GE Water System E4 User Manual

OSMONICS  
TM  
E4, E4LE, EZ4 SERIES  
WATER PURIFICATION  
MACHINES  
INSTALLATION, OPERATION,  
AND MAINTENANCE  
MANUAL  
GE Infrastructure  
Water & Process Technologies  
 
INSTALLATION, OPERATION AND  
MAINTENANCE MANUAL  
E4, E4LE, AND EZ4 SERIES  
WATER PURIFICATION MACHINES  
TABLE OF CONTENTS  
Page  
1
2.0  
INSTALLATION  
2.1  
2.2  
2.3  
2.4  
2.5  
2.6  
2.7  
2.8  
Mounting the Unit  
Plumbing  
1
1
2
2
2
3
4
5
Installing Clean-In-Place Valves  
Concentrate Outlet Connections  
Feed Water Requirements  
Transporting Pure Water (Permeate) to Point-of-Use  
Pressure Correction Factors  
Electrical  
2.8.1 Single-Phase Electrical  
2.8.2 Three-Phase Electrical  
Machine Control  
5
5
6
2.9  
2.9.1 Economy Model  
6
2.9.2 Deluxe Model  
6
2.10 Pretreatment for Water Purification  
2.11 Machine Start-Up Preparation  
2.12 Machine Start-Up  
7
7
7
2.13 Temperature Correction Factors  
2.14 Recovery  
2.15 Autoflush Timer  
9
10  
11  
11  
11  
12  
13  
13  
13  
14  
15  
2.15.1 Programming the Autoflush Timer  
2.15.2 Setting-Up the Autoflush Timer Clock  
2.15.3 Programming the Autoflush Timer Clock  
2.15.4 Programming Twenty-Four Hour or Seven Day Schedules  
2.15.5 Changing a Program  
2.15.6 Deleting a Program  
2.15.7 Troubleshooting the Autoflush Timer  
2.16 Calibrating the Conductivity Probe  
 
Page  
2.17 Operation and Maintenance  
2.17.1 Daily Flushing for the Economy Model  
2.17.2 Daily Flushing for the Deluxe Model  
2.18 Pre-Filter Cartridge  
2.19 Membrane Element Cleaning  
2.19.1 Step Wise Cleaning  
2.19.2 Procedure to Clean with a CIP Pump  
2.20 Suction Cleaning  
2.21 Changing Out Membrane Elements  
2.22 Troubleshooting  
16  
16  
16  
17  
17  
17  
17  
19  
20  
22  
LIST OF FIGURES  
Figure  
Description  
2.1  
2.2  
2.3  
2.4  
2.5  
Three-Phase Allen Bradley Motor Starter  
Setting-Up the Correct Time on the Autoflush Timer  
Programming the Timer  
Conductivity Probe Display  
Clean-In-Place Pump and Tank Hook-Up  
6
11  
13  
15  
18  
LIST OF TABLES  
Table  
Description  
2.1  
2.2  
2.3  
2.4  
Connections  
1
3
4
E-Series Feed Water Requirements  
Pressure Correction Factors  
Flow Specifications for E4-Series Machines  
10  
 
 
2.0  
INSTALLATION  
2.1 Mounting the Unit  
When installing your new GE Infrastructure Water & Process Technologies reverse  
osmosis (RO) machine, allow at least 45-inches (114 cm) above the machine for mem-  
brane element removal and loading. If space is not available, the entire membrane  
element housing can be removed for membrane element change outs. If the mem-  
brane element housings are to be removed to change out the membrane elements,  
at least 6-inches (15.2 cm) is required at the end of each membrane element housing  
and 24-inches (61 cm) behind the machine.  
2.2  
Plumbing  
The feed water source must be able to provide water quantity and pressures to main-  
tain an operating feed water pressure of 30 - 60 psig (2.1 - 4.1 barg). If the feed water  
pressure with the machine is in excess of 60 psig (4.1 barg) or fluctuates by more than  
5 psig (0.34 barg) a pressure regulator should be installed up stream of the machine  
Inlet. If proper water pressure cannot be maintained to the RO, a booster pump may  
need to be installed in front of the pretreatment to provide the proper water quantity  
and pressure for the operation of the machine.  
Table 2.1  
Connections  
E4/EZ4/E4LE*  
MACHINE  
INLET  
inches (cm)  
PERMEATE  
inches (cm)  
CONCENTRATE  
inches (cm)  
2200  
4400  
0.75 (1.90)  
0.75 (1.90)  
0.75 (1.90)  
0.75 (1.90)  
0.75 (1.90)  
0.75 (1.90)  
0.50 (1.27)  
0.50 (1.27)  
0.50 (1.27)  
0.75 (1.90)  
0.75 (1.90)  
0.75 (1.90)  
0.50 (1.27)  
0.50 (1.27)  
0.50 (1.27)  
0.75 (1.90)  
0.75 (1.90)  
0.75 (1.90)  
6600  
8800  
11000  
13200  
*
Low Energy Membrane Elements  
1
 
2.3  
Installing Clean-In-Place Valves  
NOTE: Clean-In-Place (CIP) valves are not included with the machine. The CIP  
valves must be purchased and installed by the customer.  
When installing the CIP valves, a three-way valve should be installed in the inlet feed  
stream of the machine. The tees on the permeate and concentrate lines should be  
installed with two-way valves. All valves should be installed in a manner that will  
allow circulation of the cleaning chemicals through the machine and back to the CIP  
container during cleaning.  
CAUTION:  
If CIP valves are not installed when machine is installed, provisions  
must be made to bypass permeate and concentrate to drain for flush-  
ing at start-up.  
WARNING:  
NEVER OPERATE THE MACHINE WITH THE CONCENTRATE OR PER-  
MEATE LINES BLOCKED. SEVERE DAMAGE TO THE UNIT MAY RESULT.  
2.4  
Concentrate Outlet Connections  
Connect proper size drain line to the concentrate outlet (Table 2.1) and run to an open  
drain. The drain capacity needs to be large enough to properly drain the feed water  
flow of the RO. The maximum concentrate back pressure is 60 psig (4.1 barg) for the  
RO machine.  
CAUTION:  
Operation above 60 psig (4.1 barg) concentrate back pressure may  
damage the machine.  
2.5  
Feed Water Requirements  
The following feed water requirements must be met before installing your new E4  
machine to ensure quality permeate and extended membrane element life. Refer to  
Table 2.2 (E-Series Feed Water Requirements) for feed water information.  
2
 
Table 2.2  
E-Series  
Feed Water Requirements  
Temperature  
Inlet Pressure  
Typical:  
Limits:  
50° - 85°F (10° - 29°C)  
33° - 104°F (0.16° - 40°C)  
Minimum:  
Maximum:  
30 psig (2.1 barg)  
60 psig (4.1 barg)  
Chlorine  
0 parts per million (ppm)  
(continuous feed)  
Operating pH  
5.5 - 8.5  
Silt Density  
Index (SDI)  
Less than or equal to 5 to minimize  
membrane element fouling and  
extend cleaning intervals.  
Refer to ASTM* standard D4189.  
*
American Standard for Testing Materials  
2.6  
Transporting Pure Water (Permeate) to Point-of-Use  
The pure water, or permeate, is in an aggressive state and should only be transport-  
ed 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 concen-  
trate piping sizes. Refer to Connections (Table 2.1) for inlet, permeate, and concen-  
trate piping sizes.  
WARNING:  
MACHINE DAMAGE MAY OCCUR IF PERMEATE BACK PRESSURE  
EXCEEDS 60 PSIG (4.1 BARG) DURING OPERATION.  
3
 
2.7  
Pressure Correction Factors  
It is often necessary to operate RO machines with permeate back pressure. Permeate  
back pressure will decrease permeate production. See Table 2.3 (Pressure Correction  
Factors) to calculate loss of permeate.  
Table 2.3  
Pressure Correction  
Factors  
PRESSURE  
% LOSS OF  
PERMEATE FLOW  
CORRECTION  
FACTOR (PCF)  
BACK PRESSURE  
E4/EZ4  
E4LE  
10%  
20%  
30%  
40%  
50%  
60%  
E4/EZ4  
E4LE  
10 psig (0.7 barg)  
20 psig (1.4 barg)  
30 psig (2.0 barg)  
40 psig (2.7 barg)  
50 psig (3.4 barg)  
60 psig (4.1 barg)  
5%  
0.95  
0.90  
0.80  
0.70  
0.60  
0.50  
0.90  
0.80  
0.70  
0.60  
0.50  
0.40  
10%  
15%  
20%  
25%  
30%  
WARNING:  
WARNING:  
IF PERMEATE BACK PRESSURE EXCEEDS 60 PSIG (4.1 BARG)  
MACHINE DAMAGE MAY OCCUR.  
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.  
4
 
2.8  
Electrical  
This RO machine requires two supply voltages; the control voltage and the  
pump motor voltage.  
2.8.1 Single-Phase Electrical  
The control voltage can be connected to either a 115 VAC, 60 Hertz or  
220 VAC, 50 Hertz single-phase power supply. The RO control circuit  
should always be installed on at least a 15 Amp, single-phase dedi-  
cated circuit. Reverse osmosis machines with 115 VAC, single-phase  
control voltage include an eight-foot (2.4 m) cord which plugs into a  
three-prong grounded receptacle. All machines shipped with a  
220 VAC, single-phase control circuit are shipped with an eight-foot  
electrical cord, but customers must provide electrical plug.  
2.8.2 Three-Phase Electrical  
The three-phase pump motor requires a 15 AMP dedicated circuit.  
Always verify correct voltage and Amp rating by checking voltage tag  
on the starter box or by checking electrical specifications on the  
pump. The motor is wired for 460 Volts, 60 Hertz, three-phase voltage  
from the factory (Figure 2.1, Three-Phase Allen Bradley Motor Starter).  
The pump motor can be rewired to 208 or 230 Volts. If this is done, a  
wiring change must be made internally in the pump motor and a  
higher amperage relay and starter may need to be installed. All field  
wiring must comply with applicable local and national electrical  
codes.  
After checking the voltage tag on the motor starter to ensure the  
available voltage and amperage are correct, connect the provided  
three-phase power to the motor starter (Figure 2.1). This can be done  
by connecting the three phase power to the top of the starter relay  
terminals: L1, L2, and L3. A separate, fused disconnect for the motor  
wiring with proper protection for the Horsepower and Amp draw of  
the motor is recommended. All field wiring must comply with applic-  
able local and national electrical codes. See Figure 2.1 for three-  
phase Allen Bradley Starter Hook-Up.  
5
 
Figure 2.1  
Three-Phase  
Allen Bradley Motor Starter  
2.9  
Machine Control  
2.9.1 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 complete and complies with local and national electrical codes, move onto  
Section 2.10 (Pretreatment for Water Purification).  
NOTE:  
2.9.2 Deluxe Model  
To remotely control the Deluxe Model (DLX), with float switches and/or pre-  
External control contacts are normally closed, dry contacts.  
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  
6
 
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.  
2.10  
Pretreatment for Water Purification  
A water analysis of your feed water should have been performed, as part of the plan-  
ning 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 provided. If  
the machine is moved to a different water source, a new water analysis should be  
taken before operating the machine.  
Your RO is designed to operate on 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 chlorine may cause irre-  
versible damage to the Thin-layer composite (TLC) polyamide (PA) membrane ele-  
ments in your machine. Daily water checks are recommended to ensure the integri-  
ty of your pretreatment and RO system.  
2.11  
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.  
CAUTION:  
Improperly flushed pretreatment may cause serious RO machine  
problems at start-up.  
2.12  
Machine Start-Up  
STEPS  
1.  
2.  
Turn the feed water supply ON, while checking for leaks in the pretreatment  
and inlet feed water lines.  
Check to ensure power to the motor is de-energized and the ON/OFF button  
on the machine is in the OFF position.  
3.  
4.  
5.  
Plug in the factory-supplied power for the control voltage.  
For initial start-up, redirect the permeate and concentrate lines to the drain.  
Open the concentrate and recycle flow control valves two complete turns.  
These valves are positioned on the flow control plumbing in the top right rear  
section of the machine.  
7
 
6.  
Turn the ON/OFF button on the machine ON. System will open allowing water  
to flow through the machine to the drain through the permeate and concen-  
trate CIP valves.  
Let the machine run to drain for 5 - 10 minutes. This provides a wet start-up  
of the pump and removes any air in the system.  
7.  
8.  
Turn the ON/OFF button on the machine to the OFF position.  
Re-energize the pump power and trigger the ON/OFF button on the machine  
to check rotation of the pump motor. Observing from the back of the pump  
motor, pump rotation should be clockwise. If rotation is wrong, de-energize  
the pump voltage from the source and switch any two of the three-phase  
wires coming in on top of the three-phase starter. Re-energize the pump volt-  
age and re-check, to ensure correct rotation for the start-up and operation of  
your machine.  
WARNING:  
IF THE RO PUMP IS STARTED WITH INCORRECT ROTATION  
(i.e., BACKWARDS), A NOTICEABLE DROP IN FLOWS AND  
PRESSURES WILL RESULT. IF PUMP MOTOR OPERATES BACK-  
WARDS FOR ANY LENGTH OF TIME, PUMP DAMAGE MAY  
RESULT.  
After correct rotation has been verified, you are now ready to start the  
machine and set the flows and pressures.  
9.  
With the recycle and concentrate orifices still two (2) turns open and ade-  
quate feed water available, start the machine by turning the ON/OFF button  
to the ON position.  
10.  
As the pump starts to build pressure, begin to adjust the orifices in the follow-  
ing manner: start by slowly closing the concentrate orifice while slowly open-  
ing the recycle valve.  
Primary Pressure for Normal Operation at 77°F (25°C)  
E4-Series:  
220 psi (15.2 bar) at 77°F (25°C)  
115 psi (7.9 bar) at 77°F (25°C)  
EZ4/E4LE-Series:  
While you are doing these valve adjustments, to obtain correct flows and  
pressures, observe the primary or pump pressure. The pump pressure, while  
adjusting the orifices, should never operate outside of these ranges:  
E4-Series Range:  
190 - 275 psi (13.1 - 19.0 bar)  
100 - 140 psi (6.9 - 9.6 bar)  
EZ4/E4LE-Series Range:  
8
 
The concentrate valve is drilled, and when completely closed the machine is  
running at the correct concentrate flow for a 75% recovery (Table 2.4, Flow  
Specifications for E4-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.  
CAUTION:  
Optimum recovery will vary according to water quality.  
2.13 Temperature Correction Factor  
If the temperature of the inlet feed water is not 77°F (25°C), refer to Technote 113 for  
Temperature Correction Factors.  
NOTE: Optimum recovery will vary according to water quality.  
9
 
2.14 Recovery  
The machine flow specifications listed below are based on 25°C (77°F).  
Table 2.4  
Flow Specifications for  
E4-Series Machines  
E4-Series  
Recovery  
Units  
2200  
4400  
6600  
8800  
11000  
50-75%  
LPM/GPM  
28.9/7.6  
13200  
50-75%  
LPM/GPM  
34.7/9.2  
50-75%  
LPM/GPM  
50-75%  
LPM/GPM  
11.6/3.06  
50-75%  
LPM/GPM  
17.3/4.6  
50-75%  
LPM/GPM  
23.1/6.1  
Permeate Rate 5.8/11.6  
Concentrate  
Rate  
5.8/11.6  
1.9/0.5  
11.6/3.06  
3.9/1.0  
17.3/4.6  
5.8/1.5  
23.1/6.1  
7.7/2.0  
28.9/7.6  
9.6/2.5  
34.7/9.2  
(50%)  
Concentrate  
Rate  
11.6/3.06  
(75%)  
Feed Rate  
(50%)  
11.5/3.0  
7.7/2.0  
23.2/6.1  
15.4/4.1  
34.7/9.2  
23.1/6.1  
46.2/12.2  
30.8/8.2  
57.8/15.3  
38.5/10.2  
69.4/18.3  
46.2/12.2  
Feed Rate  
(75%)  
10  
 
2.15  
Autoflush Timer  
2.15.1 Programming the Autoflush Timer  
The Autoflush timer clock operates and displays in real time, but the Autoflush  
feature will only work when the RO machine is operating. When the machine  
is operating in the Autoflush Mode, the total flow through the machine is  
increased. This provides extra cross flow which flushes the loose foulants  
from the surface of the membrane elements. When the machine is operating  
in the Autoflush Mode a slight drop in permeate production, as well as a  
decrease in the primary and final pressures may be observed. An ideal way  
to set the timer up is to program ten Autoflush sequences, with a 10 to 15  
minute duration, per 24 hours. To do this, follow the procedure below.  
2.15.2 Setting Up the Autoflush Timer Clock  
IMPORTANT:  
Before proceeding with setting the timer and programming  
the unit, press the RESET KEY to clear all data. After press-  
ing the RESET KEY, the display may show A.M., this is in mili-  
tary time mode.  
If the machine is in Military Time, do the following:  
SELECTING AM/PM OR MILITARY TIME  
After pressing reset, the display may show  
A.M.(right). The numbered day symbols will be flash-  
ing ON and OFF.  
If the display does not show A.M., it is in military time  
mode (24:00 hr.). To change to A.M./P.M. mode, press  
and hold the  
h
Key and press the  
± 1h Key once, A.M. will appear in the display.  
If display is in A.M.. mode and military mode is  
desired, press and hold the h Key, press the  
± 1h Key once.  
Figure 2.2  
Setting-Up the Correct Time  
on the Autoflush Timer  
11  
 
STEPS  
1.  
While holding down the Clock Key ( ), press the h key to advance to  
the current minute.  
2.  
3.  
While holding down the Clock Key ( ), press the h key to advance to  
the current minute.  
While holding down the Clock Key ( ), press the h key to advance to  
the current minute.  
NOTE: If the h and m keys are held down for longer than 2 seconds,  
the numbers will advance rapidly.  
If the days are flashing, it indicates the day of the week was not set  
when setting the time. The timer cannot be programmed unless the  
day of the week is entered. Each year, in the spring, press the Button  
to advance the time one hour (Daylight Savings Time). In the fall,  
press the button to set the timer back one hour (Daylight Savings  
Time).  
2.15.3 Programming the Autoflush Timer Clock  
This timer will accept up to 20 programs. Each program consists of the fol-  
lowing:  
1.  
2.  
3.  
ON/OFF Command  
Time of Day (hours and minutes)  
Single day or multiple days  
IMPORTANT:  
The current time of day and day of the week must be set  
prior to programming the timer. See Section 2.15.3 (Setting  
Up the Autoflush Timer).  
12  
 
2.15.4 Programming Twenty-Four Hour or Seven Day Schedules  
NOTE:  
It is helpful to write out the program schedules before programming  
the time.  
Example:  
Figure 2.3  
Programming the Timer  
2.15.5 Changing a Program  
Select the program to be changed with the Prog. Key. A new set of days may  
be selected with the Day Key just as in the initial programming. Hour and  
minute can be changed with the h and m Keys.  
2.15.6 Deleting a Program  
To delete one or a few programs: Press the Prog. Key until the desired pro-  
gram is displayed:  
1.  
2.  
3.  
Press the m Key to :59 and press once again to blank out.  
Press h Key to 11 P.M. and press once again to blank out.  
Press the Clock Key, ( ) display will flash for several seconds and then  
enter the Run Mode.  
4.  
Using the Reset Key will delete ALL programs, the time of day, and day  
of the week.  
13  
 
2.15.7 Troubleshooting the Autoflush Timer  
PROBLEM:  
SOLUTION:  
Days are flashing, pressing any Key does nothing except  
“Hand” Key turns output ON and OFF.  
Time of Day and Day of Week have not been set.  
See Section 2.15.3 (Setting-Up the Autoflush Timer Clock).  
PROBLEM:  
SOLUTION:  
Time of day was set while holding the Clock Key down, but  
days are still flashing.  
Current day of week was not set while holding down  
the Clock Key. See Setting-Up the Autoflush Timer Clock  
(Section 2.15.2).  
PROBLEM:  
SOLUTION:  
It is 10 A.M. and a ON program for 8 A.M. was entered, but  
the output is not ON.  
The ON or OFF was not entered as part of the program.  
ON or OFF must be selected.  
14  
 
2.16 Calibrating the Conductivity Probe  
STEPS  
1.  
2.  
Make sure the calibration meter is in Measure Mode (with the MEAS LED  
light ON).  
Immerse the Conductivity Probe in a 13.00 microSiemens (mS) prepared solu-  
tion.  
3.  
4.  
Immerse and agitate Conductivity Probe, and wait for the reading to stabilize.  
Calibrate the meter by adjusting the CAL adjustment screw until the Liquid  
Crystal Display (LCD) display reads 13 mS of the solution.  
The meter is now calibrated  
NOTE:  
The alarm function on the conductivity meter is not used on E4/EZ4/E4LE-  
Series machines.  
Figure 2.4  
Conductivity Probe Display  
15  
 
2.17 Operation and Maintenance  
The operation and maintenance of an E-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 operat-  
ing shift. A Start-Up Data Sheet (Technote 105) should have been completed at start-  
up containing pertinent facts on the operation of your machine. These two records  
are invaluable in diagnosing the performance of the equipment, and must be kept for  
reference. If you have questions concerning the operation of your machine or the  
method of data recording, contact the manufacturer.  
Three preventative maintenance procedures, which must be done on a regular basis,  
are as follows:  
1.  
2.  
3.  
Change the pre-filter cartridges as needed. Pressure drop across the pre-fil-  
ters should not exceed 8 psi (0.6 bar).  
Clean the RO membrane elements with approved cleaners at least quarterly,  
depending on feed water quality.  
Flush the RO machine daily.  
2.17.1 Daily Flushing for the Economy Model  
If your E4-Series machine is an ECN Model it needs to be manually flushed  
daily. The DLX E4-Series machine is equipped with an Autoflush Timer  
(Section 2.15, Autoflush Timer). A daily manual flush must be performed. To  
flush the machine:  
1.  
With the machine running, open the concentrate valve 1/2 - 3/4 turn.  
NOTE: During flushing procedure, the machine must be running.  
2.  
3.  
Allow the machine to operate with the concentrate valve open (Step 1)  
for 10 - 15 minutes.  
After 10 - 15 minutes, return the concentrate valve to its previous set-  
ting, 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.  
2.17.2 Daily Flushing for the Deluxe Model  
The DLX Model machine includes an Autoflush Timer Option. The Autoflush  
Timer Option automatically flushes the machine at preset  
intervals.  
16  
 
2.18 Pre-filter Cartridge  
A 5 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 118, P/N 1233377).  
A pressure drop across the filter of 8 psi (0.55 bar) or more during operation indicates  
that the pre-filters cartridge(s) need changing. Use only GE approved filters rated for  
5 microns or less. Do not attempt to clean used filters.  
IMPORTANT NOTE:  
Failure to change the pre-filter cartridge according to these  
requirements will void machine warranty.  
2.19 Membrane Element Cleaning  
GE recommends that you clean your RO every quarter, depending on the quality of  
your feed water. Cleaning of the membrane elements is vital because contaminants  
can build up on the membrane element surfaces, reducing the permeate flow rate  
and affecting the quality of the permeate.  
2.19.1 Step Wise Cleaning  
This RO machine and many others have a centrifugal pump on them.  
Centrifugal pumps are not designed to draw water. They are designed to  
operate with flooded suction only. The manufacturer recommends using a  
Clean-In-Place (CIP), or booster pump, to provide water pressure and flow to  
the RO machine pump from the CIP container.  
2.19.2 Procedure to Clean with a CIP Pump  
STEPS  
1.  
With the machine running, open the CIP permeate valve, close the  
permeate service valve and fill the CIP tank with permeate water.  
When the container is filled to desired level, turn machine OFF.  
2.  
3.  
4.  
5.  
Add and mix up the cleaners in the CIP container. Please use only  
PA membrane element compatible cleaners.  
Close the inlet feed water supply valve to the machine and open the  
CIP inlet feed water to the CIP container.  
Close the permeate valve to point of use and also the concentrate  
valve drain.  
Open the CIP valves, allowing permeate and concentrate to return to  
the CIP container.  
17  
 
When set properly, the RO machine, the CIP pump, and the CIP con-  
tainer should be assembled in a loop configuration to recirculate the  
water through the machine and back to the container during clean-  
ing. The size of the CIP container should be a minimum of three times  
the permeate rate.  
CAUTION  
GE recommends the use of a CIP or booster pump to  
provide the proper feed water pressure and quantity  
to the RO machine during cleaning.  
Figure 2.5  
Clean-In-Place Pump  
and Tank Hook-Up  
With the machine set-up in the CIP configuration and the cleaning solution  
mixed in the container, you are now ready to start the CIP process. Follow the  
Steps below.  
STEPS  
1.  
2.  
3.  
Check to ensure that the feed, permeate, and concentrate valves and  
line are open and unrestricted in the tank loop.  
Start the CIP and RO machine pumps together. As they start up,  
observe all RO machine pressures and flows.  
Recycle the cleaning solution for about 15 minutes. Damage may  
result to membrane elements if the temperature of the CIP solution  
exceeds 105°F (40°C). If the water temperature exceeds 100°F (38°C),  
place bags of ice into the CIP container to absorb the extra heat.  
4.  
After recirculating the cleaner for 15 minutes, shut down the RO and  
the CIP pump.  
18  
 
5.  
6.  
Let the CIP solution dwell in the machine for 20 minutes.  
After the 20 minute dwell time, start the CIP recirculation process  
again for 10 minutes.  
7.  
After the 10 minute recirculation time is complete, de-energize the  
machine. Then, open the inlet water line and route the concentrate  
and permeate lines to the drain.  
8.  
9.  
Start the RO machine and flush to drain for 20 minutes. Verify the per-  
meate quality is good before returning to normal operation.  
After permeate quality is verified as good, route the permeate to point  
of use and concentrate to drain. You are now ready for normal oper-  
ation.  
2.20  
Suction Cleaning  
GE does not recommend the suction cleaning method to clean the E4-Series RO  
machine. If using suction cleaning, reference cleaning with a CIP pump above  
(Section 2.19.2, Procedure to Clean with a CIP Pump).  
STEPS  
1.  
2.  
Arrange the RO and the CIP container in a closed loop situation with the  
cleaning solution, reference Section 2.19 (Membrane Element Cleaning).  
Move the L1 and L2 wires on the pressure switch across to the motor termi-  
nals (Figure 2.1, Three Phase Allan Bradley Motor Starter). The wires can also  
be temporally jumped.  
3.  
4.  
5.  
Open the inlet feed valve.  
Start the RO machine  
As the machine starts up on inlet feed water, slowly close the inlet feed water  
valve while slowing opening the feed water valve to the CIP tank.  
You will begin to hear the RO pump draw the CIP solution into the machine  
and circulate it back into the CIP tank. After achieving prime, observe the RO  
closely to ensure that you do not loose pump prime, which may result in  
pump damage.  
6.  
Refer to the CIP cleaning procedure (Section 2.19.2) for cleaning steps.  
WARNING:  
LOSS OF PRIME DURING SUCTION CLEANING MAY RESULT IN  
SERIOUS DAMAGE TO THE PUMP.  
19  
 
NOTE:  
As previously mentioned, the manufacturer recommends use  
of a CIP or booster pump to circulate the cleaning solution  
during membrane element cleaning.  
7.  
8.  
After suction cleaning cycle is complete, reopen inlet water and flush machine  
to drain for twenty minutes.  
After permeate quality is verified as good, return machine to normal opera-  
tion mode.  
2.21  
Changing Out Membrane Elements  
CAUTION:  
Replacement membrane elements are shipped from the factory in a  
plastic bag with a small amount of bactericide solution to prevent bio-  
logical growth. When installing the membrane elements, always pro-  
vide adequate ventilation and wear gloves while handling the mem-  
brane elements as recommended. The membrane elements must be  
kept moist at all times in to prevent possible damage to the mem-  
brane element material.  
STEPS  
1.  
Remove the top end caps and clamps from the membrane element housings.  
Lubricate all O-rings and brine seals, and the PVC membrane element stems  
(stingers) with a non-petroleum based lubricate (i.e., glycerin or poly water).  
2.  
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 element up. Slowly turn the membrane element as you lower it  
into the membrane element housing. As you reach the bottom of the hous-  
ing 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 hous-  
ing the brine seal will be on the top.  
3.  
4.  
Next, load the up flow membrane elements, by lubricating all brine seals, O-  
rings, and the membrane element stingers. With the up flow membrane ele-  
ment 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 ele-  
ment 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 ele-  
ment housing.  
20  
 
5.  
6.  
Reattach the housing clamp and tighten.  
Next reconnect the permeate and concentrate lines.  
The machine is ready for start-up.  
21  
 
2.22 Troubleshooting  
This troubleshooting guide can assist you in identifying common operating problems you  
may experience with your machine. Many of these problems can be easily corrected by the  
operator, 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:  
1.  
2.  
3.  
4.  
5.  
Machine installation date  
Model number  
Serial number  
Weekly log sheets  
Detailed description of problem.  
T R O U B L E S H O O T I N G G U I D E  
PROBLEM  
POSSIBLE CAUSE  
SOLUTION  
Low Operating  
Pressure  
Insufficient feed water pressure Open the feed pressure, open the  
or flow  
feed water valve, check for  
restrictions  
Clogged pre-filter  
High flow rates  
Replace the cartridge.  
Close the concentrate valve, check  
the permeate and concentrate flow  
rates and adjust if necessary.  
Excessive permeate flow may indi-  
cate a damaged O-ring.  
Dirty or fouled membrane  
elements  
Flush and clean the membrane  
elements.  
Solenoid valve not opening  
Clean or replace the solenoid valve.  
22  
 
T R O U B L E S H O O T I N G G U I D E  
PROBLEM  
POSSIBLE CAUSE  
SOLUTION  
Low Operating  
(continued)  
Pump rotating backwards  
(three-phase power only)  
Switch any two of the three-phase  
leads to the motor starter.  
Insufficient electrical power  
Pump not operating correctly  
Low operating pressure  
Check the fuses or circuit breaker,  
measure the voltage.  
See pump instructions.  
Low Permeate Flow  
Rate  
See possible causes for low  
pressure.  
Dirty or fouled membrane  
elements  
Flush and clean membrane  
elements  
Operating on cold water less  
than 55°F (13°C)  
Install a hot/cold feed water tem-  
pering valve if more permeate flow  
is needed. Operate with a feedwa-  
ter temperature of 72° - 75°F  
(22° - 25°C).  
Membrane elements installed  
backwards or damaged  
concentrate seal  
Install membrane elements in the  
direction of fluid flow. Flush and  
clean the machine immediately.  
Membrane elements with damaged  
concentrate seals should be  
cleaned and may be returned for  
repair.  
Flow meter inaccurate  
Check the flow rate manually with a  
stop watch and calibrated  
container.  
23  
 
T R O U B L E S H O O T I N G G U I D E  
PROBLEM  
POSSIBLE CAUSE  
SOLUTION  
Low concentrate flow  
rate, normal or higher  
than normal pressure  
Concentrate valve plugged  
Remove the concentrate valve step  
and/or disassemble the plumbing.  
Clean the valve  
Concentrate outlet line  
restricted  
Examine the concentrate line for  
obstructions or kinks, repair or  
replace the tubing.  
Flow meter inaccurate  
Dirty concentrate valve  
Check the flow rate manually with a  
stop watch and calibrated  
container.  
High operating pressure  
Disassemble and clean the  
plumbing to the valve  
Recycle or concentrate valve  
plugged  
Disassemble the plumbing to the  
recycle valve and remove foreign  
particles. Check the concentrate  
valve stem.  
Inaccurate pressure gauge  
Replace or calibrate the gauge as  
required.  
Restricted or reduced  
permeate flow rate  
See possible causes for low  
permeate rate.  
Excessive pressure drop  
[over 50 psig (3.0 barg)]  
(high primary pressure -  
low final pressure)  
Restricted flow after  
pump outlet  
Check for blockage of the concen-  
trate flow at the inlets and outlets of  
the membrane element housings.  
24  
 
T R O U B L E S H O O T I N G G U I D E  
PROBLEM  
POSSIBLE CAUSE  
SOLUTION  
Excessive pressure drop Telescoped membrane element  
Flush and clean the membrane  
elements  
[over 50 psig (3.0 barg)]  
(high primary pressure -  
low final pressure)  
(continued)  
covering membrane element  
housing outlet port  
Severely fouled or dirty  
membrane elements  
Flush the machine then clean it with  
detergent.  
Water flowing when  
Inlet solenoid valve not closing Clean or replace the valve. Clean  
machine is turned OFF  
or seating properly  
the membrane elements with deter-  
gent immediately. Water must not  
pass through the inlet when the  
machine is OFF.  
Declining rejection  
(high permeate  
conductivity)  
Dirty or fouled membrane  
elements  
Flush and clean the membrane  
elements  
O-ring seal broken or damaged Replace the O-ring, check the seal-  
ing surfaces on the O-ring groove,  
interconnectors and end caps.  
Replace the damaged parts.  
Change in incoming water  
quality  
Open the concentrate valve and  
flush. Test the water for pH, hard-  
ness, TDS and iron content. A water  
analysis should be sent to GE  
Infrastructure for review.  
Inaccurate conductivity monitor  
or fouled probe  
Calibrate the monitor with a DS  
standard solution or check the  
readings with another conductivity  
meter. Replace or clean the probe.  
Check the connections between the  
probe and monitor.  
25  
 
T R O U B L E S H O O T I N G G U I D E  
PROBLEM  
POSSIBLE CAUSE  
SOLUTION  
Switch ON, unit not  
operating  
Pressurized storage switch or Check the permeate back pressure  
float switch has cut power to  
machine  
or position of float in the storage  
tank.  
Fluid temperature higher than  
Allow the machine to cool; check  
100F (38C) or thermal overload the feed water supply and/or amp  
in motor  
draw to the motor.  
No power to machine  
Check the fuses or circuit breakers,  
measure the voltage.  
Deluxe (DLX) electrical  
machine shutdown  
Motor and/or pump not  
operating properly  
See the pump instructions. Contact  
GE Infrastructure for possible repair  
or replacement.  
Alarm condition has turned  
machine OFF  
Restart the machine by pushing the  
alarm bypass. Check all possible  
alarm conditions: inlet pressure or  
motor starter overload  
Motor starter overloaded, heater  
tripped  
Turn the switch OFF. Rest the  
heater(s). Check the motor amp  
draw and the line voltage.  
Timing relay defective/burned  
out  
Replace the relay.  
26  
 
 
For more information call 952-933-2277 or 800-848-1750 in the U.S., or visit www.gewater.com.  
GE Infrastructure  
Water & Process Technologies  
North American Sales  
5951 Clearwater Drive  
Minnetonka, MN  
55343-8995  
Euro/Africa Sales  
230 rue Robert Schurman  
ZA des Uselles  
77350 Le Mée sur Seine  
FRANCE  
Asia/Pacific Sales  
1044/8 SOI 44/2  
Sukhumvit Road Parkanog  
Bangkok 10110  
USA  
THAILAND  
(952) 933-2277 Phone  
(952) 933-0141 Fax  
+33 1 64 10 2000 Phone  
+33 1 64 10 3747 Fax  
+66 2 38 14213 Phone  
+66 2 39 18183 Fax  
© 2005, General Electric Company. All rights reserved.  
P/N 1161875 Rev. D  
 

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