Troubleshooting #
System Troubleshooting #
Problem: Pump inlet pressure switch fails to close after start-up (PRS1)
Potential Causes/Solutions:
- Municipal Water Supply is turned OFF to unit
- Verify municipal water is turned ON
- Air supply is OFF or is adjusted to less than 80 psi needed to open ASCO 8290 air operated valves. A leak in the air line to the valve can also create this fault
- Verify that the air supply is 80 psi
- Carbon Block has high pressure drop due to debris or clogged blocks
- Verify Valve A is actuating (red indicating nipple visible on head of valve)
- A failed switch (or corrosion in the connector) can cause a high resistance and cause the system to fault
- Verify sensor cable is installed correctly
Problem: Reduced RO flow rate (PRS2)
Potential Causes/Solutions
- Restriction in the RO flow loop (lines, membranes, recirculation loop, reject orifice, etc) which increase the RO pump pressure rapidly during operation. A spike in pressure above the setpoint will result in a shutdown.
- Verify there is nothing clogged in the system
- Damaged membranes which are fouled are restricting the RO flow, commanding higher pressure.
- Replace membrane if flow is 20% lower than the target for the tank level at which you are operating
- Water temperatures lower than 40F will create a reduced RO flow rate. The membrane flow will drop approximately 2% for each degree F the water temperature drops below 77F. As the water reaches 40F, the pump pressure required to generate flow reaches a maximum pressure.
- If the feed water is consistently at or below 40F, consider installing an in-line water heater or a hot water mixing water.
- If the water feed temperature is always low (40-50F), consult with innovateIT for a recommendation on a cold-water membrane (DuPont XLE-440i membrane would improve cold weather performance)
Problem: RO production cycle not starting as tank drops
Potential Causes/Solutions
- Tank level sensor is disconnected or has failed
- Verify the connector pin (longer pin connect to GND), drain tank and replace sensor if necessary
- The PLC calibration screen which allows the system to function is set for an incorrect storage tank height storage tanks
- Re-span tank to recalibrate level sensor
- The 0-5 psi sensor allow use of tanks up to 11.5 foot tall if needed for a non-standard installation
- Re-span tank to recalibrate level sensor
Problem: Recirculation flow switch not closing
Potential Causes/Solutions
- This switch will not close if the RO pump pressure is less than 70 psi.
- Increase production flow rate in the HMI setting screen.
Problem: Re-pressurization pump flow switch
Potential Causes/Solutions
- Repress pump does not turn on
- Verify switch operation by removing switch and manually activating the switch to ensure the switch closes as flow increases.
- Valve D is not opening
- Enter MANUAL mode and bump start transfer pump
- Too much resistant after Valve D
- Ensure the plumbing line is not shut off by a ball valve or other impedance further downstream
HMI Fault Codes #
- 1 – SENSOR 01 (FLOW METER) SIGNAL FAULT
- Delay: —
- Cause: Signal could be high/low, or sensor disconnected
- 2 – SENSOR 02 (TANK LEVEL) SIGNAL FAULT
- Delay: —
- Cause: Signal could be high/low, or sensor disconnected
- 3 – SENSOR 03 (PRODUCTION PUMP DISCHARGE PRESSUERE) SIGNAL FAULT
- Delay: —
- Cause: Signal could be high/low, or sensor disconnected
- 4 – SENSOR 04 (CARBON FILTER INLET SENSOR) SIGNAL FAULT
- Delay: —
- Cause: Signal could be high/low, or sensor disconnected
- 5 – SENSOR 05 (CARBON FILTER OUTLET SENSOR) SIGNAL FAULT
- Delay: —
- Cause: Signal could be high/low, or sensor disconnected
- 6 – SENSOR 06 (TEMPERATURE SENSOR) SIGNAL FAULT
- Delay: —
- Cause: Signal could be high/low, or sensor disconnected
- 7 – PUMP DISCHARGE LOW PRESSURE SWITCH FAILED TO CLOSE
- Delay: 20s
- Cause: Pressure switch located before the inlet to the pump is too low
- 8 – PUMP DISCHARGE VFD FAULT RELAY
- Delay: 5s
- Cause: VFD is faulted
- 9 – TRANSFER PUMP MOTOR STATER OVERLOAD RELAY
- Delay: 5s
- Cause: Overload relay tripped
- 10 – PRODUCTION PUMP PRESSURE OVER LIMIT
- Delay: 10s
- Cause: Production pump is creating more than 200 psi
- 11 – CARBON FILTER DIFFERENTIAL PRESSURE TO HIGH
- Delay: 3s
- Cause:The differential pressure between the carbon filter sensors is too high
- 12 – PRODUCTION PUMP FEEDBACK SIGNAL BAD QUALITY
- Delay: 10s
- Cause: Check signal wiring from the pump
- 13 – PRODUCTION PUMP IS NOT RUNNING
- Delay: 10s
- Cause: Run status relay on pump did not close
- 14 – TRANSFER PUMP FLOW SWITCH IS OPEN
- Delay: 30s
- Cause: No flow was detected after the production pump. Check Valve D – sensor could be stuck or Transfer Pump never ran.
- 15 – LOW PRESSURE DURING CLEAN/FLUSH MODE
- Delay: 5s
- Cause: Flow meter is reading less the 1gmp during flush
- 16 – CONCENTRATE FLOW SWITCH FAIL TO CLOSE
- Delay: 5s
- Cause: No flow was detected through the concentrate return line. Sensor stuck or pump never ran.
- 17 – PRODUCTION TANK HAS OVERFILLED OR IS IN TROUBLE
- Delay: —
- Cause: Production tank over flowed, valves may be stuck open
- 18 – EMERGENCY STOP HAS BEEN DEPRESSED
- Delay: 1s
- Cause:E-Stop engaged
- 19 – PRODUCTION TANK WAS NOT SPANNED. DEFAULT VALUE USED.
- Delay: —
- Cause:Fill the tank and set the span on the maintenance screen – value should be around 2500
- 20 – CARBON FILTER INLET & OUTLET SENSORS REVERSED
- Delay: —
- Cause: Carbon filter sensor see a -2psi difference, sensor is plugged in backwards
- 21 – VALVE B FAILED TO OPEN
- Delay: 10s
- Cause:Flow meter seeing less than .5 gpm during run mode