GE E4-11000, Operation And Maintenance Manual

Page 1: ...1 E4 E4LE EZ4 Series Water Purification Machines Operation and Maintenance Manual 2 200 GPD to 13 200 GPD 8 3 m3 day to 50 m3 day July 4 2014 Document PN 1161875 Rev G http www gewater com ...

Page 2: ...entrate Outlet Connections 9 2 5 Feed Water Requirements 10 2 6 Transporting Pure Water Permeate to Point of Use 10 2 7 Pressure Correction Factors 10 2 8 Electrical 11 2 8 1 Single Phase Electrical 11 2 8 2 Three Phase Electrical 11 2 9 Machine Control 12 2 9 1 Economy Model 12 2 9 2 Deluxe Model 12 3 PREPARATION AND STARTUP 12 3 1 Pretreatment for Water Purification 12 3 2 Machine Start Up Prepa...

Page 3: ...MEMBRANE MACHINES 26 List of Tables Table 1 Flow Specifications for E4 Machines 50 75 Recovery 8 Table 2 Connections 8 Table 3 Feed Water Requirements 10 Table 4 Pressure Correction Factors 10 Table 5 Troubleshooting Guide 22 List of Figures Figure 1 Normal vs Crossflow Filtration 5 Figure 2 Membrane Element with Interconnectors 5 Figure 3 Cross Sectional View of Membrane Element 6 Figure 4 Princi...

Page 4: ...e Qc The flow rate of water containing rejected solids to drain in gpm or gph lpm or m3 h 1 1 3 Feed Rate Qf The flow rate of incoming water in gpm or gph lpm or m3 h Feed water rate equals permeate rate plus concentrate rate 1 1 4 Reverse Osmosis RO The separation of one component of a solution from another component by means of pressure exerted on a semipermeable membrane In other words reversin...

Page 5: ...pacer allows for movement of the concentrate past the membrane and the permeate carrier carries the purified water out of the membrane element GE Water Process Technologies manufactures a patented spiral wound membrane element with a turbulent flow design This membrane module collects the purified water within the central tube the permeate tube The E8 RO machine utilizes between 8 and 20 membrane ...

Page 6: ...Concentration Cc Concentrate Concentration Cavg Average Concentration in Machine 1 1 9 Salt Ionic Passage The percent of dissolved salts passed through the membrane or 100 minus rejection 1 1 10 Recovery Permeate rate divided by feed rate expressed as a percentage For example 33 recovery means that out of a given feed rate 33 is produced as purified water permeate 1 1 11 Salt Ionic Rejection The p...

Page 7: ...way as to indicate the permeate flow you can expect from the machine and other specifications Example RO E4 4400 DLX 460 6 HR PA RO indicates the machine is a reverse osmosis machine E4 indicates the machine series E and 4 inch housings membrane elements 4400 indicates the rated permeate flow in thousands of gallons per day at 77 F 25 C i e 4400 4400 gallons per day DLX indicates the deluxe model ...

Page 8: ... for membrane element removal and loading If space is not available the entire membrane element housing can be removed for membrane element change outs If the membrane element housings are to be removed to change out the membrane elements at least 6 inches 15 2 cm is required at the end of each membrane element housing and 24 inches 61 cm behind the machine 2 2 Plumbing The feed water source must ...

Page 9: ...T 2 4 Concentrate Outlet Connections Connect proper size drain line to the concentrate outlet Table 2 and run to an open drain The drain capacity needs to be large enough to properly drain the feed water flow of the RO The maximum concentrate back pressure is 60 psig 4 1 barg for the RO machine CAUTION Operation above 60 psig 4 1 barg concentrate back pressure may damage the machine CAUTION A vacu...

Page 10: ...89 American Standard for Testing Materials 2 6 Transporting Pure Water Permeate to Point of Use The pure water or permeate is in an aggressive state and should only be transported from the machine to the point of use in food grade flexible nylon stainless steel SS tubing or polyvinyl chloride PVC material for the inlet permeate and concentrate piping sizes Refer to Connections Table 2 for inlet pe...

Page 11: ...stomers must provide electrical plug 2 8 2 Three Phase Electrical The three phase pump motor requires a 15 AMP dedicated circuit Always verify correct voltage and Amp rating by checking voltage tag on the starter box or by checking electrical specifications on the pump The motor is wired for 460 Volts 60 Hertz three phase voltage from the factory Figure 5 Three Phase Allen Bradley Motor Starter Th...

Page 12: ...are normally closed dry contacts 2 9 2 Deluxe Model To remotely control the Deluxe Model DLX with float switches and or pretreatment lockout remove the jumper noted on the electrical drawing and wire in the float switches and pretreatment components in series After all field wiring is complete and complies with local and national electrical codes move onto Section 3 1 Pretreatment for Water Purifi...

Page 13: ... Turn the feed water supply ON while checking for leaks in the pretreatment and inlet feed water lines Check to ensure power to the motor is de energized and the ON OFF button on the machine is in the OFF position Plug in the factory supplied power for the control voltage For initial start up redirect the permeate and concentrate lines to the drain Open the concentrate and recycle flow control val...

Page 14: ...ration at 77 F 25 C E4 Series 220 psi 15 2 bar at 77 F 25 C EZ4 E4LE Series 115 psi 7 9 bar at 77 F 25 C While you are doing these valve adjustments to obtain correct flows and pressures observe the primary or pump pressure The pump pressure while adjusting the orifices should never operate outside of these ranges E4 Series Range 190 275 psi 13 1 19 0 bar EZ4 E4LE Series Range 100 140 psi 6 9 9 6 ...

Page 15: ...eal way to set the timer is to program ten Autoflush sequences with a 10 to 15 minute duration per 24 hours To do this follow the procedure in the Technote 126 containing the programming manual for the Autoflush Timer 3 6 Calibrating the Conductivity Probe 1 Make sure the calibration meter is in Measure Mode with the MEAS LED light ON 2 Immerse the Conductivity Probe in a HI 7033 prepared calibrat...

Page 16: ...concerning the operation of your machine or the method of data recording contact the manufacturer Three preventative maintenance procedures which must be done on a regular basis are as follows 1 Change the pre filter cartridges as needed Pressure drop across the pre filters should not exceed 8 psi 0 6 bar 2 Clean the RO membrane elements with approved cleaners at least quarterly depending on feed ...

Page 17: ...ressure drop across the filter of 8 psi 0 55 bar or more during operation indicates that the pre filters cartridge s need changing Use only GE approved filters rated for 5 microns or less Do not attempt to clean used filters IMPORTANT NOTE Failure to change the pre filter cartridge according to these requirements will void machine warranty 4 3 Membrane Element Cleaning GE recommends that you clean...

Page 18: ...trate to return to the CIP container When set properly the RO machine the CIP pump and the CIP container should be assembled in a loop configuration to recirculate the water through the machine and back to the container during cleaning The size of the CIP container should be a minimum of three times the permeate rate CAUTION GE recommends the use of a CIP or booster pump to provide the proper feed...

Page 19: ... before returning to normal operation 9 After permeate quality is verified as good route the permeate to point of use and concentrate to drain You are now ready for normal operation 4 4 Suction Cleaning GE does not recommend the suction cleaning method to clean the E4 Series RO machine If using suction cleaning reference cleaning with a CIP pump above Section 4 3 2 Procedure to Clean with a CIP Pu...

Page 20: ...ll times in to prevent possible damage to the membrane element material 1 Remove the top end caps and clamps from the membrane element housings Lubricate all O rings and brine seals and the PVC membrane element stems stingers with a non petroleum based lubricate i e glycerin or poly water 2 Load the down flow membrane elements first by inserting the membrane element into the membrane element housi...

Page 21: ...l the end cap on the membrane element by first aligning the stinger into the hole in the end cap and then turn the end cap slowly clockwise as you push it down into the membrane element housing 5 Reattach the housing clamp and tighten 6 Next reconnect the permeate and concentrate lines The machine is ready for start up ...

Page 22: ...e feed pressure open the inlet feed valve check for restrictions and consider installing a feed water boost pump Clogged pre filter Replace the pre filters Solenoid valve not opening Clean or replace the solenoid valve Clean air line for adequate pressure Check regulator for correct operation and setting Low operating pressure High flow rates Close the orifice bypass valve check the permeate and c...

Page 23: ...te manually with a stopwatch and calibrated container such as CIP tank Low concentrate flow rate normal or higher than normal pressure Concentrate valve plugged Disassemble and the clean the plumbing to the valve Concentrate outlet line restricted Examine the concentrate line for obstructions or a closed valve Flow meter inaccurate Check the flow rate manually with a stopwatch and calibrated conta...

Page 24: ... through the inlet when the machine is off Repair or replace valve components as necessary Declining rejection high permeate conductivity Dirty or fouled membranes Clean the membranes O ring seal broken or damaged Replace the O ring check the sealing surfaces on the O ring groove interconnectors and end caps Replace damaged parts NOTE This typically only happens immediately after membrane installa...

Page 25: ...mp draw of the motor No power to machine Check the fuses or circuit breakers measure the voltage Deluxe DLX Electrical machine shutdown Alarm condition has turned off machine Restart the machine by pushing the alarm bypass Check all possible alarm conditions inlet pressure and push alarm reset switch Motor and or pump not operating properly See the pump instructions Contact GE for repair of replac...

Page 26: ...UTHORIZATION RGA PROCEDURE Refer to addendum Technote 114 8 WARRANTY GUARANTEE Refer to addendum Technote 100 for the machine Warranty Guarantee document 9 START UP DATA Refer to addendum Technote 101 for the machine startup data sheet document 10 DAILY LOG DATA FOR GE WATER AND PROCESS TECHNOLOGIES MEMBRANE MACHINES Refer to addendum Technote 106 for the daily log data sheet document ...