System Startup #
ELECTRICAL INSTALLATION TO BE PERFORMED BY A QUALIFIED ELECTRICIAN. FOLLOW ALL LOCAL CODES.
NOTE: Before starting up a unit, please make sure to refer to the Installation Requirements and Installation sections in this Reverse Osmosis Instruction Manual before activation.
NOTE: Verify phase rotation from utility power supply to the R.O. System. This is critical for pump rotation to operate correctly
Going to START mode (which starts the RO pump) before purging air from the pump can result in compromised pump shaft seal or, if left long term, may require the pump to be replaced
- Verify all drain ports are closed (membrane housing, carbon manifold, and RO tank)
- Set the air regulator to 80 PSI. Slowly turn on the municipal water.
- Press down the red air valve on top of the carbon housing to bleed air out of carbon housing.
- Release carbon tank air valve when water stream is developed from the red valves.
- This process may take 10-15 MINUTES or more but it is a critical step to protect the system during initial start-up or after any maintenance during which air could enter any part of the system.
- Turn on the utility power from the wash to the R.O. System.
- Turn 480VAC Main Disconnect switch to ON position (on the front of the enclosure)
- Press the power button on the HMI and wait until the Overview Screen appears. verify the HMI screen is the same as the one in fig. 5 – 1. If not, please contact support@innovateITcarwash.com for more information. 9.
- Place the unit in MANUAL mode before moving to the air valve testing page (fig. 5 – 1).
fig. 5 – 1 – HMI Overview Screen
- Navigate to the AIR VALVE TESTING PAGE by pressing the square in the upper right corner of the HMI and verify Valve A is open (fig. 5 – 2).
fig. 5 – 2 – Air Valve Testing Page
- Loosen the Production Pump priming vent plug (fig. 5 – 3) with a 10mm wrench until there is constant stream flowing, then tighten the vent plug.
- Verify there is a constant stream of water flow out of the check valve.
- Verify all the air out of the pump, lines, and membranes before operating the production pump. This process will take 30-40 sec after Valve A is open. Valve A needs to remain open to allow water to start filling the RO storage tank in order to bleed the re-press pump before operation. This also allows time for municipal water to saturate the membranes.
fig. 5 – 3/4 – Production Pump (left) and Transfer Pump (right) priming vent plug
- Loosen the Transfer (Re-Pressurization) Pump priming vent plug with a 10mm wrench until there is constant stream flowing then tighten the Vent plug back in (fig. 5 – 4).
- Cycle all the valves on the Air Valve Testing page by opening and closing each valve (B, C, D, and E).
- Verify the direction of rotation of the pump motors. The correct direction of rotation is shown by the arrow on the black casing by the priming vent valve (fig. 5 – 5-6). The motor direction should be counterclockwise when viewed from the top.
NOTE: Verify that both Grundfos Transfer Pump and Production Pump motors are rotating correctly. This needs to be done by the electrician prior to completing electrical installation.
NOTE: If the pump fan rotate clockwise, stop the pump and turn off the Main disconnect and the utility supply power.
fig. 5 – 5/6 – Production Pump (left) and Transfer Pump (right) motor rotation direction
- To (Bump start) both Grundfos pumps (Transfer Pump and Production Pump), press Open (Pump ON) for a second, then press Close (Pump OFF) (fig 5 – 7).
fig. 5 – 7 – Bump starting Production and Transfer Pumps
- Repeat steps (10-14). This process will eliminate any air trapped in the pumps.
- Check the system for leaks and repair any leaks before continuing operation.
NOTE: Default Tank span is set to 2500SP but can be adjusted to a higher number if needed (Follow steps 20-23).
- Navigate to the MAINTENANCE screen by pressing the Maintenance button on bottom of the HMI. (fig. 5 – 7)
- Press START (Tank Fill) to fill the tank with municipal water from solenoid E. (fig. 5 – 8).
- Press the STOP when water is at top of the tank (first elbow). 2500SP is recommended.
- Press Set (Tank span).
Fig. 5 – 8 – HMI Maintenance Screen
NOTE: To avoid tank overflow the RO unit will not operate if the Tank level sensor is reading a current outside of the 4-20mA sensor operating limits.
- Return to the OVERVIEW screen and place unit in AUTO mode by selecting START (fig. 5 – 9).
fig. 5 – 9 – HMI Overview screen and Start button
- Verify tank is filling.
- Verify Reject water is flowing to the reject.
- The initial RO water produced by the unit will need to be dumped down the drain. During the first 2 hours of RO production the water is high concentrate.
- The initial TDS from the unit will be high (50-150 PPM) because of manufacturing chemicals rinsing from the dry membrane.
- The TDS will slowly go down as the unit operates, stabilizing in the 1-20 PPM TDS range (based on the TDS of the feed water) within the first few hours of operation.
- If the TDS of the RO remains higher than 20 PPM a seal in the RO housing may be damaged.
- Operator will need to identify the damaged seal ring and replace it. (See Troubleshooting section for more information)
- With new membranes, normal TDS will remain below 10 TDS.
- Verify the RO Pump shuts down once the RO tank is FULL, and the unit goes into flush mode after 15min of inactivity.
- During the FLUSH CYCLE air valves A and C close, and air valve B opens.