors Machine performance is based on a feed water temperature of 77 F 25 C If feed water temperature is other than 77 F 25 C reference Table 2 4 Temperature Correction Factors to confirm machine s performance 2 10 Recovery The machine flow specifications listed below are based on 77 F 25 C Table 2 4 E2 EZ2 Series Flow Specifications for Machines E2 EZ2 Series 1400 2100 Units 1125 1690 2535 Recovery Range 33 50 33 50 33 50 33 50 33 50 95 98 95 98 95 98 95 98 95 98 Permeate Rate 0 3 0 07 0 5 0 11 0 9 0 20 1 2 0 27 1 8 0 40 gpm m h Concentrate Rate gpm m h 0 07 0 14 0 11 0 07 0 20 0 13 0 27 0 54 0 41 0 82 2 11 Permeate Back Pressure Correction Factors It is often necessary to operate RO machines with permeate back pressure Permeate back pressure will decrease permeate production See Table 2 5 Permeate Back Pressure Correction Factors to calculate loss of permeate Table 2 5 E2 EZ2 Series Permeate Back Pressure Correction Factors LOSS OF PRESSURE BACK PERMEATE CORRECTION PRESSURE FACTOR PCF 10 psig 0 7 barg 20 psig 1 4 barg 30 psig
11. e 3 2ol e ing IER hape ESC EPICA a asa e le 3 2 8 Machine Start Up Preparations ll 3 2 8 1 Pretreatment for Water Purification aesceseeeereoraneceeesaeiceeonesaeseoneseesaeeaneseceseoteneoneseeseoseseecaee 3 2 8 2 Machine Start Up Preparation iii 4 29 Machine StartUp mnn 4 Zi REI 7 2 11 Permeate Back Pressure Correction Factors 8 2 12 Operation and Maintenance 9 ET 9 2 14 Daily Flushing l 9 2 15 Membrane Element Cleaning iii 10 2 16 Membrane Element Removal 12 2 17 Membrane Element Replacement iii 12 2 18 Troubleshooting 15 LIST OF FIGURES Figure Description 2 1 Flow Control Centet collinare 2 2 Closed Loop Membrane Element Cleaning nn 2 3 Membrane Element Installation 2 4 Membrane Element Direction for Installation iii LIST OF TABLES Table Description 2 1 E2 EZ2 Series Machine Piping Connections csseumanenennene 2 2 E2 EZ2 Series Feed Water Requirements 2 3 E2 EZ2 Series Primary Pressure Range 2 4 Flow Specifications for E2 EZ2 Series Machines 2 5 Permeate Back Pressure Correction Factors NOTE This manual along with all GE Infrastructure manuals is available at www ge water com O NaNe 2 0 INSTALLATION 2 1 Mounting the Unit DD 2 3 When installing vour new GE Osmonics reverse osmosis RO machine allow at least 45 inches 114 3 cm above the machine for membrane element removal and loading If space is not available the entire membrane element housing can be removed for membrane element change
12. er information Table 2 2 E2 EZ2 Series Feed Water Requirements Temperature Typical 50 85 F 10 29 C Limits 33 104 F 0 60 40 C Inlet Pressure Minimum 30 psig 2 1 barg Maximum 60 psig 4 1 barg Chlorine 0 parts per million ppm continuous feed Operating pH Silt Density Index Less than or equal to 5 to minimize SDD membrane element fouling and extend cleaning intervals Refer to ASTM Standard D4189 American Standard for Testing Materials Transporting Pure Water Permeate to Point of Use Pure water or permeate is in an aggressive state and should only be transported from the machine to the point of use in food grade flexible nylon stainless steel SS tubing or polyvinyl chloride PVC material for the inlet permeate and concentrate piping sizes Refer to Connections Table 2 1 E2 EZ2 Series Machine Plumbing Connections for inlet permeate and concentrate piping sizes WARNING MACHINE DAMAGE MAY OCCUR IF PERMEATE BACK PRES SURE EXCEEDS 60 PSI 4 1 BAR DURING OPERATION 2 6 Za 2 8 Machine Control 2 6 1 Economy Model To remotely control the Economy Model ECN with float switches and or pre treatment lockout remove the jumper between terminals 4 and 5 and wire in the float switches or pretreatment components in series After all field wiring is com plete and complies with local and national electrical codes move onto Section 2 7 Single Phase Electrical
13. ergized and the ON OFF button on the machine is in the ON position 3 Plug in the factory supplied power cord NOTE Fifty 50 Hertz models require customer supplied plug compatible with existing outlet 4 For initial start up redirect the permeate and concentrate lines to the drain for start up flush 5 Open the concentrate and recycle flow control valves two 2 complete turns These valves are positioned on the flow control plumbing Figure 2 1 Flow Control Center WARNING ONCE MACHINE IS OPERATING FLUSH CONCEN TRATE AND PERMEATE TO THE DRAIN FOR 20 30 MINUTES FLUSHING ENSURES ALL BIOCIDES AND CONTAMINATES ARE REMOVED FROM THE MEMBRANE ELEMENTS Turn the ON OFF button on the machine ON As the pump starts to build pressure begin to adjust the valves in the following manner start by slowly closing the concentrate valves while slowly opening the recycle valve Figure 2 1 Flow Control Center CAUTION Monitor machine to ensure inlet pressure of 30 60 psi 2 1 4 1 bar is maintained during operation After 20 30 minutes of flushing permeate to the drain ensure all chemical residue has been removed before hooking up to point of use While operating the pressure range should never operate outside of the pressure ranges displayed in Table 2 3 E2 EZ2 Series Primary Pressure Range Table 2 3 E2 EZ2 Series Primary Pressure Range E2 EZ2 Series Operating 220 psi Pressure 15 2 bar Operating 165 2
14. ine inlet feed water port Figure 2 2 E2 EZ2 Series Closed Loop Membrane Element Cleaning 6 Mix the appropriate cleaning compound in the 5 gallons of permeate water in the CIP container according to the cleaning label instructions 7 Turn machine ON and allow machine to recirculate the cleaning solution for 10 15 minutes NOTE The incoming feed pressure should be 30 psi 2 1 bar As machine starts up it will achieve prime and begin to draw solution into the machine and circulate the solution back into the CIP container If the machine makes noise or primarv pressure does not climb to normal operat ing pressure Table 2 3 E2 EZ2 Series Primarv Pressure Range turn machine OFF Refer to Troubleshooting Section 1 18 Once pressure range is corrected continue start up procedure As the machine runs normallv check CIP tank to ensure that the CIP inlet line to the machine is submerged in the cleaning solution so the pump prime will not be lost 11 2 16 10 11 12 13 After circulaiting the macine for 10 15 minutes or solution has reached 95 F 35 C shut machine OFF Dump solution Repeat Setps 6 8 With machine OFF Step 8 let cleaning solution dwell in machine for 15 30 minutes After 15 30 minutes reconnect feed to RO unit and connect concentrate and per meate to drain Turn machine ON and flush permeate water to the drain for 10 15 minutes This ensures that all cleaning agents h
15. ng on cold Check the water temperature water If needed install a hot cold tempering valve Permeate production rate is dependent on 77 F 25 C Refer to Section 2 5 Temperature Correction Factor Membrane elements installed Refer to Section 2 18 for cor incorrectly rect membrane element installation procedure Membrane elements with damaged brine seals may be returned for repair For low permeate production it is wise to test the permeate pro duction of each membrane element Brine seal has rolled or been Refer to Section 2 18 for cor damaged rect membrane element installation Dirty or fouled membrane Flush and or clean the elements machine Backpressure on the permeate Reduce permeate line back line pressure Check for restric tions in permeate plumbing 16 TROUBLESHOOTING GUIDE Useful life of membrane element s expired Low permeate production continued Inaccurate permeate flow meter DLX only Dirty or fouled membrane element s Low concentrate flow with normal or high operating pressure O rings on membrane ele ment s unseated or damaged parts Declining rejection high permeate conductivity Useful life of membrane ele ment s expired Change in incoming water quality ON OFF switch ON machine not running No power to machine Install new membrane ele ment s See Spare Parts List Section 2 20 Check the flow rate manually with a stop watch and a
16. o long the life of the membrane elements Local conditions will determine the frequency of cleaning Cleaning may be required when 1 The permeate quality begins to decline 2 The reading on the final pressure gauge begins to change noticeably GE recommends that you clean your E2 EZ2 Series RO machine every quarter You may have to clean the RO machine more frequently depending on the quality of your feed water Cleaning of the membrane elements is vital because contanimants can build up on the membrane element surfaces reducing the permeate flow rate and affecting the quali ty of the permeate To clean the membrane elements NOTE Itis always best to start with the acid or inorganic cleaner STEPS 1 Remove and replace the pre filter cartridge Section 2 14 Pre filter Cartridge NOTE For best results GE recommend pre filters be replaced before and after cleaning 2 In a clean container collect approximatelv five 5 gallons 19 Liters of RO permeate water 3 Turn machine and water supplv OFF 10 O DA TO DRAIN RO MACHINE Figure 2 2 E2 EZ2 Series Closed Loop Membrane Element Cleaning NOTE This clean container will be referred to as the Clean In Place CIP container 4 Disconnect and route the inlet permeate concentrate lines from their service locations to the CIP container Figure 2 2 E2 EZ2 Series Closed Loop Membrane Element Cleaning 9 Connect the CIP feed line to the E2 EZ2 Series mach
17. outs If the membrane element housings are to be removed to change out the membrane elements at least 25 inches 65 3 cm is required at one end of each membrane element housing and 6 inches 15 2 cm behind the machine Plumbing The feed water source must be able to provide water quantitv and pressures to maintain an operating feed water pressure of 30 60 psi 2 1 4 1 bar If the feed water pressure with the machine is in excess of 60 psi 4 1 bar or fluctuates bv more than 5 psi 0 34 bar a pressure regulator should be installed upstream of the machine inlet If prop er water pressure cannot be maintained to the RO a booster pump mav need to be installed in front of the pretreatment to provide the proper water quantity and pressure for the oper ation of the machine Plumbing Connections Connect proper size drain line to the concentrate outlet Table 2 1 E2 EZ2 Series Machine Piping Connections and run to an open drain The drain capacity needs to be large enough to properly drain the feed water flow of the RO Table 2 1 E2 EZ2 Series Machine Piping Connections CONNECTIONS 0 38 0 96 Permeate 0 38 0 96 inch cm Concentrate 0 38 0 96 inch cm 2 4 2 0 Feed Water Reguirements The following feed water requirements must be met before installing vour E2 EZ2 Series machine to ensure qualitv permeate and extended membrane element life Refer to Table 2 2 E2 EZ2 Series Feed Water Requirements for feed wat
18. part of the planning and engineering that went into developing your RO system The water analysis will provide information on what type of pretreatment may be required and what recovery the machine can be run at on the feed water provid ed If the machine is moved to a different water source a new water analysis should be taken before operating the machine 2 9 Your RO is designed to operate on softened tap feed water with an SDI of 5 or less The pH should be in a range of 5 5 8 5 Exposure to any levels of chlo rine may cause irreversible damage to the Thin layer composite TLC polyamide PA membrane elements in your machine Daily water checks are recommend ed to ensure the integrity of your pretreatment and RO system Refer to Table 2 2 E2 EZ2 Series Feed Water Requirements 2 8 2 Machine Start Up Preparation Check the function and integrity of your pretreatment equipment Ensure that your water softener and activated carbon filters have been leaked checked and properly flushed before starting up your RO machine WARNING IMPROPERLY FLUSHED PRETREATMENT MAY CAUSE SERIOUS RO MACHINES PROBLEMS AT START UP WARNING NEVER OPERATE THE MACHINE WITH THE CON CENTRATE OR PERMEATE LINES BLOCKED SEVERE DAMAGE TO THE UNIT MAY RESULT Machine Start Up STEPS 1 Turn the feed water supply to the machine ON while checking for leaks in the pretreatment and inlet feed water lines 2 Check to ensure power to the motor is de en
19. urn the membrane element as you lower it into the membrane 12 element housing As you reach the bottom of the housing slowly guide the PVC stem or stinger on the end of the membrane element into the head of the end cap As the membrane element slides into the housing the brine seal will be on the top Figure 2 4 Direction of Membrane Element Installation Figure 2 3 Membrane Element Installation Next load the up flow membrane elements by lubricating all brine seals O rings and the membrane element stingers With the up flow membrane element and the brine seal will be on the bottom of the membrane element Turn the membrane element slowly as you lower it down into the housing As with the down flow membrane element one must slowly guide the PVC stinger on the end of the membrane element into the end cap Reinstall the end caps by using non petroleum based lubricant to lubricate the O ring inside the end cap Reinstall the end cap on the membrane element by first aligning the stinger into the hole in the end cap and then turn the end cap slowly clockwise as you push it down into the membrane element housing Reattach the housing clamp and tighten Reattach the feed line and flush permeate and concentrate lines to the drain for 25 30 minutes Take appropriate tests to insure biocide has been flushed from the machine Reconnect permeate line to point of use The machine is now ready for operation 13
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