The innovateIT R.O. System has been designed to provide a long life and require minimum maintenance. The best method to maintain this system is to take a few minutes daily to review and record the operational data from the system and examine the unit for leaks or any indication of a mechanical or electrical fault.
If a change in performance or operation is observed, it is essential to take corrective action quickly to minimize the potential damage to the membranes or other parts of the system.
There are elements of the system that will require replacement during normal maintenance actions. These items are listed in the following section.
Replacement Parts #
Catalytic Carbon Block Assembly #
NOTE: The standard activated carbon blocks are highly effective in removing free chlorine from feed water that has been treated with chlorine. However, chloramines are harder to remove and require special catalytic carbon blocks to remove the chloramine.
Based on your municipal water supplier, water treatments vary significantly across the country with many differing levels of sanitizing agents used and variation throughout the year.
Please consult with innovateIT Car Wash Equipment LLC to determine the type of carbon block to use and the estimated replacement interval as the dosing level in PPM, water pH, and chloramine mixture will greatly impact the performance of the carbon blocks. If the estimated life of the carbon block is too short, innovateIT Car Wash Equipment will recommend the use of a traditional carbon filter.
innovateIT uses a Catalytic Carbon Block to remove both chlorine and chloramine to maximize the longevity of the membrane.
Carbon Filter #
Verify free chlorine/chloramine level on the outlet of the carbon filter manifold. This should be done every week, and the carbon filter must be replaced if the unit is not removing the chlorine/chloramine from the municipal water (<0.10 PPM)
Some municipalities increase chlorine/chloramine levels for a few months each year to sanitize the distribution system so verifying complete chlorine removal is critical to proper operation of the system.
RO Membrane System (Membranes and O-Ring Seals in Housing) #
Clean or replace membranes when the TDS levels exceed 20PPM, or the RO generation flow rate reduces by 20% of the design flow rate.
Membrane failures are normally initiated by free chlorine “breakthrough,” which damages the membranes by creating holes in the membrane.
Every effort has been made to utilize the best equipment available to ensure long life and low maintenance costs, as some car wash systems accumulate thousands of cycles per day.
Pressure Switches #
The Dietz pressure switch PS1 has a design life of over 1 million cycles.
ASCO 8290 Air Vales (A-D) #
These valves are designed for multi-million cycle design life, which converts to a 5–10-year lifespan in most car wash systems. Solenoid Valve D will experience the highest cycle counts and a spare should be available once the unit reaches 1 million cars.
Air Pilot Valves #
These valves typically have a multi-million cycle life.
The Grundfos pumps are designed for a 20,000-hour life. Units have successfully provided RO for over 3 million cars without pump repair or replacement.
Electrical/Controller Hardware #
The motor contactors for the Transfer Pump experience high cycles in the car wash application. It is recommended that the operator contact innovateIT help for spare parts.
The Overload Relay for the Production Pump will also experience high cycles during busy day, so having an extra parts in hand is recommended.
The PLC controller and associated equipment are reliable unless the ambient temperature of the controller exceeds the maximum temperature (104 F ambient) for UL508 Standard.
Maintenance Schedule #
Checking Free Chlorine Level
- While the unit is running, drain out a small amount of sample water from an outgoing ball valve on the carbon filter manifold. The ball valve has ¼” push connect build in for ease of use (fig. 6.2 – 1).
- If the result of is free of chlorine (0.00 PPM or <0.10 PPM) the unit carbon filter is working well. If not, the carbon filter will need to be replaced.
fig. 6.2 – 1 – Carbon filter ball valve
NOTE: If not replace soon, the chlorine will damage the membrane on the unit.
Visual Inspection (Leaking/Bad Hose)
- Check for Leak/Dripping water from connection/manifold, pumps, etc.
- Verify there is no bad hose (bend, crink, bad connection and rips).