Installation Preparation #
#
Installation Requirements #
Listed below are all the critical water specification limits and the required pre-treatment regimens.
Note: Failure to properly pre-treat the water may result in reduced membrane life and premature membrane failure and is not covered under the limited warranty.
Feed Water Limits and Recommended Pre-Treatment Approach
|
Specification Limit |
Recommended Pre-Treatment |
|
Water Hardness < 1 grain |
Ion-exchange Water Softener |
|
Iron (Fe) < 0.1mg/L |
Iron Filter |
|
Free Chlorine (Cl2) < 0.1 mg/l 0.1 PPM |
Activated Carbon |
|
Turbidity (dirt) SDI < 5 |
5 Micron Sediment Filter |
|
Manganese (Mn) < 0.05 mg/l |
Ion-exchange Water Softener |
|
Hydrogen Sulfide (H2S) > 0.0 mg/l |
Oxidation, Aeration |
|
Organics > 0.0 mg/l |
Activated Carbon |
|
Total Dissolved Solids 1,000 mg/l (maximum) |
Feed water must be below 1000 mg/l |
Pre-Treatment Solutions
Water Softener
For best performance and life of the RO membrane, it is recommended that the RO unit should use soft water (less than 1 grain hardness).
The capacity of the softener needs to be sized to provide continuous soft water during the RO system operation. There are options to achieve the necessary soft water volume with ability to regenerate during RO operation (multiple tanks with coordinated regeneration controller) or scheduling regen to occur after the wash is closed and the RO tank has completed the cycle to re-fill the storage tank.
Carbon Block for Chlorine Removal
Most municipal water supplies treat their water with either chlorine or chloramine. Some water suppliers will use a combination of chlorine and chloramine or change the treatment from season to season, so you must contact your municipal water supplier and determine if the water treatment will result in free chlorine in the feed water.
The DOW RO (TFC type) membranes are not tolerant towards free chlorine and as such require a chlorine filter system to remove free chlorine from the feed water. Properly sized activated carbon filters or catalytic carbon filters provide the ability to remove the free chlorine from the feed water.
A weekly check needs to be performed to ensure the carbon filter system is functioning properly and the level of free chlorine measures 0.0 PPM during system operation.Membrane failure due to chlorine exposure occurs in less than 200 hours (8 days) when exposed to a 0.5 PPM level of free chlorine.
It is critical that the carbon removal system be inspected (check chlorine removal performance, verify clock and back wash settings of filter, verify lift of media during back wash cycle) once per week.
Note: Operating the system with a depleted or non-functioning chlorine filter will immediately start to damage the RO membranes and void any warranty from the membrane manufacturer.
Additional Feed Water Pre-treatment
Water quality varies significantly in different area of the country. In addition, municipal water supplier add chemicals and adjust pH levels in the water to prevent corrosion in the distribution lines.
A water analysis should be performed at each new site to ensure that the water and pre-treatment solutions are compatible with the RO membranes.
The unit has been designed to utilize 480 VAC 3 Phase power with ground from the facility. Review the electrical schematic for required current ratings and integration of the system controller.
The primary RO pump is 7.5 HP and the re-pressurization pump is a 1.5 HP pump.
RO Power requirement is 15A, 3 Phase 480VAC fed by a trip class 10 or higher. Wiring and conduits as permitted by local code.
Solenoid D is operated by the System Controller and uses a 24 Volt DC signal to the RO System Controller. This signal is converted to a 24 Volt signal to be used in the controller.
WARNING #
The 24vac signal from the system controller can only be turned on or off at the wash controller. The 24vac signal power must be turned off at the system controller relay before opening the RO system controller for maintenance.
Installation Preparation #
RO System installation must conform to local plumbing, electrical, and sanitation codes. It is the customer’s responsibility to obtain all permits and install equipment to conform to all state and local codes.
Water Supply
The water supply must be able to supply a minimum of 25 GPM (Standard Flow/35 GPM (High Flow) at 40-60 psi to the RO unit. The flow lines need to be sized to minimize pressure drops per accepted plumbing design guidelines.
Normal operating feed flow will vary between 10 and 22 GPM depending on water temperature. At this condition, the feed water pressure should not exceed 70 psi. A pressure regulator has been installed in the feed line to reduce the water pressure to a consistent 40 psi level.
If you are using a booster pump, set the booster pump to 60 psi.
Carbon Media Filter (Clack Valve) – OPTONAL
If the municipal water treatment uses high concentration of Chloramine for sanitizing the water it may be recommended that the operator utilize a standard carbon filter. This would consist of a 10 cubic foot catalytic carbon filter with a conventional filter head.
If this approach is used, the Clack Valves located on the chlorine filter requires a 115 VAC, 1 Amp, waterproof grounded receptacle to support the Clack low voltage power supply.
Floor Drain
All water drains and overflow lines must drain to the floor drain. Plumbing should be constructed to allow a visual indication of water flowing to the drain to help diagnose proper system operation.
Note: The RO Reject tank overflow line must be sized to gravity flow 15 GPM during the initial start-up and check-out of the system. Water lines from the RO System to the RO Product and RO Reject Tanks should be sized to minimize pressure drops.
Lines should be sized for a maximum flow velocity of 120 inches/second.
Compressed Air Supply
The pilot-operated solenoid valves require a supply of compressed air to operate.
Install a compressed air supply line on the back wall of the equipment room in the vicinity of the RO unit. Add a ball valve and fitting to allow running an air-line to the pressure regulator/water separator located on the RO frame.
This air supply is required to operate the ASCO 8290 air operated solenoid valves. The air solenoids are located inside the RO system controller.
The supply pressure must be between 80-150 psi. The regulator should be adjusted to provide a minimum of 80 psi to the pilot solenoid valves.
The water separator should be checked on a daily basis to ensure dry air is supplied to the solenoid valves. Water should not be present in this separator if the main compressor filter is working properly.
Two Stage Carbon Block System For Chlorine Removal
The innovateIT RO System uses single stage carbon block to remove chlorine from the feed water. The front two housing hold the first stage blocks and the housing at the back of the frame hold the second stage blocks.
Sampling ports have been located at the top of each housing and water samples need to be taken while the unit is running to verify that the chlorine level has been reduced to below 0.10 PPM of free chlorine.
The maintenance plan is to check the chlorine level on a weekly basis and replace the blocks when there is any indication that chlorine is breaking through the carbon block. The testing should be done with a FREE CHLORINE meter and breakthrough would be any reading above 0.10 PPM of free chlorine.
Timing of replacement will be dependent on the free chlorine level of the feed water. However, it is anticipated that a first stage blocks should remove the free chlorine for approximately 100,000 cars.
When chlorine breakthrough is seen, remove the first stage blocks (front blocks) and replace with the second stage (rear blocks). Then place new carbon blocks in the rear filter housings. This approach ensures that no chlorine reaches the RO membranes.
If the municipality is using chloramine (chlorine and ammonia mixture) for sanitizing, the blocks may require more frequent replacement. In addition, only Empress Catalytic Carbon blocks should be used for removal of chloramines.
Note: The carbon blocks provide a 3 micron filtering function and do not require a sediment filter for low turbidity municipal water.
If the unit is operating with higher turbidity water than a 5 micron sediment filter should be installed before the carbon blocks to prevent particles from clogging the pores in the carbon block.
Placement #
Locate where the equipment will be installed with your installer. The RO Unit should be located 4-6 inches from the back wall.
There are a total of three water lines that must be attached to the unit:
- Municipal Water Feed – 1.5″ female NPT Hose (minimum)
- RO Reject to RO Reject Tank – 1.5″ female NPT Hose
- Re-pressurization Pump to Tunnel – 1.0″ female NPT Hose
Use 200 psi hose (Eaton BOSFLEX or equivalent) and heavy duty stainless steel hose clamps on every connection to ensure reliable operation. Lines should be positioned to minimize bends and lines from tanks should hang in a manner to minimize loading on the stainless fittings.
If needed, install additional clamps or hose supports to RO frame to reduce movement of hoses during operation.