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USFilter FlowMAX FM Series Operation And Maintenance Manual

Single pass reverse osmosis unit
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Operation and
Maintenance
Manual
FlowMAX
FM Series
FS Series
Single Pass
Reverse Osmosis Unit
Model # FMX-XX
Colorado Springs
Job # XXXXX
USFilter
10 Technology Drive
Lowell, MA 01851 USA
Tech Support (800) 783-7873
Rev. B Issue Date: 05/1999
Customer Service (800) 466-7873
P/N 68/S8601

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Summary of Contents for USFilter FlowMAX FM Series

  • Page 1 FM Series FS Series Single Pass Reverse Osmosis Unit Model # FMX-XX Colorado Springs Job # XXXXX USFilter 10 Technology Drive Lowell, MA 01851 USA Tech Support (800) 783-7873 Rev. B Issue Date: 05/1999 Customer Service (800) 466-7873 P/N 68/S8601...

  • Page 2: Table Of Contents

    Membrane Element Replacement Troubleshooting Recommended Spare Parts RO Membrane Element Long Term Storage Procedure RO Membrane Element Cleaning 5-10 APPENDIX RO Data Collection Form RO Operating Specification Sheet QA Data Sheet Drawings Component Manufacturers Literature M.S.D.S Sheets USFilter United States Filter Corporation...

  • Page 3: Manual User's Guide

    INTRODUCTION 1.1 MANUAL USER’S GUIDE This manual describes the procedures necessary to install, operate, and maintain your USFilter Reverse Osmosis System. Please read this manual carefully before installing and operating your equipment. The equipment warranty may be voided if installation or operation instructions are not followed correctly.

  • Page 4: Disclaimer Statement

    USFilter Service Department. USFilter reserves the right to make engineering refinements that may not be reflected in these manuals. The material in these manuals is for informational purposes and is subject to change without notice.

  • Page 5: General Safety Guidelines

    Refer to Material Safety Data Sheets prior to handling hazardous chemicals. Always operate the equipment at the parameters specified. Never connect the system to piping that has not been approved by USFilter. If there are any doubts, please call your USFilter local branch.
  • Page 6 Safety glasses are to be worn at all times. Earplugs should be worn when encountering high levels of noise. Gloves that offer protection from the chemicals used herein. Steel toe work boots for protection against heavy equipment and components. USFilter United States Filter Corporation...

  • Page 7: Equipment Description

    Appendix for further clarification. MAX Membrane Systems are the standard 8” RO product line for USFilter . There are four different sub groups of MAX RO units, tailored to the specific needs of the pharmaceutical and beverage industry as well as general industrial and commercial applications.
  • Page 8 These units are available with either Filmtec BW30-365 or BW30-440LE membrane elements, and Codeline FRP, side port, direct connect, pressure vessels. The standard control package is a C2000 control system. The feed piping and product piping is PVC. The flow is measured with rotameters. USFilter United States Filter Corporation...

  • Page 9: Theory Of Reverse Osmosis

    Reverse Osmosis Reverse Osmosis is the reversal of this natural phenomenon, by the application of external pressure on the solution that contains the higher concentration of dissolved ions, thus forcing USFilter United States Filter Corporation...
  • Page 10 Practical Applications Reverse osmosis becomes practical for water treatment when synthetic, semi-permeable membrane material is packaged in a suitable membrane element. Typically the elements are USFilter United States Filter Corporation...
  • Page 11 In this case, the feed water to the unit is first split into two streams with each half being directed into one of the first stage vessels. On entering these two vessels, some product USFilter United States Filter Corporation...
  • Page 12 RO reject of approximately 120 PPM which is the limit of it's solubility. If you tried to recover 80% of the water, the concentration of SiO would reach 5 times the feed water concentration or approximately 150 PPM and start to precipitate, fouling the membrane surface. USFilter United States Filter Corporation...

  • Page 13: Mechanical Component Description

    It is adjusted to shutdown the RO unit immediately if the pump discharge pressure exceeds the setpoint. High Pressure Manifold The pressurized feed water is piped through 316L stainless steel high pressure manifolding. The USFilter United States Filter Corporation...
  • Page 14 There is a sample valve on the common product line of the RO. This valve provides an opportunity to analyze the final combined product water flowing from the RO membranes. USFilter United States Filter Corporation...

  • Page 15: Electrical Component Description

    5 minutes, in which case the unit will shut down on low quality. The 4-20mA output from the monitor are wired to terminals for data acquisition if required. Alarm Horn An alarm horn is mounted to the bottom of the Control Panel to USFilter United States Filter Corporation...

  • Page 16: Functional Description

    HIGH FEED TEMPERATURE light will start to flash, and the unit will shut down. There is no time delay, this is an instantaneous shutdown. For standard TFC membranes, this switch will be set to 100 degrees F. High Pressure Pump USFilter United States Filter Corporation...
  • Page 17 Flow Alarm light will flash and a two minute timer starts. If the flow stays out of range for more than two minutes, the RO unit will shut down. Incorrect flows will cause USFilter United States Filter Corporation...
  • Page 18 If the RO is run in the HAND mode, the pretreatment interlock will be ignored. A loss of feed water will cause the unit to shut down on low feed pressure. Hand-Off-Auto Switch (HOA) Hand USFilter United States Filter Corporation...
  • Page 19 5 minutes, in the event it has not been acknowledged. It will come back on after five minutes and sound for 30 seconds, then go off again. This cycle will continue until the Alarm Silence pushbutton switch has been pushed. USFilter United States Filter Corporation...
  • Page 20 High feed water temperature Product divert to drain valve open Pretreatment lockout Storage Tank Full Switches RO Run Hand-Off-Auto (HOA) Alarm Silence Auto Flush Selector Manual-Off-Auto (MOA) Miscellaneous controls Elapsed run time indicator Alarm horn Chemical pump receptacles USFilter United States Filter Corporation...
  • Page 21 (located off skid) product to drain valve (located off skid) reject recycle throttling valve (3M systems only) USFilter United States Filter Corporation...
  • Page 22 SECTION 2-16 EQUIPMENT DESCRIPTION FLOWMAX RO MANUAL REV: B 05/1999 (THIS PAGE INTENSIONALLY LEFT BLANK) USFilter United States Filter Corporation...

  • Page 23: Installation

    Required Parts concrete anchor bolts (size determined by local seismic calculations). plumbing and electrical materials as required regulated air supply line automatic valves for auto flush feature product pressure relief valve 3.2 EQUIPMENT INSTALLATION GUIDELINES USFilter United States Filter Corporation...

  • Page 24: Equipment Installation Procedures

    Move the RO unit to the location laid down in the previous step. Safety equipment should be worn at all times to avoid personal injury while WARNING securing equipment. Drill holes in the pad through the frame tie down holes. USFilter United States Filter Corporation...
  • Page 25 Connect a regulated air supply to the inlet port of the solenoid on the bottom of the Control Panel. The air pressure needs to be 80 to 100 PSIG. The plumbing installation should now be complete. Check the plumbing to ensure all joints are properly connected and supported. Electrical Installation USFilter United States Filter Corporation...
  • Page 26 Remove the Lock-Out / Tag-Out equipment from the main power supply for the RO unit, and energize the circuit. Verify that the voltage supplied is correct and matches the Voltage Identification Tag on the pump motor and inside the Control Panel. USFilter United States Filter Corporation...

  • Page 27: Operation

    (If the pressure is too low, you may need to install a feed water booster pump to avoid low pressure fault shutdowns. If the pressure is too high, you must install an automatic pressure regulating valve to USFilter United States Filter Corporation...
  • Page 28 Allow the flushing process to run for a minimum of 15-30 minutes. This will assure all the membrane preservatives will be flushed out. When flushing is complete, re-connect the air lines and return the valves to the operating position. USFilter United States Filter Corporation...

  • Page 29: Normal Operation

    If it is full, the system will not start until the tank drops below the setup point by the tank level sensing device. If the low feed pressure light is on, the system also will not start. USFilter United States Filter Corporation...

  • Page 30: Short Term Shutdown Procedure

    There are two methods for shutting the RO unit down. Short term shut down is for when the system will be down for a short period of time, as to perform brief maintenance or service. USFilter United States Filter Corporation...

  • Page 31: Long Term Shutdown Procedure

    If longer storage is required, the membranes need to be removed and stored under more controlled conditions. Contact U.S. Filter for more details. USFilter United States Filter Corporation...
  • Page 32 SECTION 4-6 OPERATION FLOWMAX RO MANUAL REV: B 05/1999 (THIS PAGE INTENSIONALLY LEFT BLANK) USFilter United States Filter Corporation...

  • Page 33: Maintenance

    Drain the water in the filter housing by opening the drain valve. Remove the old filter cartridge elements and dispose of them. Rinse the filter housing out with fresh water. USFilter United States Filter Corporation...

  • Page 34: Membrane Element Replacement

    Be sure to make note of which end cap came out of which end of the pressure vessel so they may be reinstalled in the same vessels. Push the old membrane elements out of the pressure vessel in the direction of the flow USFilter United States Filter Corporation...
  • Page 35 Carefully reinstall the retaining rings in both ends of the pressure vessel. Once all the membranes are replaced, reinstall the product piping connections. Check all connections and vessels carefully. The RO unit is now ready to be put back into service. USFilter United States Filter Corporation...

  • Page 36: Troubleshooting

    RO water storage tank level sensing device. PROBLEM: AUTOMATIC FEED WATER VALVE WILL NOT OPEN CAUSE ACTION Solenoid valve may have failed. Replace the solenoid valve. Feed water valve actuator may have failed. Repair or replace the actuator. USFilter United States Filter Corporation...

  • Page 37: Recommended Spare Parts

    Reset the control valves as stated in Section 3.2. Control valve may have failed. Check that there are no obstructions or damage to the control valves. Check seats on ball valves for excessive wear. 5.5 RECOMMENDED SPARE PARTS USFilter United States Filter Corporation...
  • Page 38 10 amp circuit breaker 15 amp GFCI circuit breaker Automatic reject bypass valve Automatic feed valve PRIORITY C PARTS: RO Membrane Element(s)* 1 Set RO High Pressure Pump Membranes have a shelf life of only a year. USFilter United States Filter Corporation...

  • Page 39: Ro Membrane Element Long Term Storage Procedure

    FLOWMAX RO MANUAL REV: B 05/1999 5.6 RO MEMBRANE ELEMENT LONG TERM STORAGE PROCEDURE The solution USFilter recommends is a 0.5 to 1.0% solution of sodium bisulfite. For conditions where freezing may be a problem, the solution should also contain up to 18% (by weight) glycerin or propylene glycol.
  • Page 40 The RO unit is now ready to be stored. Be sure to follow the Initial Startup in Section 4.1 when ready to put the unit back in service. USFilter United States Filter Corporation...
  • Page 41 Specific Gravity Freezing Point Freezing Point WEIGHT 15.0 C. (59 1.02415 -1.6 29.1 1.04935 -4.8 23.4 1.07560 -9.5 14.9 1.10255 -15.5 1.12985 -22.0 -7.4 1.15770 -33.6 -28.5 1.18540 -37.8 -36.0 1.21290 -19.2 -2.3 1.23950 -1.6 29.1 USFilter United States Filter Corporation...

  • Page 42: Ro Membrane Element Cleaning

    To clean the membrane elements in situ, a CIP skid (stands for Clean In Place) is required. This can be purchased from USFilter if you want to do your own cleaning. Cleaning services are available from the most of the USFilter service branches. Call the local sales and service office for details.
  • Page 43 NORMALIZED PRODUCTIVITY RATE with a minor reduction in the TOTAL DISSOLVED SOLIDS REJECTION RATE. Refer to the manual included with the optional CIP skid for complete cleaning instructions. (THIS PAGE INTENSIONALLY LEFT BLANK) USFilter United States Filter Corporation...

  • Page 44: Appendix

    RO 1 Stage Operating Pressure (PSI) RO 2 Stage Operating Pressure (PSI) RO 3 Stage Operating Pressure (PSI) RO Final Reject Operating Pressure (PSI) RO Normalized Productivity (GPM) DATA TAKEN BY: * 3M units only COMMENTS: USFilter United States Filter Corporation...
  • Page 45 EXAMPLE: MPF = 35 GPM FEED WATER TEMP = 60 F, THEN TCF = 1.44 MFP = 285 PSIG NPF = 35 x 1.44 x (225÷285) NPF = 35 x 1.44 x .789 NPF = 39.8 USFilter United States Filter Corporation...
  • Page 46 1.12 3.18 1.08 2.93 1.05 2.68 1.02 2.47 0.97 2.29 0.93 2.14 0.90 2.01 0.88 1.88 0.86 1.77 0.82 1.68 0.79 1.59 0.77 1.51 0.75 1.44 0.73 1.36 0.70 1.30 0.68 1.24 0.65 1.17 0.63 USFilter United States Filter Corporation...

  • Page 47: Ro Operating Specification Sheet

    CONDITIONS, PLEASE SUBMIT A WATER ANALYSIS OF YOUR FEED WATER TO THE U.S. FILTER ENGINEERING DEPARTMENT, AND WE WILL RUN A COMPUTERIZED RO PROJECTION FOR YOUR SYSTEM. OPERATING THE RO UNIT OUTSIDE OF THESE PARAMETERS COULD CAUSE PREMATURE MEMBRANE FAILURE OR RESULT IN ECSESSIVE CLEANING REQUIREMENTS. USFilter United States Filter Corporation...

  • Page 48: Qa Data Sheet

    SECTION 6-5 APPENDIX FLOWMAX RO MANUAL REV: B 05/1999 6.3 QA DATA SHEETS See QA Data sheet that follows this page. USFilter United States Filter Corporation...
  • Page 49 SECTION 6-6 APPENDIX FLOWMAX RO MANUAL REV: B 05/1999 (THIS PAGE INTENSIONALLY LEFT BLANK) USFilter United States Filter Corporation...

  • Page 50: Drawings

    PACKAGED SYSTEM EQUIP SPEC DRAWING S8601-038 FS6-60 PACKAGED SYSTEM EQUIP SPEC DRAWING S8601-039 FS6-72 PACKAGED SYSTEM EQUIP SPEC DRAWING ELECTRICAL DOCUMENTATION S8693-050 ALL FIXED I/O PANEL SCHEMATIC S8693-999 ALL PLC LADDER LOGIC FOR FIXED I/O PANEL SCHEMATIC USFilter United States Filter Corporation...
  • Page 51 SECTION 6-8 APPENDIX FLOWMAX RO MANUAL REV: B 05/1999 (THIS PAGE INTENSIONALLY LEFT BLANK) USFilter United States Filter Corporation...

  • Page 52: Component Manufacturers Literature

    Monitor (optional) Thornton 200pH *Only the literature that applies to your system will be included in this section. 6.6 MATERIAL SAFETY DATA SHEET(S) Title Sodium Bisulfite RO membrane preservative (THIS PAGE INTENSIONALLY LEFT BLANK) USFilter United States Filter Corporation...

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