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OPERATION AND MAINTENANCE MANUAL

FOR

GUPCO / GAS PLANT

MAX-45
REVERSE OSMOSIS SYSTEM
AES JOB NO.: 01-08-02
January 2009

REF P.O. GP-51092-ASA

Supplied By:
OASIS ENVIRONMENTAL PRODUCTS

MANUFACTURED BY:
AMERICAN ENGINEERING SERVICES, INC.
9203-A KING PALM DRIVE
TAMPA, FL 33619, USA
PHONE: (813) 621-3932
FAX: (813) 621-4085
e-mail: inquiries@aesh2o.com
MAX OPERATION AND MAINTENANCE MANUAL

TABLE OF CONTENTS
TABLE OF CONTENTS............................................................................................................... 1
SECTION 1.0 - INTRODUCTION................................................................................................. 3
SECTION 2.0 - SCOPE OF SUPPLY .......................................................................................... 4
DRAWING AND DATA SHEET LIST....................................................................................... 5
SECTION 3.0 - MATERIAL HANDLING, RECEIVING AND STORAGE..................................... 6
3.1. EQUIPMENT HANDLING .............................................................................................. 6
3.2. INITIAL EQUIPMENT RECEIPT, INSPECTION & STORAGE .................................... 12
SECTION 4.0 - EQUIPMENT INSTALLATION.......................................................................... 16
4.1. GENERAL GUIDELINES ............................................................................................. 16
4.2. SYSTEM FLUSHING & PIPE HYDRO TESTING ........................................................ 18
4.3. FILTER MEDIA LOADING (IF SUPPLIED) .................................................................. 20
SECTION 5 - TESTING AND PRE-START-UP CHECKS/PREPARATION .............................. 22
5.1. ELECTRICAL TESTING ............................................................................................... 22
5.2. INSTRUMENT CHECKS/TESTING/CALIBRATION ...................................................... 23
5.3. CHEMICAL PUMPS START-UP/CALIBRATION........................................................... 25
5.4. PUMPS CHECK-UP/MOTOR UNBALANCED TESTS .................................................. 25
5.5. VALVES PRE-START-UP /TESTS ............................................................................... 27
5.6. PRE-START-UP PREPARATION ................................................................................. 27
SECTION 6.0 - SYSTEM SAFETY PRECAUTIONS ................................................................. 34
6.1. SAFETY SUMMARY .................................................................................................... 34
6.2. GENERAL SAFETY GUIDELINES .............................................................................. 34
6.3. HANDLING HAZARDOUS CHEMICALS AND MATERIALS ....................................... 37
SECTION 7.0 - SYSTEM START-UP ........................................................................................ 41
7.1. MEMBRANE PRESERVATIVE .................................................................................... 41
7.2. FEED AND DISCHARGE PIPING (customer-supplied) ............................................... 41
7.3. PERMEATE WATER PIPING (customer-supplied): ..................................................... 41
7.4. PRODUCT WATER STORAGE (customer-supplied) .................................................. 41
7.5. FEED WATER CONDITIONS: ..................................................................................... 42
7.6. HIGH-PRESSURE OPERATION ................................................................................. 43
7.7. CLEANING EQUIPMENT ............................................................................................ 44
7.9. INSTRUMENTATION AND CONTROLS ..................................................................... 45
7.10. START-UP INSTRUCTIONS.................................................................................... 48
7.11. START-UP LOGIC: .................................................................................................. 50
7.12. SHUT-DOWN LOGIC: .............................................................................................. 52
7.13. OPERATING LOGIC OF THE CHEMICAL DOSING SYSTEMS: ............................ 53
SECTION 8.0 - SCHEDULED MAINTENANCE ........................................................................ 54
8.1. PRE-FILTERS.............................................................................................................. 54
8.2. PUMP .......................................................................................................................... 54
8.3. PRESSURE VESSELS ................................................................................................ 54
8.4. MEMBRANES .............................................................................................................. 54
8.5. HIGH PRESSURE SWITCH (if included) ..................................................................... 55
8.6. RECOMMENDED SPARE PARTS .............................................................................. 55

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MAX OPERATION AND MAINTENANCE MANUAL

8.7. LONG-TERM SHOT-DOWN PROCEDURES: ............................................................. 55


SECTION 9.0 - TROUBLESHOOTING...................................................................................... 57
9.1. GENERAL OVERVIEW ............................................................................................... 57
9.2. SYSTEM OPERATION LOG SHEET ........................................................................... 58
9.3. PLANT PERFORMANCE NORMALIZATION .............................................................. 59
9.4. TROUBLESHOOTING GUIDE..................................................................................... 61
SECTION 10.0 - MEMBRANE CLEANING PROCEDURES ..................................................... 66
10.1. MEMBRANE CLEANING REQUIREMENTS............................................................ 66
10.2. CLEANING PROCEDURES ..................................................................................... 67

APPENDIX I SYSTEM OPERATION DATA ........................................................................... I


APPENDIX II SYSTEM DRAWINGS ..................................................................................... II
APPENDIX III COMPONENT DATA AND MANUALS ......................................................... III
APPENDIX IV STANDARD LIMITED WARRANTY .............................................................VI

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MAX OPERATION AND MAINTENANCE MANUAL

SECTION 1.0 - INTRODUCTION

This manual exclusively supports the installation, operation, and maintenance of the
Max Reverse Osmosis Systems manufactured by AES, and it should not be used as a
reference to handle any other customer-supplied equipment.

The supplied RO system is designed based on the feed water conditions reported by
the customer, such as feed TDS, pH, temperature, SDI, turbidity, hardness, etc. System
performance and productivity is susceptible to any deviation from the original design
conditions. The computer projections in Appendix-I refer to the typical performance of
the system under the design conditions. New computer projections should be prepared
for any variation in the actual feed conditions.

AES believes that the information and recommendations that are included in this
manual are true and correct. The source of such information is our main suppliers, field
data, and long-term experience that we trust to be reliable. Since start-up and operating
conditions are beyond AES control, AES provides this manual in a good faith to help the
installer and operator of the system at their own risk, and cannot assume any liability for
any damage that happens during the application of such information or
recommendations.

All supplied equipment is prefabricated and assembled to minimize site work. The
required installation and site work involve installation of main equipment, positioning,
interconnecting pipe work, and wiring to each main control panel. Details and
requirement of such work are described in the subsequent chapters.

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SECTION 2.0 - SCOPE OF SUPPLY

AES has undertaken the supply of a Packaged Water Treatment Plant rated to produce
potable water at a rate of 200 m3/d from feed TDS less than 45,000 ppm at 77 F. The
Water Treatment System in this project consists of the following main equipment:

Feed Tank (By Others)


Feed Boosting System (two pumps duty/standby)
Prefiltration systems:
Two (2) MM filters 30 x 72, 2 Magnum Valve
Two (2) Carbon filters 36 x 72, 2 Magnum Valve
Six (6) Chemical dosing systems
- Prechlorination Dosing System
- Dechlorination Dosing System
- Acid Dosing System (or Biological Inhibitor Dosing
System)
- Antiscalant Dosing System
- Post Chlorination Dosing System
- Caustic Dosing System
Reverse Osmosis Unit
Cleaning System CIP
Product Water Tank (By Others)

Please refer to the proper drawings and data sheets in the following list for more
technical details:

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DRAWING AND DATA SHEET LIST

CHECK CONTENTS APPENDIX


System Performance Data Sheet I
Computer Projection I

0108002PID001 P&I Diagram II


0108002MEC002 System Overall Layout II
0108002MEC003 Frame Drawing II
0108002ELE004 PLC Panel Layout II
0108002ELE005 Control Circuit Diagram II
0108002ELE006 Digital Input Wiring Diagram II
0108002ELE007 Digital Output Wiring Diagram II
0108002ELE008 Analog Input Schematic Diagram II
0108002ELE009 Sensor Wiring Diagram II
0108002ELE010 VFD Panel Layout II
0108002ELE011 VFD Panel Schematic Diagram (A) II
0108002ELE012 VFD Panel Schematic Diagram (B) II

Spare Parts List III


Component Manuals III

AES Standard Limited Warranty IV


System Operation Log Sheet Section 9.2
Troubleshooting Guide Section 9.4

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MAX OPERATION AND MAINTENANCE MANUAL

SECTION 3.0 - MATERIAL HANDLING, RECEIVING AND STORAGE

The purpose of this section is to provide general information on the receiving and handling of
the new equipment. Specific information on the installation of equipment and components can
be found in the equipment and drawing sections of this manual. All equipment must be installed
as shown on the drawings provided for this job.

3.1. EQUIPMENT HANDLING

Unloading and handling of the major components for this job must be performed by
experienced workers using approved lifting and moving procedures. The following
subsections provide general guidelines for lifting and moving heavy equipment.

3.1.1. Major Component Handling Guidelines

i. All lifting and moving procedures must be performed by experienced


construction workers using standard rigging methods.

ii. Before beginning any equipment handling procedure, refer to the


following sections in the Occupational Safety and Health Administration
(OSHA) manual #2206: "General Industry Standards."

OSHA manual #2206

Subpart N: "Materials Handling and Storage"

Section 1910.176: "Handling Materials - General


Section 1910.178: "Powered Industrial Trucks"
Section 1910.179: "Overhead and Gantry Cranes:
Section 1919.180: "Locomotive and Truck Cranes"
Section 1919.181: "Slings"

Also, refer to any other applicable literature and information for cranes,
lift trucks, and other equipment used for lifting and moving.

iii. Make sure that all equipment used for lifting and moving is properly
maintained and is in good condition.

Always inspect slings, cables, clevises, and other equipment prior to


every lifting and moving event.

WARNING - Damaged lifting devices can cause fall in service and cause severe
personal injury or equipment damage.

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Never use slings or cables that are cut, frayed, or kinked. Refer to
OSHA manual #2206 for information on inspecting lifting devices for
damage.

All lifting hooks on cranes must be equipped with spring-loaded safety


latches to keep cables from slipping out of the hooks.

WARNING - Cables and slings can slip out of crane hooks not equipped with
safety latches. Falling loads can cause severe personal injury or
equipment damage.

Never use crane hooks that are not equipped with safety latches.

iv. When using cables or woven straps as slings or chokers, place heavy
carpeting, sections of tires, or other material between the sling and the
object being lifted. This will help protect the sling device and the object
being lifted.

v. If a component has lifting lugs or eyelets installed, use these devices for
lifting whenever possible.

vi. Do not lift a vessel or equipment skid by attaching lifting devices to


piping or other components.

vii. Be sure that components being lifted are balanced and will not tip or slip
out of a sling.

When lifting a large component, raise the object until it just clears the
surface it was resting on and then stop. Observe the object to verify that
it is balanced and is firmly held by the lifting devices. If there is any
doubt about the safety of the lifting method, set the object down and
reposition the lifting devices or else use another method.

Use extra caution when lifting equipment skids using lift points on the
skid (base). Equipment skids are often top-heavy and may tip when
lifted more than a few inches off the ground.

viii. When moving a component with a crane or a lift truck, keep the load as
low as possible at all times. This can minimize component damage if
the load tips over, slips, or falls.

Also, keep hands and feet from under raised components. If operators
must reach under a raised component to connect lifting devices or
perform other work, blocks must be placed under the component to
support it.

If operators must reach under a raised component, place some type of


heavy blocking under the component to support it if the lifting device
fails.
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MAX OPERATION AND MAINTENANCE MANUAL

ix. Once a component is connected to lifting devices and is ready to lift, a


foreman or lead person should verify that all workers are clear of the
lifting devices, the object, and the immediate lift area before proceeding
with the lift.

When a large component is to be lifted and moved, all workers in the


general area should be warned of the lifting event and should be
instructed to stand clear of the component and the lift area.

When a component is lifted with a crane or forklift, all workers must


remain in the crane or forklift and must remain in the operators view
during the lifting operation.

x. If two or more lift points on a component are connected to a single crane


or crane trolley, use cable spreader bars to prevent excessive side loads
on legs, lifting lugs, eyelets, and other lift points.

CAUTION - If a single cable run and a single crane are used to lift the bottom
of a vessel, a spreader bar must be used to prevent damage to the
vessel legs.

Vessel legs and other lift points must not be subjected to severe side
loads.

xi. If a large component must be lifted more than a few inches off the
ground, attach tag lines to the component. Workers can use these tag
lines to stabilize and control the component while it is suspended.

xii. If the equipment is to be stored temporarily, follow the instructions given


in point (3.2.2).

Always set and store vessels and skids on wooden blocks in the same
manner in which they were shipped.

3.1.2. Handling Major Components


This section gives specific guidelines for handling of major
components.

i. Lifting Container, Equipment Skids and Panels


Always lift container and/or equipment skids evenly; avoid flexing the
equipment. Also, keep the equipment level and close to the ground as it
is being moved.

WARNING - Many equipment skids or containers are top heavy and can be
unstable when lifted by their bases. These skids can tip during
lifting and can cause equipment damage and worker injury.

Always use a separate cable for each lift point to prevent cable slip at
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MAX OPERATION AND MAINTENANCE MANUAL

the crane hoods. Keep the skid as close to the ground as possible
during the lifting and moving procedures.

Finally, attach tag lines to the skid, container or other component if it


must be lifted more than a few inches off the ground. An experienced
operator is necessary to move the container.

CAUTION - Use extra care when moving control panels. These panels contain
delicate instruments that can be damaged by rough handling.

ii. Handling Other Equipment

The following outlines gives handling guidelines for smaller components.

(1) Many of the smaller components that are shipped loose for this
job can be moved using forklifts or small cranes and woven
straps.

Workers must be sure that any equipment used for moving


loose components is properly maintained and is in good
condition.

Refer to OSHA manual #2206 for more information on material


handling and handling equipment.

(2) When moving components with a forklift, be careful not to


damage the components.

Avoid "ramming" the lifting forks under pieces; use a crane or


pry bar to lift the piece up enough to drive the forks under.

Be careful not to damage tubing, indicators, and other delicate


devices or parts attached to larger components.

Make sure that any load on the forks is secure and balanced.
When carrying pipe or pipe spools on the forks, keep the forks
tilted all the way back and avoid sudden stops.

Be aware of the weight capacity of the forklift being used; do


not overload the forklift. When carrying long or wide pieces,
watch carefully when making turns.

(3) When lifting and moving individual pumps, lift by the pump base
or at any indicated lift points.

CAUTION - Do NOT lift pumps using eyelets found in the pump body or
in the drive motor. These eyelets are generally used by the
pump manufacturer during the assembly of the pump and
are not intended for lifting the entire unit.

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MAX OPERATION AND MAINTENANCE MANUAL

(4) When moving lengths of pipe or long spools with woven straps,
use two straps equally spaced from the balance point of the
piece; this will prevent tipping and loss of control of the piece
when it is lifted.

(5) Use special precautions when moving large control valves.


When lifting valves, use a woven strap at a choker around the
valve body or around the stem between an automatic actuator
and the valve body. Do not lift valves by their hand wheels or
automatic actuators. Also, be careful not to damage tubing,
indicators, and other delicate devices or parts attached to the
valves.

(6) Use extreme caution when moving instruments or components


with instruments attached. Instruments are delicate and can be
damaged by dropping or bumping them. Be especially careful
not to damage gauges or sensors attached to the instrument.

3.1.3. Handling Chemicals

Sodium hydroxide, Coagulant, Sulfuric acid and sodium hypochlorite are


all strong chemicals and can be dangerous, especially in their
concentrated forms. In addition, Antiscalant, although not highly toxic,
still requires proper handling. If these materials are not properly
handled, serious injury could result. It is important, then, to outline
some basic precautions to be followed when working with them.

Always wear protective goggles or approved facemask and rubber gloves,


which should extend at least to the mid-forearm when handling and mixing
caustic. Be sure clothing is also reasonably protective, covering all parts of
the body.
Be sure a deluge shower is nearby in case of accident as well as an
eyewash unit and know how to use them.
Where transferring from drum to carboy or chemical tank, use manual or
automatic pump - never attempt to pour by hand.
Ensure that a good ventilation system is provided in the chemical transfer or
chemical working area.
Keep chemical container closed when not in use.

a) CAUSTIC SODA (SODIUM HYDROXIDE)


Caustic may be used in either 50% liquid or 76% flake concentrated form.
In making up the 20% solution in the day tank, care must be taken,
particularly with the flake material, to avoid spattering.
Never use hot water in an attempt to aid the dissolving of flake caustic.
Always add the caustic slowly to the water with frequent or continuous
mixing to avoid excessive heat build-up and possible spattering.

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MAX OPERATION AND MAINTENANCE MANUAL

b) SULFURIC ACID
This is very strong and powerful acid and can cause serious burns if
allowed to come in contact with the skin or the eyes. Extreme care should
be taken when making up the sulfuric acid in the day tank. The sulfuric
acid is used at 77-100% strength or grade
Always transfer concentrated acids to day tanks by either manual or
motorized pump - never attempt to pour by hand.
In making up the dilute sulfuric acid solution, always add the acid to the
water in the day tank -- NEVER add the water to the acid! A violent
reaction could occur.

c) ANTISCALANT
These are stable, clear, and colorless with a characteristic odor. These
chemicals are also very corrosive. Although not highly toxic, they can
cause serious injury if allowed to come in contact with skin or eyes.
Care should be taken when handling Antiscalants
Avoid contact with concentrated caustic. Contact will result in the
evolution of heat.

d) COAGULANT
Finely divided particles suspended in surface water generally carry a
negative electrical charge and repel each other which cause turbidity in
water.
Coagulants are charge-neutralizing chemicals to help neutralize the charges
of particles and help them agglomerate and settle. Inorganic coagulants,
generally cationic salts of iron and aluminum are commonly used.

3.1.3.1 FIRST AID IN CASE OF CONTACT WITH ACID OR CAUSTIC


i. Operating personnel who may have accidentally had caustic,
hydrochloric or sulfuric acid spilled or splashed on them should
immediately be subjected to a deluge shower until all of the chemicals
have been rinsed away. Clothing may then be removed, if necessary,
to allow continued rinsing of chemical that may have found its way to
hard to reach areas.
ii. If a plant nurse or doctor is available, persons should be seen by them
immediately. If not, a doctor should be contacted if there is any
evidence whatsoever of chemical burns. NEVER attempt to treat such
burns without advice of medically trained person.

3.1.3.2 FIRST AID IN CASE OF EYE CONTACT WITH ACID OR CAUSTIC


i. Anyone who may have had acid or caustic in even dilute form sprayed
or splashed into their eyes should IMMEDIATELY be subjected to
profuse irrigation of the eyes, preferably with an emergency eyewash
device designed for this purpose. If none is available, the deluge
shower or any other means to continuously rinse the eyes with clean
water should be used.

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ii. Continue the rinsing for a minimum of 15 minutes and be sure lids are
held apart and eye rolled to insure all areas are thoroughly rinsed free
of chemical. Contact a doctor immediately and follow any additional
instructions he may have. NEVER attempt to treat any burns by
instilling medications, eye drops, etc., into the eye unless directed by
physician.

3.2. INITIAL EQUIPMENT RECEIPT, INSPECTION & STORAGE

3.2.1. Inspection at Receipt


i. Once the equipment has been received from AES, it must be inspected
immediately for completeness and for shipping damage.
ii. Refer to the Packing List/Shipping List to verify that the items listed are
in the shipment.

CAUTION - Use care when moving equipment and components and when
opening crates.

NOTE - The equipment for this system is guaranteed by AES against defective
design, materials, and workmanship for a period of fifteen (15) months
from the date of shipment or one (1) year from the time of startup
whichever occurs first.

The warranty on individual component parts not manufactured by AES is


limited to that of the manufacturers of those components.

iii. Record the "item and crate numbers of all received pieces. Some
crates will contain several different tagged items; these crates should be
opened temporarily to check the different items.

Compare the item and crate numbers recorded to those shown on the
shipping list, and check off each item (on the shipping list) that has been
located. if items appear to be missing, contact the carrier and AES
immediately.

NOTE - Some small components that were removed from major components
during preparation for shipping may not have item numbers.

These untagged components can be identified referring to the piping


drawings and the parts lists for this job.

iv. Perform a close inspection of the major components (container, vessels


and equipment skids) and of piping and other components already
installed on these components. Damage to these components is easy
to miss during a quick inspection.

Make sure that gauges, sample piping, and tubes have not been broken
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off. Also, look for broken or bent piping.

Pay particular attention to any fiberglass or plastic vessels; these


vessels are easily damaged by rough handling.

NOTE - Any equipment damage found must be reported to the carrier and/or
AES immediately.

v. Perform a close inspection of all shipping crates and boxes and of other
loose components. Verify that no damage has occurred to these pieces.

Check for visible damage to crates, piping, and piping ends. If a crate or
box appears damaged, open the crate or box and investigate further.

NOTE - Any equipment damage found must be reported to the carrier and/or
AES immediately.

Avoid releasing equipment for assembly until all damage claims and/or
shortage problems have been resolved.

If the equipment will be stored before being assembled, reseal any


crates that were opened for inspection.

vi. If the equipment is to be stored prior to final assembly, refer to the


storage procedures given in the following point (3.2.2).

3.2.2. Storage of Unassembled Components


Use the following instructions if the equipment will be stored before it is
actually assembled.

i. Complete all of the inspection procedures as given in point (3.2.1).

ii. Place a copy of the marked-up shipping list and the written list of
received item numbers together and store them in a safe place. If
necessary, make copies of these lists and distribute them to the
individuals who will be involved in the assembly of the equipment.

iii. If any crates were opened for the inspection procedures, reseal these
crates securely.

iv. Select a location where all of the AES equipment will fit and can be
safely stored.

Avoid separating the AES equipment components.


On large jobsites, it is easy for small components to become misplaced
or lost. Always try to group the AES equipment in one place. If the
equipment must be separated, note the exact locations of all pieces on
the shipping list or the written list of received pieces.

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CAUTION - Use extreme caution when moving the AES equipment. Be careful
not to drop fragile items or to damage parts when lifting with
forklifts.

v. Store the AES equipment indoors where it will be protected from


sunlight and adverse weather conditions.

CAUTION - RO membranes should be stored indoors and should be protected


from freezing or overheating.

Set the vessels, skids, and other components on wooden blocks to keep
them out of any standing water and to protect their painted surfaces.

If the equipment will be stored for a long period of time, cover it with
plastic or canvas tarps to protect it from water, dust, etc.

vi. If the equipment will be stored outside, special precautions must be


taken.

NOTE - AES does not recommend storing any equipment outdoors.

Items that can be damaged by water must be securely wrapped with


plastic and covered with tarps.

Store the equipment in a shaded area or cover it with light-colored tarps.


If the outdoor temperature is very warm, remove all vessel manhole
covers to allow air circulation.
When the outdoor temperature is below 32 deg F (0 deg C), it is
important to verify that the vessels, piping, pumps, and other parts are
drained of liquids. Expanding ice can damage vessels and other
components.

Open all hand valves on the equipment to allow trapped water and
moisture to escape.

CAUTION - Always drain all liquids from components that must be stored in
freezing temperatures. Expanding ice can damage vessels and
other components.

Plastic pipe must not be exposed to direct sunlight. High temperatures


can distort and damage plastic piping.

vii. When equipment has been stored in extremely hot or cold temperatures
and then is moved to an assembly area, always allow the equipment
temperature to stabilize before beginning assembly. This is especially
important if the equipment is very cold.

viii. When the equipment is taken out of storage, the original shipping list
and the written list of received pieces should be retrieved and used to
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MAX OPERATION AND MAINTENANCE MANUAL

double-check the existing equipment. Any pieces noted as missing at


this time must be located as quickly as possible to avoid delays in
assembly and startup of the equipment.
ix. Prior to assembly of the equipment, perform a quick recheck for
possible equipment damage. Use the applicable procedures in this
manual.

3.2.3. Storage of Chemicals

Use the following guidelines in storing the chemicals.


i. Store the Chemicals in a secure dry place with proper ventilation.
ii. Chemicals should be stored in accordance with standard DOT
(Department Of Transportation) guidelines and local regulations.
Chemicals with extreme opposite properties may not be stored side by
side to avoid hazardous conditions.
iii. Review the MSDS for detailed guidelines

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SECTION 4.0 - EQUIPMENT INSTALLATION

4.1. GENERAL GUIDELINES

All equipment and mechanical components listed on the part list must be installed
according to the AES drawings for this job. Only qualified electricians, installers,
operators, maintenance personnel, and/or construction personnel shall be allowed to
perform any work relating to the system in order to avoid serious injuries or equipment
damage. All work should be performed in accordance with accepted plumbing, wiring,
and construction procedures.

AES standard System Operation Data Log sheet is provided for quality control and
record purposes, refer to section-9.2. This is a guideline only, and may be substituted
using clients own format and standards.

After Testing is completed, it is suggested that the forms be kept in a separate binder
for reference purposes.

4.1.1. Major Component Installation & Alignment

i Prior to pipe installation, all skid and tanks should be correctly located and
properly aligned.

Workers must pay particular attention to elevations and to center-to-center


dimensions.

ii All equipment must be level and resting solidly on the plant floor before further
construction is allowed.

WARNING - Empty vessels may tip forward suddenly and without warning, causing
equipment damage or injury to workers. Always brace vessels securely
until they are loaded or are bolted to the plant floor.

4.1.2. Chemical System Installation (if shipped loose)

Because of the hazardous chemicals used with cleanup systems, special


attention must be paid to the installation of any chemical-handling components.

WARNING - Most of the used chemicals in RO treatment are highly corrosive. Bodily
contact with these chemicals can cause severe burns or blindness.
Failure to install, pretest, and operate the chemical system properly can
result in serious injury to workers due to leaks and mechanical
malfunctions.

i. Always use acid and caustic resistant materials for the chemical system
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components.

ii. All supplied caution and warning labels must be installed and maintained at
chemical storage tanks and other components. If labels are lost or damaged,
new labels are available from AES or the component manufacturer.

iii. Be sure that check valves are properly installed.

iv. When installation is complete, the entire chemical system must be pressure
tested before actual chemicals are introduced.

4.1.3. Utilities and Other Peripheral Equipment

This section covers utilities and equipment that are required to operate this
system but that are not in AESs scope of supply. The equipment and utilities
listed here must be connected and operating before AESs equipment can be
operated.

i. Electrical: Proper power connections are required for the supplied equipment.
Refer to Electrical drawings for specific power requirements.

ii. Pumps: All customer-supplied pumps must be leveled, aligned, piped, wired,
and checked for proper rotation.

CAUTION - Many pump manufacturers ship their pumps without lubricants installed;
these lubricants are often shipped in separate containers. As soon as
these pumps are mounted and aligned the proper types and quantities of
lubricants should be located and installed in the pumps.

iii. Wiring: All customer performed wiring of control valves and instruments must
be completed.

iv. Feed Line: The inlet feed stream must be piped properly as per drawings.
Customer-supplied feed piping should be of non-corrosive material. Feed
piping made of corrosive material may cause serious membrane fouling. The
pipe size of the customer-supplied feed line to each of the supplied equipment
must be at least the same inlet size of such equipment.

v. Storage Tanks: Any storage tanks used with this system (product, feed, etc.)
must be piped and ready to hold liquids. If possible, these tanks should be
filled with water and checked for leaks prior to beginning operation. Be sure
storage tanks are clean before introducing any liquids.

vi. Drain Line: The outlet drain stream must be piped properly as per drawings.
Customer-supplied drain piping should be of non-corrosive material. The pipe
size of the customer-supplied drain line from each of the supplied equipment
must be at least the same outlet size of such equipment.

CAUTION - The drain piping run should be as straight and as short as possible. Pipe
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elbows, tees, and other fittings combined with long pipe runs can
increase backpressure to the point that proper drain flows cannot be
achieved.

vii. Pipe Flushes: All necessary pipe flushes and other sanitation procedures
required should be performed at this time.

CAUTION - Do NOT flush pipes into the equipment.

WARNING - Bolts could possibly loosen during shipment and all bolt connections need to
be checked before testing.

viii. Some instruments may be shipped loose (if any) to prevent damage during
shipping, install the instruments, ie. Pressure gauges, flow meters, etc. in the
proper location.

4.1.4. PVC Piping, Air Tubing and Support

i. Install the PVC cover plate in the designated location and apply sealant after
the pipes are installed.
ii. Ensure that pipe routes are braced and supported properly in accordance to
recommended manufacturer.
iii. PVC clamps shall be provided with gasket between the clamps and PVC. The
gasket will allow movement of the pipe as the pipes expands.
iv. For heavy equipment or valves, the support should be both sides of the valve
or fitting.
v. Install air release valves at the highest point on the piping to removed
entrapped air.

4.1.5. Electrical Conduit, Support and Wiring

i. Ensure that pipe routes or conduit routes are braced and supported properly in
accordance with recommended manufacturer.
ii. Install the communication wiring and power wiring using acceptable electrical
code of practice and standard.
iii. Terminate the wirings in accordance with drawings.

4.2. SYSTEM FLUSHING & PIPE HYDRO TESTING

4.2.1. System Flush Procedures


The piping and other components must be flushed thoroughly prior to the
installation of RO elements. The flushing procedures are critical to the proper
startup and operation of the equipment.

i. Customer Supplied Inlet Piping Flushes


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(1) All system inlet piping must be flushed thoroughly before it is


connected to the AES system.

Newly-installed piping usually contains welding slag, dirt, and other


debris that will plug filters and can damage pumps.

(2) If the inlet piping runs have already been connected to the skid, the
piping must be disconnected at this time.

(3) Each inlet piping run must be flushed with clean, clear water at the
maximum possible velocity.

The piping turns should be flushed one at a time while workers


observe the effluent flow of water.

(4) Each piping run must be flushed for as long as required to obtain a
clean effluent.

(5) If possible, the effluent flow from the process feed piping should be
checked for its silt density index during the flush procedures.

The feed piping should be flushed until the SDI is the same as that of
the normal feed supply.

(6) When a piping run has been flushed thoroughly, it can be connected to
the AES system.

ii. Chemicals and flush Tank

Inspect the interiors of all liquid tanks. If dirt or other material is present, use
clean water to rinse out the tanks.

Immediately replace the tank covers to keep dirt out. Keep the tank covers
in place except when mixing the chemicals.

4.2.2. Pressure Testing

When all equipment and components have been installed, the system must be
pressure tested with water.
Note: Usually, all piping is pressure tested in AES Factory prior to shipping.
However, after pressure testing and before shipping some parts are loosened
to avoid breakage during transport.

When site interconnecting piping is completed, it is necessary to retest the


piping prior to operation. Any leaks must be repaired and the leak test
repeated before the system is placed in operation. Study the following
guidelines before performing the pressure test.

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WARNING- Mechanical failure during pressure testing can result in serious injury to
workers. Do not exceed the pressure rating of components when performing
pressure tests. Wear eye and face protection when performing pressure tests.

General Pressure Test Guidelines

(1) Be sure that the piping and vessels to be tested are filled with water.
This minimizes the possibility of injuries should a mechanical failure
occur during the pressure testing.

WARNING- Do not pressure test vessels with compressed air. If a mechanical failure
occurs while the system is pressurized with air, the released air can propel
fragments of metal or plastic, resulting in personnel injury.

Pipes that will carry concentrated chemicals should be pressure tested with
low-pressure air.

(2) Do not pressurize vessels and piping over the maximum design
pressure without AES approval.

(3) During the pressure testing, stand away from vessel windows, inline
sight glassed, glass-tube flow meters, and plastic piping. These are the
components that are most likely to fail during pressure testing.

(4) Relieve all pressure from the system before attempting to repair any
leaks.

(5) Any leaking valves must be adjusted, repaired, or replaced and then
retested before the system is operated.

NOTE- If an automatic control valve leaks when closed, check to see if it uses
"bottoming" stops. If these stops are present, adjust the stops according to
the valve manufacturer's instructions.

4.3. FILTER MEDIA LOADING (IF SUPPLIED)

Steps required before loading the media:

i. Remove the top opening and inspect the condition of the laterals inside the filters.
Check that these were not damaged during shipment.
ii. If no damage, install the control valve and tighten properly. When damage occurs,
advise AES as this may require replacement.
iii. Flush and Hydro-test the system, section 4.2.
iv. Locate the filter media, check the labels on the pallet and check if they
correspond to the bill of material.
v. Segregate the different types of filter media.
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vi. Observe proper safety when loading filter media, see safety section.

The following procedures are for hand loading the media:

i. Remove the control valve.


ii. Fill the vessel(s) with chlorine free water until the water level in each vessel is
approximately half.
iii. Media should be filled in accordance with the media order in Appendix - III
iv. Load the media slowly into the tank to avoid breaking the internal distribution
system.
v. Use a plastic paddle to evenly distribute the media after each different level of the
media is introduced into the filter.
vi. Continue the loading procedure until the required amount and type of media has
been installed.
vii. After all the media is loaded in the tank, complete filling the tank with chlorine free
water from a hose with low flow rate.
viii. Replace the control valve.
ix. Repeat the procedures for each filter tank.

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SECTION 5 - TESTING AND PRE-START-UP


CHECKS/PREPARATION
This section describes the following:

1. Electrical Testing
2. Pneumatic Line Testing
3. Instrument Checks/Testing/Calibration
4. Chemical Pumps Test/Calibration
5. Pumps Check-up/Motor Unbalanced Tests
6. Valves Pre-start Checks/Tests
7. Pre-start-up Checks and Preparation

5.1. ELECTRICAL TESTING

The following general guidelines for checking the electrical materials and termination
points shall be conducted prior to introduction of power in the system. Check for
physical damage, cell fit and alignment, bolt tightness cleanliness of bushings and free
operation of starters, circuit breakers during connection.

5.1.1 3PH Feeder Breakers


The breaker and incoming feeder connected cable shall be subjected to a 1000
VDC megger test for 1 minute. (Care should be taken to ensure test voltages are
not induced into electronic equipment when testing the outgoing supply cables).

5.1.2 3PH Power Cables


Cables shall be given an insulation resistance test using a megger meter at 1000
VDC for a period of one minute for phase to phase and phase to ground
readings. (Use meter discharge facility or short cables to ground before touching
tested cables).

5.1.3 Single Phase Power Cables


Cables shall be given an insulation resistance test using insulation resistance
tester at 500 VDC for a period of one minute between conductors (including
neutrals) and conductors to ground prior to connecting the cables to the
appliances.

Data shall be recorded on the appropriate data sheet.

5.1.4 Secondary Ground Grid.


The secondary ground grid shall be given a Drop of Potential ground test prior
to being connected to the Primary Ground Grid.

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Equipment grounding to motors, transformers, etc. shall be routed in the same


conduit as the feeder cables to that equipment. Equipment skids which are
fabricated from conductive materials shall be grounded to the main ground ring.

All paint shall be removed from the area where the ground lug is attached or
bolted to the skid. A light smear of Vaseline should be coated on the ground lug
faces prior to attaching it to the skid or frame.

Ensure that grounding terminals are secure and tight during the check-out
inspection.

5.1.5 Electrical Conduits.


Inspect conduits for any damage which may have occurred during the
construction phase of the project. Check all pull boxes and Tees to ensure that
no covers are missing. Cable fill space shall not exceed 40% of the conduit area.

Metallic conduits must be grounded each end at the connecting panel by means
of a grounding lug connection on the conduit securing nut which shall be
connected to the panel ground bus by means of a ground wire.

5.1.6 Control Wiring


Shall be subject to a continuity test only. Testing of these wires from each point
of termination shall suffice prior to the discrete signal check-out. This procedure
will apply to the control wires for the level switches installed in site to the Main
RO Panel.

5.1.7 Instrumentation Wiring


Shall be tested for continuity as part of the loop check-out.

5.1.8 Panel Testing


Once all electrical checks are completed, Panels can be powered up. During
this time, power supply indicating lights and instrument display shall be noticed
and checked.

5.2. INSTRUMENT CHECKS/TESTING/CALIBRATION

All instruments in the equipment are wired and tested as much as possible in AES
shop. Most of the instruments are factory calibrated, however some instruments need
to be re-calibrated at site and set-points changed if required.

5.2.1 Low Pressure Switch


This will be adjusted and tested to activate or close/open the contact at the rated
pressure (see set-points list). Pressure setting can be adjusted either:
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While the system is in operation (on line) OR


Prior to operation, bench tests.
Follow the installation procedures as per vendors manual.

Adjustment During Operation


When adjusting the low pressure setting, slowly close the valve before the pressure
switch, observe the falling pressure and adjust your pressure setting as required.

Bench Test
i. Remove the pressure switch in the line.
ii. Using Handheld Pneumatic Pressure Tester, connect the pressure line of
the tester to the pressure switch.
iii. Using electric meter, connect the line and neutral wires.
iv. Operate the pneumatic tester and raise the pressure.
v. Adjust the pressure setting so that it will activate or close/open the contact
when pressure is reached.

5.2.2 Flow indicator/transmitter


The flow indicator/transmitters were designed for the given pipe size and flow,
hence no adjustment. In case calibration is required, please refer to the operating
manual of the flow indicators.

5.2.3 Level Switches


Whenever possible, the level switches are installed in the tanks at the right
elevation and wired. However, in some instances, the wiring has to be done on
site. Follow the drawing for the installation of the conduit, wiring and termination.
Adjust the level of the high/low level switches located in the tanks. Refer also to
the Level Switch Manual.

5.2.4 Pressure gauges


These instruments are factory calibrated and would not require calibration. In case
calibration is required, please follow the procedure below:
i. Remove the pressure gauge in the line.
ii. Using Handheld Pneumatic Pressure Tester, connect the pressure line of
the tester to the pressure gauge.
iii. Operate the pneumatic tester and raise the pressure.
iv. Report to AES if the pressure gauge is not operating properly.

5.2.5 Analytical instruments


These instruments are factory tested/calibrated. However, before start-up the
instruments are required to be calibrated as per the instruction manual. Please
refer to the attached component data sheets in Appendix-III.

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5.3. CHEMICAL PUMPS START-UP/CALIBRATION

The chemical pump operates in ranges at a certain pressure. All chemical pumps can
be operated manually or automatically. During manual operation, the pump can be
calibrated as follows:
1. Put water (not chemicals) in the chemical tank.
2. Prime the pump as per its O&M manual.
3. The pump rate is defined as,
Pump Rate = % Stroke * % Speed * pump maximum capacity.
4. While the RO system is running, measure the pump flow by measuring the declining
level in the chemical tank versus operating time.
5. Based on the flow rate, the pump actual rate can be determined. If there is a big
difference between the actual and calculated rates, please contact AES.

If level switches are included, please check the following:


1. Check if the level switch contact is closed at normal level and contact opens if water
level is below the level switch.
2. Check that each dosing pump is on (or off), when its low level contact is open (or
closed). See O&M manual (pump contact is normally closed NC).

5.4. PUMPS CHECK-UP/MOTOR UNBALANCED TESTS

WARNING- Do not run the motors with the pump coupled in dry condition. This
condition will damage the pump. Refer to the start-up procedure in the
Pumps Manual.

5.4.1 No Load/Full Load Testing


i Pumps can be checked with the motors coupled as Full Load condition
AND/OR Motors can be tested separately under No Load conditions.
ii To test the motors in Full Load condition or No Load conditions, follow the
instructions in next steps below.
iii If No Load test is to be conducted, motors have to be uncoupled with the
pump and reinstalled after test is complete. Follow the uncoupling and re-
installation of the motors as per the pump manual instructions.
iv Record the Full Load or No Load current in the Motor nameplate and Run
the Motor with Pump or Motor Only.
v Compare the actual current with the nameplate current. If the actual current
is more than 10 % of the nameplate current, there is a probability that pump
or motor has a problem. Please report this condition to AES.

5.4.2 3-Phase Unbalanced Testing

WARNING- To prevent changing motor rotation, the motor leads should be rolled in
the same direction.
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IMPORTANT NOTES:
Hook-ups below 5 % = system unbalanced.
Hook-ups over 5% - If the unbalance moves with the motor leads, the unbalance is
caused by the motor, contact AES. If the unbalance remains with the terminals,
the unbalance is in the power supply contact power company.

1. This can be done with motor only or with coupled pump and motor.
2. Measure the current on each leg of the three phase motors as per 1st, 2nd and 3rd
hook-up wiring diagram below, fig. 5.1.
3. Run the test at least 30 minutes each hook-up.
4. Calculate percentage of current unbalance for all three hook-ups as per example below:

Hook Up 1 Hook Up 2 Hook Up 3


T1 = 51 Amps T3 = 50 Amps T2 = 50 Amps
T2 = 46 Amps T1 = 48 Amps T3 = 49 Amps
T3 = 53 Amps T2 = 52 Amps T1 = 51 amps

5. Add up three readings for hook-up number 1, divide by three to obtain the average, in
this example, hook-up number 1 average = 50 amps.
6. Calculate the greatest amp difference from the average, i.e. 50 amps 46 = 4 amps.
7. Divide this difference by the average to obtain the percentage of unbalance, i.e. 4 amps
/ 50 amps = 0.08 or 8 %.
8. In this case, hook-up 1 = 8%, hook-up 2 = 4 %, and hook-up 3 = 2 %.
9. Use hook-up with the lowest current unbalance.

SUPPLY SUPPLY
1ST HOOKUP 2ND HOOKUP 3RD HOOKUP

L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3

STARTER STARTER STARTER STARTER STARTER STARTER

T1 T2 T3 T1 T2 T3 T3 T1 T2 T2 T3 T1

MOTOR MOTOR
Fig. 5.1 Motor Testing Wiring Diagram
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5.4.3 Vibration/Motor Rotation Test


1. Pumps/Motor vibration and rotation test can be checked using instruments
suited for the purpose. This is normally checked if vibration or rotation is in
doubt. In most cases, this is not necessary.
2. Follow the testing procedures in the instrument manual.

5.5. VALVES PRE-START-UP /TESTS

There are several types of valves supplied in this project. Each and every valve has to be
checked to determine if it is opening and closing properly.

5.5.1 Manual Butterfly or Ball Valves test the valve by manually opening and closing
action. Make sure that it can be opened and closed 100 %. Sometimes the valve
is very hard to open and close, correct this by removing the valve and check if it
hits pipe fitting, etc. In the case of ball valves, check that the ball is undamaged and
seals are OK. Change if defective.

5.5.2 Check or Non return valves these valves are checked before installation.
However, check during operation if the flow is acceptable.

5.5.3 4-Function valve Most of chemical pumps are supplied with four function valves
which are used to prime the system. This valve is used during the starting up of
the chemical pumps by adjusting or switching the knob. Refer to chemical pump
pre-start up, Section 5.3.
5.5.4 Automatic Feed Valve This valve was tested in AES. However, as soon as
power is available, valve should be checked using the system ON-OFF-AUTO
switch and the valve operation observed.
5.5.5 3-Way valves These valves are tested at AES before shipping. However, they
should be checked again before installation. Place the valves on the manual
position and make sure that they rotate easily. If the rotation is hard, remove the
valve and check for any damage in the ball, ball seat, or seals. Change if defected.

5.6. PRE-START-UP PREPARATION

1) Backwashing of filters This will clean the filter media and remove dust/fine particles.
If not removed, SDI (Silt Density Index) will be high. SDI limit after filtration is 3.0-5.0.
During this time, SDI should be tested. If SDI is more than 5.0, AES should be
consulted to solve this problem, before operating the RO system.
2) Cartridge Filters Installation.
3) Chemical preparation.
4) Instrument Calibration and Testing Equipment.

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For systems shipped without membranes, the following steps should be added:
5) Sanitizing the lines this process kills bacteria in pipes, which is a requirement before
membrane loading.
6) De-sanitization to remove traces of chlorine as chlorine is detrimental to the
membranes.
7) Membrane Loading

5.6.1 Initial Backwashing of Filters


Sand and Anthracite contain fines and other impurities, which are required to be
removed prior to using the media for filtration. These fines and impurities are
removed by initial backwashing one filter at a time. In this project, initial
backwashing is executed as follows:

i. At this stage, all the valves of the media filters have been tested manually.
ii. Check the availability of power supply to valves.
iii. Check the availability of water in the Service Line.
iv. Check valve manual for valve position during backwash mode.
v. Manually set the valve at the backwash position (check the valve manual).
Water will flow into the filter in backwash mode.
vi. Warning too much pressure and flow will carry away the media into the
drain. A drain flow control valve on the outlet of the backwash line is
provided to prevent the washing of the media out to the drain.
vii. Observe the backwash water by getting a sample every 10 minutes in a
clean beaker.
viii. After 15- 25 minutes, change the valve positions to rinse mode for about 5-
10 minutes.
ix. Repeat the process within two-hour period.
x. After two (2) hours, the backwash water should be clear. If not, continue
backwashing until the backwash water comes out clean.
xi. Check the SDI of each filter. A good backwash will indicate a lower SDI.
xii. After backwashing all filters, pre-treatment is now ready for testing.

5.6.2 Cartridge Filter Loading and Startup

i. Close the inlet valve on the feed water before the cartridge filter(s).
ii. Open the filter vent and drain port.
iii. Open the cartridge filter housing(s), inspecting the interior of the housing(s)
and removing any foreign material.
iv. Check filter manual for the loading of the cartridges into the housing(s).
v. Close the filter drain and vent ports, and open the inlet valve to allow feed
water to fill the cartridge filter(s).
vi. Open the vent port at the top of the housing(s) until all air has bled out.
vii. Close the vent port.

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5.6.3 Membrane Loading


(Only if membranes are supplied loose or need to be replaced)
What you need to know before starting the RO
Before you start loading the membranes & starting up the RO, familiarize
yourself with the following:
BRINE SEAL
The brine seal is an O-ring located at one end of the RO membrane. This O-ring
prevents the RO reject or brine from mixing with feed water on the opposite side.
Before you load the membranes, you need to know the feed end of the housing,
identify the location of the brine seal on the RO membrane, and insert the RO
membrane - brine seal first in the direction of the feed. As you can see from the
above sketch, this O-ring is actually inserted inside the U-cup of the feed spacer.
The membranes are equipped with two feed spacers one on each end. You
must apply lubrication using glycerin before you insert the membrane.

Brine Seal (O'ring) Inside U-Cup U-Cup Without Brine Seal

Feed Spacer

Permeate Tubing

FIGURE 5.1: RO MEMBRANES COMPONENTS

INTERCONNECTORS & END ADAPTERS


Interconnectors are used to connect membrane to membrane, while the end
adapters are used to connect membranes to RO housing head - which only
implies to the 1st and the last membranes. Inside the interconnectors & end
adapters, there are O-rings. These O-rings require lubrication. Apply glycerin
on all O-rings before inserting the interconnectors or adapters.

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Interconnectors

Feed Reject
Last Membrane Second Membrane First Membrane

End Adapters

FIGURE 1.2: RO MEMBRANES INTERCONNECTORS & ADATERS

REQUIREMENT FOR MEMBRANE LOADING:


RO membranes
Interconnectors one per each membrane
End Adapters per housing 2 per each pressure vessel
Minimum two people
Glycerin as needed
Gloves, clean cloth, heavy-duty pliers, rubber mallet, etc
Remove heads from RO pressure housings (check the manual of the
pressure vessels)

5.6.3.1 Pre-Loading Instructions

1 Prior to loading membrane elements, record the serial number of each element.

2 When loading the elements, record the installed location (housing number or
name) of each element.

CAUTION- Do not unpack an element unless it will be installed immediately. Do not set an
exposed element on any surface. Any dirt or particulate matter can contaminate
the element. The elements must not become contaminated and must not be
allowed to dry out. Wear rubber gloves, eye protection, and protective clothing
when handling the elements.

WARNING- RO elements are typically shipped in a preservative/disinfectant solution that


may cause eye and skin irritation.

CAUTION- To prevent contamination of the RO elements, the working area should be


properly clean.

3 Verify that all of the flush procedures given in section 4.0 have been completed.

4 Open the sample valves at the RO modules to relieve all internal pressure.

5 Loosen the unions and remove the split couplings for the inlet and outlet piping
at the ends of the RO modules.

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CAUTION- Be careful not to lose any o-rings or gaskets for the piping connectors.

6 Mark the pressure vessels endplates and related components to indicate their
proper location. Because of minor variations in the piping dimensions,
components must be returned to their original locations to avoid stress on the
inlet and outlet piping.

7 Water will flow from the pressure vessels onto the floor when the end plates are
removed. Make provisions for this flow of water as necessary.

8 Select the vessel to be loaded first, and open it up using the manufacturer
instructions.

9 Inspect the vessel and components for cleanliness and damage. Wash
components with Chlorine free filtered/softened water if additional cleaning is
warranted.

10 Load the required RO elements into the vessel using the loading instructions that
are shown below.

11 As soon as all of the pressure vessels have been loaded with elements, perform
the startup procedures for the RO system. The pressure vessels must be filled
with water to prevent drying of the elements.

NOTE- Following installation of new RO elements, the system must be flushed to drain
for a minimum of 3 hours to remove all traces of the shipping chemicals.

Loading Instructions
The most important thing that you need to know before loading membranes in a
specific RO vessel is the feed end on that RO housing? (The opposite end is
always reject). Once you identify the feed end, you may load the membranes.

Assuming that you already removed all end plates (feed side & reject side) from
all housings, identify the feed end of the RO vessel.

1. Remove RO membranes from the box. Each RO membrane is equipped with


interconnectors
2. Apply glycerin on the brine seal
3. Insert the 1st membranes a shown below. As you can see, the brine seal
goes in last in the direction of feed. Leave portion of this membrane
protruded outside the housing.

Feed Direction

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4. Install interconnector on the 1st membrane after applying glycerin on the O-


rings.
5. Insert the 2nd membrane inside the interconnector of the 1st membrane.
Make sure on the opposite end of the vessel someone is holding back the 1st
membrane with a long PVC piping or a long stick. This is the only way you
can push the 1st membrane into the 2nd one.
6. Repeat the above procedure until all membranes are loaded.
7. Install one end adapter on the last RO membrane.
8. Install the end plate and connect it to the above end adapter. Again install
the end plate while making sure some one is holding or pushing back against
the membranes from the other side of the housing.
9. Install the end adapter on the opposite side and reinstall the end plate on this
side. This step is not easy - It requires a lot of pressure against the
membranes until they are all squeezed & positioned between the two end
plates. If there is no pressure, this is an indication that one of the
interconnector did come out loose. If this occurs, do not install this end plate.
Remove all membranes until you identify the problem and repeat the above
steps.
10. Repeat the above steps for each RO vessel on the RO skid.

5.6.3.2 Removal of RO Elements

It might be necessary to remove one membrane during this procedure. When


removing the elements, adhere to the following guidelines.

1. Before removing the elements, perform a normal cleanup sequence for the
RO skid and make sure that all cleanup chemicals are rinsed from the
pressure vessels.
2. Close all isolating hand valves on the skid.
3. Open the sample valves at the RO pressure vessels to relieve all pressure in
the modules.
4. Loosen the unions and remove the split couplings or the inlet and outlet
piping at the ends of the RO pressure vessels to be serviced.
5. Mark the element housing endplates and related components to indicate their
proper location. Because of minor variations in the piping dimensions,
components must be returned to their original locations to avoid stress on the
inlet and outlet piping.

CAUTION- Be careful not to lose any o-rings or gaskets for the piping connectors.

6. Water will flow from the element housings onto the floor when the end plates
are removed. Make provisions for this flow of water as necessary.
7. Select the housing to be unloaded first, and open it up using the
manufacturer instructions.
8. Remove the RO elements from the vessel

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9. If the elements will be reinstalled later, store them as directed in the element
manufacturer's literature.
10. When elements are reinstalled in the housing, use the loading procedures.

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SECTION 6.0 - SYSTEM SAFETY PRECAUTIONS


This section contains general safety guidelines that workers must follow when installing,
operating, and maintaining RO Water Treatment Plant Systems.

This section must be read and understood prior to system startup. The guidelines listed here
must be followed at all times to prevent worker injury and equipment damage.

6.1. SAFETY SUMMARY

CHEMICALS SAFETY

Health hazards: Range from mildly irritating to extremely corrosive, depending on the
specific chemical exposure.
Further Information: Refer to the Material Safety Data Sheets (MSDS) supplied
with the specific chemical

OPERATIONS SAFETY

Description: High-voltage electricity (115+ VAC)


Health hazard: Can potentially cause severe burns, cardiovascular failure, and
death

Description: High pressures (15+ psig) - pneumatic or liquid


Health hazard: Possibility of various physical injuries from accidental release of high
pressure

Description: High temperatures (120+ deg F)


Health hazard: Possibility of burns from accidental contact with hot process fluid or
equipment

Description: High-speed rotational mechanical components (i.e., Pumps and


motors)
Health hazard: Possibility of injury from accidental contact with rotating parts
Further Information: Reference the applicable equipment manufacturers literature.

6.2. GENERAL SAFETY GUIDELINES

a. Operator Training
Equipment operators must be trained in the operation of the equipment and in the
proper handling of hazardous chemicals. Only experienced operators who have
studied this entire manual should be allowed to operate the equipment.

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WARNING - Highly corrosive chemicals are used to clean the membranes and in the process.
Contact with these chemicals can cause severe burns or blindness. Equipment
operators must be trained in the safe use and handling of hazardous chemicals.

b. First-Aid Equipment
First-aid equipment, eyewashes, and emergency showers must be available in
areas where chemicals are stored or used. Facilities such as eyewashes and
showers must conform to national and local safety codes and laws.

c. Personal Protective Equipment


Workers must wear safety glasses, face shields, respirators, protective clothing, or
other appropriate safety gear when working with hazardous materials, such as
corrosive cleanup chemicals.

All measures must be taken to avoid contact between hazardous chemicals and
exposed skin.

Refer to the Material Safety Data Sheets (MSDS's) supplied by the chemical
manufacturer for information on recommended safety wear for specific chemicals.

d. Equipment Access
Workers must use caution when accessing equipment. All measures must be
taken to prevent falls and other accident when equipment is being installed or
serviced.

Use extreme caution when working around the system components. Valve
handles, sample pipes, and other protruding components can cause severe injury
to body parts that strike them. Workers should wear hard hats and safety glasses
and should move cautiously when working under piping and around the
equipment.

If equipment to be installed or serviced is above an operator's normal reach, use


safe, approved ladders or lifting devices to reach the required area.

e. Electricity
Operators and workers must use caution when working with motors, control
panels, and other electrical components. These components must be properly
wired and grounded, and should not be allowed to come in contact with process
fluids or other liquids.

WARNING - Electricity can shock, injure, or cause death.


Always disconnect and lockout electrical power for panels or components before
performing repairs or service. Electrical control panels and instruments must be
properly grounded.

f. Pumps
Any pumps that are supplied loose must be properly mounted to avoid movement
and excessive vibration.

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MAX OPERATION AND MAINTENANCE MANUAL

Motor drive safety shields must be properly installed, and all supplied WARNING
and CAUTION signs and labels must be maintained at the device.

WARNING - Contact with rotating drive mechanisms can cause severe personal injury.

Never operate pumps without safety shields around the motor drive mechanisms.

g. Automatic System Testing


An automatically controlled system, including the cleanup system, must be test-run
without process liquids prior to the initial operation of the equipment. Operators
must be sure that the entire system operates properly before using chemicals or
process liquids.

WARNING - Improper flows of corrosive chemicals or other liquids during a system test run can
cause worker injury or equipment damage.

During a test run of a system, all hand valves must remain closed to prevent the
accidental entry of process fluids.

h. Pressures
Extreme caution must be used when working with high air or liquid pressures.
Pressure monitoring devices must always be installed and working properly. The
system must be operated within the proper pressure limits.

WARNING - The sudden release of pressure from pressurized components can cause severe
injury to workers.

Relieve all pressure from piping and components before performing service.

i. Servicing System Components and Equipment

Before performing maintenance on system components and equipment, and


especially when disassembling individual components, workers must be certain
that the components are isolated from pressure, fluids, and electricity. Spring-
loaded devices, such as valves, must be in their "relaxed" state--that is, with no
compression on the loading spring --to avoid the sudden and accidental motion of
individual parts.

Refer to the individual vendor component literature in Volume III for specific
maintenance guidelines.

j. Servicing Automatically Controlled Component

Workers must use extreme caution when servicing automatically controlled


components. Sudden and unexpected operation of components being serviced
can cause severe injury to the workers involved.

Before working on automatically controlled components, make sure that the


automatic controller is disabled to the point that it can not be used to operate
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MAX OPERATION AND MAINTENANCE MANUAL

remote components. Close lock, and tag valves and lockout and tag electrical
motor starters and other electrical devices.

Finally, inform other operators and control room workers of repairs or servicing in
progress.

WARNING - Accidental and unexpected operation of remote components can cause personal
injury or death.

If controller programming or program modification is performed while system


components are being serviced, disconnect the controller output devices or the
individual component tubing or wiring to avoid accidental operation.

6.3. HANDLING HAZARDOUS CHEMICALS AND MATERIALS

Important information about hazards related to the chemicals and materials used with
this system is located in this section. Operators must read the material in this section
carefully and must be familiar with basic first-aid procedures for specific chemicals.

a. Equipment Owner Responsibilities


i. Refer to the Material Safety Data Sheets (MSDS's) for each of the
chemicals that will be used for the system - these are available from the
chemical suppliers. Become familiar with the handling and first -aid
requirements for each chemical.
ii. Install safety showers, eyewashes, and medical kits in the areas where
hazardous chemicals are stored and used.
iii. Post hazardous chemicals warning signs in the area.
iv. Maintain the clothing and equipment that is necessary to protect operating
personnel, in accordance with the requirements of the chemical MSDS.
v. Provide adequate water supply to flood areas of spills.
vi. Instruct operating personnel in the safe handling practices, first aid
measures, and cleanup procedures outlined in the chemical MSDS.
vii. Establish and enforce safety procedures for operators

b. Operator Precautions
i. When working around or handling a hazardous chemical, wear the personal
protective equipment required by the chemical MSDS.
ii. Know locations of safety showers and eyewashes.
iii. If chemicals are mixed manually, add chemicals slowly to the full amount of
water and stir the solution. Never add water to a chemical because boiling
and spattering can result.

c. Safety Concerns Acid


Sulfuric acid can cause severe burns to the skin and eyes. The skin and/or eyes
should be flushed with water immediately for a minimum of 15 minutes. Inhalation
of acid vapors may cause coughing, chest pains, difficulty breathing, or
unconsciousness. Ingestion of acid may be fatal. If swallowed, do NOT induce
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MAX OPERATION AND MAINTENANCE MANUAL

vomiting; give water, milk, or milk of magnesia. Get immediate medical


attention.
Protective safety goggles, face shield, protective suit, and rubber gloves must be
worn when working on the equipment or manually pumping acid from the bulk tank
to the day tank.

Any maintenance of the acid feed system must include precautionary steps as
defined by established work practices around or near electrical and/or mechanical
components. A Lock-Out/Tag-Out procedure should be used to confirm the
applicable components are taken out-of-service for maintenance. That procedure
should include the maintenance group conducting the activity, facility control room
operating the equipment, and appropriate supervisory staff.

d. Safety Concerns Caustic Soda


Sodium hydroxide or caustic can cause severe burns or irritation to the skin and
eyes. The skin and/or eyes should be flushed with water immediately for a
minimum of 15 minutes. Ingestion of sodium hydroxide may be fatal. If
swallowed, do NOT induce vomiting; give water, milk, or milk of magnesia. Get
immediate medical attention.
Protective safety goggles, face shield, protective suit, and rubber gloves must be
worn when working on the equipment or manually pumping caustic from the bulk
tank to the day tank.

Any maintenance of the caustic feed system must include precautionary steps as
defined by established work practices around or near electrical and/or mechanical
components. A Lock-Out/Tag-Out procedure should be used to confirm the
applicable components are taken out-of-service for maintenance. That procedure
should include the maintenance group conducting the activity, facility control room
operating the equipment, and appropriate supervisory staff.

e. Safety Concerns Antiscalant


The antiscalant chemical can be a mild skin and eye irritant. The skin and/or eyes
should be flushed with water immediately. Medical evaluation must be conducted
if chemical is contacted with the eyes.

Any maintenance of the antiscalant feed system must include precautionary steps
as defined by established work practices around or near electrical and/or
mechanical components. A Lock-Out/Tag-Out procedure should be used to
confirm the applicable components are taken out-of-service for maintenance. That
procedure should include the maintenance group conducting the activity, facility
control room operating the equipment, and appropriate supervisory staff.

f. Safety Concerns Coagulant


Coagulant can cause severe irritation and burns to the skin on contact. The skin
should be flushed with water immediately then wash skin with soap and water or
more plain water. Get prompt medical attention. Eye contact with sodium
hypochlorite can cause severe irritation and burns and/or eye corrosion.
Immediately flush eyes with a directed stream of clear water for at least 15
minutes while forcibly holding eyelids apart to assure complete irrigation of all eye
and lid tissues. Get immediate medical attention.
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MAX OPERATION AND MAINTENANCE MANUAL

Ingestion of Coagulant may cause pain and inflammation of the mouth and
digestive system, burns and perforation of the esophagus or stomach, vomiting,
circulatory collapse, confusion, delirium, and coma. If ingested, do NOT induce
vomiting. Never give anything by mouth to an unconscious person. Give large
quantities of milk or gelatin solution. If these are not available, give large quantities
of water. If vomiting occurs spontaneously, keep airways clear and give more
milk, gelatin solution or water. Get immediate medical attention.

Protective safety goggles, face shield, protective suit, and rubber gloves must be
worn when working on the equipment or manually pumping coagulant from the
bulk tank to the day tank.

Any maintenance of the coagulant feed system must include precautionary steps
as defined by established work practices around or near electrical and/or
mechanical components. A Lock-Out/Tag-Out procedure should be used to
confirm the applicable components are taken out-of-service for maintenance. That
procedure should include the maintenance group conducting the activity, facility
control room operating the equipment, and appropriate supervisory staff.

g. Safety Concerns Cartridge Filtration


Operation and/or maintenance of the cartridge filter system does not have specific
safety concerns. Working with any portion of the RO train should include the
Lock-Out/Tag-Out procedure to isolate either a portion of or the entire train.

Safety procedures for working with system components, which may contain water
which has been chemically treated, should be observed. The cartridge filters have
contained water which has been pH adjusted, using sulfuric acid. The cartridge
filters have also contained water which has been treated with antiscalant chemical.
Exposure of either sulfuric acid or antiscalant to skin and eyes may result in an
injury. Appropriately, gloves, safety goggles, clothing, etc. should be worn.

Any maintenance of the cartridge filter feed system must include precautionary
steps as defined by established work practices around or near electrical and/or
mechanical components. A Lock-Out/Tag-Out procedure should be used to
confirm the applicable components are taken out-of-service for maintenance. That
procedure should include the maintenance group conducting the activity, facility
control room operating the equipment, and appropriate supervisory staff.

h. Safety Concerns Reverse Osmosis System


Safety procedures for working with system components, which may contain water
which has been chemically treated, should be observed. The RO membranes
have contained water which has been pH adjusted, using sulfuric acid. The RO
pressurization pumps have also contained water which has been treated with
antiscalant chemical. Exposure of either sulfuric acid or antiscalant to skin and
eyes may result in an injury. Appropriately, gloves, safety goggles, clothing, etc.
should be worn.

During the periods of a system shutdown, biocide solutions may be used to


preserve the RO membranes. Appropriate protection must be used, including
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MAX OPERATION AND MAINTENANCE MANUAL

gloves, safety goggles, and clothing. Consult the chemicals Material Safety Data
Sheet for the specific precautions.

Any maintenance of the RO membrane system must include precautionary steps


as defined by established work practices around or near electrical and/or
mechanical components. A Lock-Out/Tag-Out procedure should be used to
confirm the applicable components are taken out-of-service for maintenance. That
procedure should include the maintenance group conducting the activity, facility
control room operating the equipment, and appropriate supervisory staff.

i. Safety Concerns- Instruments


Operation and/or maintenance of the instrumentation & control system does not
have specific safety concerns. Working with any portion of the RO facility should
include the Lock-Out/Tag-Out procedure to isolate either a portion of or the entire
train.

Any maintenance of the system must include precautionary steps as defined by


established work practices around or near electrical and/or mechanical
components. A Lock-Out/Tag-Out procedure should be used to confirm the
applicable components are taken out-of-service for maintenance. That procedure
should include the maintenance group conducting the activity, facility control room
operating the equipment, and appropriate supervisory staff.

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MAX OPERATION AND MAINTENANCE MANUAL

SECTION 7.0 - SYSTEM START-UP


Reverse Osmosis Systems provided by AES have been engineered and fabricated to run in a
safe and trouble-free manner when they are operated and maintained as specified in this
manual. The operators and service personnel should be alert to the following points:

7.1. MEMBRANE PRESERVATIVE

All AESs packaged RO systems are shipped fully assembled and wired. When
shipping the system loaded with membranes, membranes will be filled with a
preservative solution to avoid biological fouling during shipping period. This
preservative solution is typically a biocide solution of food-grade Sodium Metabisulfite.
Such preservative must be completely flushed out of the membranes before using the
product water for human consumption. AES recommends diverting the product line to
the drain and flushing the machine for 1-2 hours at low pressure of 30-50 psi, and then
operating at normal operating pressure (based on the computer projection in Appendix-I
for another 30 minutes, before diverting the product line back to the Point-of-Use
(POU), the permeate tank.

7.2. FEED AND DISCHARGE PIPING (customer-supplied)

Max RO systems are manufactured with corrosion-resistance piping made of schedule


80 PVC (low pressure piping) and 2205 Duplex Stainless Steel (high pressure piping).
Customer-supplied feed and discharge piping should be of similar material and the
same pipe size as the system Inlet/Outlet as a minimum. Feed piping made of corrosive
material will cause membrane fouling.

7.3. PERMEATE WATER PIPING (customer-supplied):


A single line is provided for delivery of permeate water from the system. Under NO
CIRCUMSTANCES should the diameter of the customer-supplied permeate pipe to the
point-of-use be less than the permeate outlet from the system, as this could create
permeate back pressure and decrease the efficiency of the machine. Permeate piping
should be fee of any corrosive material.

7.4. PRODUCT WATER STORAGE (customer-supplied)

The maximum productivity of the system can be reached when the product water flows
free of any back pressure to an atmospheric tank. Permeate back pressure will have a

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MAX OPERATION AND MAINTENANCE MANUAL

negative impact on the product flow rate. It is strongly recommended to disinfect the
product water in the product storage tank to guarantee continuous protection against
bacteriological contamination of the water that is reserved for human consumption.

7.5. FEED WATER CONDITIONS:

The membrane computer projection and system performance data sheet in Appendix-I
outline the feed water conditions assumed during the design of this system. Any
change in the feed water conditions from the design conditions may substantially affect
on the performance of the machine. If your system is not performing as expected,
please contact AESs agent immediately. The following characteristics of the feed water
measured directly before the membranes should be fulfilled for the optimum
performance. Unless specifically considered in the design of your system, any change
in the feed water conditions from what is listed below may reduce the performance of
the system, damage the machine components, and invalidate the warranty of the
membranes.

7.5.1. TURBIDITY & SDI (Silt Density Index):


The turbidity of the feed water to the membranes should be less than 0.5 NTU
and the silt density index at 15 minutes (SDI 15) should be less than 3.0;
otherwise, an additional pretreatment will be required.

7.5.2. TEMPERATURE:
The optimum productivity of the system will be reached at the design
temperature that is shown in the system performance data sheet. Lower
temperatures will reduce the flow rate, while improving the quality of the
permeate (lower permeate TDS). Higher temperatures will increase the
permeate flow rate and decrease the quality of the product water (higher
permeate TDS). To void causing damage to the membranes, the feed water
temperature should always be above 4 degrees C and NEVER exceed 45
degrees C.

7.5.3. pH:
The membranes should not be exposed during cleaning, or in shutdown period,
to water of pH less than two (2) nor greater than eleven (11). During
continuous operation, the pH should not be less than four (4) nor greater than
nine (9).

7.5.4. FEED PRESSURE:


Feed pressure to the system should be controlled to provide a steady, non-
turbulent flow to the inlet connection of the unit. Feed pressure of about 20-30
psi after the cartridge pre-filter is optimal. The system is equipped with a low
inlet pressure switch that should be adjusted to shut the system off if the feed
pressure is less than 15-20 psi. This will prevent the high pressure pump from
running dry and protect it against cavitation.

7.5.5. TOTAL DISOLVED SOLIDS (TDS)


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MAX OPERATION AND MAINTENANCE MANUAL

Permeate flow rate and quality will directly depend on the TDS of the feed
water. If the feed water TDS exceeds the design value (check system
performance data sheet), the permeate flow rate will decrease and its TDS will
increase at the same operating pressure. If the feed TDS decreased from the
design value, the productivity of the system could increase. Nevertheless,
operators should never increase the productivity of the system without
consulting AES as it may cause serious membrane fouling. If feed water
conditions changed more than 10% from the design assumptions, new
membrane computer projections would be needed to simulate the actual feed
water conditions.

7.5.6. SCALING AND FOULING AGENTS:


The membranes should be maintained in a clean condition, unfouled by
suspended particulate, precipitates, or/and biological growth. If scaling or
fouling occurs, or normalized element flow declines by ten percent (10%),
cleaning procedures should be initiated as it is explained in SECTION-10.0

WARNING cleaning process should be applied immediately if the normalized system flow
rate or permeate quality decreased by 10%. Any delay may result in an
irreversible membrane damage and permanent loss of a considerable amount
of membrane active surface area.

Feed water to the membranes should not contain ANY chlorine, ozone,
permanganate, or other oxidizing agents. Such oxidizing agents will cause the
membrane material to deteriorate.

Iron, calcium, magnesium, and any heavy metals in the feed water should be
pre-treated prior to the membranes. Antiscalant and/or antifoulant injections
are recommended as a pre-treatment for these inorganic foulants. RO
permeate should be used when diluting such chemicals. Calcium present in
untreated water may form a precipitate with the antiscalant at high antiscalant
concentrations. Precautions must also be taken so there is no microbiological
growth in the antiscalant dilution tank. The antiscalant must not be diluted more
than what it is recommended by the chemical supplier. Antiscalant in powder
form should not be stored in liquid form after dissolving for more than one week
to keep its original efficiency. Antiscalant should be injected into the feed
stream before the pre-filter to guarantee complete mix with the feed water. In a
few cases, it might be necessary to use acid injection in addition to the
antiscalant, which will depend on the feed water analysis.

7.6. HIGH-PRESSURE OPERATION

The 3rd year typical operating pressure of the system is stated in the System
Performance Data Sheet in Appendix-I. Under no circumstances should the system be
operated at a pressure 10% higher than the 3rd year typical operating pressure without
consulting with AES.

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MAX OPERATION AND MAINTENANCE MANUAL

7.7. CLEANING EQUIPMENT

The Max systems are equipped with cleaning ports for membrane cleaning. The
cleaning ports should be used to connect feed, reject, and permeate piping to an
external cleaning station. If the optional clean-in-place (CIP) system is elected, the
cleaning ports will be replaced by cleaning valves that are installed on a skid-mounted
cleaning station (CIP) and labeled as CLEANING VALVES. Most of the cleaning ports
and cleaning valves are located on the high-pressure side. Hence, operators must
ensure that the cleaning ports are capped and the cleaning valve positions are not
changed during the normal operation (service mode) to avoid serious injury and/or
membrane damage. Please refer to the instruction labels on such valves for the normal
position during operation.

7.8. CLEAN-IN-PLACE optional feature (skip if not applicable)

The Clean-In-Place (CIP) option includes an integrated cleaning equipment on the skid
of the Max system. The CIP usually includes a CIP pump, a flow meter, a pressure
gauge, and a cleaning tank. It might also include cleaning separation valves for Array-
by-Array cleaning and immersion heaters with temperature controller (optional
features). The following precautions should be followed by the operator:

7.8.1. Cleaning involves the circulation of dangerous chemicals through the


membranes. The low pH cleaning chemicals usually have pH value of 2, while
high pH cleaning chemicals have pH value of 11. The use of such chemicals
should always be in compliance with the safety instructions on the MSDS of
each chemical.

7.8.2. Cleaning tank is usually supplied off the skid (if tank is installed on the skid,
move to the next point). The tank will include bulkheads for easy connection
with the cleaning ports of the CIP on the skid of the RO. Interconnecting piping
between the tank and the CIP will be supplied by AES; however, connecting
the tank to the CIP will be customer-responsibility.

7.8.3. The system should be flushed for 25-20 minutes after cleaning is done to flush
out any residual cleaning chemicals. Permeate should be diverted to the drain
all the time during the cleaning and flushing process. Please follow the
membrane cleaning instructions in SECTION-10.0 for more details on the
cleaning process and precautions.

7.8.4. Immersion heaters may be included with the CIP to control the temperature of
the cleaning solution. These heaters are controlled by a temperature controller
to keep the solution at the required temperature. The immersion heaters must
never be operated without the temperature controller and thermocouple probe
in proper condition and function. The temperature of the cleaning solution
should NEVER exceed 45 C (113 F) to avoid serious damage to the
membranes. Note that circulating the water during the cleaning will raise the
temperature of the cleaning solution much higher than the initial temperature.
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MAX OPERATION AND MAINTENANCE MANUAL

Extra care should be used when working around the immersion heaters to
ensure that heaters are at a safe temperature before touching them.

7.8.5. Only permeate water free of any chlorine or other oxidizers should be used to
dilute the cleaning solution to the desired concentrate and pH. Chlorinated
water should never be used at any time during cleaning the membranes.

7.8.6. At the end of the cleaning process, cleaning pump must be flushed with
permeate water to avoid corrosion due to the aggressive effect of the cleaning
chemicals.

7.9. INSTRUMENTATION AND CONTROLS

Max system is equipped with many control features with which the operator should be
familiar to ensure safe and smooth operation. The most important controls and
instruments on the Max system are listed in the following:

7.9.1. Hand (ON)-OFF-AUTO (H-O-A) Switches


Three-position switches intended for on/off control of the Max system. In the
AUTO mode the system will be controlled by a signal from an external
permeate storage tank level switch and/or a signal for the level switch of the
Antiscalant dosing tank (if level switch option is elected). Such a signal will
cause the reverse osmosis system to start if antiscalant tank is full and the
level of the water in the permeate tank is under a set level (Low Level Switch);
otherwise, the system will shut down. If the system is in the HAND (ON)
mode, it will continue to operate regardless of any level control signals;
however, it still controlled by a signal from the low pressure switch.

7.9.2. Pressure gauges


Max system is equipped with many liquid-filled pressure gauges to monitor the
pressure. The pressure gauges are typically installed at the following points:
a) Prefilter Inlet: Pressure at this point should be at least 30 psi.
b) Prefilter Outlet: Pressure at this point should be at least 20 psi. It is
recommended to change the prefilter cartridges at least at a monthly
basis to keep them clean to minimize the pressure loss across the filter.
c) High Pressure Pump Discharge:
d) Membrane Inlet Feed Pressure: The inlet pressure to the membranes
vessels. Please refer to the computer projection for the typical inlet
pressure to the membranes.
e) Turbine Inlet Pressure: The concentrate inlet pressure to the turbine.
f) Concentrate: The final discharge out of the turbine.
g) Permeate: The combined line of the product. The permeate pressure
should be kept as low as possible. Permeate back pressure will have a

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MAX OPERATION AND MAINTENANCE MANUAL

negative impact on permeate flow rate. Although the machine is equipped


with a check valve on the permeate line of each individual pressure
vessels, AES recommends to install another check valve on the combined
permeate water line after the machine as an extra protection to eliminate
any chance of membrane damage due to the static permeate back
pressure while the machine is shut-down.

7.9.3. Flow Meters


Digital, paddle-wheel type flow meters installed on the final permeate and
concentrate main lines (an optional flow meter may be installed on the feed
line). Flow rate is measured in gallons per minute (gpm).

7.9.4. Conductivity Monitor


Digital display continuously monitors the conductivity of the water. It is usually
installed on the permeate line, but an optional one could also be installed on
the feed line.

7.9.5. Emergency Stop


This is a red mushroom button that should be used only in emergency
situations. Pressing this button will immediately stop the machine as well as
ALL the system functions and features. If the machine is stopped by using this
button, the inlet automatic shut-down valve (solenoid or motorized ball valve)
will remain open until the button is released.

7.9.6. Feed Supply Valve


It is a true union, schedule 80 PVC, ball valve mounted in line prior to the pre-
filter and chemical dosing ports. It is used to disconnect the machine from the
feed whenever it is needed.

7.9.7. Inlet Automatic Shut-Off Valve


This is an automatic two-way ball valve (or a normally-closed solenoid) that
opens/closes to allow/stop feed water flow to the system.

7.9.8. Low Pressure Switch


This is an automatic switch that shuts down the system, if feed water pressure
before the high pressure pump is under 15-20 psi in order to protect the high
pressure pump from dry running.

7.9.9. High Pressure Pump Throttle Valve: (If not applicable, skip to 7.9.10)
A manually regulated, 316 stainless steel globe valve or gear-driven ball valve
installed on the high-pressure pump discharge to control the feed flow rate to
the membranes. This valve should be used to throttle the pump to reach the
required feed flow per the membrane computer projection in order to maintain
the membrane recovery (permeate flow rate / first array feed flow rate) at the
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MAX OPERATION AND MAINTENANCE MANUAL

design value. Pumps that are controlled by VFD are not provided with a throttle
valve.

WARNING - The throttle valve should never be 100% closed, except during cleaning the
membranes to protect the pump and the instrument sensors on the feed line
from the aggressive effect of the cleaning chemicals.

7.9.10. Turbine Manual Bypass Valve


A manually regulated valve that is built-in the body of the turbine. It is used to
control the concentrate inlet flow to the turbine. Opening this valve will result in
decreasing the concentrate inlet flow to the turbine which will decrease the
turbine boosting pressure, and hence decrease the membrane feed inlet
pressure. This will result in decreasing the permeate flow rate and system
recovery.

WARNING - Running the machine at a membrane recovery lower than that is recommended
by AES in the membrane computer projection and System Performance Data
Sheet in Appendix-I may cause serious telescoping damage to the membranes
due to the high feed cross flow velocity in the membranes.

7.9.11. Turbine Automatic Bypass Valve


This is an automatic motorized two-way ball valve that is installed on the
bypass line around the turbine. It opens during the start-up for a few seconds
to provide a smooth start-up at a relatively low pressure, and then it shuts
down to divert the concentrate line to the turbine which will boost the
membrane inlet pressure and increase the permeate flow to the normal rate.
This valve will also open before the shutdown, which will decrease the
backpressure on the flush pump and enable permeate flush water to flow free
of the turbine restriction to the drain. In addition, this valve will open, if the
Flush switch of the CIP turns to the ON position at the end of the cleaning
cycle. This will divert the cleaning chemicals in the CIP tank to the drain
bypassing the turbine.

In addition to the above-mentioned items, any of the flowing optional features might be
included with the system per customer request (skip whatever is not included). These
components are integral parts of the overall system control and are not designed for
manual intervention or override.

7.9.12. High Pressure Switch


An electronic switch designed to shut the system down, if the feed water
pressure at the discharge of the high pressure pump exceeds a set value. This
value should be set on site during the commissioning of the system. It is
usually 10% above the normal 3rd-year membrane inlet pressure.

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MAX OPERATION AND MAINTENANCE MANUAL

7.9.13. Automatic Permeate Flush Motorized Ball Valve


A three-way motorized ball valve, designed to control the permeate flow to the
point-of-use or to the permeate flush tank. The 3-way motorized ball valve will
automatically divert all the permeate water into the flush tank on the start-up
until the permeate flush tank is full. Once the permeate tank is full, the valve
will automatically divert the permeate back to the point-of-use.

7.9.14. Permeate Divert 3-Way Ball Valve


Directs permeate flow to drain when the permeate TDS is above the set point,
and to the permeate tank when the TDS is below the set point.

7.9.15. pH or ORP Meter


Digital Display continuously monitors the pH or the ORP of the water at the pH
sensor point.

7.9.16. Chemical Dosing Pumps


Skid mounted chemical metering pumps for in-line chemical injection. The
pumps should have control knob for the stroke (may have another knob for the
speed). If the knob speed is not included, consider the speed 100% and use
the following equation to adjust the injection rate of the pump:

Injection Rate = Pump Maximum Capacity * %Speed * %Stroke

Injection rate should be advised by the chemical supplier based on the feed
water analysis and the water flow rate.

7.10. START-UP INSTRUCTIONS

The following step-by-step procedure is recommended when starting up an RO system


for the first time or after an extended period of inactivity. This procedure covers only the
reverse osmosis system. Refer to the individual manuals of other components, such as
the controller of the multi media filters or injection systems, for the proper start-up and
set up steps. It may be necessary to complete those steps before continuing with this
procedure.

1) Examine the inlet and outlet piping to ensure that all piping is securely attached,
there are no leaks, and that all manual ball valves are in an open position. Confirm
that the electrical connections are securely in place and Emergency Stop is not
depressed. Verify that the sediment pre-filter cartridges are installed (they are
usually shipped separate in a box attached to the machine skid).

2) Once the feed water supply is connected to the system and the inlet manual ball
valve is open, confirm that the pre-filter inlet and outlet pressure gauges (if they
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MAX OPERATION AND MAINTENANCE MANUAL

are included) show positive inlet pressure. If no pressure is detected, check the
feed water supply and valve positions. Pressure should be 20-25 psi at the inlet of
the pre-filter.

3) Open the concentrate control valve and pump throttle valve (if applicable)
completely.

4) If the inlet shut-off valve is provided with H-O-A switch, position this switch on the
Hand (ON) mode. The valve should turn open to allow feed water flow into the RO
system.

5) If the inlet shut-off valve is not provided with H-O-A switch, start the machine by
putting the H-O-A switch of H.P. pump on the Hand (ON) mode, once the
automatic inlet shut-off valve opens press the emergency stop button to prevent
the R.O. pump from starting. The emergency button will stop the machine
immediately, but it will keep the inlet shut-off valve open to allow the feed water to
flush through the system to drain.

6) Allow feed water to flow continually into the membranes for 1-2 hours. CAUTION:
ALLOWING THIS LOW-PRESSURE FLOW TO CONTINUE FOR AN EXCESSIVE
PERIOD OF TIME MAY LEAD TO MEMBRANE SCALING OR FOULING!

7) Turn the H-O-A switch of the HP pump and inlet shut-off valve to the OFF position,
and then pull the emergency stop button to its original condition. Once the
emergency stop button is pulled out, the inlet shut-off valve will go back to its
normal close position and stop the feed water from entering the machine.

8) Close the pump throttle valve (if included) to about half open and make sure that
the concentrate control valve (if included) is entirely open. Configure the permeate
outlet piping downstream of the machine to enable the permeate to be discarded
to drain.

9) Start the R.O. system again by placing the Inlet shut-off valve and HP pump H-O-
A switches in the Hand (ON) position.

10) Check the rotation of the pump and make sure that it is in the right direction based
on the indication on the pump.

11) Allow the machine to run in a fast-flush condition for about 15-30 minutes
(relatively low pressure without restriction from the concentrate control valve if
provided). The turbine automatic bypass valve should be manually open.

12) Stop the R.O. system by placing the H-O-A switches in the OFF position.
Manually close the turbine automatic bypass valve and place it on the automatic
position.

13) Start the R.O. system again by placing the Inlet shut-off valve and HP pump H-O-
A switches in the Hand (ON) position.

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MAX OPERATION AND MAINTENANCE MANUAL

14) Adjust the concentrate control valve (if included), pump throttle valve or VFD (if
included), and turbine manual bypass valve to obtain the design flow and system
recovery as indicated on the computer projection and System Performance Data
Sheet that are included in Appendix-I. Run the R.O. system in Hand (ON) mode
for 30-60 minutes, while discarding all permeate to drain.

15) Compare the flow, TDS, and pressure readings to the projected values to confirm
that all the operating parameters such as concentrate flow, permeate flow,
membrane feed pressure, concentrate pressure, permeate conductivity, etc. are to
specifications.

16) Stop the R.O. system by placing the H-O-A switches in the OFF position.
Configure the downstream permeate piping to direct the permeate to the point-of-
use.

17) If a point-of-use storage tank is being used and automatic operation of the system
is desired, place the HP Pump and inlet switch H-O-A switches on the AUTO
position. In the AUTO position, the system starts in response to the position of the
permeate storage tank float switches.

18) After one hour of operation, measure and record on a data sheet the following
parameters:
a- The reading of all the pressure gauges along the system.
i- Inlet/Outlet of pre-filter
ii- Pump discharge pressure
iii- Turbine concentrate inlet pressure
iv- Turbine concentrate discharge pressure (disposal pressure)
v- Turbine feed outlet pressure (membrane inlet pressure)
vi- Permeate back pressure
b- Permeate and concentrate rates, using the flow meters or a calibrated
volume container and a stopwatch.
c- Feed temperature, conductivity, and pH
d- Permeate conductivity.

A data sheet and daily log sheet should be a part of the daily maintenance of
the RO system. This information is critical to the factory warranty and trouble
shooting process.

7.11. START-UP LOGIC:

The system will following this logic on every start-up:


1) The On-Off-Auto (H-O-A) selecting switch of the Automatic Feed Inlet Valve (MBV-1):
a- On position: MBV-1 will open, but the High Pressure Pump will not start.

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b- Auto position: MBV-1 will be in a stand-by mode waiting for a call for water
from the Point-Of-Use (low level switch signal in the permeate storage tank)
to open.
2) The On-Off-Auto selecting switch of the High Pressure Pump
a- On position: the HP pump will run on a manual mode only if the minimum
inlet pressure is exceeded. (It will only look at the Low Pressure Switch).
b- Auto position: The following procedure will take place in order, if there is a
call for water from the permeate storage tank (low level switch signal) :
i. Automatic Feed Inlet Valve (MBV-1) and Automatic Fast Flush Valve
(MBV-2) will open. The green lights of the Feed Inlet Valve and the
Flush should turn ON.
ii. Two seconds after MBV-1 completely opens, the PLC will send a
110 V signal to the feed pump to start. Feed pump has to be in
Auto mode to run.
iii. Five second after MBV-1 completely opens, the HP pump will start, if
the following conditions are met:
- Minimum inlet pressure is exceeded
- Antiscalant dosing pump is in On or Auto position
- Low level switch of the antiscalant dosing tank is
activated (tank is full)
- The HP pump should start and continue to run even if all
the other dosing pumps are in Off position or any of the
other dosing tanks is empty.
iv. Ten (10) seconds after the HP pump starts, MBV-2 will close, the
green light of the Flush will turn off, and membrane feed pressure
will start increasing to the normal operating level per the RO
projection in Appendix-I.
v. Three-way ball valves MBV-3 and MBV-4 will divert the permeate to
the CIP tank until the tank is full (the High Level Switch (HLS) of the
CIP tank is activated).
vi. When the tank is full, MBV-3 will divert the permeate to Point of Use
(P.O.U.) (permeate storage tank), If the permeate conductivity is
under the set point (1000 uS/cm).
vii. If permeate conductivity is above the set point, MBV-3 and MBV-4
will divert the permeate to drain after ten (10) second delay and the
red light of High Permeate Conductivity Alarm) will turn on until the
permeate conductivity drops under the set point.
viii. If permeate conductivity decreased under the set point, MBV-3 and
MBV-4 will divert the permeate back to the P.O.U. and the red light
of High Permeate Conductivity Alarm) will turn off.

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7.12. SHUT-DOWN LOGIC:

The system will following this logic on shut-down:


1) Upon activating the High Level Switch in the P.O.U. tank (tank full signal), the
system will shut down after performing the following automatic permeate flush
(APF) procedure:
a- MBV-1 will close, while MBV-2 opens.
b- MBV-5 will open
c- Five second after MBV-5 completely opens, the flush pump (CIP pump) will
start the permeate flush.
d- Flush pump will continue flushing until the flush tank (CIP tank) is empty (Low
Level Switch (LLS) is activated).
e- Upon activating the CIP LLS, MBV-5 and MBV-2 will close.

The system will not start again in Auto mode unless the Low Level Switch of the
P.O.U. tank is activated (tank empty signal). The system in On mode will continue
operating despite the status of the High/Low level switches of the P.O.U. tank.
2) If Feed ORP is greater than the set point (200 mV), the RO system will shut down
immediately and the red light of High Feed ORP Alarm will turn on. System will
perform permeate flush and follow the above-listed normal shut down procedure.
3) If feed pressure drops under the set point (15 psi), the system will shut down after
two (2) seconds and the red light of Low Pressure Alarm will turn on. System will
not perform permeate flush on shut down.
4) If membrane pressure increased above the set point (should be set at 10% above
the normal 3rd year operating pressure), the system will shut down immediately
and the red light of High Pressure Alarm will turn on. System will not perform
permeate before shut down.
5) The system is also equipped with a pretreatment Lock-Out option. If any of the
pretreatment filters starts a backwash cycle, the RO plant will shutdown without
performing permeate flush. The feed pump will continue running to provide the
required feed flow and pressure for the backwash.
6) If there is no default, when the backwash cycle finishes the system should
automatically start-up following the above listed start-up procedure (except filling
the CIP). The filters should be alternating to allow only one filter to go into
backwash in a time.
7) If the system receives a pretreatment Lock-Out signal while it is idle, the feed
pump will turn on to fulfill the requirement of the backwash of the filters until it is
completely finished. When the backwash cycle is done, the feed pump will stop
and the system will remain idle unless there is a call for water from the permeate
storage tank (Tank Low level signal).

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7.13. OPERATING LOGIC OF THE CHEMICAL DOSING SYSTEMS:

1) The RO system is equipped with six chemical dosing systems:


a- Pre-Chlorination Dosing System with a remote dosing point on the feed tank
b- Dechlorination Dosing System on feed stream
c- Biological Antifoulant Dosing System on feed stream
d- Antiscalant Dosing System on feed stream for scale inhibition
e- Caustic Dosing System on permeate stream for permeate pH adjustment.
f- Post Chlorination Dosing System permeate stream for permeate disinfection.
2) Each dosing system is provided with a chemical dosing pump, 35 gallon chemical
tank, tank low level switch, On-Off-Auto selecting switch, and green and red
indicating lights.
3) The red light of any chemical dosing system will turn on if the low level switch in its
tank is activated (tank is empty). If the pump is set in On or Auto position and
its chemical tank is full, the corresponding green light should turn on.
4) If chemical dosing pump selecting switch is in On position, dosing pump should
work in manual mode despite the status of the level switch in its tank (even if tank
is empty).
5) RO HP pump should start and continue running in Auto mode despite the status
of the level switches in the chemical dosing tanks, EXCEPT the level switch of the
antiscalant tank.
6) If the low level switch in the antiscalant tank is activated (tanks is empty), The RO
system will not start in the Auto mode. If running in the Auto mode, the RO
system will immediately shut down upon the receipt of a low level signal from the
antiscalant tank.
7) RO HP pump should start and continue running in Auto position despite the
selected operating mode of the dosing pumps (even if dosing pumps are Off),
EXCEPT the antiscalant pump.
8) The RO HP pump will not start in Auto mode, unless the antiscalant dosing pump
is in either On or Auto position. If running in Auto mode, the RO system will
immediately shut down if the antiscalant pump is turned off.
9) The caustic dosing pump in Auto position will be controller by the permeate pH
meter. It will automatically stops if the permeate pH reaches a level of 7.50. The
pump will start dosing again if the permeate pH drops to a level of 7.00.

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MAX OPERATION AND MAINTENANCE MANUAL

SECTION 8.0 - SCHEDULED MAINTENANCE


Periodic maintenance is the life stream for the protection of the RO system and its vital
components. The operators and maintenance personnel should pay specific attention to the
periodic maintenance of the following elements:

8.1. PRE-FILTERS
The sediment pre-filter is the last pretreatment item that the feed water should pass
through before it reaches the membranes. No pretreatment should be after this filter.
Cartridge filters with a 5-micron rating as minimum are typically recommended before the
membranes by the membrane manufacturer. Refer to the System Performance Data
Sheet in Appendix-I for the number and type of cartridges recommended for this system.

Regular periodic maintenance of the pre-filtration system is vital to the life span of the
membranes. The cartridges should be replaced when the pressure drop across them
exceeds 10 PSI. Although some filter cartridges are designed to be able to be cleaned
and re-used, AES strongly recommends replacing the cartridges with new ones. The
cartridges should be changed at least once a month, regardless the pressure drop across
them.

8.2. PUMP
Check the bearings, contactors, and sealing at least once a year. Also, the pump motors
need to be greased at least twice a year. Check the attached pump manuals for the
regular maintenance and service as well as the recommended schedule of oil changes if
applicable.

8.3. PRESSURE VESSELS


The pressure vessels should be maintained in a good condition without any damage to
withstand the operating pressure. Although periodic maintenance is not required for the
vessels, it is advisable that the O-rings, port seals, and other sealing components be
closely inspected and replaced when the end plugs are removed for any reason.

8.4. MEMBRANES
The RO membranes should last at minimum 3-5 years with proper pre-treatment.
However, production or rejection can decline over time as a result of scale formation or
biological foulants. Refer to SECTION-9.0, System Troubleshooting for more information
on identifying the cause of performance decline. If the permeate flow rate decreases by
10%, the elements should be cleaned, providing the drop in flow was not caused by
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MAX OPERATION AND MAINTENANCE MANUAL

reduced temperature or pressure. Failure to clean the elements at this time could result in
difficulty in restoring the unit to the normal flow rate, and will void the membrane
warranty. Check SECTION-10.0 for proper cleaning procedures and chemicals. Running
the machine without 5-micron cartridge pre-filter before the membranes will also void the
warranty on the membranes and the pumps. Note that cleaning should cause
improvement in the permeate quality.

8.5. HIGH PRESSURE SWITCH (if included)


As the membranes age, the production and rejection may decline slightly, requiring
occasional increases in the operating pressure to reach the desired performance
according to the membrane computer projections of the different years of operation. The
high pressure switches may have to be adjusted to a higher pressure cut-off point.
Please refer to the operating manual of the high-pressure switch for setting and
adjustment. The set value should not be more than 10% over the values in the computer
projection of the third year.

8.6. RECOMMENDED SPARE PARTS


AES recommends the following spare parts to be carried for maintenance:
- High pressure pump repair kit and seal kit
- Turbine service kit
- O-rings, brine seals, end adapters, and inter-connectors for pressure vessels
and membranes
- Filter cartridges for prefilter
- Pressure switches
- Electrical components such as fuses, breakers, lamps, etc.
- Service kits for chemical doing pumps
- Spare actuators for solenoids and motorized ball valves.

The above-mentioned list is only a guide of the minimum recommended spare parts;
however, the final list should be determined according to the shipping options to the site,
and the dependability of the facility on the RO system.

8.7. LONG-TERM SHOT-DOWN PROCEDURES:


The following shut-down procedures should be followed for any shut-down period
exceeding a week, unless the machine is flushed daily for at least 10 minutes:

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MAX OPERATION AND MAINTENANCE MANUAL

1- Use a mixture of 1% (by weight) of Sodium Bisulfite (membrane preservative) - food


grade, not cobalt activated - and 20% (by weight) propylene glycol as an antifreeze
(the antifreeze can be omitted, if freezing is not a concern).
2- Fill the CIP tank with the previous mixture before shutting down. On shut down, the
the system will perform a permeate flush cycle and the membranes will get entirely
soaked in the preservative. Permeate should be directed to drain while loading the
preservative into the membranes.

CAUTION- Do NOT allow the permeate at this step to reach the permeate tank.

3- The pH of the preservative should never drop below pH 3. A pH decrease can occur
when bisulfite is oxidized to sulfuric acid. This precaution is extremely important
because the salt rejection of the membranes will be affected badly at low pH
storage.

CAUTION- The pH of the preservative should be checked at least every month to


make sure that it does NOT drop under pH 3.

4- The preservative should be changed and a new solution should be used every two
months.

5- After the shot-down period ends, the RO has to be flushed for at least 30 minutes at
low pressure, then 15 minutes at normal operating pressure to discard all the
preservative in the drain before sending the permeate back to the permeate tank.

CAUTION- Permeate should be directed to drain while flushing the preservative


from the membranes. DO NOT ALLOW THE PERMEATE AT THIS
STEP TO REACH THE PERMEATE TANK.

Formaldehyde may be used in place of sodium bisulfite as preservative at 3.0% (by


weight). Formaldehyde is a more effective biocide than bisulfite and is not
decomposed by oxygen.

CAUTION- Handling formaldehyde requires much more precautions due to its


TOXICITY and CARCINOGENICITY.

However, Elements stored in formaldehyde do not need frequent observation. The


preservative solution should be renewed after 12 months. Extreme care should be
taken in handling formaldehyde and in flushing the system after use.

WARNING- NEVER ALLOW ANY TRACES OF FORMALDEHYDE TO REACH


THE PERMEATE TANK OR THE POINT-OF-USE.

WARNING- USE FORMALDEHYDE AT YOUR OWN RESPONSIBILITY.

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MAX OPERATION AND MAINTENANCE MANUAL

SECTION 9.0 - TROUBLESHOOTING

9.1. GENERAL OVERVIEW

The performance of the RO system is very susceptible to any change in the feed
conditions. Consequently, continuous monitoring of the system and daily documentation
of the operation data (inputs/outputs) are essential for the early diagnosis of any problem
with the system. AES included in section 9.2 a system-operating log sheet that is very
helpful in keeping a daily record of system operation data. The pertained data should be
recorded and the system-operating data sheet should be filled on a daily basis. It is
essential that such a process takes place every day at the same time of the day in order
to minimize the feed condition variations. All the data sheets should be kept in the
operating file for future references. They will be used as the performance trends for
trouble shooting purpose, when a problem occurs. These documents are very important
to process any warranty claim.

This section also includes a trouble shooting guide that is very useful in fast diagnosis of
RO operation problems. If the trouble shooting guide does not include solution for the
RO performance decline, you should contact your AES representative immediately.

WARNING- ignoring the problem and continuing the operation with the declining
performance may result in a permanent damage to the membranes and/or
other major components.

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9.2. SYSTEM OPERATION LOG SHEET

COMPANY: START-UP DATE:


LOCATION: LAST CLEANING:
DATE:
TIME:
OPERATING HOURS:
MM Filter Inlet Pressure
MM Filter Outlet Pressure
Carbon Filter Inlet Pressure
Carbon Filter Outlet Pressure
Cartridge Filter Inlet Pressure
Cartridge Filter Outlet Pressure
Cartridge Filter Differential Pressure
HP Pump Discharge Pressure
1st Array Feed Pressure
Turbine Concentrate Inlet Pressure
Concentrate Disposal Pressure
Permeate Back Pressure
Permeate Flow Rate
Concentrate Flow Rate
Feed Flow Rate
%Recovery
Feed TDS (ppm)
Permeate TDS (ppm)
%Rejection
Feed ORP (mV)
Feed pH
Permeate pH
Iron In Feed (ppm)
Total Hardness In Feed (As CaCo3)
Feed Turbidity (NTU)
Feed SDI
Pre-chlorination Dosage
Dechlorination Dosage
Biological Antifoulant Dosage
Antiscalant Dosage

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MAX OPERATION AND MAINTENANCE MANUAL

9.3. PLANT PERFORMANCE NORMALIZATION

The RO machine is one of the most vulnerable equipment of the entire water treatment
system. The performance of the machine and the efficiency of the operation will greatly
rely on the quality and conditions of feed stream. Exposing the membranes to feed water
of poor quality due to insufficient pretreatment or dramatic shift in the feed conditions
from the design guidelines may cause a serious drop in the performance of the machine;
in addition to extensive damage to its membranes. Consequently, continuous monitoring
of the machine performance and early detection of any deviation from the normal
operation are vital to the efficiency of the operation and the life spare of the membranes.
Membrane performance is negatively affected by the following factors:

- Membrane Compaction that is a natural deterioration in membrane surface area


and productivity with time (about 5% per year), which requires increasing
operating pressure with time in order to maintain system productivity (permeate
flow rate).
- The feed water analysis, feed TDS, feed pH, feed temperature, and %recovery.

Feed temperature has a great impact on the membrane productivity. For instance, a feed
temperature drop of 9 F (5o C) will cause a product flow rate drop of about 13%, which is
normal.

The following formula can be used to calculate the expected membrane productivity rate
at any feed temperature, driven from the normal productivity rate at 77 F (25 C):

Productivity Rate = (Productivity Rate at 77 F) / (Correction Factor)

The following chart provides temperature correction factors by membrane manufacturer:

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MAX OPERATION AND MAINTENANCE MANUAL

TEMPERATURE CORRECTION FACTORS BY MEMBRANE MANUFACTURERS


Toray or Fluid
C F Filmtec Trisep Desal
Hydranautics Systems
1 33.8 2.21 2.15 2.43 2.22 2.27
2 35.6 2.14 2.07 2.34 2.16 2.21
3 37.4 2.06 2.01 2.25 2.04 2.14
4 39.2 1.99 1.94 2.16 1.99 2.08
5 41.0 1.92 1.87 2.08 1.93 2.01
6 42.8 1.85 1.81 2.00 1.87 1.94
7 44.6 1.79 1.75 1.92 1.79 1.87
8 46.4 1.73 1.70 1.85 1.74 1.80
9 48.2 1.67 1.64 1.77 1.66 1.74
10 50.0 1.62 1.59 1.71 1.63 1.67
11 51.8 1.56 1.54 1.63 1.57 1.62
12 53.6 1.51 1.49 1.58 1.51 1.55
13 55.4 1.46 1.44 1.53 1.45 1.48
14 57.2 1.42 1.40 1.48 1.43 1.41
15 59.0 1.37 1.35 1.42 1.38 1.34
16 60.8 1.33 1.31 1.37 1.32 1.37
17 62.6 1.28 1.27 1.33 1.27 1.32
18 64.4 1.24 1.23 1.28 1.25 1.28
19 66.2 1.20 1.20 1.24 1.21 1.23
20 68.0 1.17 1.16 1.19 1.18 1.18
21 69.8 1.13 1.13 1.14 1.14 1.14
22 71.6 1.10 1.09 1.11 1.11 1.10
23 73.4 1.06 1.06 1.07 1.07 1.07
24 75.2 1.03 1.03 1.03 1.04 1.03
25 77.0 1.00 1.00 1.00 1.00 1.00
26 78.8 0.97 0.97 0.97 0.98 0.93
27 80.6 0.94 0.94 0.94 0.95 0.94
28 82.4 0.91 0.92 0.91 0.92 0.91
29 84.2 0.89 0.89 0.89 0.88 0.88
30 86.0 0.86 0.87 0.86 0.85 0.85
31 87.8 0.84 0.84 0.86 0.82
32 89.6 0.81 0.82 0.82 0.79
33 91.4 0.79 0.80
34 93.2 0.77 0.77
35 95.0 0.75 0.75
36 96.8 0.72 0.73
37 98.6 0.70 0.71
38 100.4 0.68 0.69
39 102.2 0.67 0.68
40 104.0 0.65 0.66
41 105.8 0.63 0.64
42 107.6 0.61 0.62
43 109.4 0.60 0.61
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9.4. TROUBLESHOOTING GUIDE

1) SCALING:

Permeate Flow: Decreases


Salt Passage: Increases
Pressure Drop: Increases

Location: In the last array

Verification: - Complete water analysis is required


- Calculate LSI of the reject
- Check the concentration of CaSO4, BaSO4, SrSO4 and
CaCO3 in the reject stream and compare it with their
maximum solubility.
- Contact your AES agent

Treatment: - Increase the antiscalant and/or acid dosage per AES


recommendation.
- Decrease system recovery, if maximum solubility of CaSo4
and/or CaCO3 is exceeded.
- Contact AES for recommendations on the proper cleaning
chemicals. Note that low pH cleaner will clean only CaCO3.
- Clean CaCO3 with AWC C-234
- Clean CaSO4, BaSO4, and SrSO4 with AWC C-238 and/or
AWC C-239

2) SILICA FOULING:

Permeate Flow: Decreases


Salt Passage: Decreases
Pressure Drop: Increases

Location: Colloidal silica will precipitate in the first array. Dissolved silica
will form scale in the last array.

Verification: - Analysis of SiO2 in feed water and cleaning solution


- Check the concentration of SiO2 in the reject stream and
compare it to its maximum solubility.
- Contact your AES agent.

Treatment: - Improve Pretreatment to remove colloidal silica.


- Use a proper antifoulant, if SiO2 concentration exceeds the
solubility limits but still under 250 ppm. If it exceeds 250
ppm, decrease system recovery.
- Clean with AWC C-236

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3) METAL OXIDE FOULING:

Permeate Flow: Decreases


Salt Passage: Normal to increases
Pressure Drop: Increases

Location: Most sever in the first array

Verification: - Analysis of metal ions in cleaning solution


- Consult with AES.

Treatment: - Improve Pretreatment to remove metal oxides.


- Clean with AWC C-225

4) ORGANIC FOULING:

Permeate Flow: Decreases


Salt Passage: Decreases or slightly increases
Pressure Drop: Normal to Increases

Location: First Array

Verification: Membrane autopsy (destructive test)

Treatment: - Use efficient organic removal pretreatment such as an


activated carbon filter.
- Clean with AWC C-227

5) BIOLOGICAL FOULING:

Permeate Flow: Decreases


Salt Passage: Normal to slightly increases
Pressure Drop: Normal to Increases

Location: First array, but it could extend to all arrays

Verification: Bacteria count in permeate and reject. In addition, look for


slime in pipes, membranes and pressure vessels.

Treatment: - Use AWC A-106, Biological Antifoulant


- Replace cartridge filters more often.
- Clean with AWC C-237

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6) COLLOIDAL FOULING:

Permeate Flow: Decreases


Salt Passage: Slightly decreases or increases
Pressure Drop: Increases

Location: Mainly first array

Verification: SDI test on feed water after the cartridge prefilter

Treatment: - Improve Pretreatment for colloidal removal.


- consider adding a cartridge filter less than 5-micron
downstream of the existing one.
- Clean with AWC C-237 or AWC C-227

7) OXIDATION FOULING:

Permeate Flow: Increases


Salt Passage: Considerably increases
Pressure Drop: Decreases

Location: All arrays, but most sever in the first array

Verification: - Oxygen Reduction Potential (ORP) analysis to feed water.


- Membrane autopsy (destructive test)

Treatment: - Increase the dosage of sodium bisulfite


- Add ORP monitor/controller on feed line, and set it to shut
the RO down at maximum 200 mV.
- Change membranes.

8) MEMBRANE ABRASION BY DEBRIS:

Permeate Flow: Increases


Salt Passage: Considerably increases
Pressure Drop: Decreases

Location: Mainly in the first array

Verification: - Microscopic solid analysis of feed.


- Check the Total Suspend Solids (TSS) in feed
- Membrane autopsy (destructive test)

Treatment: - Check all filters for possible media leakage.


- Use better quality cartridge filters.
- Consider adding a cartridge filter less than 5-micron
downstream of the existing one.

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- Change membranes

9) PERMEATE O-RING LEAKS:

Permeate Flow: Normal


Salt Passage: Increases
Pressure Drop: Normal

Location: Any pressure vessel

Verification: - Probe test.


- Check the TDS of the individual permeate lines of the
pressure vessels

Treatment: Replace damaged O-rings.

10) BRINE SEAL LEAKS:

Permeate Flow: Decreases


Salt Passage: Slightly increases
Pressure Drop: Decreases

Location: Any pressure vessel

Verification: Check the brine seals of the membranes of the concerned


array for any defects or displacement.

Treatment: Replace damaged brine seals.

11) MEMBRANE TELESCOPING:

Permeate Flow: Increases


Salt Passage: Considerably increases
Pressure Drop: Normal to slightly decreases

Location: Any Array

Verification: - Compare flows and pressures to system performance data


sheet and computer projection
- Check the anti-telescoping devises of the membranes in the
suspected presser vessels for any cracks. Visually, check
the membrane ends under the telescoping devise for
telescoping shapes (convex in the direction of the feed).

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MAX OPERATION AND MAINTENANCE MANUAL

Treatment: - Increase membrane recovery to decrease feed flow rate


(feed flow rate to each 8-pressure vessel should be under
70 gpm).
- Replace damaged membranes.

12) RECOVERY TOO HIGH:

Permeate Flow: Normal to decreases


Salt Passage: Increases
Pressure Drop: Normal

Location: Any Array

Verification: Compare flows and pressures to system performance data


sheet and computer projection.

Treatment: - Reduce membrane recovery to increase concentrate flow


rate (concentrate flow rate out of each 8-pressure vessel
should be over 16 gpm).
- Calibrate flow meters for accurate reading.
- If performance does not improve, apply complete membrane
cleaning.

65
MAX OPERATION AND MAINTENANCE MANUAL

SECTION 10.0 - MEMBRANE CLEANING PROCEDURES

10.1. MEMBRANE CLEANING REQUIREMENTS

Membrane cleaning can be performed using a variety of techniques and


equipment. Enclosed are the step-by-step instructions recommended by the
manufacturer of the membranes. Max systems are either equipped with cleaning
ports to permit easy connection from an external cleaning station (separate
cleaning station), or a Clean-In-Place option (CIP) which is an integrated cleaning
system connected permanently to the RO machine. In the event that the optional
CIP system is installed, no additional equipment is necessary. If the CIP is not
included, a separate cleaning station will be needed to perform the cleaning
process.

It is of paramount importance that the attached instructions of the original


membrane manufacturer regarding solution concentration, pH, temperature, flow
rate, and pressure be followed. Refer to the labels on the cleaning valves for their
proper positions and directions during cleaning. The exact sequence in which the
control valves are opened or closed, and their exact positions during cleaning will
determine the success of a cleaning cycle. Always be certain of the position of
each valve before changing from a normal R.O. production mode to a cleaning
mode. FAILURE to properly configure valves for the corresponding operating
mode could result in DAMAGE to the pumps, membranes, and/or valves.

If Clean-In-Place (CIP) option is included, filling of the cleaning solution tank can
be done as it follows:

1- If the (CIP) is using the permeate flush tank:


Placing the FLUSH switch in OFF position prior to shutting the RO down will
maintain the tank full by preventing the FLUSH.
2- If The CIP is using its own tank:
Manually divert the permeate flow from the RO machine to the CIP tank (by
using the 3-way manual ball valve on the permeate line) while the RO
machine is running in AUTO mode. If the cleaning tank includes level
switches, the RO will stop once the CIP is full and will not start again until the
Low Level Switch of the CIP is activated by emptying the solution tank. If the
cleaning tank does NOT include level switches, stop the RO manually, when
the level of the water in the cleaning tank reaches the desired level.

CAUTION- if the cleaning tank to be filled from an external source, the water must be
free of ANY residual oxidants such as chlorine or bromine.

The CIP system involves high flow rate pumping of dangerous chemicals
through the pressure vessels. The chemicals used have pH values as low as
2 and as high as 11. Use of these chemicals should always be done in a

66
MAX OPERATION AND MAINTENANCE MANUAL

manner consistent with the safety instructions on the MSDS for each
chemical.

This procedure is written assuming a two-step process, low pH followed by a


high pH cleaning for each array (bank). This two-step should be carried out
separately for each array (bank) of the multi-array machines starting from the
first array upstream and ending with the last array, respectively. If you are
departing from this procedure, ensure that you have an adequate flow path. It
is highly recommended to complete both steps whenever a cleaning is
performed. The following cleaning procedures should be carried out in
compliance with the recommended cleaning instructions of the membrane
manufacturer that are included herewith in the same section.

10.2. CLEANING PROCEDURES

1- Fill the cleaning tank with oxidant free water


2- Shut-down the RO system.
3- Close the pump discharge valve (pump throttle valve if applicable) and
the concentrate valve 100%.
4- Check the P&ID to verify the positions of the valves of the cleaning
feed/return of the first array. Comply with the cleaning signs on each
valve.
5- If CIP is not included, connect the RO cleaning ports of the first array
(feed, concentrate return, and permeate return) to the separate cleaning
station.
6- Add the desired cleaning chemical in the solution tank (check the
cleaning instructions of the membrane manufacturer at the end of this
section for the cleaning chemicals, cleaning flow rate, temperature, pH,
and pressure).
Note: generally it is recommended that the system be cleaned with a low pH
cleaner followed by a high pH cleaner.
7- Recycle the cleaning solution from the cleaning pump to the solution
tank for 10 minutes either by using the CLEAN-OFF-MIX automatic
recycle switch (place it in MIX position) if it is available with the cleaning
station; otherwise, use the manual recycle diaphragm valves on the
cleaning station.
8- After adequate mixing direct the cleaning solution to the RO machine by
placing the control of the cleaning station in the clean position if an
automatic switch is available with the cleaning station; otherwise, use
the manual diaphragm valves on the cleaning station.

67
MAX OPERATION AND MAINTENANCE MANUAL

9- Adjust cleaning flow to the desired value (45-35 gpm per 8-pressure
vessel) using the diaphragm throttle valve after the cleaning pump. The
pressure should be around 50-60 psi.
10- Operate in this mode for a minimum of 60 minutes to allow sufficient
time to clean the membranes. Monitor the system pH, temperature,
pressure and flow. It may be necessary to add additional chemical to
maintain the pH in the desired cleaning range (check the cleaning
instructions of the membrane manufacturer at the end of this section).
11- Place the clean control in the OFF position and allow the membranes to
soak in the cleaning solution for at least one hour (in case of heavy
fouling, overnight soaking may be recommended).
12- Repeat steps (9) to (11) as many times as necessary, then go to (13).
13- Repeat steps (4) to (12) for each array, then move to step (14)
14- Open the solution tank drain to empty the tank into the drain.
CAUTION- Comply with the local environmental regulation in regard to flushing chemical
into the drain. You may need to neutralize the cleaning solution to pH 7.00
before sending it to drain. Some local regulation may forbid flushing the
cleaning solution to the drain even after neutralization. Check with your local
environmental authority for the applicable regulation.
15- Place the R.O control and valves in the run mode (refer to the P&ID for
the normal operation positions of the valves). Permeate should be
directed to the cleaning tank during this step to be discarded into the
drain. Flush the system (in low pressure operation) to the drain until the
pH and TDS reading return to normal and stabilize.
CAUTION- Do NOT allow permeate to flow into the permeate tank during this operation.
16- Close the cleaning tank drain after the previous flush is complete and
the cleaning tank is entirely empty.
17- Fill the solution tank with oxidant free water (permeate from the RO
system)
18- Place the R.O control in the off position.
19- Repeat steps (3) to (16) again by using high pH cleaning solution, then
go to (20)
20- Return the valve line up to the normal operation condition. Please refer
to the P&I Diagram for this step
The following step will return the R.O. to automatic operation if the levels
switches of point of use are used.
21- Place the R.O. control in the AUTO position.

68
MAX OPERATION AND MAINTENANCE MANUAL

APPENDIX I SYSTEM OPERATION DATA


SYSTEM PERFORMANCE DATA SHEET

Customer: GUPCO
Project: 200 m3/d (36.7 US.gpm) SWRO, w/CIP
AES Order #: 108002
Model: Max-45 Customer-Provided Fee
Feed Limitations: Analysis
Maximum Feed Turbidity before prefilter 1 NTU Ca N/A
Maximum Feed SDI before prefilter 3 15 min. Mg N/A
Maximum Feed Free Chlorine Level 0.1 ppm Na N/A
Maximum Feed Temperatrure C 45 C K N/A
Minimum Feed Temperature C 4 C Ba N/A
Minimum Feed Pressure at Prefilter Intlet 30 psi Sr N/A
Minimum Feed Pressure at Prefilter Outlet 20 psi Cl N/A
Maximum Feed Pressure at Prefilter Outlet 60 psi HCO3 N/A
Design Criteria: SO4 N/A
Desin Permeate Flow Rate 36.7 gpm NO3 N/A
Design Temperature C 25 C NH4 N/A
Design Raw Water TDS 45,000 ppm F N/A
Design Raw Water pH 7.00 Fe N/A
Acid Dosage (100% concentrate) 0 ppm SiO2 N/A
Design Recovery 37% B N/A
Customer-Supplied Feed Flow Rate 99.2 gpm pH N/A
Number of 2.75" x 30", 5 micron prefilter cartridges 10 TDS N/A
Start-Up Operation:
H.P. Pump Discharge Pressure 640 psi
Membrane Inlet Pressure 923 psi
Concentrate Pressure 910 psi
Third Year Operation:
H.P. Pump Discharge Pressure 640 psi
Membrane Inlet Pressure 943 psi
Concetrate Pressure 930 psi
TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009

Toray Incorporated 2002 Page 1

Project: Start-Up
Comments:

Prepared For:
Location:
Prepared By:
Date Prepared: 28 August 2006

System Results

Flow Rates Gal/min Concentrations mg/l


RO Feed 99.2 RO Feed TDS 44788
Permeate 36.7 Permeate TDS 274
Concentrate 62.5 Concentrate TDS 70934
Total Feed 99.2 Total Feed TDS 44788
Total Product 36.7 Total Product TDS 274

System Details Single Stage Design


Temperature: 25.0 Deg C Water Type: Surface Supply
System Recovery: 37.0 %

Pass 1 Units: Pressure - Psi Flow - Gal/min TDS - mg/l

Array 1 Recovery: 37.0% Concentrate TDS: 70934 Concentrate Flow: 62.5

Total Total Element Feed Perm Feed Delta Perm


Bank Vessels Elements Model Flow Flow Press Press TDS
TM820-
1 3 18 99.2 36.7 923 7.33 274
370
Total 3 18 99.2 36.7 274

Concentration, Saturation and pH Data mg/l

Ion Permeate Treated Feed Feed Concentrate


Ca 2.01 1020 1020 1618
Mg 2.84 1445 1445 2292
Na 101 14033 14033 22217
K 0.0243 3.0 3.0 4.75
Ba 0.0 0.0 0.0 0.0
Sr 0.0 0.0 0.0 0.0
NH4 0.0 0.0 0.0 0.0
Fe 0.0 0.0 0.0 0.0
HCO3 1.8 180 180 284
Cl 162 26000 26000 41177
SO4 5.31 2100 2100 3330
NO3 0.0735 4.0 4.0 6.31
F 0.0013 0.3 0.3 0.48
B 0.24 1.0 1.0 1.45
SiO2 0.0077 1.0 1.0 1.58
TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009
Ion Permeate Treated Feed Feed Concentrate
PO4 0.0 0.0 0.0 0.0
CO3 1.55E-05 0.5 0.5 1.44
CO2 18.6 18.6 18.6 18.6
TDS 274 44788 44788 70934
pH 5.17 7.0 7.0 7.18
Saturation Data (%)
CaSO4 0.0034 34.8 34.8 63.5
CaPO4 0.0 0.0 0.0 0.0
CaF2 1.12E-09 0.22 0.22 1.0
BaSO4 0.0 0.0 0.0 0.0
SiO2 0.0061 0.8 0.8 1.27
SrSO4 0.0 0.0 0.0 0.0
LSI -5.79 0.48 0.48 1.3
SDSI -5.67 -0.49 -0.49 -0.0027

Toray Incorporated 2002 Page 2


TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009
System Summary

System Configuration

System Type:
Feed Predosing?: No
Feed Afterdosing?: No
Interpass Dosing?: No
Product Dosing?: No
Feed CO2 Stripping?: No
Interpass CO2 Stripping?: No
Product CO2 Stripping?: No
Raw Feed Bypass?: No
First Pass Recycle?: No
Interpass Pumping?: No

Feed Information

Water Type: Surface Supply


Temperature, Deg C: 25.0
Feed pH: 7.0
Silt Density Index: 3.0

Feed Ion Concentration (mg/l)


Ca 1020
Mg 1445
Na 14033
K 3.0
Ba 0.0
Sr 0.0
NH4 0.0
Fe 0.0
HCO3 180
Cl 26000
SO4 2100
NO3 4.0
F 0.3
B 1.0
SiO2 1.0
PO4 0.0
CO3 0.5
CO2 18.6

System Flux, Flows and Recoveries

Average System Flux: 7.95 Gal/ft2/day


Feed Flow: 99.19 Gal/min
Product Flow: 36.70 Gal/min
Concentrate Flow: 62.49 Gal/min
First Pass Recovery: 37.0 %
System Recovery: 37.0 %

Toray Incorporated 2002 Page 3


TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009
First Pass Array

Interbank Pressure Drop: 0.0 Psi


Bank 1 Back Pressure: 0.0 Psi

Number of Banks: 1 Total Elements: 18

Bank # Vessels # Elements/Vessel Element Type Element Age


1 3 6 TM820-370 0

Projection reflects stabilized performance of the product.


Site performance may indicate lower feed pressure and higher salt passage until product is stabilized.

Toray Incorporated 2002 Page 4


TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009
Process Data

Flow Units: Gal/min


Pressure Units: psi

Concentrate
62.5

Net Feed
Feed 37.0%
99.2 99.2

Product
36.7

System Recovery 37.0%

Flow Rates Gal/min Concentrations mg/l


RO Feed 99.2 RO Feed TDS 44788
Permeate 36.7 Permeate TDS 274
Concentrate 62.5 Concentrate TDS 70934
Total Feed 99.2 Total Feed TDS 44788
Total Product 36.7 Total Product TDS 274

System Data Single Stage Design


Temperature: 25.0 Deg C

Stage 1
Fouling Allowance 85.0 %
Salt Passage Increase Per Year 10.0 %
Feed Pressure 923 Psi
Interbank Loss 0.0 Psi
Element Age 0.0 Years

Interbank Boost Pressure Stage 1

Toray Incorporated 2002 Page 5


TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009
Stream Data

Units: Pressure - psi Flow - Gal/min TDS - mg/l Saturation - %

System 1st Pass Total System System


Stream ---> Feed Feed Permeate Product Concentrate
Ca 1020 1020 2.01 2.01 1618
Mg 1445 1445 2.84 2.84 2292
Na 14033 14033 101 101 22217
K 3.0 3.0 0.0243 0.0243 4.75
Ba 0.0 0.0 0.0 0.0 0.0
Sr 0.0 0.0 0.0 0.0 0.0
NH4 0.0 0.0 0.0 0.0 0.0
Fe 0.0 0.0 0.0 0.0 0.0
HCO3 180 180 1.8 1.8 284
Cl 26000 26000 162 162 41177
SO4 2100 2100 5.31 5.31 3330
NO3 4.0 4.0 0.0735 0.0735 6.31
F 0.3 0.3 0.0013 0.0013 0.48
B 1.0 1.0 0.24 0.24 1.45
SiO2 1.0 1.0 0.0077 0.0077 1.58
PO4 0.0 0.0 0.0 0.0 0.0
CO3 0.5 0.5 1.55E-05 1.55E-05 1.44
CO2 18.6 18.6 18.6 18.6 18.6

TDS 44788 44788 274 274 70934


pH 7.0 7.0 5.17 5.17 7.18
LSI 0.48 0.48 -5.79 -5.79 1.3
Stiff-Davis -0.49 -0.49 -5.67 -5.67 -0.0027
BaSO4 Sat 0.0 0.0 0.0 0.0 0.0
CaSO4 Sat 34.8 34.8 0.0034 0.0034 63.5
CaPO4 Sat 0.0 0.0 0.0 0.0 0.0
CaF2 Sat 0.22 0.22 1.12E-09 1.12E-09 1.0
SrSO4 Sat 0.0 0.0 0.0 0.0 0.0
SiO2 Sat 0.8 0.8 0.0061 0.0061 1.27

Flow 99.2 99.2 36.7 36.7 62.5


Temp, Deg C 25.0 25.0 25.0 25.0 25.0
Pressure 923 923 0.0 0.0 915
Osm Pressure 476 476 3.27 3.27 745

Toray Incorporated 2002 Page 6


TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009
Element Data

Pass 1, Bank 1 Units: Pressure - psi, Flow - Gal/min, TDS - mg/l, Saturation - %, Flux - gal/ft2/day

Bank Permeate Back Pressure: 0.0

Elem 1 Elem 2 Elem 3 Elem 4 Elem 5 Elem 6


Permeate Ions
Ca 1.04 1.34 1.77 2.39 3.25 4.43
Mg 1.47 1.9 2.51 3.38 4.6 6.28
Na 52.3 67.5 89.0 120 163 222
K 0.0126 0.0163 0.0215 0.0289 0.0392 0.0534
Ba 0.0 0.0 0.0 0.0 0.0 0.0
Sr 0.0 0.0 0.0 0.0 0.0 0.0
NH4 0.0 0.0 0.0 0.0 0.0 0.0
Fe 0.0 0.0 0.0 0.0 0.0 0.0
HCO3 0.94 1.21 1.6 2.15 2.91 3.96
Cl 83.9 108 143 192 262 356
SO4 2.75 3.55 4.69 6.32 8.6 11.7
NO3 0.0385 0.0496 0.0653 0.0876 0.12 0.16
F 0.0007 0.0008 0.0011 0.0015 0.002 0.0028
B 0.15 0.18 0.22 0.28 0.35 0.42
SiO2 0.0043 0.0054 0.007 0.0091 0.0121 0.016
PO4 0.0 0.0 0.0 0.0 0.0 0.0
CO3 3.97E-06 6.74E-06 1.20E-05 2.24E-05 4.27E-05 8.23E-05
CO2 18.6 18.6 18.6 18.6 18.6 18.6
TDS 143 184 243 327 444 605
pH 4.9 5.0 5.12 5.25 5.37 5.5
LSI -7.36 -6.49 -5.98 -5.54 -5.13 -4.75
Stiff-Davis -6.5 -6.17 -5.82 -5.45 -5.07 -4.68
Conc Saturation
BaSO4 Sat 0.0 0.0 0.0 0.0 0.0 0.0
CaSO4 Sat 39.4 44.3 49.4 54.5 59.2 63.5
CaF2 Sat 0.3 0.41 0.54 0.68 0.84 1.0
SrSO4 Sat 0.0 0.0 0.0 0.0 0.0 0.0
SiO2 Sat 0.88 0.97 1.05 1.13 1.2 1.27
Flow
Feed 33.1 30.0 27.4 25.2 23.4 22.0
Permeate 3.06 2.63 2.2 1.79 1.43 1.13
Pressure
Feed 923 921 920 918 917 916
Net Driving 371 323 276 232 194 161
Pressure Drop 1.57 1.39 1.25 1.13 1.04 0.96
Feed Osmotic 476 523 572 620 666 708
Other Parameters
% Recovery 9.26 8.77 8.03 7.11 6.11 5.13
B Conc Pol 1.11 1.1 1.09 1.07 1.06 1.05
A Value 2.29E-09 2.27E-09 2.23E-09 2.16E-09 2.07E-09 1.97E-09
B Value 1.66E-08 1.70E-08 1.74E-08 1.78E-08 1.83E-08 1.88E-08
Flux 11.9 10.3 8.57 6.98 5.57 4.39

Toray Incorporated 2002 Page 7


TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009
Errors & Warnings

Warning - High LSI. LSI > zero. Concentrate CaCO3 greater than saturation. Scale inhibitor required.
The feed water analysis was balanced with added Na or Cl.

Database version used for design : 2.028

WARRANTY DISCLAIMER. NO WARRANTIES ARE GIVEN IN CONNECTION WITH THIS SOFTWARE OR ITS USE. THIS SOFTWARE IS NOT WARRANTED
FOR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. This software is provided as an aid for the design of reverse osmosis systems
incorporating membrane elements sold by Toray Industries, Inc., Toray Membrane America, Inc. and ROPUR AG. Such companies do not assume any
responsibilities or liability in connection with this software or any results obtained or damages incurred in connection with its use. The user of the software shall be
solely responsible for any designs created using the software and therefore should have the necessary technical skills and experience to design reverse osmosis
systems. Although it is anticipated that system designs will be reviewed by application engineers of one of the companies mentioned above, such companies do not
assume any responsibility or liability arising out of such review. Any warranty of systems or system designs will be provided only as expressly stated in a written
document signed by an authorized representative of the company issuing the warranty.

Toray Industries, Inc. Membrane Products Dept. TEL: (+81) 47-350-6030


8-1, Mihama 1-chome, Urayasu, Chiba 279-8555, Japan Fax: (+81) 47-350-6066

TORAY Membrane America, Inc. ROPUR AG


USA, South America, Canada Europe, Middle East and Africa Tel: +41 (61) 415 87 10
12520 High Bluff Drive, Suite 120 Tel: +1 (858) 523 0476 Grabenackerstrasse 8
San Diego, CA 92130, USA Fax: +1 (858) 523 0861 CH-4142 Munchenstein 1, Switzerland Fax: +41 (61) 415 87 20

Toray Incorporated 2002 Page 8


TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009

Toray Incorporated 2002 Page 1

Project: 1st Year


Comments:

Prepared For:
Location:
Prepared By:
Date Prepared: 28 August 2006

System Results

Flow Rates Gal/min Concentrations mg/l


RO Feed 99.2 RO Feed TDS 44788
Permeate 36.7 Permeate TDS 303
Concentrate 62.5 Concentrate TDS 70918
Total Feed 99.2 Total Feed TDS 44788
Total Product 36.7 Total Product TDS 303

System Details Single Stage Design


Temperature: 25.0 Deg C Water Type: Surface Supply
System Recovery: 37.0 %

Pass 1 Units: Pressure - Psi Flow - Gal/min TDS - mg/l

Array 1 Recovery: 37.0% Concentrate TDS: 70918 Concentrate Flow: 62.5

Total Total Element Feed Perm Feed Delta Perm


Bank Vessels Elements Model Flow Flow Press Press TDS
TM820-
1 3 18 99.2 36.7 939 7.35 303
370
Total 3 18 99.2 36.7 303

Concentration, Saturation and pH Data mg/l

Ion Permeate Treated Feed Feed Concentrate


Ca 2.22 1020 1020 1618
Mg 3.14 1445 1445 2292
Na 111 14033 14033 22211
K 0.0268 3.0 3.0 4.75
Ba 0.0 0.0 0.0 0.0
Sr 0.0 0.0 0.0 0.0
NH4 0.0 0.0 0.0 0.0
Fe 0.0 0.0 0.0 0.0
HCO3 1.99 180 180 284
Cl 179 26000 26000 41167
SO4 5.87 2100 2100 3330
NO3 0.0811 4.0 4.0 6.3
F 0.0014 0.3 0.3 0.48
B 0.26 1.0 1.0 1.44
SiO2 0.0085 1.0 1.0 1.58
TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009
Ion Permeate Treated Feed Feed Concentrate
PO4 0.0 0.0 0.0 0.0
CO3 1.91E-05 0.5 0.5 1.44
CO2 18.6 18.6 18.6 18.6
TDS 303 44788 44788 70918
pH 5.21 7.0 7.0 7.18
Saturation Data (%)
CaSO4 0.0041 34.8 34.8 63.5
CaPO4 0.0 0.0 0.0 0.0
CaF2 1.58E-09 0.22 0.22 1.0
BaSO4 0.0 0.0 0.0 0.0
SiO2 0.0067 0.8 0.8 1.27
SrSO4 0.0 0.0 0.0 0.0
LSI -5.65 0.48 0.48 1.3
SDSI -5.54 -0.49 -0.49 -0.0031

Toray Incorporated 2002 Page 2


TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009
System Summary

System Configuration

System Type:
Feed Predosing?: No
Feed Afterdosing?: No
Interpass Dosing?: No
Product Dosing?: No
Feed CO2 Stripping?: No
Interpass CO2 Stripping?: No
Product CO2 Stripping?: No
Raw Feed Bypass?: No
First Pass Recycle?: No
Interpass Pumping?: No

Feed Information

Water Type: Surface Supply


Temperature, Deg C: 25.0
Feed pH: 7.0
Silt Density Index: 3.0

Feed Ion Concentration (mg/l)


Ca 1020
Mg 1445
Na 14033
K 3.0
Ba 0.0
Sr 0.0
NH4 0.0
Fe 0.0
HCO3 180
Cl 26000
SO4 2100
NO3 4.0
F 0.3
B 1.0
SiO2 1.0
PO4 0.0
CO3 0.5
CO2 18.6

System Flux, Flows and Recoveries

Average System Flux: 7.95 Gal/ft2/day


Feed Flow: 99.19 Gal/min
Product Flow: 36.70 Gal/min
Concentrate Flow: 62.49 Gal/min
First Pass Recovery: 37.0 %
System Recovery: 37.0 %

Toray Incorporated 2002 Page 3


TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009
First Pass Array

Interbank Pressure Drop: 0.0 Psi


Bank 1 Back Pressure: 0.0 Psi

Number of Banks: 1 Total Elements: 18

Bank # Vessels # Elements/Vessel Element Type Element Age


1 3 6 TM820-370 1

Toray Incorporated 2002 Page 4


TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009
Process Data

Flow Units: Gal/min


Pressure Units: psi

Concentrate
62.5

Net Feed
Feed 37.0%
99.2 99.2

Product
36.7

System Recovery 37.0%

Flow Rates Gal/min Concentrations mg/l


RO Feed 99.2 RO Feed TDS 44788
Permeate 36.7 Permeate TDS 303
Concentrate 62.5 Concentrate TDS 70918
Total Feed 99.2 Total Feed TDS 44788
Total Product 36.7 Total Product TDS 303

System Data Single Stage Design


Temperature: 25.0 Deg C

Stage 1
Fouling Allowance 85.0 %
Salt Passage Increase Per Year 10.0 %
Feed Pressure 939 Psi
Interbank Loss 0.0 Psi
Element Age 1.0 Years

Interbank Boost Pressure Stage 1

Toray Incorporated 2002 Page 5


TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009
Stream Data

Units: Pressure - psi Flow - Gal/min TDS - mg/l Saturation - %

System 1st Pass Total System System


Stream ---> Feed Feed Permeate Product Concentrate
Ca 1020 1020 2.22 2.22 1618
Mg 1445 1445 3.14 3.14 2292
Na 14033 14033 111 111 22211
K 3.0 3.0 0.0268 0.0268 4.75
Ba 0.0 0.0 0.0 0.0 0.0
Sr 0.0 0.0 0.0 0.0 0.0
NH4 0.0 0.0 0.0 0.0 0.0
Fe 0.0 0.0 0.0 0.0 0.0
HCO3 180 180 1.99 1.99 284
Cl 26000 26000 179 179 41167
SO4 2100 2100 5.87 5.87 3330
NO3 4.0 4.0 0.0811 0.0811 6.3
F 0.3 0.3 0.0014 0.0014 0.48
B 1.0 1.0 0.26 0.26 1.44
SiO2 1.0 1.0 0.0085 0.0085 1.58
PO4 0.0 0.0 0.0 0.0 0.0
CO3 0.5 0.5 1.91E-05 1.91E-05 1.44
CO2 18.6 18.6 18.6 18.6 18.6

TDS 44788 44788 303 303 70918


pH 7.0 7.0 5.21 5.21 7.18
LSI 0.48 0.48 -5.65 -5.65 1.3
Stiff-Davis -0.49 -0.49 -5.54 -5.54 -0.0031
BaSO4 Sat 0.0 0.0 0.0 0.0 0.0
CaSO4 Sat 34.8 34.8 0.0041 0.0041 63.5
CaPO4 Sat 0.0 0.0 0.0 0.0 0.0
CaF2 Sat 0.22 0.22 1.58E-09 1.58E-09 1.0
SrSO4 Sat 0.0 0.0 0.0 0.0 0.0
SiO2 Sat 0.8 0.8 0.0067 0.0067 1.27

Flow 99.2 99.2 36.7 36.7 62.5


Temp, Deg C 25.0 25.0 25.0 25.0 25.0
Pressure 939 939 0.0 0.0 932
Osm Pressure 476 476 3.61 3.61 745

Toray Incorporated 2002 Page 6


TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009
Element Data

Pass 1, Bank 1 Units: Pressure - psi, Flow - Gal/min, TDS - mg/l, Saturation - %, Flux - gal/ft2/day

Bank Permeate Back Pressure: 0.0

Elem 1 Elem 2 Elem 3 Elem 4 Elem 5 Elem 6


Permeate Ions
Ca 1.17 1.5 1.96 2.61 3.51 4.76
Mg 1.66 2.12 2.77 3.69 4.98 6.74
Na 59.0 75.3 98.2 131 176 238
K 0.0142 0.0182 0.0237 0.0315 0.0424 0.0573
Ba 0.0 0.0 0.0 0.0 0.0 0.0
Sr 0.0 0.0 0.0 0.0 0.0 0.0
NH4 0.0 0.0 0.0 0.0 0.0 0.0
Fe 0.0 0.0 0.0 0.0 0.0 0.0
HCO3 1.06 1.35 1.76 2.34 3.15 4.25
Cl 94.7 121 158 210 283 382
SO4 3.1 3.96 5.18 6.9 9.31 12.6
NO3 0.0434 0.0552 0.072 0.0955 0.13 0.17
F 0.0007 0.0009 0.0012 0.0016 0.0022 0.003
B 0.16 0.2 0.24 0.3 0.36 0.44
SiO2 0.0048 0.006 0.0076 0.0099 0.013 0.017
PO4 0.0 0.0 0.0 0.0 0.0 0.0
CO3 5.10E-06 8.46E-06 1.48E-05 2.69E-05 5.04E-05 9.55E-05
CO2 18.6 18.6 18.6 18.6 18.6 18.6
TDS 161 205 268 357 480 649
pH 4.95 5.05 5.16 5.28 5.41 5.53
LSI -6.83 -6.27 -5.83 -5.42 -5.03 -4.66
Stiff-Davis -6.35 -6.03 -5.7 -5.34 -4.97 -4.6
Conc Saturation
BaSO4 Sat 0.0 0.0 0.0 0.0 0.0 0.0
CaSO4 Sat 39.3 44.2 49.2 54.2 59.0 63.5
CaF2 Sat 0.3 0.4 0.53 0.68 0.83 1.0
SrSO4 Sat 0.0 0.0 0.0 0.0 0.0 0.0
SiO2 Sat 0.88 0.96 1.05 1.13 1.2 1.27
Flow
Feed 33.1 30.1 27.5 25.3 23.5 22.0
Permeate 3.0 2.6 2.2 1.81 1.46 1.16
Pressure
Feed 939 938 936 935 934 933
Net Driving 390 342 295 251 212 178
Pressure Drop 1.57 1.4 1.25 1.13 1.04 0.96
Feed Osmotic 476 522 570 618 664 707
Other Parameters
% Recovery 9.07 8.65 8.0 7.17 6.23 5.3
B Conc Pol 1.11 1.1 1.09 1.07 1.06 1.05
A Value 2.14E-09 2.12E-09 2.08E-09 2.02E-09 1.94E-09 1.85E-09
B Value 1.85E-08 1.88E-08 1.92E-08 1.97E-08 2.03E-08 2.09E-08
Flux 11.7 10.1 8.57 7.06 5.7 4.54

Toray Incorporated 2002 Page 7


TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009
Errors & Warnings

Warning - High LSI. LSI > zero. Concentrate CaCO3 greater than saturation. Scale inhibitor required.
The feed water analysis was balanced with added Na or Cl.

Database version used for design : 2.028

WARRANTY DISCLAIMER. NO WARRANTIES ARE GIVEN IN CONNECTION WITH THIS SOFTWARE OR ITS USE. THIS SOFTWARE IS NOT WARRANTED
FOR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. This software is provided as an aid for the design of reverse osmosis systems
incorporating membrane elements sold by Toray Industries, Inc., Toray Membrane America, Inc. and ROPUR AG. Such companies do not assume any
responsibilities or liability in connection with this software or any results obtained or damages incurred in connection with its use. The user of the software shall be
solely responsible for any designs created using the software and therefore should have the necessary technical skills and experience to design reverse osmosis
systems. Although it is anticipated that system designs will be reviewed by application engineers of one of the companies mentioned above, such companies do not
assume any responsibility or liability arising out of such review. Any warranty of systems or system designs will be provided only as expressly stated in a written
document signed by an authorized representative of the company issuing the warranty.

Toray Industries, Inc. Membrane Products Dept. TEL: (+81) 47-350-6030


8-1, Mihama 1-chome, Urayasu, Chiba 279-8555, Japan Fax: (+81) 47-350-6066

TORAY Membrane America, Inc. ROPUR AG


USA, South America, Canada Europe, Middle East and Africa Tel: +41 (61) 415 87 10
12520 High Bluff Drive, Suite 120 Tel: +1 (858) 523 0476 Grabenackerstrasse 8
San Diego, CA 92130, USA Fax: +1 (858) 523 0861 CH-4142 Munchenstein 1, Switzerland Fax: +41 (61) 415 87 20

Toray Incorporated 2002 Page 8


TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009

Toray Incorporated 2002 Page 1

Project: 2nd Year


Comments:

Prepared For:
Location:
Prepared By:
Date Prepared: 28 August 2006

System Results

Flow Rates Gal/min Concentrations mg/l


RO Feed 99.2 RO Feed TDS 44788
Permeate 36.7 Permeate TDS 333
Concentrate 62.5 Concentrate TDS 70899
Total Feed 99.2 Total Feed TDS 44788
Total Product 36.7 Total Product TDS 333

System Details Single Stage Design


Temperature: 25.0 Deg C Water Type: Surface Supply
System Recovery: 37.0 %

Pass 1 Units: Pressure - Psi Flow - Gal/min TDS - mg/l

Array 1 Recovery: 37.0% Concentrate TDS: 70899 Concentrate Flow: 62.5

Total Total Element Feed Perm Feed Delta Perm


Bank Vessels Elements Model Flow Flow Press Press TDS
TM820-
1 3 18 99.2 36.7 941 7.35 333
370
Total 3 18 99.2 36.7 333

Concentration, Saturation and pH Data mg/l

Ion Permeate Treated Feed Feed Concentrate


Ca 2.44 1020 1020 1618
Mg 3.46 1445 1445 2292
Na 122 14033 14033 22204
K 0.0295 3.0 3.0 4.74
Ba 0.0 0.0 0.0 0.0
Sr 0.0 0.0 0.0 0.0
NH4 0.0 0.0 0.0 0.0
Fe 0.0 0.0 0.0 0.0
HCO3 2.19 180 180 284
Cl 196 26000 26000 41156
SO4 6.46 2100 2100 3330
NO3 0.0891 4.0 4.0 6.3
F 0.0015 0.3 0.3 0.48
B 0.27 1.0 1.0 1.43
SiO2 0.0092 1.0 1.0 1.58
TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009
Ion Permeate Treated Feed Feed Concentrate
PO4 0.0 0.0 0.0 0.0
CO3 2.33E-05 0.5 0.5 1.44
CO2 18.6 18.6 18.6 18.6
TDS 333 44788 44788 70899
pH 5.25 7.0 7.0 7.18
Saturation Data (%)
CaSO4 0.0049 34.8 34.8 63.5
CaPO4 0.0 0.0 0.0 0.0
CaF2 2.20E-09 0.22 0.22 1.0
BaSO4 0.0 0.0 0.0 0.0
SiO2 0.0073 0.8 0.8 1.27
SrSO4 0.0 0.0 0.0 0.0
LSI -5.51 0.48 0.48 1.3
SDSI -5.42 -0.49 -0.49 -0.0035

Toray Incorporated 2002 Page 2


TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009
System Summary

System Configuration

System Type:
Feed Predosing?: No
Feed Afterdosing?: No
Interpass Dosing?: No
Product Dosing?: No
Feed CO2 Stripping?: No
Interpass CO2 Stripping?: No
Product CO2 Stripping?: No
Raw Feed Bypass?: No
First Pass Recycle?: No
Interpass Pumping?: No

Feed Information

Water Type: Surface Supply


Temperature, Deg C: 25.0
Feed pH: 7.0
Silt Density Index: 3.0

Feed Ion Concentration (mg/l)


Ca 1020
Mg 1445
Na 14033
K 3.0
Ba 0.0
Sr 0.0
NH4 0.0
Fe 0.0
HCO3 180
Cl 26000
SO4 2100
NO3 4.0
F 0.3
B 1.0
SiO2 1.0
PO4 0.0
CO3 0.5
CO2 18.6

System Flux, Flows and Recoveries

Average System Flux: 7.95 Gal/ft2/day


Feed Flow: 99.19 Gal/min
Product Flow: 36.70 Gal/min
Concentrate Flow: 62.49 Gal/min
First Pass Recovery: 37.0 %
System Recovery: 37.0 %

Toray Incorporated 2002 Page 3


TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009
First Pass Array

Interbank Pressure Drop: 0.0 Psi


Bank 1 Back Pressure: 0.0 Psi

Number of Banks: 1 Total Elements: 18

Bank # Vessels # Elements/Vessel Element Type Element Age


1 3 6 TM820-370 2

Toray Incorporated 2002 Page 4


TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009
Process Data

Flow Units: Gal/min


Pressure Units: psi

Concentrate
62.5

Net Feed
Feed 37.0%
99.2 99.2

Product
36.7

System Recovery 37.0%

Flow Rates Gal/min Concentrations mg/l


RO Feed 99.2 RO Feed TDS 44788
Permeate 36.7 Permeate TDS 333
Concentrate 62.5 Concentrate TDS 70899
Total Feed 99.2 Total Feed TDS 44788
Total Product 36.7 Total Product TDS 333

System Data Single Stage Design


Temperature: 25.0 Deg C

Stage 1
Fouling Allowance 85.0 %
Salt Passage Increase Per Year 10.0 %
Feed Pressure 941 Psi
Interbank Loss 0.0 Psi
Element Age 2.0 Years

Interbank Boost Pressure Stage 1

Toray Incorporated 2002 Page 5


TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009
Stream Data

Units: Pressure - psi Flow - Gal/min TDS - mg/l Saturation - %

System 1st Pass Total System System


Stream ---> Feed Feed Permeate Product Concentrate
Ca 1020 1020 2.44 2.44 1618
Mg 1445 1445 3.46 3.46 2292
Na 14033 14033 122 122 22204
K 3.0 3.0 0.0295 0.0295 4.74
Ba 0.0 0.0 0.0 0.0 0.0
Sr 0.0 0.0 0.0 0.0 0.0
NH4 0.0 0.0 0.0 0.0 0.0
Fe 0.0 0.0 0.0 0.0 0.0
HCO3 180 180 2.19 2.19 284
Cl 26000 26000 196 196 41156
SO4 2100 2100 6.46 6.46 3330
NO3 4.0 4.0 0.0891 0.0891 6.3
F 0.3 0.3 0.0015 0.0015 0.48
B 1.0 1.0 0.27 0.27 1.43
SiO2 1.0 1.0 0.0092 0.0092 1.58
PO4 0.0 0.0 0.0 0.0 0.0
CO3 0.5 0.5 2.33E-05 2.33E-05 1.44
CO2 18.6 18.6 18.6 18.6 18.6

TDS 44788 44788 333 333 70899


pH 7.0 7.0 5.25 5.25 7.18
LSI 0.48 0.48 -5.51 -5.51 1.3
Stiff-Davis -0.49 -0.49 -5.42 -5.42 -0.0035
BaSO4 Sat 0.0 0.0 0.0 0.0 0.0
CaSO4 Sat 34.8 34.8 0.0049 0.0049 63.5
CaPO4 Sat 0.0 0.0 0.0 0.0 0.0
CaF2 Sat 0.22 0.22 2.20E-09 2.20E-09 1.0
SrSO4 Sat 0.0 0.0 0.0 0.0 0.0
SiO2 Sat 0.8 0.8 0.0073 0.0073 1.27

Flow 99.2 99.2 36.7 36.7 62.5


Temp, Deg C 25.0 25.0 25.0 25.0 25.0
Pressure 941 941 0.0 0.0 934
Osm Pressure 476 476 3.97 3.97 745

Toray Incorporated 2002 Page 6


TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009
Element Data

Pass 1, Bank 1 Units: Pressure - psi, Flow - Gal/min, TDS - mg/l, Saturation - %, Flux - gal/ft2/day

Bank Permeate Back Pressure: 0.0

Elem 1 Elem 2 Elem 3 Elem 4 Elem 5 Elem 6


Permeate Ions
Ca 1.3 1.65 2.15 2.86 3.85 5.2
Mg 1.84 2.34 3.05 4.06 5.46 7.37
Na 65.1 82.9 108 143 193 260
K 0.0157 0.02 0.0261 0.0346 0.0465 0.0626
Ba 0.0 0.0 0.0 0.0 0.0 0.0
Sr 0.0 0.0 0.0 0.0 0.0 0.0
NH4 0.0 0.0 0.0 0.0 0.0 0.0
Fe 0.0 0.0 0.0 0.0 0.0 0.0
HCO3 1.17 1.49 1.94 2.57 3.45 4.64
Cl 105 133 174 231 310 418
SO4 3.43 4.37 5.7 7.58 10.2 13.8
NO3 0.0478 0.0608 0.0791 0.1 0.14 0.19
F 0.0008 0.001 0.0014 0.0018 0.0024 0.0033
B 0.18 0.21 0.26 0.32 0.39 0.47
SiO2 0.0052 0.0065 0.0083 0.0108 0.0141 0.0185
PO4 0.0 0.0 0.0 0.0 0.0 0.0
CO3 6.26E-06 1.04E-05 1.80E-05 3.27E-05 6.11E-05 0.0001
CO2 18.6 18.6 18.6 18.6 18.6 18.6
TDS 178 226 295 391 526 709
pH 4.99 5.09 5.2 5.32 5.44 5.57
LSI -6.57 -6.1 -5.69 -5.3 -4.92 -4.55
Stiff-Davis -6.22 -5.91 -5.58 -5.22 -4.86 -4.49
Conc Saturation
BaSO4 Sat 0.0 0.0 0.0 0.0 0.0 0.0
CaSO4 Sat 39.3 44.1 49.2 54.2 59.0 63.5
CaF2 Sat 0.3 0.4 0.53 0.68 0.83 1.0
SrSO4 Sat 0.0 0.0 0.0 0.0 0.0 0.0
SiO2 Sat 0.88 0.96 1.04 1.12 1.2 1.27
Flow
Feed 33.1 30.1 27.5 25.3 23.5 22.0
Permeate 2.99 2.6 2.2 1.81 1.47 1.17
Pressure
Feed 941 940 938 937 936 935
Net Driving 393 345 298 254 215 181
Pressure Drop 1.57 1.4 1.25 1.13 1.04 0.96
Feed Osmotic 476 522 569 617 664 706
Other Parameters
% Recovery 9.04 8.63 7.99 7.17 6.25 5.33
B Conc Pol 1.11 1.1 1.09 1.07 1.06 1.05
A Value 2.11E-09 2.10E-09 2.06E-09 2.00E-09 1.92E-09 1.83E-09
B Value 2.03E-08 2.07E-08 2.12E-08 2.17E-08 2.24E-08 2.30E-08
Flux 11.6 10.1 8.57 7.07 5.72 4.57

Toray Incorporated 2002 Page 7


TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009
Errors & Warnings

Warning - High LSI. LSI > zero. Concentrate CaCO3 greater than saturation. Scale inhibitor required.
The feed water analysis was balanced with added Na or Cl.

Database version used for design : 2.028

WARRANTY DISCLAIMER. NO WARRANTIES ARE GIVEN IN CONNECTION WITH THIS SOFTWARE OR ITS USE. THIS SOFTWARE IS NOT WARRANTED
FOR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. This software is provided as an aid for the design of reverse osmosis systems
incorporating membrane elements sold by Toray Industries, Inc., Toray Membrane America, Inc. and ROPUR AG. Such companies do not assume any
responsibilities or liability in connection with this software or any results obtained or damages incurred in connection with its use. The user of the software shall be
solely responsible for any designs created using the software and therefore should have the necessary technical skills and experience to design reverse osmosis
systems. Although it is anticipated that system designs will be reviewed by application engineers of one of the companies mentioned above, such companies do not
assume any responsibility or liability arising out of such review. Any warranty of systems or system designs will be provided only as expressly stated in a written
document signed by an authorized representative of the company issuing the warranty.

Toray Industries, Inc. Membrane Products Dept. TEL: (+81) 47-350-6030


8-1, Mihama 1-chome, Urayasu, Chiba 279-8555, Japan Fax: (+81) 47-350-6066

TORAY Membrane America, Inc. ROPUR AG


USA, South America, Canada Europe, Middle East and Africa Tel: +41 (61) 415 87 10
12520 High Bluff Drive, Suite 120 Tel: +1 (858) 523 0476 Grabenackerstrasse 8
San Diego, CA 92130, USA Fax: +1 (858) 523 0861 CH-4142 Munchenstein 1, Switzerland Fax: +41 (61) 415 87 20

Toray Incorporated 2002 Page 8


TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009

Page 1

Project: 3rd Year


Comments:

Prepared For:
Location:
Prepared By:
Date Prepared: 28 August 2006

System Results

Flow Rates Gal/min Concentrations mg/l


RO Feed 99.2 RO Feed TDS 44788
Permeate 36.7 Permeate TDS 367
Concentrate 62.5 Concentrate TDS 70876
Total Feed 99.2 Total Feed TDS 44788
Total Product 36.7 Total Product TDS 367

System Details Single Stage Design


Temperature: 25.0 Deg C Water Type: Surface Supply
System Recovery: 37.0 %

Pass 1 Units: Pressure - Psi Flow - Gal/min TDS - mg/l

Array 1 Recovery: 37.0% Concentrate TDS: 70876 Concentrate Flow: 62.5

Total Total Element Feed Perm Feed Delta Perm


Bank Vessels Elements Model Flow Flow Press Press TDS
TM820-
1 3 18 99.2 36.7 943 7.36 367
370
Total 3 18 99.2 36.7 367

Concentration, Saturation and pH Data mg/l

Ion Permeate Treated Feed Feed Concentrate


Ca 2.68 1020 1020 1617
Mg 3.8 1445 1445 2291
Na 134 14033 14033 22196
K 0.0324 3.0 3.0 4.74
Ba 0.0 0.0 0.0 0.0
Sr 0.0 0.0 0.0 0.0
NH4 0.0 0.0 0.0 0.0
Fe 0.0 0.0 0.0 0.0
HCO3 2.41 180 180 284
Cl 216 26000 26000 41143
SO4 7.1 2100 2100 3329
NO3 0.0978 4.0 4.0 6.29
F 0.0017 0.3 0.3 0.48
B 0.29 1.0 1.0 1.41
SiO2 0.01 1.0 1.0 1.58

Toray Incorporated 2002


TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009
Ion Permeate Treated Feed Feed Concentrate
PO4 0.0 0.0 0.0 0.0
CO3 2.85E-05 0.5 0.5 1.44
CO2 18.6 18.6 18.6 18.6
TDS 367 44788 44788 70876
pH 5.29 7.0 7.0 7.18
Saturation Data (%)
CaSO4 0.0059 34.8 34.8 63.4
CaPO4 0.0 0.0 0.0 0.0
CaF2 3.06E-09 0.22 0.22 0.99
BaSO4 0.0 0.0 0.0 0.0
SiO2 0.0079 0.8 0.8 1.27
SrSO4 0.0 0.0 0.0 0.0
LSI -5.38 0.48 0.48 1.3
SDSI -5.3 -0.49 -0.49 -0.004

Toray Incorporated 2002 Page 2


TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009
System Summary

System Configuration

System Type:
Feed Predosing?: No
Feed Afterdosing?: No
Interpass Dosing?: No
Product Dosing?: No
Feed CO2 Stripping?: No
Interpass CO2 Stripping?: No
Product CO2 Stripping?: No
Raw Feed Bypass?: No
First Pass Recycle?: No
Interpass Pumping?: No

Feed Information

Water Type: Surface Supply


Temperature, Deg C: 25.0
Feed pH: 7.0
Silt Density Index: 3.0

Feed Ion Concentration (mg/l)


Ca 1020
Mg 1445
Na 14033
K 3.0
Ba 0.0
Sr 0.0
NH4 0.0
Fe 0.0
HCO3 180
Cl 26000
SO4 2100
NO3 4.0
F 0.3
B 1.0
SiO2 1.0
PO4 0.0
CO3 0.5
CO2 18.6

System Flux, Flows and Recoveries

Average System Flux: 7.95 Gal/ft2/day


Feed Flow: 99.19 Gal/min
Product Flow: 36.70 Gal/min
Concentrate Flow: 62.49 Gal/min
First Pass Recovery: 37.0 %
System Recovery: 37.0 %

Toray Incorporated 2002 Page 3


TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009
First Pass Array

Interbank Pressure Drop: 0.0 Psi


Bank 1 Back Pressure: 0.0 Psi

Number of Banks: 1 Total Elements: 18

Bank # Vessels # Elements/Vessel Element Type Element Age


1 3 6 TM820-370 3

Toray Incorporated 2002 Page 4


TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009
Process Data

Flow Units: Gal/min


Pressure Units: psi

Concentrate
62.5

Net Feed
Feed 37.0%
99.2 99.2

Product
36.7

System Recovery 37.0%

Flow Rates Gal/min Concentrations mg/l


RO Feed 99.2 RO Feed TDS 44788
Permeate 36.7 Permeate TDS 367
Concentrate 62.5 Concentrate TDS 70876
Total Feed 99.2 Total Feed TDS 44788
Total Product 36.7 Total Product TDS 367

System Data Single Stage Design


Temperature: 25.0 Deg C

Stage 1
Fouling Allowance 85.0 %
Salt Passage Increase Per Year 10.0 %
Feed Pressure 943 Psi
Interbank Loss 0.0 Psi
Element Age 3.0 Years

Interbank Boost Pressure Stage 1

Toray Incorporated 2002 Page 5


TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009
Stream Data

Units: Pressure - psi Flow - Gal/min TDS - mg/l Saturation - %

System 1st Pass Total System System


Stream ---> Feed Feed Permeate Product Concentrate
Ca 1020 1020 2.68 2.68 1617
Mg 1445 1445 3.8 3.8 2291
Na 14033 14033 134 134 22196
K 3.0 3.0 0.0324 0.0324 4.74
Ba 0.0 0.0 0.0 0.0 0.0
Sr 0.0 0.0 0.0 0.0 0.0
NH4 0.0 0.0 0.0 0.0 0.0
Fe 0.0 0.0 0.0 0.0 0.0
HCO3 180 180 2.41 2.41 284
Cl 26000 26000 216 216 41143
SO4 2100 2100 7.1 7.1 3329
NO3 4.0 4.0 0.0978 0.0978 6.29
F 0.3 0.3 0.0017 0.0017 0.48
B 1.0 1.0 0.29 0.29 1.41
SiO2 1.0 1.0 0.01 0.01 1.58
PO4 0.0 0.0 0.0 0.0 0.0
CO3 0.5 0.5 2.85E-05 2.85E-05 1.44
CO2 18.6 18.6 18.6 18.6 18.6

TDS 44788 44788 367 367 70876


pH 7.0 7.0 5.29 5.29 7.18
LSI 0.48 0.48 -5.38 -5.38 1.3
Stiff-Davis -0.49 -0.49 -5.3 -5.3 -0.004
BaSO4 Sat 0.0 0.0 0.0 0.0 0.0
CaSO4 Sat 34.8 34.8 0.0059 0.0059 63.4
CaPO4 Sat 0.0 0.0 0.0 0.0 0.0
CaF2 Sat 0.22 0.22 3.06E-09 3.06E-09 0.99
SrSO4 Sat 0.0 0.0 0.0 0.0 0.0
SiO2 Sat 0.8 0.8 0.0079 0.0079 1.27

Flow 99.2 99.2 36.7 36.7 62.5


Temp, Deg C 25.0 25.0 25.0 25.0 25.0
Pressure 943 943 0.0 0.0 935
Osm Pressure 476 476 4.36 4.36 745

Toray Incorporated 2002 Page 6


TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009
Element Data

Pass 1, Bank 1 Units: Pressure - psi, Flow - Gal/min, TDS - mg/l, Saturation - %, Flux - gal/ft2/day

Bank Permeate Back Pressure: 0.0

Elem 1 Elem 2 Elem 3 Elem 4 Elem 5 Elem 6


Permeate Ions
Ca 1.43 1.82 2.37 3.15 4.23 5.71
Mg 2.02 2.58 3.36 4.46 6.0 8.1
Na 71.8 91.3 119 158 211 285
K 0.0173 0.022 0.0287 0.038 0.051 0.0687
Ba 0.0 0.0 0.0 0.0 0.0 0.0
Sr 0.0 0.0 0.0 0.0 0.0 0.0
NH4 0.0 0.0 0.0 0.0 0.0 0.0
Fe 0.0 0.0 0.0 0.0 0.0 0.0
HCO3 1.29 1.64 2.13 2.82 3.78 5.09
Cl 115 147 191 253 340 458
SO4 3.78 4.81 6.27 8.33 11.2 15.1
NO3 0.0527 0.0669 0.0869 0.11 0.15 0.21
F 0.0009 0.0011 0.0015 0.002 0.0027 0.0036
B 0.19 0.23 0.28 0.34 0.41 0.49
SiO2 0.0057 0.0071 0.009 0.0117 0.0152 0.0199
PO4 0.0 0.0 0.0 0.0 0.0 0.0
CO3 7.66E-06 1.27E-05 2.20E-05 3.99E-05 7.45E-05 0.0001
CO2 18.6 18.6 18.6 18.6 18.6 18.6
TDS 196 249 324 430 577 778
pH 5.03 5.13 5.24 5.36 5.48 5.6
LSI -6.36 -5.94 -5.55 -5.17 -4.8 -4.44
Stiff-Davis -6.1 -5.79 -5.46 -5.1 -4.74 -4.38
Conc Saturation
BaSO4 Sat 0.0 0.0 0.0 0.0 0.0 0.0
CaSO4 Sat 39.3 44.1 49.1 54.2 59.0 63.4
CaF2 Sat 0.3 0.4 0.53 0.67 0.83 0.99
SrSO4 Sat 0.0 0.0 0.0 0.0 0.0 0.0
SiO2 Sat 0.88 0.96 1.04 1.12 1.2 1.27
Flow
Feed 33.1 30.1 27.5 25.3 23.5 22.0
Permeate 2.98 2.59 2.2 1.82 1.47 1.18
Pressure
Feed 943 941 940 938 937 936
Net Driving 394 346 300 256 217 182
Pressure Drop 1.57 1.4 1.25 1.13 1.04 0.96
Feed Osmotic 476 522 569 617 663 706
Other Parameters
% Recovery 9.02 8.62 7.99 7.18 6.26 5.34
B Conc Pol 1.11 1.1 1.09 1.07 1.06 1.05
A Value 2.10E-09 2.09E-09 2.05E-09 1.99E-09 1.91E-09 1.82E-09
B Value 2.24E-08 2.28E-08 2.33E-08 2.39E-08 2.46E-08 2.53E-08
Flux 11.6 10.1 8.56 7.08 5.73 4.58

Toray Incorporated 2002 Page 7


TorayRO v 2.0.28 File: 045000.tro 27 Apr 2009
Errors & Warnings

Warning - High LSI. LSI > zero. Concentrate CaCO3 greater than saturation. Scale inhibitor required.
The feed water analysis was balanced with added Na or Cl.

Database version used for design : 2.028

WARRANTY DISCLAIMER. NO WARRANTIES ARE GIVEN IN CONNECTION WITH THIS SOFTWARE OR ITS USE. THIS SOFTWARE IS NOT WARRANTED
FOR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. This software is provided as an aid for the design of reverse osmosis systems
incorporating membrane elements sold by Toray Industries, Inc., Toray Membrane America, Inc. and ROPUR AG. Such companies do not assume any
responsibilities or liability in connection with this software or any results obtained or damages incurred in connection with its use. The user of the software shall be
solely responsible for any designs created using the software and therefore should have the necessary technical skills and experience to design reverse osmosis
systems. Although it is anticipated that system designs will be reviewed by application engineers of one of the companies mentioned above, such companies do not
assume any responsibility or liability arising out of such review. Any warranty of systems or system designs will be provided only as expressly stated in a written
document signed by an authorized representative of the company issuing the warranty.

Toray Industries, Inc. Membrane Products Dept. TEL: (+81) 47-350-6030


8-1, Mihama 1-chome, Urayasu, Chiba 279-8555, Japan Fax: (+81) 47-350-6066

TORAY Membrane America, Inc. ROPUR AG


USA, South America, Canada Europe, Middle East and Africa Tel: +41 (61) 415 87 10
12520 High Bluff Drive, Suite 120 Tel: +1 (858) 523 0476 Grabenackerstrasse 8
San Diego, CA 92130, USA Fax: +1 (858) 523 0861 CH-4142 Munchenstein 1, Switzerland Fax: +41 (61) 415 87 20

Toray Incorporated 2002 Page 8


MAX OPERATION AND MAINTENANCE MANUAL

APPENDIX II SYSTEM DRAWINGS


B

A
D

8
8

8
1747 "

1055 "
36" D X 72"H 36" D X 72"H
"3

DRAWYAH
30" D X 72"H 30" D X 72"H
EVLAV KCEHC

2" PVC 2" PVC

2" PVC 2" PVC

72"
RO PERMEATE LINE

7
7

RO CONCENTRATE LINE

"3

2" PVC 2" PVC


Van Stone Van Stone

2" PVC 2" PVC


Van Stone Van Stone
2" PVC 2" PVC
2" PVC 2" PVC

DRAWYAH
EVLAV KCEHC
Van Stone Van Stone
2" PVC 2" PVC
2" PVC 2" PVC

Van Stone Van Stone


2" PVC 2" PVC
2" PVC 2" PVC

UNION
UNION
UNION
UNION

2" PVC
2" PVC
2" PVC
2" PVC
UNION
UNION
UNION
UNION

2" PVC
2" PVC
2" PVC
2" PVC

2" PVC 2" PVC

2"
2"
2"
2"

PVC
PVC
PVC
PVC
2" PVC 2" PVC

2" PVC
2" PVC
2"
2"
2"
2"

PVC
PVC
PVC
PVC

2" PVC
2" PVC

MULTI MEDIA FILTERS CARBON FILTERS


FEED WATER PUMP SKID

8
351 "
RO FEED LINE

6
6

5
5

336"
4

4
TOP VIEW

3
3

72"

2
2

PROJECT NAME
200 m3/d SWRO - AWC # 5934 AMERICAN ENGINEERING
SCALE

CLIENT
SERVICES, INC.
CHECKED

APPROVED
DRAWN BY
TES

1
1

Oasis Environmental Products - GUPCO


PROJECT NO.

9203-A KING PALM DRIVE, TAMPA FLORIDA 33619


DRAWING NO.
NTS

TITLE PH: (941) 375-3299 / FAX: (813) 621-4085


OVERALL LAYOUT - TOP VIEW
REV BY DESCRIPTION DATE APPROVED
THIS DRAWING CONTAINS PROPRIETARY INFORMATION AND
STATUS
DESIGNS OWNED BY AMERICAN ENGINEERING SERVICES, INC. ALL ORIGINATOR SUBMISSION NO.
0108002

DESIGNS, MANUFACTURING, REPRODUCTION, USE, PATENT RIGHTS,


DATE
DATE

DATE

AES
0108002MEC002

SIZE DISCIPLINE AND SALES RIGHTS REGARDING THE SAME ARE EXPRESSLY
ORIGINATOR'S DWG. NO. SPEC. REFERENCE NO.
REV

RESERVED BY AMERICAN ENGINEERING SERVICES, INC.


MECHANICAL
8-23-2008

B
B
C

A
D
B

A
C
D

30"

8
8

ALLEN BRADLEY

7
7

SIGNET 3-8900
MULTIPARAMETER

CONCENTRATE FLOW
PREM. pH - PERM. TEMPERATURE
PREM. FLOW - PERM. CONDUCTIVITY

SCREEN
SCREEN
SCREEN

ALARM LIST
24"

RO OPERATION

CIP OPERATION

FRONT ELEVATION

6
6

FEED ORP
SIGNET 3-8900
MULTIPARAMETER

FEED pH - FEED TEMPERATURE


FEED FLOW - FEED CONDUCTIVITY

PanelView C1000

5
5
4

2.5" (W) X 3" (D) WIREWAY

4
AB1VV435U

AB1VV435U

AB1VV435U
4PDT
RELAY

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U
4PDT
RELAY

AB1VV435U
X'FORMER

AB1VV435U

AB1VV435U
220VAC/110VAC

AB1VV435U

AB1VV435U
4PDT
RELAY

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U
4PDT
RELAY

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1 AC24
4PDT
RELAY

AB1VV435U AB1VV435U

AB1VV435U AB1VV435U

AB1VV435U AB1VV435U

AB1VV435U AB1VV435U

AB1VV435U AB1VV435U
4PDT
RELAY

AB1VV435U AB1VV435U

AB1 AC24

AB1VV435U
AB1VV435U

AB1VV435U
AB1VV435U

AB1 AC24

AB1VV435U AB1VV435U

3
AB1VV435U AB1VV435U
4PDT
RELAY

AB1VV435U AB1VV435U

AB1VV435U AB1VV435U

AB1 AC24

AB1VV435U
PLC

AB1VV435U
3

AB1VV435U
4PDT
RELAY

AB1VV435U

AB1VV435U

AB1VV435U
LAYOUT

AB1VV435U

AB1VV435U
4PDT
RELAY

AB1VV435U

AB1 AC24

AB1VV435U

AB1VV435U
SUPPLY

AB1VV435U

AB1VV435U
4PDT
RELAY

2" (W) X 3" (D) WIREWAY


2" (W) X 3" (D) WIREWAY
2" (W) X 3" (D) WIREWAY

AB1VV435U
24 VDC POWER

AB1VV435U

AB1VV435U

AB1VV435U
C60N

480 Vac
MG24501
multi 9

4PDT

AB1VV435U
RELAY
2A-type D

O-OFF

AB1VV435U
INTERNAL COMPONENT

AB1VV435U
C60N

480 Vac
MG24501
multi 9

AB1VV435U
2A-type D

O-OFF

AB1VV435U
4PDT

AB1VV435U
RELAY
C60N

480 Vac
MG24501
multi 9

AB1VV435U
2A-type D

O-OFF

AB1VV435U

AB1VV435U
C60N

480 Vac
MG24501
multi 9

AB1VV435U
2A-type D

O-OFF

4PDT

AB1VV435U
RELAY

AB1VV435U
C60N

480 Vac
MG24501
multi 9

AB1VV435U
2A-type D

O-OFF

AB1VV435U

AB1VV435U
C60N

2
2

480 Vac
MG24501
multi 9

4PDT

AB1VV435U
2A-type D

RELAY
O-OFF
MERLIN GERIN MERLIN GERIN MERLIN GERIN MERLIN GERIN MERLIN GERIN MERLIN GERIN

AB1VV435U

2.5" (W) X 3" (D) WIREWAY

PROJECT NAME
200 m3/d SWRO - AWC #5934 AMERICAN ENGINEERING
SCALE

CLIENT
SERVICES, INC.
CHECKED

APPROVED
DRAWN BY

1
1

OASSIS ENVIRONMENTAL PRODUCTS - GUPCO


PROJECT NO.

9203 KING PALM DRIVE, SUITE A, TAMPA FLORIDA 33619


DRAWING NO.
NTS

TITLE PH: (941) 375-3299 / FAX: (813) 621-4085


PLC PANEL LAYOUT
REV BY DESCRIPTION DATE APPROVED
THIS DRAWING CONTAINS PROPRIETARY INFORMATION AND
STATUS
DESIGNS OWNED BY AMERICAN ENGINEERING SERVICES, INC. ALL ORIGINATOR SUBMISSION NO.
0108002

DESIGNS, MANUFACTURING, REPRODUCTION, USE, PATENT RIGHTS,


DATE
DATE

AS BUILT
DATE

0108002ELE004

AES
SIZE DISCIPLINE AND SALES RIGHTS REGARDING THE SAME ARE EXPRESSLY
ORIGINATOR'S DWG. NO. SPEC. REFERENCE NO.
REV

RESERVED BY AMERICAN ENGINEERING SERVICES, INC.


20090206

B ELECTRICAL
B

A
C
D
8 7 6 5 4 3 2 1

APPROVED
INPUT WIRING DIAGRAM 1762 - IA8
1762 - L40AWAR INPUT WIRING
1/0 TB
24 RO TANK LOW LEVEL

DATE
COM 0 24
110 VOLTS CB5

SPEC. REFERENCE NO.


N 1/1
H 25 MBV-2 OPEN SIGNAL
0/0 TB

SUBMISSION NO.
25
0 HP PUMP IN AUTO
0
1/2
26
D 0/1 26
MBV-3 OPEN SIGNAL D
1 CIP MIXED
1

DESCRIPTION
1/3
27 MBV-4 OPEN SIGNAL
0/2 27
2 CIP FLUSH
2 1/4
28 MBV-5 OPEN SIGNAL
0/3 28
COM 1
3 PRETREATMENT LOCKOUT 1/5
3 29

AES
29 MBV-6 OPEN SIGNAL

ORIGINATOR'S DWG. NO.


0/4
4 1 FEED PUMP 1 AND 2 IN AUTO 1/6
4 30 HIGH ORP
30
2
1/7

ORIGINATOR
BY
31 HIGH PERM
0/5 31
5 RO TANK HIGH LEVEL
5

REV
AC COMMON
0/6

THIS DRAWING CONTAINS PROPRIETARY INFORMATION AND


DESIGNS OWNED BY AMERICAN ENGINEERING SERVICES, INC. ALL
DESIGNS, MANUFACTURING, REPRODUCTION, USE, PATENT RIGHTS,
AND SALES RIGHTS REGARDING THE SAME ARE EXPRESSLY
RESERVED BY AMERICAN ENGINEERING SERVICES, INC.
AMERICAN ENGINEERING
6 MBV-1 IN AUTO

9203 KING PALM DRIVE, SUITE A, TAMPA FLORIDA 33619


6 AC COMMON
C 0/7

PH: (941) 375-3299 / FAX: (813) 621-4085


COM 2 N C

SERVICES, INC.
7 HP PUMP OVERLOAD
7

0/8 R 15
8 PRE-CHLORINATION IN WATER
8

0/9 R 16
9 DE-CHLORINATION IN AUTO
9

0/10 R 17
10 BIOFOULANT IN AUTO
10
H
0/11 R 18
11 ANTISCALANT IN AUTO CB5
11

0/12 R 19
12 CAUSTIC PUMP IN AUTO
12

0/13 R 20
13 POST CHLORINATION IN AUTO
13
B B

OASSIS ENVIRONMENTAL PRODUCTS - GUPCO


0/14
14 RESET ALARM

200 m3/d SWRO - AWC #5934

DIGITAL INPUT WIRING DIAGRAM


14

0/15
15 EMERGENCY STOP
15

ELECTRICAL
0/16

AS BUILT
16 CLEANING SELECTED
16

0/17
17 MBV-1 OPEN SIGNAL
17

0/18
18 HP-1 RUNNING FEED BACK
18

DISCIPLINE
PROJECT NAME
0/19
19 LPS
19
A

STATUS
CLIENT

SIZE
TITLE

B
0/20
A 20
20 HPS
PROJECT NO.
0108002
0/21
21 CLEANING TANK LOW LEVEL DRAWN BY DATE
21 20090206
CHECKED DATE
0/22
22 CLEANING TANK HIGH LEVEL APPROVED DATE
22

0/23 SCALE REV


23 CLEANING TANK HPS
23 NTS
DRAWING NO.
0108002ELE005

8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

APPROVED
1762 - L40AWAR
OUTPUT WIRING DIAGRAM 1762 - OW16
110V AC
2A
OUPUT RELAY
H 110V SLOT 2

DATE
L1
CB5
DIGITAL OUTPUT

SPEC. REFERENCE NO.


N
N N
CB5 110 VOLTS

SUBMISSION NO.
G
2/0 TB
D LPS INDICATOR D
VAC 0 34 R

DESCRIPTION
0/0
N 2/1
HPS INDICATOR
35 R
VAC 1 0/1
MBV-1 OPEN RELAY 2/2
R2

0/2

AES
MBV-5 OPEN RELAY 2/3

ORIGINATOR'S DWG. NO.


R3 PRE-TREATMENT LOCKOUT
37 R
0/3
VAC 2 2/4
ANTISCALANT "ON" RELAY
R4 HIGH FEED ORP
38 R

ORIGINATOR
BY
0/4
DECLORINATION "ON" RELAY 2/5
R5 HIGH PERM CONDUCTIVITY
39 R

REV
0/5
VAC 3 BIOFOULANT "ON" RELAY 2/6

THIS DRAWING CONTAINS PROPRIETARY INFORMATION AND


DESIGNS OWNED BY AMERICAN ENGINEERING SERVICES, INC. ALL
DESIGNS, MANUFACTURING, REPRODUCTION, USE, PATENT RIGHTS,
AND SALES RIGHTS REGARDING THE SAME ARE EXPRESSLY
RESERVED BY AMERICAN ENGINEERING SERVICES, INC.
AMERICAN ENGINEERING
R6 HP PUMP OVERLOAD
R

9203 KING PALM DRIVE, SUITE A, TAMPA FLORIDA 33619


40
C 0/6

PH: (941) 375-3299 / FAX: (813) 621-4085


2/7
MBV-4 OPEN RELAY C

SERVICES, INC.
R7 HP PUMP START
R1
0/7
CAUSTIC "ON" RELAY 2/8
R8 FLUSH INDICATOR
41 G
0/8
MBV-2 OPEN RELAY 2/9
R9

0/9
VAC 4 2/10
CLEANING PUMP START
R10

0/10
PRE-CHLORINATION "ON" RELAY 2/11
R11

0/11
POST CHLORINATION "ON" RELAY 2/12
R12

0/12
MBV-3 OPEN RELAY 2/13
R13
B B

OASSIS ENVIRONMENTAL PRODUCTS - GUPCO


VAC 5 2/14

200 m3/d SWRO - AWC # 5934

WIRING DIAGRAM
0/13
MBV-6 OPEN RELAY 2/15
R14

ELECTRICAL
0/14
FEED FEED PUMP START

AS BUILT
PUMP
CP

DIGITAL OUTPUT

DISCIPLINE
PROJECT NAME
A

STATUS
CLIENT

SIZE
TITLE

B
A
PROJECT NO.
0108002
DRAWN BY DATE
20090206
CHECKED DATE

APPROVED DATE

SCALE REV

NTS
DRAWING NO.
0108002ELE006

8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

APPROVED
1762 - IF4 1762 - IF4
ANALOG 4 CHANNEL INPUT ANALOG 4 CHANNEL INPUT
SLOT 3 SLOT 4

DATE

SPEC. REFERENCE NO.


3/0+ 4/0+ TB
A01 A03

SUBMISSION NO.
52 11 + FEED ORP 60 + PERM CONDUCTIVITY

3/0- 3-8900 MULTI-PARAMETER B 4/0- 3-8900 MULTI-PARAMETER A


D A01
12 - 59
A03
-
D

DESCRIPTION
3/1+ 4/1+
A02 A04
50 13 + FEED PH 58 + PERM PH

3/1- 3-8900 MULTI-PARAMETER B 4/1- 3-8900 MULTI-PARAMETER A


A02 A04
49 14 - 57 -

AES
3/2+ 4/2+
A01 A01

ORIGINATOR'S DWG. NO.


48 11 + PERM FLOW 56 + FEED FLOW

3/2- 4/2-
3-8900 MULTI-PARAMETER A 3-8900 MULTI-PARAMETER B
A01 A01
47 12 - 55 -

ORIGINATOR
BY
3/3+ 4/3+
A02 A02
46 13 + REJECT FLOW 54 13 + FEED CONDUCTIVITY

REV
3/3- 3-8900 MULTI-PARAMETER A 4/3- 3-8900 MULTI-PARAMETER B

THIS DRAWING CONTAINS PROPRIETARY INFORMATION AND


DESIGNS OWNED BY AMERICAN ENGINEERING SERVICES, INC. ALL
DESIGNS, MANUFACTURING, REPRODUCTION, USE, PATENT RIGHTS,
AND SALES RIGHTS REGARDING THE SAME ARE EXPRESSLY
RESERVED BY AMERICAN ENGINEERING SERVICES, INC.
A02 A02

AMERICAN ENGINEERING
45 14 - 53 14 -

9203 KING PALM DRIVE, SUITE A, TAMPA FLORIDA 33619


C

PH: (941) 375-3299 / FAX: (813) 621-4085


C

SERVICES, INC.
COMMON COMMON

COMMON COMMON

1762 - IF4
ANALOG 4 CHANNEL INPUT
SLOT 5
HP PUMP DISCHARGE PRESSURE
TRANSDUCER
5/0+
B B

OASIS ENVIRONMENTAL PRODUCTS - GUPCO


67 2 + 24V DC

5/0-

200 m3/d SWRO - AWC #5934


POWER SUPPLY

ANALOG INPUT WIRING DIAGRAM


68 -

HP INLET PRESSURE
TRANSDUCER

ELECTRICAL
5/1+

AS BUILT
65 2 1 + 24V DC

5/1- POWER SUPPLY


66 -

MEMBRANDE FEED PRESSURE


TRANSDUCER
5/2+

DISCIPLINE
PROJECT NAME
63 2 1 + 24V DC

5/2-
POWER SUPPLY
A

STATUS
CLIENT
-

SIZE
TITLE
64

B
A TURBINE INLET PRESSURE
PROJECT NO.
TRANSDUCER
0108002
5/3+
DRAWN BY DATE
61 2 1 + 24V DC 20090206
CHECKED DATE
5/3- POWER SUPPLY
- APPROVED DATE
62
SCALE REV

NTS
DRAWING NO.
0108002ELE007

8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

APPROVED
3-8900.621C
I/0 MODULE 3-8900.401-7
+5VDC (BLACK) 1
FREQUENCY

DATE
FREQ. INPUT (RED) 2
INPUT 1

SPEC. REFERENCE NO.


FEED FLOW SENSOR
GND (SHIELD) 3

SUBMISSION NO.
FREQUENCY +5VDC (BLACK) 4
D INPUT 2
D
FREQ. INPUT 2 (RED) 5
OR

DESCRIPTION
S3 L S3 L (RED) 6 FEED CONDUCTIVITY

INPUT 2 GND (WHITE/SHIELD) 7


+5VDC (BLACK) 8 PERMEATE CONDUCTIVITY SENSOR

AES
S3 L
S3 L (RED)
3 GND

ORIGINATOR'S DWG. NO.


9 2 DATA

INPUT 1 1 V+

GND (WHITE/SHIELD) 10
SW1

ORIGINATOR
11

BY
D3

ANALOG OUTPUT 1 +
(IF APPLICABLE) - 12

REV
+SVDC PERMEATE PH SENSOR
ANALOG OUTPUT 2 + 13

THIS DRAWING CONTAINS PROPRIETARY INFORMATION AND


DESIGNS OWNED BY AMERICAN ENGINEERING SERVICES, INC. ALL
DESIGNS, MANUFACTURING, REPRODUCTION, USE, PATENT RIGHTS,
AND SALES RIGHTS REGARDING THE SAME ARE EXPRESSLY
RESERVED BY AMERICAN ENGINEERING SERVICES, INC.
AMERICAN ENGINEERING
S3L DATA
4

9203 KING PALM DRIVE, SUITE A, TAMPA FLORIDA 33619


(IF APPLICABLE) -
3

C 14 SIGNAL

PH: (941) 375-3299 / FAX: (813) 621-4085


2

SERVICES, INC.
1
GROUND

3-8900 MULTI-PARAMETER A

3-8900.621C
I/0 MODULE 3-8900.401-7
+5VDC (BLACK) 1
FREQUENCY FREQ. INPUT (RED) 2
INPUT 1 PERMEATE FLOW SENSOR
B B

OASSIS ENVIRONMENTAL PRODUCTS - GUPCO


GND (SHIELD) 3

200 m3/d SWRO - AWC #5934


FREQUENCY +5VDC (BLACK) 4
INPUT 2

SENSOR WIRING DIAGRAM


FREQ. INPUT 2 (RED) 5
OR
S3 L (RED)

ELECTRICAL
S3 L 6 CONCENTRATE FLOW SENSOR

AS BUILT
INPUT 2 GND (WHITE/SHIELD) 7
+5VDC (BLACK) 8 +5VDC FEED PH
S3 L S3L DATA
S3 L (RED)
4

9 3

INPUT 1 2 SIGNAL

DISCIPLINE
1

GND (WHITE/SHIELD) 10 GROUND

PROJECT NAME
ANALOG OUTPUT 1 + 11 A

STATUS
CLIENT

SIZE
TITLE

B
A (IF APPLICABLE) - 12
PROJECT NO.
+5VDC FEED ORP
ANALOG OUTPUT 2 + 13 0108002
S3L DATA
4

(IF APPLICABLE)
DRAWN BY DATE
-
3

14 2

1
SIGNAL
CHECKED
20090206
DATE
GROUND
APPROVED DATE

3-8900 MULTI-PARAMETER B SCALE REV

NTS
DRAWING NO.
0108002ELE008

8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

APPROVED
36"

DATE

SPEC. REFERENCE NO.


SUBMISSION NO.
D D

DESCRIPTION
CIRCUIT BREAKER
MERLIN GERIN MERLIN GERIN MERLIN GERIN MERLIN GERIN
multi 9 multi 9 multi 9 multi 9 30 A
C60N C60N C60N C60N SQUARE D
FAL 34030
2A-type D
480 Vac
2A-type D
480 Vac
2A-type D
480 Vac
2A-type D
480 Vac
GV3M63
RELAY RELAY RELAY RELAY RELAY MG24501 MG24501 MG24501 MG24501
SQUARE D SQUARE D 480V~ 250V
ON

AES
4PDT 4PDT 4PDT 4PDT 4PDT O-OFF O-OFF O-OFF O-OFF
LC1D4011 LC1D4011

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U
AB1 AC24

AB1 AC24

AB1 AC24

AB1 AC24
I

ORIGINATOR'S DWG. NO.


30
O

OFF

RED GREEN RED GREEN

ORIGINATOR
BY
ON - OFF - AUTO ON - OFF - AUTO
GEN
ER

EM

REV
Y
GREEN AMBER
2.5" (W) X 3" (D) WIREWAY

THIS DRAWING CONTAINS PROPRIETARY INFORMATION AND


DESIGNS OWNED BY AMERICAN ENGINEERING SERVICES, INC. ALL
DESIGNS, MANUFACTURING, REPRODUCTION, USE, PATENT RIGHTS,
AND SALES RIGHTS REGARDING THE SAME ARE EXPRESSLY
RESERVED BY AMERICAN ENGINEERING SERVICES, INC.
PO T S

AMERICAN ENGINEERING
FEED INLET MBV-1 HIGH PRESSURE PUMP RESET POWER ON

9203 KING PALM DRIVE, SUITE A, TAMPA FLORIDA 33619


RELAY
4PDT
C

PH: (941) 375-3299 / FAX: (813) 621-4085


C

RELAY
4PDT

SERVICES, INC.
RELAY
4PDT
RED GREEN RED GREEN RED GREEN RED GREEN RED GREEN RED GREEN

RELAY
VFD

4PDT
RELAY
4PDT
ON - OFF - AUTO ON - OFF - AUTO ON - OFF - AUTO ON - OFF - AUTO ON - OFF - AUTO ON - OFF - AUTO

RELAY
4PDT
AB1VV435U

48"
AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

PRECHLORINATION DECHLORINATION ANTISCALANT BIO-ANTIFOULANT POST CHLORINATION


CAUSTIC DOSING
AB1VV435U

DOSING DOSING DOSING DOSING DOSING AB1VV435U

MITSUBISHI
AB1VV435U

AB1VV435U

AB1VV435U

2.5" (W) X 3" (D) WIREWAY

3.5" (W) X 3" (D) WIREWAY


AB1VV435U

2" (W) X 3" (D) WIREWAY


AB1VV435U

AB1VV435U

AB1VV435U

ELECTRIC
AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

F700 VFD
GREEN GREEN
AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

OFF - ON ON - OFF - AUTO


AB1VV435U

AB1VV435U

AB1VV435U

B B
AB1VV435U

OASSIS ENVIRONMENTAL PRODUCTS - GUPCO


AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

200 m3/d SWRO - AWC #5934


AB1VV435U

CIP FLUSH CIP OPERATION


AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

VFD PANEL LAYOUT


AB1VV435U

AB1VV435U

ELECTRICAL
AB1VV435U

AB1VV435U

AB1VV435U

RED RED RED RED RED RED


AB1VV435U

AS BUILT
AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

PRETREATMENT LOW PRESSURE HIGH PRESSURE HP PUMP HIGH FEED ORP HIGH PERMEATE AB1VV435U

LOCKOUT ALARM ALARM OVERLOAD ALARM ALARM CONDUCTIVITY ALARM AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

AB1VV435U

DISCIPLINE
PROJECT NAME
A

STATUS
CLIENT

SIZE
TITLE

B
A
PROJECT NO.
0108002
DRAWN BY DATE

INTERNAL COMPONENT LAYOUT


20090206

FRONT ELEVATION
CHECKED DATE

APPROVED DATE

SCALE REV

NTS
DRAWING NO.
0108002ELE009

8 7 6 5 4 3 2 1
B

A
D

8
8

7
7

6
6

336"
336"

TOP VIEW
FRONT VIEW

5
5

72"
4

72"

4
34"

3
3

72"
8
583 "
RIGHT SIDE VIEW

2
2

72"

PROJECT NAME
200 m3/d SWRO - AWC # 5934 AMERICAN ENGINEERING
SCALE

CLIENT
SERVICES, INC.
CHECKED

APPROVED
DRAWN BY
TES

1
1

Oasis Environmental Products - GUPCO


PROJECT NO.

9203-A KING PALM DRIVE, TAMPA FLORIDA 33619


DRAWING NO.
NTS

TITLE PH: (941) 375-3299 / FAX: (813) 621-4085


FRAME
REV BY DESCRIPTION DATE APPROVED
THIS DRAWING CONTAINS PROPRIETARY INFORMATION AND
STATUS
DESIGNS OWNED BY AMERICAN ENGINEERING SERVICES, INC. ALL ORIGINATOR SUBMISSION NO.
0108002

DESIGNS, MANUFACTURING, REPRODUCTION, USE, PATENT RIGHTS,


DATE
DATE

DATE

AES
0108002MEC003

SIZE DISCIPLINE AND SALES RIGHTS REGARDING THE SAME ARE EXPRESSLY
ORIGINATOR'S DWG. NO. SPEC. REFERENCE NO.
REV

RESERVED BY AMERICAN ENGINEERING SERVICES, INC.


MECHANICAL
8-23-2008

B
B
C

A
D
8 7 6 5 4 3 2 1

APPROVED
220V AC
H BLUE R6
001 112
GRAY ~ BIOFOULANT PUMP ON

DATE
MI
001

SPEC. REFERENCE NO.


120 R HP PUMP STOP 112
INDICATION 112 G BIOFOULANT PUMP

SUBMISSION NO.
ON INDICATION

R1 R21
D 001 121 R17 D
M HP PUMP START 001 113

DESCRIPTION
113 R BIOFOULANT TANK
A1 A2 LOW LEVEL

121
121 G HP PUMP RUNNING R8
001 108
~
INDICATION
CAUSTIC PUMP ON

AES
ORIGINATOR'S DWG. NO.
R2
001 119
~ MBV-1 OPEN
108
108
G CAUSTIC PUMP
MBV-1 ON INDICATION

ORIGINATOR
BY
119
119 G MBV-1 OPEN R19

REV
INDICATION 001 109
109 R CAUSTIC TANK

THIS DRAWING CONTAINS PROPRIETARY INFORMATION AND


DESIGNS OWNED BY AMERICAN ENGINEERING SERVICES, INC. ALL
DESIGNS, MANUFACTURING, REPRODUCTION, USE, PATENT RIGHTS,
AND SALES RIGHTS REGARDING THE SAME ARE EXPRESSLY
RESERVED BY AMERICAN ENGINEERING SERVICES, INC.
AMERICAN ENGINEERING
LOW LEVEL INDICATION

9203 KING PALM DRIVE, SUITE A, TAMPA FLORIDA 33619


R2
C 001

PH: (941) 375-3299 / FAX: (813) 621-4085


118
~ MBV-1 CLOSE R11 C

SERVICES, INC.
001 110
MBV-1 CLOSED ~ PRE-CHLORINATION
PUMP ON
118
118 R MBV-1 CLOSE
INDICATION 110
110 G PRE-CHLORINATION
PUMP ON INDICATION
R3
001
~ MBV-5 OPEN
001
R14
111
MBV-5 111 R PRE-CHLORINATION
LOW LEVEL INDICATION
R4
001 110
~ ANTI-SCALANT PUMP
001
R12
106
~
POWER ON
POST CHLORINATION
ON RELAY
B B

OASSIS ENVIRONMENTAL PRODUCTS - GUPCO


110
110 G ANTI-SCALANT
POWER ON INDICATION 106

200 m3/d SWRO - AWC #5934


106 G POST CHLORINATION

VFD PANEL SCHEMATIC DIAGRAM


PUMP ON INDICATION
R17
001 111
111 R ANTISCALANT TANK R20

ELECTRICAL
LOW LEVEL INDICATION 001 107
107 R POST CHLORINATION

AS BUILT
TANK LOW INDICATION
R5
001 114
~ DECHLORINATION R9

~
POWER ON
MBV-2 OPEN

MBV-2

DISCIPLINE
114

PROJECT NAME
114 G DECHLORINATION POWER
ON INDICATION R13

~ A

STATUS
CLIENT
MBV-3 OPEN

SIZE
TITLE

B
A 001
R16
115
MBV-5
PROJECT NO.
115 R DECHLORINATION
R14 0108002
TANK LOW INDICATION

~
DRAWN BY DATE
MBV-6 OPEN 20090206
CHECKED DATE
MBV-6
APPROVED DATE

SCALE REV

NTS
DRAWING NO.
0108002ELE010

8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

APPROVED
RED 110V AC WHITE

H-O-A

DATE
H N 01 96 96

SPEC. REFERENCE NO.


A 96 R11 PRE-CHLORINATION
RELAY

SUBMISSION NO.
PLC R15
H-O-A
01 124 124
D 124 R1 HP PUMP START D
0:0/10

DESCRIPTION
H-O-A
PLC
01 91 91
91 R12 POST-CHLORINATION
0:2/7 RELAY
PLC R20
H-O-A
01 122 122

AES
122 R2 MBV-1 OPEN
0:0/11

ORIGINATOR'S DWG. NO.


RELAY
PLC PLC
01
R13 MBV-3 OPEN
RELAY

ORIGINATOR
BY
0:0/1 0:0/12

PLC PLC

REV
01 01
R3 MBV-5 OPEN R14 MBV-6 OPEN
RELAY RELAY

THIS DRAWING CONTAINS PROPRIETARY INFORMATION AND


DESIGNS OWNED BY AMERICAN ENGINEERING SERVICES, INC. ALL
DESIGNS, MANUFACTURING, REPRODUCTION, USE, PATENT RIGHTS,
AND SALES RIGHTS REGARDING THE SAME ARE EXPRESSLY
RESERVED BY AMERICAN ENGINEERING SERVICES, INC.
AMERICAN ENGINEERING
0:0/2 0:0/13

9203 KING PALM DRIVE, SUITE A, TAMPA FLORIDA 33619


H-O-A
C

PH: (941) 375-3299 / FAX: (813) 621-4085


01 93 93 C

SERVICES, INC.
93 R4 ANTI-SCALANT
RELAY
PLC R18

0:0/3
H-O-A
01 95 95
95 R5 DECHLORINATION
RELAY
PLC R16

0:0/4
H-O-A
01 94 94
94 R6 BIOFOULANT
RELAY
B R17 B

OASSIS ENVIRONMENTAL PRODUCTS - GUPCO


PLC

200 m3/d SWRO - AWC #5934

VFD PANEL SCHEMATIC DIAGRAM


0:0/5

PLC
01
R7 MBV-4 OPEN

ELECTRICAL
0:0/6 RELAY

AS BUILT
H-O-A
01 92 92
92 R8 CAUSTIC RELAY

PLC R19

DISCIPLINE
PROJECT NAME
0:0/7

PLC
A

STATUS
01

CLIENT

SIZE
TITLE
R9 MBV-2 OPEN

B
A 0:0/8 RELAY
PROJECT NO.

PLC 0108002
01 DRAWN BY DATE
R10 CLEANING PUMP 20090206
0:0/9 START RELAY CHECKED DATE

APPROVED DATE

SCALE REV

NTS
DRAWING NO.
0108002ELE011

8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

APPROVED
INCOMING POWER SUPPLY
380VAC, 3 PHASE, 50 HZ
(BY OTHERS)

DATE
{

SPEC. REFERENCE NO.


SUBMISSION NO.
D L3 L2 L1 D
MCCB

DESCRIPTION
GND 125A, 125AF
3P, 50HZ

AES
L3 L2 L1

ORIGINATOR'S DWG. NO.


L1 L1
L1
L2 L2
L2

ORIGINATOR
L3 L3

BY
L3

REV
N
GND GND

THIS DRAWING CONTAINS PROPRIETARY INFORMATION AND


DESIGNS OWNED BY AMERICAN ENGINEERING SERVICES, INC. ALL
DESIGNS, MANUFACTURING, REPRODUCTION, USE, PATENT RIGHTS,
AND SALES RIGHTS REGARDING THE SAME ARE EXPRESSLY
RESERVED BY AMERICAN ENGINEERING SERVICES, INC.
AMERICAN ENGINEERING

9203 KING PALM DRIVE, SUITE A, TAMPA FLORIDA 33619


G
C

PH: (941) 375-3299 / FAX: (813) 621-4085


#12 AWG #2 AWG #12 AWG C

SERVICES, INC.
THHN WIRE THHN WIRE THHN WIRE
CB1

220 VAC

L1 L2 L3
MSP
3P, 50HZ L1 L2 L3 CONTROL
14-20A TRANSFORMER
95A
110 VAC
F-700
VARIABLE L1
FREQUENCY DRIVE

B B

OASSIS ENVIRONMENTAL PRODUCTS - GUPCO


25A
H N G

200 m3/d SWRO - AWC # 5934


CB2 2A CB3 2A CB4 CB5
T1 T2 T3 GND T1 T2 T3 GND

ELECTRICAL
POWER DIAGRAM

AS BUILT
CP-1 HP-1

RELAYS 24 VDC MULTIPARAMETER MICROLOGIX1200


CLEANING/FLUSHING PUMP HIGH PRESSURE PUMP VALVES & PUMPS 3-8900 PLC
5.5 KW, 380 VAC, 3 PHASE, 50 HZ + -
60 HP, 380 VAC, 3 PHASE, 50 HZ

DISCIPLINE
FLA = 81A

PROJECT NAME
A

STATUS
CLIENT
PANEL VIEW

SIZE
TITLE

B
COMPONENT
A
PROJECT NO.
0108002
DRAWN BY DATE
20090206
CHECKED DATE

APPROVED DATE

SCALE REV

NTS
DRAWING NO.
0108002ELE012

8 7 6 5 4 3 2 1
MAX OPERATION AND MAINTENANCE MANUAL

APPENDIX III COMPONENT DATA AND MANUALS


AMERICAN ENGINEERING SERVICES
CUSTOMER: GUPCO / GAS PLANT
PROJECT: 0108002

RECOMMENDED SPARE PARTS LIST

PART NUMBER DESCRIPTION


CIP PUMP - GRUNDFOS PUMP - SERVICE KIT
PSGP96494662 Shaft Seal Cartridge, KUHE D22
PSGP96416597 Gasket, EPDM
PSGP96416729 Wear Parts, 3-7 Stages
PSGP96416580 Bottom Bearing, 1-14 Stages
PSGP96416574 Bearing, 3-7 Stages
INSTRUMENTS
INSGF328505141 Conductivity Sensor 5-5000 Ppm
INSGF328505142 Conductivity Sensor 50-100,000 Ppm
INSGF32754 pH Electrode Flat 0-147 CPVC
INSGF32775 ORP Electrode Flat 10k-Id Resistor
INSES301LFW254N Pressure Gauges SS, Lower Mount Connection, 2-1/2 Dial, 0/1500 Psi, Liquid Filled
INSES301LFW254E Pressure Gauge SS, Lower Mount Connection, 2-1/2 Dial, 0/100 Psi, Liquid Filled
FEED PUMP - AMPCO
PSA5098405 Seal kit
PSA8100117 Wear ring
PSA8107647 Shaft sleeve
PSA8102727 Impeller screw
TURBINE - FEDCO
TSF8H0030TBE Thrust bearing kit: E-thrust bearing and O-ring
Complete Overhaul Kit: E-Rotor, Diffuser, Bearings and O-Rings *
HIGH PRESSURE PUMP - FEDCO
PSF8M0020MTK Maintenance Kit: Balance Disc And Mechanical Seal Kits
Complete Overhaul Kit: Maintenance kit, O-Ring, Threaded Nipple, Retaining Ring Kits, Stage Assembly
MEMBRANE SPARE PARTS
MST6020 Interconnector for Toray Membranes
MST6010 O-rings for Toray Membranes
PRESSURE VESSEL SPARE PARTS
VSP6100442MK Head Seal
VSP6110229N Perm Port Seal
VSP6110221N Adapter Seal
VSP6110119N PWT Seal
VSP4080034 Bearing Plate *
VSP4080177-2 Sealing plate *
FITTINGS AND VALVES
FSP4MCS4-316 Straight Connector for H.P. switch 1/4" OD Tube x OD Tube, 316SS
EL150BW-2205 Elbow 1-1/2" BW, Duplex SS
INSGFPV8S030 Instrument insert fittings 3" pipe *
INSGFPV8T015F Instrument insert fittings 1-1/2" pipe *
ELECTRIC SPARE PARTS
EASVB1C10 Electric Actuator Valves 3"
EASVB1C07 Electric Actuator Valves 1/2" to 2"
ELESM3TX7144-1E5 Socket for miniature relay single module 4 PL, panel / Din Rail, screw term
ELESM3RT1026-1AP60Contactor, S0, 25A, 240VAC ,3P, Screw
ELESM5SY4103-7 Supplementary Protector,1P ,3A , Curve C
ELESM5SY4102-7 Supplementary Protector,1P ,2A , Curve C

Page 1 of 2
AMERICAN ENGINEERING SERVICES
CUSTOMER: GUPCO / GAS PLANT
PROJECT: 0108002

RECOMMENDED SPARE PARTS LIST

PART NUMBER DESCRIPTION


ELESM3RV1921-1M MSP Short Circuit, 1 NO & 1 NC
ELESM52SX2CAB Selector Switch, 3 Pos, white insert, short lever
ELESM52BAK Contact block, 1 NO
ELESM52BAJ Contact block, 1 NC
ELESM52PY4NN Pilot light, no lens, 240V
ELESM52RA4P2 Plastic lens kit, Red
ELESM52RA4P3 Plastic lens kit, Green
ELESM52RA4P9 Plastic lens kit, Amber
ELESM52AENC Inc. Lamp, 120V, 2.5W Type #120 MB
OTHER RECOMMENDED PARTS
I050P300S1SD Cartridge Filter 30" Long, 5 micron (20 ea per Box)
* Ensurance Parts

Page 2 of 2
MAX OPERATION AND MAINTENANCE MANUAL

COMPONENT MANUALS

TABLE OF CONTENTS

1. Cartridge Filter Housing


2. MM Filter controller
3. Feed Pump
4. RO Controller
5. High Pressure Pump
6. Turbine
7. Pressure Vessels
8. Membrane elements
9. Chemical Dosing Pumps
10. Pressure gauges
11. Pressure transmitter
12. Multiparameter analyzer
12.1. pH ORP Sensor
12.2. Flow Sensor
12.3. Conductivity Sensor
13. PVC Motorized Ball Valves
14. SS Motorized Ball Valves
15. Ball valve/check valve & diaphragm valves
16. CIP Pump
17. Vortec
FILTER CARTRIDGE VESSEL (EFC, EFCS, and EFCT Series)
INSTALLATION AND OPERATING
INSTRUCTIONS

Vessel Installation DOE Filter Cartridge Installation

1. Filter housing can be floor or skid mounted by 1. Place an Excel filter cartridge of correct length,
use of bolts into bottom of legs. end cap, and preferred micron rating over each
tube guide.
2. Carefully note the INLET and OUTLET
connections as marked on the end plate lower 2. Replace upper seal nuts (Fig 1, #3), and hand
(lower end plate Figure 1, #13). tighten until snug against top of cartridge.

3. Please note that the inlet and out let connections 3. Replace the upper end plate (Fig 1, #5) and hand
can be configured as follows: tighten cover bolts (Fig 1, #10).

Standard Slip Fit connection. 4. The housings designed sealing mechanism is a


Pipe Stub Connection side piston seal that actually increases the seal
Flanged connection. compression of the O-Ring as the pressure
increases. It is not necessary to tighten cover bolts
4. Connect the housing(s) into your filtration system more than hand tight. Excessive tightening may
in the proper direction of flow. damage tie rods and render vessel inoperative.

Note: All necessary parts are supplied with the


housings except the vent plug and filter cartridges.
Install the proper Excel cartridge best suited for
your application and a proper vent plug. We
recommend a large drain valve downstream of the
housing to remove debris accumulated during
filter change-out.

Tube Guide Installation

1. Remove the upper end plate (Fig 1, #5) by


loosening the cover bolts (Fig 1, #10).

2. Attach lower seal nut (Fig 1, #4) to tube guide


(Fig 1, #1). Tighten lower seal nut to the top of
the threading at the bottom end of the tube
guide. (tighten until resistance is felt, followed
by one more turn).

3. With the lower seal nut fully secured carefully


screw in bottom end of tube guide into the flow
block (without over-tightening). (Figure 1)
222 O-RING SEAL Filter Installation Maintenance (Cont)

This type of housing is designed to accept SOE 1. Open the drain valve on the flange (or
flat end type cartridges (Excel code 3). downstream, if applicable) and loosen vent
plug on top to drain solution from the
1. Remove the cartridge retaining plate. housing.

2. Moisten cartridge O-rings with water, silicone 2. When the vessel is drained, unbolt (Fig 1,
grease, or other compatible fluid. Insert #10) and remove upper end plate (Fig 1, #5).
cartridges into seat cups (Fig 1, #2) with a
twisting motion. 3. Removed used filter cartridges.

3. Place the cartridge retaining plate on top of the 4. Place an Excel filter cartridge over each
cartridges so that the legs of the plate point guide.
away from the filter elements.
5. Replace upper seal nuts (Fig 1, #3) until
4. Legs of cartridge retaining plate may need to be snug against top of cartridge.
trimmed, depending on type of cartridge used.
6. Replace the upper end plate and hand
Operation tighten cover bolts. The housings designed
sealing mechanism is a side piston seal that
1. Loosen cover vent plug to allow any trapped air actually increases the seal compression of
to escape. the O-Ring as the pressure increases. It is
not necessary to tighten cover bolts more
2. Open inlet valve to filter slowly and check for than hand tight. Excessive tightening may
O-Ring leak (ie. Water leaking out of the top of damage tie rods and render vessel
the vessel). inoperative.

3. Tighten vent plug when liquid appears around 7. We recommend changing the o-ring on the
the plug. upper seal plate annually; we also
recommend applying anti-seize on the
4. Place inlet valve in open position from threaded ends of the tie-rods periodically to
filtration. reduce the possibility of corrosion.

Maintenance

As the Excel cartridge filters remove


contamination; the pressure drop across the unit will
increase. In normal operation, the Excel filter
cartridges should be changed when the differential
pressure reaches 15-20 psig. In no case should
45psig differential pressure be exceeded. When the
filter cartridges are expended, close the INLET and
OUTLET valves. An additional T fitting and valve
may be installed between the inlet valve and the inlet
of the filter to act as a drain.
Logix Magnum IT and Cv Valves
Installation and Service Manual
Table Of Contents

1.0 Installation Profile Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.0 Introduction to the Logix Magnum Cv and Magnum IT Valve Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


2.1 Assembling the Control to the Magnum Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Magnum General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Magnum Cv Dimensional Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.0 General Installation Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12


3.1 Typical Installation Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.0 Flow Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5.0 Identifying the Logix Control: 742/742F Time Clock or 762/762F Demand and Magnum Valve. . . . . . . 20

6.0 General Logix Series Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

7.0 742/762 Series Initial Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

8.0 Initial Programming Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24


Logix Magnum Time Clock 742/298 - 5-Cycle Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Logix Magnum Demand 762/298 - 5-Cycle Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Logix Magnum Time Clock 742F/293 - 3-Cycle Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Logix Magnum Demand 762F/293 - 3-Cycle Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

9.0 Regeneration Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

10.0 Placing Conditioner into Operation (turning on the water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

11.0 Programming the Logix for Manganese Greensand Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33


11.1 Special Applications How to Program the 742/762 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

12.0 Things You Might Need to Know. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

13.0 742/762 Level II Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

14.0 Cycle Time Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

15.0 Accessing History Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

16.0 Control Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

17.0 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
17.1 Troubleshooting: Logix Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
17.2 Troubleshooting: Magnum IT and Cv Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

18.0 Magnum Valve Cartridge Removal Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

19.0 Performance Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49


19.1 Injector Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
19.2 Magnum Injector Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

1
20.0 Magnum Flow Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
20.1 Refill Control Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
20.2 Drain Line Flow Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
20.3 Recommended Backwash Flow Rates for Various Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
20.4 Logix Magnum It and Cv Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

21.0 Replacement Components: Logix Magnum Conditioner/Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56


21.1 Camshaft and Pilot Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
21.2 Camshaft Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
21.3 Magnum Valve Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
21.4 Injector Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
21.5 Refill Flow Control Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
21.6 Magnum IT Flow Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
21.7 Installation Adapter Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
21.8 Miscellaneous Kits and Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

2
1.0 Installation Profile Summary
Installation Date: _______________________________ Electronic Demand Settings
Installation Location: ____________________________ P1 Time of day ________________
Installer(s): _____________________________________ P2 Day of week ________________
Phone Number:_________________________________ P3 Time of regeneration ________________
Valve Number: _________________________________ P4 Number of days between regeneration (99 day
calendar override) ________________
Application Type: (Softener) (Filter) (Dealkalizer)

Water Source: P5 (742 only) Day of week regeneration __________


(Public Well) (Private Well) Regeneration Frequency:
(Surface Supply) S M T W T F S
(Other) 1 2 3 4 5 6 7
Water Test Results: P6 Amount of regenerant used per regeneration or filter
backwash time (salt setting) ________________
Hardness: _______________ Iron: _______________
Other: ________________________________________ P7 System capacity ________________

Misc: P8 Hardness ________________

Capacity: ________ Flow Rates: ____ min. ______ max. P9 Units of measure ________________

Tank Size: Diameter _________ Height: ___________ P10 Clock mode ________________

Resin or Media Volume: __________________________ P11 Service interval ________________

Resin or Media Type: ____________________________ P12 Remote regeneration switch delay ____________

Brine Tank Volume:______________________________ P13 Refill sensor control (conditioner only) _________

Salt Setting per Regeneration: _____________________ 0 = Off


1 = Salt detector only
Control Valve Configuration: 2 = Chlorine generation
Valve Type: ____________________________________ P14 Refill rate (conditioner only) ________________
(Hard Water Bypass) (No Hard Water Bypass) P15 Draw rate (conditioner only) ________________
Refill Control:_______________________________ gpm P16 Reserve type ________________
Injector Control: ____________________________ gpm P17 Initial average or fixed reserve _______________
Backwash Control: __________________________ gpm P18 Flow sensor select ________________
P19 K-factor or pulse equivalent ________________

3
2.0 Introduction to the Logix Magnum Cv and Magnum IT Valve Series
The Magnum CvTM and Magnum IT TM Series valves offer a The Magnum valve is available in either a
high degree of installation simplicity and flexibility. 1-1/2-inch (3.81-cm) Magnum CvTM or a 2-inch
Figure 2.1 provides an overview of the major components (5.08-cm) Magnum IT configuration. Throughout this
and connections of the 2-inch manual, the 2-inch (5.08-cm) Magnum Cv is shown in
(5.08-cm) Magnum IT valve. illustrations where the model type is irrelevant to what is
being demonstrated.

Re
ge Time
n Ti &
m Da
Sa e & Day SU
MO
lt Am
y TU
Ca ount WE
pa TH
Ha city FR
rdne
ss SA
DA
YS

Logix 742/762

Figure 2.1

4
2.1 Assembling the Control to the Slide Camshaft
Magnum Valve Slide the camshaft toward the back of the valve by
The control and the Magnum valve work together as an pressing on the release tab and pulling on the back end of
integral system to ensure synchronization. Follow the the camshaft (Figure 2.4). The front end of the camshaft
steps outlined below to install the control on the Magnum will be flush with the mounting plate.
valve.

Remove Cam Cover Release Tabs


Remove the cam cover by pressing in on the cover release
tabs (Figure 2.2). Note the cover locking tab and the slot in
the top plate. When you reassemble the cover, the locking
tab is placed in the slot first and the cover lowered into
position.

Locking Tab and Slot

Figure 2.4

Mount Control
Mount the control onto the valve by sliding the mounting
tabs over the mounting plate. Note that all models of
Magnum controls mount to the valve in the same manner
(Figure 2.5).

Mounting Tabs
Cover Release Tabs

Figure 2.2

Align Camshaft
The camshaft is keyed and should only be engaged or
disengaged when in the position illustrated (Figure 2.3). If
the camshaft is not in the proper position, rotate the cam
assembly counterclockwise until the camshaft arrow
aligns with pillow block arrow.

Camshaft Arrow Pillow Block Arrow Mounting Plate

Figure 2.5

Engage Assembly
The camshaft will not rotate by hand when engaged with
the controller. The Logix Magnum controller contains a
motor with gears that drive a socket. The camshaft is
keyed to only properly engage the socket when the Logix
controller is in the treated water (Home) position. Refer to
Section 7 for instructions on rotating the camshaft.
If the camshaft is pulled back and not engaged it can be
rotated counterclockwise. Rotate the camshaft to align
Figure 2.3 the arrows (Figure 2.3). If the Logix Magnum controller is

5
not in the treated water position, cycling the power will
cause the socket to rotate to that position.
Engage the control by pressing on the release tab and
pushing the camshaft into the control (Figure 2.6). Do not
force the camshaft. If the camshaft does not slide freely
into the control, check the alignment of the camshaft to
the controller. Ensure it is in the proper position (Figure 2.3).
The Logix controller moves to the treated water (home)
position when first power is applied. Refer to Section 7 for
initial power up.

Release Tab and Figure 2.7


Camshaft
No Hardwater Bypass Feature
The Magnum control valve may be configured for Hard
Water Bypass or No Hard Water Bypass. With Hard
Water Bypass, unsoftened or unfiltered water is allowed to
bypass the Magnum control valve during regeneration or
backwash. With No Hard Water Bypass, a valve cartridge
ensures that no unsoftened or unfiltered water bypasses
the valve during regeneration or backwash.
It is easy to observe which option is installed in the valve.
Note that the Hard Water Bypass End Cap has much
longer standoffs than the No Hard Water Bypass
cartridge. The No Hard Water Bypass assembly looks
identical to the other three valve cartridges on the valve
and has a label identifying the cartridge assembly (Figure
2.8).
Figure 2.6
To disassemble the control from the valve, reverse the
assembling procedure. No Hard Water Bypass
No Unfiltered Water Bypass
Inlet, Outlet and Drain Connections Normal Standoffs

The inlet, outlet, and drain connections are designed to


accept a GE Water Technologies supplied CPVC or brass
adapter (Figure 2.7). The adapters provide a convenient
union for the three connection ports on the valve. In
addition, they incorporate a positive O-ring face seal for
ease of installation and leak free operation. DO NOT
Extended Standoffs
OVERTIGHTEN THE ADAPTERS. As a general guideline, hand
tightening the nut onto the valve is adequate. If additional
tightening is required, never exceed a quarter turn beyond
the hand tight position.
The outlet of the 2-inch Magnum IT has an integrated
turbine. The turbine measures the flow of water through
the outlet. This information is used by the controller to With Hard Water Bypass
determine the best time to recycle. End Cap

Figure 2.8

6
Hydraulic Output Signal
An optional hydraulic output signal is available on the Magnum Tank Adapter
valve. An optional cam lobe on pilot valve #6 is used on the
camshaft assembly to initiate the hydraulic output signal The tank adapter on the control valve is designed to be
during regeneration or backwash (Figure 2.9). The compatible with a 4 inch-8UN (8 threads per inch) tank
hydraulic line pressure signal is available through the opening. In addition, the adapter is designed to accept a
1/4-inch connection on the back of the valve marked full 1-1/2-inch (3.81-cm) riser pipe with outside diameter of
AUX. See Figure 2.10. Remove the tube cap installed for 1.90 to 1.91 inches (48.26 to 48.51 mm) (Figure 2.11). The
shipping. riser pipe is sealed by an O-ring on the inside of the tank
adapter (Figure 2.11). It is recommended that the riser pipe
Optional cam lobes available are: extend beyond the top of the tank by 1/4 inch 3/8 inch (6
P/N 1000554 Provides a hydraulic signal from the mm 9 mm).
beginning of BACKWASH through the start
of REFILL.

P/N 1000553 Provides a hydraulic signal from the


beginning of BACKWASH through the end
of REFILL.
P/N 1041064 Breakaway cam. Can be programmed to O-ring
Tank O-ring

send a hydraulic signal at any time during


Top of Riser

0.25"
the REGENERATION or BACKWASH cycle. (6.4 mm)
Note: The camshaft must be turning for Top of Tank .375"
(9.5 mm)
the signal to change states, i.e. switch .375" (9.52 mm)

from OFF to ON, or from ON to OFF.


Riser
O-ringO-ring

Figure 2.11

Optional Switch Assembly


A single optional feedback switch kit is available to provide
an electrical signal during the entire regeneration or
backwash cycle (Figure 2.12). The switch may be wired in
the Normally Open or Normally Closed position and is
Optional Cam rated for 0.1 amp at 125 volts AC. An optional 5.0 amp
Lobe Position #6 switch at 1/10 HP 125/250 volts AC is available upon
Hydraulic Output request.
Signal

Figure 2.9

Common

Auxiliary
Hydraulic
Output Port
AUX

Normally Open

Pilot Drain Port


Normally Closed

Figure 2.10 Figure 2.12

7
Optional multi-switch kits are available to provide
additional electrical or switch closure signals during the
regeneration or backwash cycles. Coupled with the
optional breakaway cams, signals can be sent to external
system equipment at virtually any time while the control/
camshaft motor is running. Consult the instruction sheet
covering the multi-switch option for additional application
and programming information. The instruction sheet is
sent with the switch kit.

8
2.2 Magnum General Specifications

Operating and Environmental


Dynamic Pressure ................................................................................................................................................. 25 to 100 psig (172 to 688 kPa)
100 psig (688kPa) maximum in Canada
Operating Water Temperature Range.......................................................................................................................... 34 to 100 oF (1 to 36oC)
Ambient Temperature Range............................................................................................................................................ 34 to 120 oF (1 to 50oC)
Cap Bolt Torque ............................................................................................................................................... 35 to 40 inch lbs. (3.95 to 4.51 Nm)

Connections
Inlet and Outlet ....................................................................................................................................................................... 1-1/2 inch Magnum Cv
2-inch Magnum IT
Tank....................................................................................................................................................................................................................... 4-inch 8UN
Brine...................................................................................................................................................................................................................3/4-inch NPT
Pilot Drain and Auxiliary Hydraulic Out .............................................................................................................................1/4-inch tube fitting
Riser Pipe Fitting............................................................................................................................................................................1-1/2 inch (3.81-cm)
Drain ...................................................................................................................................................................................................1-1/2 inch (3.81-cm)

Physical
Dimensions .................................................................................................................................................. Refer to drawings on pages 9 and 10
Approximate Weight (Valve and Control) ................................................................................................................................23.3 lbs. (10.6 kg.)

Electrical*
Voltage - Logix 742/762 Series Control........................................................................................... 12 VAC wall mount transformer only
Power Consumption...............................................................................................................................................................................................4 watts

*See section on Electronic Controls for alternative electrical configurations.

9
2.3 Magnum Cv Dimensional Specifications
1 1/2-inch Inlet, Outlet and Drain
13-1/2
(34.2 cm)
9
(22.9 cm)

7-1/2
(19.0 cm)

2-15/16
(7.5 cm)
1-11/16
(4.3 cm)

9-3/4
7 (24.8 cm)
(17.8 cm)
14
(35.6 cm)
19-1/2
(49.5 cm)

3-15/16
(10.1 cm)
6-7/16
(16.4 cm)

7-1/2
(19 cm)

22-3/16
(56.4 cm)

11-3/4
29.9 cm)

1-1/16
(2.7 cm)

15-1/16
38.2 cm)

10
2.4 Magnum IT Dimensional Specifications
2-Inch Inlet and Outlet, 1 1/2-Inch Drain
13-1/2
(34.2 cm)

9
(22.9 cm)

7-1/2
(19 cm)

2-15/16
(7.5 cm)
1-11/16
(4.3 cm)

7 6-1/2
(17.8 cm) (16.5 cm)
9-3/4
(24.8 cm)
16-1/4
(41.3 cm)

4-1/2 4-1/2
(11.4 cm) (11.4 cm)

4-7/16
(11.3 cm)

13-15/16
(35.5 cm)

26-11/16
(67.8 cm)

11-3/4
(29.9 cm)

1-1/16
(2.7 cm)

15-7/16 4-7/16
(39.2 cm) (11.3 cm)

11
3.0 General Installation Information
Please review the following items thoroughly to ensure an Magnum Valve Installation Guide (Top
efficient and safe installation of the water treatment Mount)
system. The typical installation line drawings for the Before the installation of the internal distribution system
Magnum valves are shown on page 14. and loading of the media into the tank, the Magnum valve
Operating Conditions - A minimum dynamic must be temporarily installed onto the tank. This will
operating water pressure of 25 psig (172 kPa) is ensure that correct alignment of the inlet and outlet piping
required for the Magnum control valve to operate once the internals are installed and the media is loaded
properly. Water pressure is not to exceed 125 psig (862 onto the tank.
kPa). In Canada, water pressure is not to exceed 100 psig 1. Install tank O-ring into the tank adapter section at the
(688 kPa). Water temperature is not to exceed 100oF bottom of the Magnum valve. Be sure to lightly
(36oC). Do not subject the valve to freezing conditions. lubricate the O-ring with the 100% silicone lubricant
Space Requirements - Allow adequate space for the provided with the valve. Lubricant is mainly used to
water treatment system and associated piping. The hold O-ring in place during the valve installation.
General Specifications section (page 9) provides the 2. Screw the Magnum valve onto the empty tank until
overall dimensions of the control valve as well as the O-ring touches the top of the tank.
dimensional reference information for each of the
connection ports. A minimum of 4 1/2 inches (11.5 cm) 3. Turn (tighten) the Magnum valve an additional 60 to
front and rear clearance is required for cartridge assembly 90 (max).
and removal. 4. Align valve with plumbing connections to minimize
Plumbing - Always follow good plumbing practices and unnecessary stress.
conform to local codes. Check existing pipes for lime and/ 5. For reference, place a mark on the tank beneath the
or iron buildup. Replace piping if heavy buildup exists and front center of the Magnum valve.
initiate the proper treatment to prevent additional
6. Remove the Magnum valve in preparation for
occurrences. Locate the equipment close to a drain that is
installation of the internals and media loading.
capable of handling the maximum drain flow rate during
backwash. 7. Prior to loading media, make sure the tank alignment
is correct using the mark on the front of the tank.
Flexible Connectors - Some tanks expand and contract
over the acceptable range of operating water pressures of 8. Cut riser 1/4-inch above the top of the tank, plus or
the Magnum control valve. The use of flexible connectors minus 3/8 inch. Place riser inside the tank.
is recommended on polywound or fiberglass tank 9. Load media following your suppliers
installations of 24-inch (60.96-cm) diameter and larger. recommendations.
Follow the tank manufacturers instructions for more
information. 10. Follow piping recommendations to provide support
and flexibility. Layout piping to accommodate for FRP
Inlet and Outlet Piping - Inlet and outlet plumbing should tanks and piping dimensional changes and potential
be adequately supported to avoid excessive loads on the water hammering. Flexible connectors may be
valve. Install a manual bypass system to provide for needed.
occasions when the water conditioner must be bypassed
for servicing. 11. Proper pipe alignment is needed.

Drain LIne Piping - To prevent mineral loss during Flex connectors are recommended when installing valves
backwash, and to ensure proper operation of the Magnum on FRP tanks that are 24 inches or larger in diameter.
Cv Series control valve, A DRAIN LINE FLOW CONTROL
must be plumbed into the drain line prior to placing the
valve in the service mode. Flow controls from 5 to 40 gpm
(18.92 to 151.4 Lpm) are available from GE Water
Technologies and can be easily installed in the drain line.
Flow controls greater than 40 gpm (151.4 Lpm) must be
plumbed externally. Selection of the proper drain line flow
control depends on the tank size and media used for the
installation. See Section 20.2 and 20.3.

12
The following general drain line piping guidelines should
be observed:
1 inch (2.54 cm) or larger piping
Should not exceed 20 feet (6.1 m)
Should not be elevated higher than five feet above the
control valve
No shut-off valves should be installed in drain line
Auxiliary Hydraulic
Minimal number of elbows and fittings should be
Output Port - Plugged
installed in drain line
Piping must be self-supporting
Flow control should be installed as close to the Pilot Drain Port
Magnum Cv Series control valve as possible if an
external flow control is used.
Figure 3.2

Electrical

TH
FR
SA
DA
YS
CAUTION: This valve and control are for dry location use
only unless used with a Listed Class 2 power supply
WE
TU
MO
SU

y
Da
e& y
Time & Dant
m ou
n Ti Am city

suitable for outdoor use.


ge lt
Re Sa Capa ss
rdne
Ha

1. Electrical requirements for the installation depends on


the configuration of the control.
Drain Line Flow Control Disk
2. The standard North American Series Logix electronic
control is supplied with a 12 volt wall mount
Figure 3.1
transformer. Optional wall mount transformers are
Brining System - The Magnum control valve utilizes available in the following configurations: Japanese
timed water refill to add water to the salt tank. A refill tube plug @ 100 volts/50 or 60 Hz, Australian/Argentine
with check ball is required in the brine tank that does not plug @ 240 volts/50 Hz, British plug @ 240 volts/50 Hz,
restrict the refill or brine draw flow rate capabilities of the European/Italian plug @ 230 volts/50 Hz. Optional
valve. Although not required, a separate brine valve (safety transformers must be ordered separately for all
float) system is recommended for use with Magnum international 12 VAC configurations.
installations. Select a High-Flow brine valve that does not
restrict the refill or brine draw flow rate capabilities of the Lubricants
valve. The Performance Injectors and Magnum Flow It is very important that 100% silicone lubricant is the only
Controls section (Sections 19.0 and 20.0) of this manual lubricant used for installing the Magnum control valve. Any
contains flow rate information for various size injectors other lubricant may cause material degradation and
and refill controllers. potential failure of the valve components.
Pilot Drain - During regeneration, a small amount of NOTE: Some silicone based lubricants contain
water (200 ml or 1 cup) is discharged from the 1/4-inch petroleum-based ingredients. If there is a question about
(6.3-mm) tube fitting on the back of the valve marked the lubrication that you are using contact the lubricant
DRAIN (Figure 3.2). To prevent this water from being manufacturer to be sure the product is 100% silicone.
discharged to the floor, plumb this connection to a non-
pressurized drain or to the brine tank. Do not plug or
apply back pressure to the pilot drain at any time.
Crimping the pilot drain line or installing the line to go up,
which causes backpressure, prevents the diaphragm
cartridges from shifting properly through the cycles of
regeneration or backwash.

13
3.1 Typical Installation Drawings

Inlet Valve

Manual Bypass Valve


Drain Line Flow Control
(Required)
Rege Time
n Time &
Day SU
Salt & Day MO
Amou TU
Capa nt WE
TH
Hardncity FR
ess SA
DAYS

Drain
Outlet Valve

Logix Control Turbine (Standard


with Logix Control)
Brine Line
1.5" Riser Tube
Note: Support Inlet and
Outlet piping adequately.

Hub & Lateral

Magnum Cv Brine Tank

Rege Time
n Time&
Day SU
Salt & MO
AmoDay TU
Capa unt WE
TH
Hard city FR
ness SA
DAYS

Magnum IT

Figure 3.3 Magnum Cv and Magnum IT, Single Tank Softener Units with Logix Electronic Control

14
4.0 Flow Diagrams
The Magnum control valve utilizes a series of pilot valves to 3-cycle filter configuration. Both the Hardwater Bypass
properly position the diaphragm valve cartridges (Figure and No Hardwater Bypass service flow diagrams are
4.1). The pilot valves are activated by the camshaft (Figure presented.
4.2). The flow diagrams that follow represent the Service
Cycle for a 5-cycle conditioner and

Spring Spring

Figure 4.1 Pilot Valve Principle of Operation, Front View

Back

Front

Figure 4.2 Cam Assembly

15
Magnum 5-Cycle Conditioner Hard Water Bypass
Outlet
Service Cycle

Brine
Tank

Hard Water
Bypass Refill
Control

3 2
Tank Bottom
6 5 4 3 2 1 B2 B1 Pilot
Valves

Pilot Drain

Aux. Pilot Injector

16
Output Screen Servi

Figure 4.3
Injector

Tank Top
Pilot
Screen

4 1 Untreated
Water

Treated
Water

Backwash
Water

Regenerant

6 5 4 3 2 1 B2 B1
Service CLSD CLSD OPEN CLSD OPEN OPEN CLSD CLSD

Backwash CLSD OPEN CLSD OPEN OPEN CLSD CLSD CLSD


Inlet Drain
Brine/Slow Rinse CLSD OPEN CLSD OPEN CLSD OPEN OPEN OPEN

Fast Rinse CLSD OPEN OPEN OPEN CLSD OPEN CLSD CLSD

Refill/Service CLSD CLSD OPEN CLSD OPEN OPEN OPEN OPEN


Resin Tank
Magnum 5-Cycle Conditioner No Hard Water Bypass
Service Cycle
Outlet

Brine
Tank

No Hard
Water Bypass Refill
Control

3 2
Tank Bottom
6 5 4 3 2 1 B2 B1 Pilot
Valves

Pilot Drain

Aux. Pilot Injector


Output

17
Screen
Injector
Se

Figure 4.4
Tank Top
Pilot
Screen

4 1 Untreated
Water

Treated
Water

Backwash
Water

Regenerant

6 5 4 3 2 1 B2 B1
Service CLSD CLSD OPEN CLSD OPEN OPEN CLSD CLSD

Backwash CLSD OPEN CLSD OPEN OPEN CLSD CLSD CLSD


Inlet Drain
Brine/Slow Rinse CLSD OPEN CLSD OPEN CLSD OPEN OPEN OPEN

Fast Rinse CLSD OPEN OPEN OPEN CLSD OPEN CLSD CLSD

Refill/Service CLSD CLSD OPEN CLSD OPEN OPEN OPEN OPEN


Resin Tank
Magnum 3-Cycle Filter: Unfiltered Water Bypass
Service Cycle
Outlet

Unfiltered
Water Bypass

3 2
Tank Bottom
6 5 4 3 2 1 B2 B1 Pilot
Valves

Pilot Drain

Aux. Pilot

18
Output

Figure 4.5
Plugged Injector

Tank Top
Pilot
Screen

4 1 Untreated
Water

Treated
Water

Backwash
Water

Regenerant

Inlet Drain 6 5 4 3 2 1 B2 B1
Service CLSD CLSD OPEN CLSD OPEN OPEN CLSD CLSD

Backwash CLSD OPEN CLSD OPEN OPEN CLSD CLSD CLSD

Fast Rinse CLSD OPEN OPEN OPEN CLSD OPEN CLSD CLSD
Media Tank
Magnum 3-Cycle Filter: No Unfiltered Water Bypass
Service Cycle
Outlet

No Unfiltered
Water Bypass

3 2
Tank Bottom
6 5 4 3 2 1 B2 B1 Pilot
Valves

Pilot Drain

Aux. Pilot

19
Output

Figure 4.6
Plugged Injector

Tank Top
Pilot
Screen

4 1 Untreated
Water

Treated
Water

Backwash
Water

Regenerant

Inlet Drain 6 5 4 3 2 1 B2 B1
Service CLSD CLSD OPEN CLSD OPEN OPEN CLSD CLSD

Backwash CLSD OPEN CLSD OPEN OPEN CLSD CLSD CLSD

Fast Rinse CLSD OPEN OPEN OPEN CLSD OPEN CLSD CLSD
Media Tank
20
5.0 Identifying the Logix Control: 742/742F Time Clock or 762/762F Demand and
Magnum Valve
If you are unsure of your control model, simply remove
the cover and disconnect the controller module from the
control valve. In the back of the control valve is a silver
label that shows your model number and version revision.

Model number:
either 742/742F or
762/762F

GE Infrastructure GE Infrastructure
Milwaukee, WI USA Milwaukee, WI USA
Autotrol Brand Autotrol Brand
Model 762 Model Magnum/762
12 V/ 60 Hz/ 4W 12 V/ 60 Hz/ 4W

VERSION 1.02 VERSION 1.02


WO#4340000 WO#4340000
Ser. No: 740090052683-3 Ser. No: MAG058060634

Serial number with date code

Figure 5.1 Figure 5.2

How To Read the Serial Number

Ser. No. MAG 058 07 0634

Model Day of Year Unit Number


the Year

Figure 5.3

20
6.0 General Logix Series Instructions
6.1 Display Icons Logix Controller

1 2
18 11 10
17
3
SU MO TU WE TH FR SA DAYS
16
Time & Day 4
15
Regen Time & Day PM 5
Salt MIN
g/L 6
14
13 x2 KG
7
12 Capacity
28
27
Hardness CHP x100
Lbs/ft 3
8
19
20
25 24 21 9
26 23 22

Figure 6.1
NOTE: In normal operation and during programming,
only a few of the icons are actually displayed.

1. Days of the week. The flag immediately below the 11. Locked/unlocked indicator. In Level I programming
day appears when that day has been programmed this is displayed when the current parameter is
as a day the system should regenerate (used with locked-out. It is also used in Level II programming to
7-day timer programming). indicate if the displayed parameter is locked (icon
flashes) when controller is in Level I.
2. See #3
12. When "x2" is displayed, a second regeneration has
3. This cursor is displayed when the days between been called for.
regeneration are being programmed (used with .5 to
99 day regeneration programming). 13. The recycle sign is displayed (flashing) when a
regeneration at the next time of regeneration has
4. One of these cursors is displayed to indicate which been called for. Also displayed (continuous) when in
day will be programmed into the controller. regeneration.
5. "PM" indicates that the time displayed is between 14. The display cursor is next to "SALT" when
12:00 noon and 12:00 midnight (there is no AM programming the amount of regenerant. If the
indicator). PM indicator is not used if clock mode is set controller is on a 3-cycle filter then backwash time is
to 24-hour. programmed.
6. When "MIN" is displayed, the value entered is in 15. The display cursor is next to "REGEN TIME & DAY"
minute increments. when programming the time of regeneration and the
7. When g/L is displayed, the value for regenerant days of regeneration.
amount entered is in grams/Liter. 16. The display cursor is next to "TIME & DAY" when
8. When "Kg" is displayed, the value entered is in programming the current time and day.
kilograms or kilograins. 17. The hourglass is displayed when the motor is running.
9. Four digits used to display the time or program value. The camshaft should be turning.
Also used for error codes. 18. These cursors appear next to the item that is
10. Colon flashes as part of the time display. Indicates currently displayed.
normal operation (742 only). 19. X100 multiplier for large values.

21
20. When Lbs/ft3 is displayed the value for regenerant 6.3 Programming Conventions
amount entered is in pounds/cubic foot. The 700 series controller is programmed using the
21. Faucet is displayed when the current flow rate is buttons on the keypad. The programming instructions are
displayed. Control may show the faucet and "0", described two ways whenever a section has keypad
indicating no flow. input.
First, a table shows simplified instructions. Second, text
22. Maintenance interval display turns on if the months follows that describes the action. In each table:
in service exceed the value programmed in P11.
"Action" lists the event or action desired.
23. Used with #24, #25, and #26. Displays a sequence "Keys" are listed as:
number or a value.

24. History Values (H). The number displayed by #23 UP for up arrow
identifies which history value is currently displayed.
DOWN for down arrow
25. Parameter (P). Displayed only in Level II Programming.
The number displayed by #23 identifies which SET for set
parameter is currently displayed.
REGEN for regeneration
26. Cycle (C). The number displayed by #23 is the current
cycle in the regeneration sequence. "Duration" describes how long a button is held down:
P/R for press and release
27. Hardness settingonly used with 760 and 762 HOLD for press and hold
controllers. X sec for a number of seconds to press the button
28. Capacity displayshows estimated system capacity. and hold it down
"Display" calls out the display icons that are visible.
6.2 Keypad Buttons

1 4

2 3

Figure 6.2
1. DOWN arrow. Generally used to scroll down or incre-
ment through a group of choices.

2. SET. Used to accept a setting that normally becomes


stored in memory. Also used together with the arrow
buttons.

3. UP arrow. Generally used to scroll up or increment


through a group of choices.

4. Regenerate. Used to command the controller to


regenerate. Also used to change the lock mode.
NOTE: If a button is not pushed for thirty seconds,
the controller returns to normal operation
mode. Pushing the Regenerate button
immediately returns the controller to normal
operation.

22
7.0 742/762 Series Initial Power-Up
Initial Power Up

SU MO TU WE TH FR SA DAYS
Time & Day
Regen Time & Day
Salt

Capacity
Hardness

Before mounting the controller check the position of the


camshaft. The correct rotation position is when the arrows
on the camshaft and the arrows on the pillow block line up
(see Figure 2.3).
If the arrows do not line up, rotate the camshaft by hand
counterclockwise. Once the arrows line up, pull the
camshaft back (see Figure 2.4).
Mount the Control
1. Mount the controller on the valve. Do not engage the
camshaft.
2. Apply power to the controller. The display will show an
hour glass and Err3. This is an indication that the
controller is moving to the treated water (HOME
position). Err3 will change and the hour glass will
disappear when the cycle is complete.
NOTE: If more than two minutes elapses, verify that the
motor is turning the camshaft socket. If it is not
turning, contact your dealer.
3. Engage the camshaft with the controller.
NOTE: The 700 Series controller features a self-test
sequence. At first power-up of the control, you
may see a number such as 1.00, 1.02, 1.04, or
2.00 displayed. This is an indication that the
self-test is not completed. To complete the test,
verify that the turbine cable is connected. Blow
air into the turbine port (valve outlet) to spin the
turbine. The controller verifies that the turbine
works and the self-test finishes. Proceed with the
initial start-up procedure.

23
8.0 Initial Programming Instructions
8.1 Start-Up Programming Day of the Week
The Logix Magnum control can be quickly programmed Program this setting to the actual day of the week. The
by following the sequential procedures on the following Logix control is then properly calibrated to allow accurate
pages. Additional customization information is in Section recovery of average daily water usages for each day of
13.0 742/762 Level II Programming. Listed below is the week. See Section 15.0 Accessing History Values for
general information about the programming features. more information.
Valve Type Time of Regeneration or Backwash
Your systems OEM may have performed this setting. If so A fully adjustable clock setting allows regenerations or
proceed to the next step. backwashes to be programmed at any time of the day.
Also used to offset regenerations or backwashes when
This setting is used to calibrate the Logix program to
two systems are plumbed in series.
the actual valve type. Identification stickers on the
Logix control and the valve body show the control and Days Override
valve type. See Section 5.0 Identifying the Logix
Can be used as a backup for 762 Demand systems.
Control for more information.
Represents the days between regeneration. Also can be
Valve models displayed by the Logix control programmed as a 7-Day clock on 742 Time clock controls
255 255, 7-cycle conditioner (see Section 9.0).
263 Performa, 3- cycle filter Regenerant Dosage (762/742 5-Cycle
268 Performa, 5-cycle conditioner
Conditioners) or Backwash Time (762F/742F
273 Performa Cv, 3-cycle filter
278 Performa Cv, 5-cycle conditioner
3-Cycle Filters)
293 Magnum, 3-cycle filter 762/742 Conditioners: Represents salt dosage per
298 Magnum, 5-cycle conditioner cubic foot of media. See Table 8.1 for salt dosages
and capabilities.
762F/742F Filters: Represents the backwash cycle
Program System Size time in minutes. This is fully adjustable.
Your systems OEM manufacturer may have performed Capacity
this setting. If so, proceed to setting the Time of Day. The
system size setting represents the amount of media in the Calculated by the Logix software, using the resin volume,
tank. regenerant dosage, and hardness settings. Can be
overridden for 762 5-cycle conditioners. "View Only " for
Time of Day 742 5-cycle conditioners. See Section 13.0 I to program as
The Time of Day is preset in the factory at 1200 pm metric equivalent.
operating as a 12-hour clock. This setting can be changed Hardness
to operate as a 24-hour clock. See Section 13.0 Level II
Programming. Program actual water hardness of feed water. See Section
13.0 Level II Programming to program as metric
equivalent.

24
Logix Magnum Time Clock 742/298 - 5-Cycle Conditioner
Screen Buttons to Description Range
Press
SU MO TU WE TH FR SA DAYS
Time & Day
Regen Time & Day
Salt Amount then or 1. Valve Type
press
Select 298
Capacity
Hardness

SU MO TU WE TH FR SA DAYS
Time & Day
Regen Time & Day
2. Resin Volume
Salt Amount then or Select correct resin volume Cubic feet: 3.00
Capacity
press to
Hardness
20.00
SU MO TU WE TH FR SA DAYS
Time & Day
Regen Time & Day PM
press 3. Time of Day (12 hr.)
Salt Amount
then or Set to time of day
Capacity
press Note: Setting includes PM indicator.
Hardness

SU MO TU WE TH FR SA DAYS
Time & Day
Regen Time & Day
press 4. Day of Week
Salt Amount
then
Set to actual day of the week
or
Capacity
Hardness
press

SU MO TU WE TH FR SA DAYS
Time & Day
Regen Time & Day
press 5. Time of Regeneration
Salt Amount
then Set to desired time of regeneration
or
Capacity
Hardness
press

Time & Day


SU MO TU WE TH FR SA DAYS
6. Days Between Regeneration
Regen Time & Day
press Set to desired days between Days: .5
Salt Amount
then regeneration to
or
Capacity or 99
Hardness
press *Set at 0 to program as a 7-day
timer
SU MO TU WE TH FR SA DAYS
Time & Day
press 7. Salt Dosage
Regen Time & Day
Lbs/ft3: 3
Salt Amount
then or Set to desired desired dosage to
Capacity
press lbs per cubic feet of resin 18
Hardness

SU MO TU WE TH FR SA DAYS
Time & Day
Regen Time & Day
press 8. Estimated Capacity (view only)
Salt Amount Based on resin volume and
Capacity KG salt setting
Hardness

Programmming is complete

Service Display
SU MO TU WE TH FR SA DAYS
Time & Day
Regen Time & Day
Salt Amount
PM
Displays actual day of the week
and time of day
Capacity
Hardness

* See Section 8.2 for details.

25
Logix Magnum Demand 762/298 - 5-Cycle Conditioner
Screen Buttons to Description Range
Press
SU MO TU WE TH FR SA DAYS
Time & Day
Regen Time & Day
Salt Amount then or 1. Valve Type
press
Select 298
Capacity
Hardness

SU MO TU WE TH FR SA DAYS
Time & Day
Regen Time & Day
2. Resin Volume
Salt Amount then or Select correct resin volume Cubic feet: 3.00
Capacity
press to
Hardness
20.00
SU MO TU WE TH FR SA DAYS
Time & Day
Regen Time & Day
press 3. Time of Day (12 hr.)
Salt Amount
then or Set to time of day
Capacity
press Note: Setting includes PM indicator.
Hardness

SU MO TU WE TH FR SA DAYS
Time & Day
Regen Time & Day
press 4. Day of Week
Salt Amount
then
Set to actual day of the week
or
Capacity
Hardness
press

SU MO TU WE TH FR SA DAYS
Time & Day
Regen Time & Day
press 5. Time of Regeneration
Salt Amount
then Set to desired time of regeneration
or
Capacity
Hardness
press

SU MO TU WE TH FR SA DAYS
Time & Day
press 6. Days Override Days: .5
Leave at 0 to disable
Regen Time & Day
Salt Amount
then to
or or
Capacity 99
Hardness
press Set to desired days override
SU MO TU WE TH FR SA DAYS
Time & Day
press 7. Salt Dosage
Regen Time & Day
Lbs/ft3: 3
Salt Amount
then or Set to desired desired dosage to
Capacity Lbs/ft
3
press lbs per cubic feet of resin 18
Hardness

SU MO TU WE TH FR SA DAYS
Time & Day
press 8. Capacity
Regen Time & Day
Kilograins: 1
Salt Amount Capacity calculated by
to override press to
Logix control
Capacity KG 900
Hardness
then or Use to OVERRIDE calculated
press capacity
SU MO TU WE TH FR SA DAYS
Time & Day
press 9. Hardness
Regen Time & Day
Grains/gal: 3
Salt Amount
then Set to actual water hardness
or to
in grains per gallon
Capacity
Hardness
press 200

Programmming is complete

Service Display
SU MO TU WE TH FR SA DAYS
Time & Day
Regen Time & Day
Salt Amount
Capacity Remaining (gallons)
Capacity
Toggles back and forth
Hardness between displays when in
the service position

SU MO TU WE TH FR SA DAYS
Time & Day
Regen Time & Day
Flow Rate GPM
Salt Amount

Capacity
Hardness

26
Logix Magnum Time Clock 742F/293 - 3-Cycle Filter
Screen Buttons to Description Range
Press
SU MO TU WE TH FR SA DAYS
Time & Day
Backwash Time & Day
Backwash Length then or 1. Valve Type
press
Select 293
Capacity

SU MO TU WE TH FR SA DAYS
Time & Day
Backwash Time & Day
2. Program Type
Backwash Length Select "F"
press
Capacity

SU MO TU WE TH FR SA DAYS
Time & Day
Backwash Time & Day
PM press 3. Time of Day (12 hr.)
Backwash Length
then or Set to time of day
Capacity
press Note: Setting includes PM indicator.

SU MO TU WE TH FR SA DAYS
Time & Day
Backwash Time & Day
press 4. Day of Week
Backwash Length
then
Set to actual day of the week
or
Capacity
press

SU MO TU WE TH FR SA DAYS
Time & Day
Backwash Time & Day press 5. Time of Backwash (12 hr)
Backwash Length
then Set to desired time of backwash
or
Capacity
press

SU MO TU WE TH FR SA DAYS 6. Days Between Regeneration


Set to desired days between
Time & Day
Backwash Time & Day press Days: .5
Backwash Length
then
regeneration to
or or 99
*Set to 0 to program as a 7-day
Capacity
press
timer
SU MO TU WE TH FR SA DAYS
Time & Day
Backwash Time & Day
press 7. Backwash Length (minutes) Minutes: 1
Set to desired backwash length
Backwash Length
MIN then or to
Capacity
press 200

Programmming is complete

Service Display
SU MO TU WE TH FR SA DAYS
Time & Day
Regen Time & Day
Salt Amount
PM Displays actual day of week and
time of day.
Capacity
Hardness

* See Section 8.2 for details.

27
Logix Magnum Demand 762F/293 - 3-Cycle Filter
Screen Buttons to Description Range
Press
SU MO TU WE TH FR SA DAYS
Time & Day
Backwash Time & Day
Backwash Length then or 1. Valve Type
press
Select 293
Capacity

SU MO TU WE TH FR SA DAYS
Time & Day
Backwash Time & Day
2. Program Type
Backwash Length Select "F"
press
Capacity

SU MO TU WE TH FR SA DAYS
Time & Day
Backwash Time & Day
PM press 3. Time of Day (12 hr.)
Backwash Length
then or Set to time of day
Capacity
press Note: Setting includes PM indicator.

SU MO TU WE TH FR SA DAYS
Time & Day
Backwash Time & Day
press 4. Day of Week
Backwash Length
then
Set to actual day of the week
or
Capacity
press

SU MO TU WE TH FR SA DAYS
Time & Day
Backwash Time & Day press 5. Time of Backwash
Backwash Length
then Set to desired time of backwash
or
Capacity
press

SU MO TU WE TH FR SA DAYS
Time & Day
Backwash Time & Day press 6. Days Override Days: .5
Backwash Length Leave at 0 to disable to
then or or 99
Capacity
press Set to desired days override
SU MO TU WE TH FR SA DAYS
Time & Day
Backwash Time & Day
press 7. Backwash Length (minutes) Minutes: 1
Set to desired backwash length
Backwash Length
MIN then or to
Capacity
press 200

SU MO TU WE TH FR SA DAYS
Time & Day
press 8. Capacity (gallons)
Backwash Time & Day
Gallons: 1
Backwash Length
then Set to desired capacity in gallons
or x 100 to
multiples of 100
Capacity
X100 press 900

Programmming is complete

Service Display
SU MO TU WE TH FR SA DAYS
Time & Day
Regen Time & Day
Salt Amount
Capacity Remaining (gallons)
Capacity
Toggles back and forth
Hardness between displays when in
the service position

SU MO TU WE TH FR SA DAYS
Time & Day
Regen Time & Day
Flow Rate GPM
Salt Amount

Capacity
Hardness

28
8.2 Exchange Capacities, Setting 7-Day Repeat the procedure to program regeneration on
Clock, Viewing Cycle Times desired days. The days selected for regeneration are
shown when the Logix control returns to the service
display.

Table 8.1 Standard Efficiency Exchange Capacity Viewing Cycle Times


1. Press and hold the UP and SET buttons for 3 seconds
Exchange
Exchange Salt when the control is in the "in service mode" to access
Salt Capacity
Capacity grams/ the "cycle time display mode". The display shows a
lbs/cu ft grams/
grains/cu ft liter small "c" followed by a number in the lower portion of
liter
the display.
3 12714 50 29.9
2. Press the UP and DOWN buttons to display the
4 15495 60 34.0 programmed cycle time.
5 17774 70 37.5
3. Press the REGEN button to exit the "cycle times
6 19661 80 40.6 display mode".
7 21250 90 43.4
8 22618 100 45.9 NOTE: For adjusting cycle times, see Section 14.0
9 23828 110 48.2 Adjusting Cycle Times.
10 24930 120 50.2
NOTE: The draw and refill cycle times cannot be
11 25962 130 52.1
changed in cycle time programming for
12 26950 140 53.8 conditioner valves. Draw and refill times are
13 27916 150 55.5 calculated using the draw and refill rates and salt
14 28873 170 58.5 amounts. The draw and refill cycle times may be
15 29829 200 62.7 programmed for 3-cycle filters.
16 30796 230 66.9
17 31783 260 71.0
18 32806 290 75.3

Setting the 7-Day Clock (742 and 742F)


Set the Days Override to "0".
Press SET to advance the display to the Backwash
Time/Day setting.
Press SET. A flashing cursor appears beneath the SU
display.
Press UP or DOWN while the cursor is flashing to
program a regeneration for that day. A black bar
appears below the day.

SU MO TU WE TH FR SA DAYS

Time/Day
Backwash Time/Day
Backwash Length

NOTE: Pressing SET again removes the black bar and


deselects the day of regeneration.

Press SET. This returns the flashing cursor to a solid


cursor.
Press UP or DOWN to navigate to other days of the
week.

29
9.0 Regeneration Modes
The 700 Series controllers can be regenerated either During a Regeneration:
automatically or manually. During a regeneration, the
total time remaining of the regeneration is displayed on
A "C#" is displayed to show current cycle.
the controller. The current cycle is shown in the lower left SU MO TU WE TH FR SA DAYS

of the display.
Time & Day
Regen Time & Day
Salt MIN
x2

Manual Regeneration: Capacity


Hardness C
Delayed Manual Regeneration Pressing the
REGENERATION key programs a delayed manual Total regen time remaining
regeneration. The regeneration icon on the LCD flashes
indicating that a regeneration starts when the time of day
Total regen time remaining is displayed on screen.
reaches the programmed time of regeneration. Pressing
the REGENERATION key again turns off the regeneration Press and hold SET to show current cycle time
icon and cancels the delayed regeneration. remaining.
Immediate Manual Regeneration Pressing and holding
the REGENERATION key for three seconds initiates an To Advance Regeneration Cycles:
immediate manual regeneration. The regeneration icon on Press and hold SET - showing current cycle time.
the LCD turns on. The control goes to the regenerating
Simultaneously press SET and UP to advance on
mode.
cycle. An hourglass displays while the cam is
Delayed Second Regeneration Pressing the advancing.
REGENERATION key while the control is in the regenerating When the cam reaches next cycle, "C2 is be
mode programs a delayed second regeneration. The x2 displayed.
icon next to the regeneration icon flashes indicating a
Repeat SET and UP to advance through each cycle.
second regeneration starts when the time of day reaches
the programmed time of regeneration. Press and hold SET and UP for 5 seconds to cancel
regen.
Double Immediate Manual Regeneration Pressing and Hourglass flashes once cancelled.
holding the REGENERATION key for three seconds while Camshaft advances to home may take 1 to 2
the control is in the regenerating mode programs minutes.
back-to-back manual regenerations. The x2 icon next to
the regeneration icon turns on indicating a second manual
regeneration starts immediately after the current Regeneration Cycles:
regeneration is complete. C1 Backwash
C2 Regeneration Draw/Slow Rinse (not used in filter
mode)
C3 Slow Rinse (not used in filter mode)
C5 Fast Rinse cycle C8 Regenerant Refill (not used
in filter mode)

30
10.0 Placing Conditioner into Operation (turning on the water)

Conditioner and 5-Cycle Filter Start-Up


After you have performed the previous initial power-up C. Allow water to run to drain until the water runs
steps, you need to place the conditioner into operation. clear from the drain line. This purges any refuse
Follow these steps carefully, as they differ from previous from the media bed.
Autotrol valve instructions.
D. Turn off the water supply and let the system stand
for about five minutes. This allows any air trapped
WARNING: Do not rotate the camshaft by to escape from the tank.
hand or damage to the unit may occur. Use 5. Add water to the regenerant tank (initial fill)
the controller to step the camshaft (conditioner and 5-cycle filters only).
electronically through the cycles.
A. Add enough water to the regenerant tank to
ensure a proper regeneration. Refer to the
1. Remove the cover from the valve. Removing the programmed salt dosage.
cover allows you to see that the camshaft is turning,
and in which cycle the camshaft is currently If the tank has a salt platform in the bottom of the
positioned. tank, add water until the water level is
approximately 1 inch (25 mm) above the platform.
2. With the supply water for the system still turned off,
position the bypass valve to the not in bypass
NOTE: We recommend that you do not put regenerant
(normal operation) position.
into the tank until after the control valve has
3. Hold the REGEN button on the controller down for 5 been put into operation. With no regenerant in
seconds. This initiates a manual regeneration. the tank, it is much easier to view water flow and
The controller indicates that the motor is turning the motion in the tank.
camshaft to the cycle C1 (Backwash) position by
flashing an hourglass. The controller displays the 6. Engage the refill cycle to prime the line between the
total regen time remaining. regenerant tank and the valve (conditioner only).
SU MO TU WE TH FR SA DAYS A. Slowly open the main water supply valve again, to
Time & Day
Regen Time & Day
the fully open position. Be sure not to open too
Salt rapidly as that would push the media out of the
Capacity
media tank.
Hardness C B. Advance the controller to the Refill (C8) position.
Flashing
From cycle C1 (Backwash), press and hold the SET
button. This displays the current cycle.
If you press and hold the SET button, the controller
indicates the time remaining in the current cycle.
While pressing the SET button, press UP to
4. Fill the media tank with water. advance to the next cycle. Continue to advance
A. While the controller is in cycle C1 (Backwash), open through each cycle until you have reached cycle
the water supply valve very slowly to C8 (Refill).
approximately the 1/4 open position. C. With the water supply completely open, when you
arrive at cycle C8 (Refill), the controller directs
water down through the line to the regenerant
WARNING: If opened too rapidly or too far,
tank. Let the water flow through the line until all air
media may be lost out of the tank into the
bubbles have been purged from the line.
valve or the plumbing. In the open position,
you should hear air slowly escaping from the Time & Day
SU MO TU WE TH FR SA DAYS

valve drain line. Regen Time & Day


Salt

Capacity
B. When all of the air has been purged from the Hardness C
media tank (water begins to flow steadily from the
drain line), open the main supply valve all of the D. Do not let the water flow down the line to the tank
way. This purges the final air from the tank. for more than one to two minutes, or the tank may
overfill.

31
E. Once the air is purged from the line, press the SET
button and the UP button simultaneously to
advance to cycle C0 (Treated Water) position.
7. Draw water from the regenerant tank.
A. From the treated water position (cycle C0),
advance the valve to the draw regenerant
position. Hold the REGEN button down for five
seconds.

The controller begins a manual regen, and


advances the control valve to the cycle C1
(Backwash). Press the SET and UP button to
advance to cycle C2 (Draw).
B. With the controller in this position, check to see
that the water in the regenerant tank is being
drawn out of the tank. The water level in the tank
should recede very slowly.
C. Observe the water being drawn from the
regenerant tank for at least three minutes. If the
water level does not recede, or goes up, check all
hose connections. C2 should be displayed.
8. If the water level is receding from the regenerant tank
you can then advance the controller back to the
treated water (C0) position by pressing SET and the
UP buttons simultaneously to advance the controller
to the C0 position.
9. Finally, turn on a faucet plumbed after the water
conditioner. Run the faucet until the water runs clear.

32
11.0 Programming the Logix for Manganese Greensand Systems
For other regenerants, after doing the steps in Section 8.2, water (75 gallons x 4 people) per day. Assume the
proceed to Special Applications. incoming water has 10 ppm of iron. Now calculate the
daily demand: multiply the gallons of water used per day
Manganese Greensand Systems (300) by the ppm of iron content (10) = 3000 ppm of daily
capacity usage.
Sizing 5-Cycle Filters Now take the system capacity (10,000), divided by the
Potassium permanganate regenerating iron filters should daily demand (3,000) = 3.3 days of capacity. Since you run
be sized for the appropriate backwash and injector sizes. out of capacity before the beginning of the fourth day, the
proper setting for days between regeneration is 3 days.
Backwash Controller
For example:
Be sure to choose the appropriate backwash flow rate
4 people x 75 gals per person = 300 gallons used
control (see Parts section) as recommended by your
media manufacturer. per day.
Injector 10 ppm iron x 300 gal/day = 3000 ppm/day

Use the same injector size as you would for your 10,000 ppm capacity 3000 ppm/day = 3.3 days of
conditioner control tank diameter. total capacity
Refill Controller Solution = regenerate every 3 days.
An FA filter can use the refill control that is featured as The above capacity numbers are based only on Fe. For
standard with a Logix controller. Use a float valve in your removal of H2S and Mn refer to the media manufacturers
potassium permanganate feeder to set potassium specifications.
permanganate dosage.
Volume/Demand Regeneration Setting
Initial Resin Volume Setting To set a 762 demand system for iron removal you must:
Programming for a manganese greensand system 1. Know your media capacity. Generally, one cubic foot
requires a few minor adjustments to the programming to of magnesium greensand can remove 10,000 ppm of
operate the control correctly. The initial resin volume iron.
should be set to the closest volume of the manganese
greensand in the system. For example, if the system 2. Know the iron concentration in your water.
contains two cubic feet of manganese greensand, To have your system regenerate on demand, set your
program in 2.00 for the resin volume. systems capacity (P7) to the appropriate factor. On the
762, it reads Kg, but you are actually working in ppm of
"Salt" Setting for KMNO4 Regenerant iron.
Be sure to set the salt dosage high enough to operate the 1. If your system is one cubic foot, set the capacity to
float shut-off in the regenerant storage tank. "10" kg, meaning 10,000. For two cubic feet, set the
capacity to "20" kg.
All other settings remain the same as mentioned in the
previous programming sections. Time & Day
SU MO TU WE TH FR SA DAYS

Regen Time & Day

Days Between Regeneration Setting (742)


Salt Amount

KG

To set the days between regenerations, consult the media


Capacity
Hardness

manufacturer for the actual capacity of the media.


In general, manganese greensand has a capacity of 2. Set your hardness to the level of ppm iron in your
10,000 ppm of removal capability per cubic foot of media. water. If you have 3 ppm of iron, set the 762 control to
Calculate the capacity of the system by taking the "3".
number of cubic feet of media and multiply by 10,000. Time & Day
SU MO TU WE TH FR SA DAYS

For example, using a 1 cubic foot system provides 10,000


Regen Time & Day
Salt Amount

ppm of removal capability.


Capacity
The next step is to calculate the demand for the system. Hardness

Multiply the predicted daily water usage by the iron


content in ppm. 3. The control calculates the remaining volume capacity
For example, an average person uses 75 gallons of water in gallons (m3) and counts down to regeneration.
per day. Four people living in a home use 300 gallons of

33
11.1 Special Applications How to
Program the 742/762

For all special flow applications that are media or


regenerant dependent, you are going to select the
injector, the backwash flow control and the refill flow
control.
You may need to change one or all the regenerating cycle
times to satisfy your equipment needs.
The Logix control must be programmed as a 3-cycle filter
to allow all cycles to be adjustable. See pages 27 or 28 to
program the Logix Magnum as a 3-cycle filter. Proceed to
the procedure listed below after completing filter
programming.
To Program The Times For All Cycles
Press and when in the "Service Mode to enter
the Cycle Time Display mode. The display will show
"C1".
Press when in the "Cycle Time Display mode.
The cycle time in minutes will flash, indicating the
cycle time can be changed.
Press or to change the flashing time.
Press to enter the selected time.
Press to navigate to another cycle.

34
12.0 Things You Might Need to Know

When the controller is first plugged in, it may display


a flashing hourglass and the message Err 3, this
means that the controller is rotating to the home
position. If the Err 2 is displayed, check that the
incoming power frequency matches the controller.
The North American controller does not run with 50
Hz input.
The preset default time of regeneration is 2:00 AM.
English or Metric? The World controller senses the
electrical input and decides which is needed. The
North American controller only runs on 60 Hz and
defaults to English units.
The Logix Series controller can be programmed to
regenerate on specific days of the week.
If electrical power is not available, the camshaft can
be rotated counterclockwise by hand if the motor is
removed.
The Logix Series controllers send commands to the
motor for camshaft movement. However, water
pressure/flow are required during the regeneration
cycle for backwash, purge and refill, and brine draw
to actually take place.
Make sure control power source is plugged in. The
transformer should be connected to a non-switched
power source.
You can start programming at the beginning by
resetting the amount of media. When viewing H0
(History Value) push and hold SET for five seconds.
The display reverts back to --- and any programmed
information is lost. Return to Logix Series Initial Power
Up.

35
13.0 742/762 Level II Programming
The Logix Series controllers are designed to operate by To enter Level II programming press and hold UP and
only setting the time of day and the day of the week. The DOWN for 5 seconds. A "P" value is displayed indicating
remaining settings have been set at the factory. These Level II.
default settings work for most applications.
SU MO TU WE TH FR SA DAYS

SET UP arrow Time & Day


Regen Time & Day
Salt Amount

Capacity
P
Hardness

DOWN For Regeneration


arrow P Value

To change a setting refer to Table 13.1. Level II menus include:


P1 = Time of day
Table 13.1 P2 = Day of week
Action Key Duration Display P3 = Time of regeneration

Enter basic Press and Shows time and P4 = Number of days between regeneration (99 day
SET calendar override)
programming Release day of week
P5 = Not used (742 only)
Move to UP or Increments
Press and P6 = Amount of regenerant used per regeneration or
desired DOWN through the
Release filter backwash time (salt setting)
display arrows displays
Enable setting Press and P7 = System capacity
SET Display flashes
to be changed Release P8 = Hardness
UP or Value changes P9 = Units of measure
Change Press and
DOWN and continues P10 = Clock mode
setting Release
arrows to flash
P11 = Service interval
Press and Display stops
Save setting SET P12 = Remote regeneration switch delay
Release flashing
P13 = Refill sensor control (conditioner only)
Normal
Return to Press and 0 = Off
REGEN operation
operation Release 1 = Salt detector only
display
2 = Chlorine generation
Press and
View history SET and P14 = Refill rate (conditioner only)
Hold for 5 HO is displayed
values DOWN P15 = Draw rate (conditioner only)
seconds
Level II Press and P16 = Reserve type
UP and
Advanced Hold for 5 P1 is displayed P17 = Initial average or fixed reserve
DOWN
Programming seconds P18 = Flow sensor select
The 742/762 features a special programming level that P19 = K-factor or pulse equivalent
allows the installing dealer to make changes to the
See the Logix Professional dealers manual for further
control for more demanding applications. The home
details on setting Level II parameters.
owner/end user should never have to access this level.

36
Table 13.2 Level I Parameters for 742/762 Single Tank Conditioner Systems

Parameter Range of Minimum Units of


Default Notes
Description Values Increment Measure

P1 Time of Day 1:00 - 12:59 AM 1 minute 12:00 PM hour: Range depends on value selected for
or PM minute P10
0:00 - 23:59

P2 Day of Week N/A 1 day None N/A Uses arrows under days of week on
overlay.

P3 Time of 1:00 - 12:59 AM 1 minute 2:00 AM hour: Range depends on value selected for
Regeneration or PM minute P10
0:00 - 23:59

P4 Calendar 0-99 1 3 days 0 = no calendar override,


Override .5 = regeneration twice a day at time
of regeneration and 12 hours later.
Calendar Override skipped if at least
one Day of Regeneration selected.
Can be locked out of changes in Level
1 programming

P5 Day of Week N/A 1 day None N/A Uses bars under days of week on
Regeneration overlay. Day of Week Regeneration is
skipped if calendar override is more
than zero. 742 only.

P6 Salt Setting 3-18 1 9 lbs/Ft3 Unit of measure depends on value in


50-290 varies 110 grams/liter P9

P7 Capacity of unit 1-900 1 (1) kilograins Unit of measure depends on value


(demand only) .1-90.0 .1 kilograms selected for P9.

P8 Hardness of 3-200 1 25 grains per Unit of measure depends on value


water 30-2000 10 400 gallon selected for P9. 762 mode only.
grams per
liter

Notes: (1) calculated depending on salt setting and resin volume. Capacity may be manually adjusted.

37
Table 13.3 Level II Parameters for 742/762 Single Tank Conditioner Systems

Parameter Range of Minimum Units of


Default Notes
Description Values Increment Measure

P9 Units of 0-1 1 (2) 0 = US,


measure 1 = Metric

P10 Clock mode 0-1 1 (2) 0 = 12 hour clock,


1 = 24 hour clock

P11 Service Interval 0-250 1 0 months Uses 30 days for each month.

P12 Remote 3-250 1 0 months Time remote switch must be active


Regeneration to start regeneration on 742 time
clock units.

P13 Chlorine 0-2 1 0 0 = No Chlorine Generator


Generator 1 = Salt check only
Options 2 = Generate Chlorine

P14 Refill Rate 1-700 1 (1) gpm x 100

P15 Draw Rate 1-700 1 (1) gpm x 100

P16 Reserve Type 0-3 1 0 0 = Variable reserve delayed


(3) regeneration
1 = Fixed reserve delayed
regeneration
2 = Variable reserve immediate
regeneration
3 = Fixed reserve
immediate regeneration

P17 Initial average 0-70 1 30 % of Depends on value entered in P16


(3) or fixed reserve Capacity

P18 Flow sensor 0-5 1 (1) 0 = Internal magnum NHWB,


(3) select 1=1 Autotrol turbine,
2=2 Autotrol turbine,
3=User define
K-Factor,
4=User defined Pulse Equivalent,
5=Internal Magnum HWB

P19 K-Factor or 1.00-99.99 0.01 0.01 K-Factor P18=3;


(3) Pulse 0-9999 1 1 Pulse Equivalent P18-4
Equivalent

Notes: (1) default selected with valve type and resin volume. (2) Factory Default is 0 for North America units and 1 for World
Units. (3) P16 through P19 skipped on 742 time clock units.

38
Table 13.4 Level I Parameters for 742/762 Single Tank 3 Cycle Filter Systems

Parameter Range of Minimum Units of


Default Notes
Description Values Increment Measure

P1 Time of Day 1:00 - 12:59 AM 1 minute 12:00 PM hour: Range depends on value selected for
or PM minute P10
0:00 - 23:59

P2 Day of Week N/A 1 day None N/A Uses arrows under days of week on
overlay.

P3 Time of 1:00 - 12:59 AM 1 minute 2:00 AM hour: Range depends on value selected for
Regeneration or PM minute P10
0:00 - 23:59

P4 Calendar 0-99 1 3 days 0 = no calendar override,


Override .5 = regeneration twice a day at time
of regeneration and 12 hours latter.
Calendar Override skipped if at least
one Day of Regeneration selected.
Can be locked out of changes in Level
1 programming

P5 Day of Week N/A 1 day None N/A Uses bars under days of week on
Regeneration overlay. Day of Week Regeneration is
skipped if calendar override is more
than zero. 742 only.

P6 Backwash Time 1-250 0 14 Minutes of backwash in 3 cycle filter


(3 cycle filter mode. Uses the arrow that points to
mode) salt amount on control in softener
mode.

P7 Capacity of unit 100-90,000 100 (1) gallons Unit of measure depends value
(demand only) 1-900 1 M3 selected for P9.

P8 Skipped

Notes: (1) default selected with valve type and resin volume.

39
Table 13.5 Level II Parameters for 742/762 Single Tank 3 Cycle Filter Systems

Parameter Range of Minimum Units of


Default Notes
Description Values Increment Measure

P9 Units of mea- 0-1 1 (2) 0 = US, 1 = Metric


sure

P10 Clock mode 0-1 1 (2) 0 = 12 hour clock, 1 = 24


hour clock

P11 Service Interval 0-250 1 0 months Uses 30 days for each


month.

P12 Remote 3-250 1 60 seconds Time remote switch must


Regeneration be active to start regener-
ation on 742 time clock
units.

P13 Skipped

P14 Skipped

P15 Skipped

P16 Reserve Type 0-3 1 0 0 = Variable reserve


(3) (demand only) delayed regeneration
1 = Fixed reserve delayed
regeneration
2 = Variable reserve
immediate regeneration
3 = Fixed reserve
immediate regeneration

P17 Initial average 0-70 1 30 % of Depends on value entered


(3) or fixed reserve Capacity in P16
(demand only)

0 = Internal magnum
NHWB, 1=1 Autotrol
Flow sensor turbine, 2=2 Autotrol
P18
select (demand 0-5 1 (1) turbine, 3=User define
(3)
only) K-Factor, 4=User defined
Pulse Equivalent,
5=Internal Magnum HWB

P19 K-Factor or 1.00-99.99 0.01 0.01 K-Factor P18=3;


(3) Pulse 0-9999 1 1 Pulse Equivalent P18-4
Equivalent

Notes: (1) default selected with valve type and resin volume. (2) Factory Default is 0 for North America units and 1 for
World Units. (3) P16 through P19 skipped on 742 time clock units.

40
14.0 Cycle Time Programming
Cycle times may be viewed by pressing and holding the Table 14.1Cycle Times
UP and SET keys for 5 seconds when the control is in the
in service mode. The display shows the small C in the Magnum Valves 293/298
lower portion of the display indicating the control is in
cycle times programming. Pressing the UP and DOWN Description Default (min) C# Displayed
keys displays the programmed time remaining in each
cycle. Pressing the REGENERATION key exits the cycle 1-Backwash 14 1
times display mode. 2-Draw (1) (3) 2 (2)