Table of Contents
Summary of Contents for Hoffman INNOVATEIT
- Page 1 HOFFMAN REVERSE OSMOSIS INNOVATE Fully Integrated, High-Efficiency R.O. Spot-Free Rinse System Instruction Manual REV2.00 Updated 11/2/2023 For Further Assistance Please Contact innovateIT Car Wash Equipment LLC 518-741-4200 option 2...
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Page 2: Table Of Contents
Table of Contents Introduction ...........................................4 1.1 Warranty ..........................................4 1.2 Safety Information ....................................4 System Overview ........................................5 2.1 Principles of Operations .................................7 2.2 System Operation ....................................7 2.2.1 Pump Inlet Pressure Switch (PS1) ........................7 2.2.2 RO Pump Pressure Switch (PS2) ........................8 2.2.3 RO Product Flow Sensor (ROFLO) ........................8 2.2.4 Tank Level Sensor ..................................8 2.2.5 Recirculation Flow Switch............................8 2.2.6 Re-Pressurization Pump Flow Switch ......................9... - Page 3 6.1 Replacement Parts ....................................28 6.1.1 Catalytic Carbon Block Assembly .........................28 6.1.2 Carbon Filter ....................................28 6.1.3 RO Mebrane System (Membranes and O-Ring Seals in Housing) ....28 6.1.4 Pressure Switches ................................29 6.1.5 ASCO 8290 Air Valves (A-D)..........................29 6.1.6 Air Pilot Air Valve .................................29 6.1.7 Pumps .........................................29 6.1.8 Electrical/Controller Hardware ........................29 6.1.9 Flow Switch ....................................29...
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Page 4: Introduction
Car Wash Equipment LLC. • Damage occurs due to the customer’s failure to observe any instructions from innovateIT Car Wash Equipment or an authorized distributor and/or requirements of the manufacturer with respect to the product. •... - Page 5 104°F maximum. innovateIT Car Wash Equipment LLC does not accept liability for accidents or damages due to negligence or disregard for the instructions in this manual. Also, the Company does not accept liability for damages due to improper use of the equipment.
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Page 6: System Overview
System Overview 2. System Overview innovateIT Car Wash Equipment LLC has developed a high-effi ciency reverse osmosis system to provide spot-free rinse service for express car wash applications. The system uses “Flow on Demand” control algorithm to adjust pump pressure based on number of cars being washed, opera- tor demand, and condition of the membranes. -
Page 7: Principles Of Operations
2.1 Principles of Operation NOTE: Most car washes operate with varying feed water temperatures over the course of the year. This unit is designed to ensure that the unit produces adequate RO for rinsing cars across a wide range of feed water temperatures and levels of dissolved solids. -
Page 8: Pump Pressure Switch (Ps2)
2.2.2 RO Pump Pressure Sensor - PS2 • This pressure sensor is used to protect the system from operating over the setpoint pressure. • The system can produce 10 GPM (Standard Flow) or 15 GPM (High Flow) of RO below 200 psi at a water temperature above 40F. -
Page 9: Re-Pressurization Pump Flow Switch
2.2.6 Re-Pressurization Pump Flow Switch The switch closes as RO pressure at the pump fl ow reaches 5 GPM. • This switch verifi es that when the RO Request for water is sent from the tunnel controller, Valve D has opened, the • delivery pump has turned ON, and RO water is fl owing to the tunnel. • If this switch fails to close it will turn off the re-pressurization pump to protect it from running in a dead-head or dry running condition. (It is recommended that you have a spare fl ow switch and cable to allow quick repair if the switch fails. -
Page 10: Tunnel Signal Command For Ro Water Delivery To Tunnel
If the unit is inactive for 15 minutes, the unit will perform a fl ush cycle. • fi g 2.3.2 - 1 - START button Note: In the event of either low RO fl ow from the system (due to failed membranes or pump problems) or if the demand from the tunnel exceeds the fl ow from the RO system, there is a municipal water line that uses a valve (E) to fi ll the RO tank if the water level drops drop below 25%. This is to protect the re-pressurization pump and ensure rinse water is delivered to the tunnel. 2.4 Tunnel Signal Command for RO Water Delivery to Tunnel This signal is controlled directly by the tunnel system controller using a 24 Volt DC relay signal to the R.O. -
Page 11: System Performance
Membranes are extremely sensitive to feed water temperature and will typically lose approximately 2% of fl ow for every 1F drop in feed water temperature at constant pressure. The innovateIT R.O. System is conservatively rated for consistent performance from 40F to 80F feed water temperatures. The system utilizes oversized membranes operating at conservative fl ux ratings combined with daily RO fl ush cycles to achieve high-quality water and long membrane life. - Page 12 branes into the membrane housings. In addition, TDS should be checked after the RO pumps runs for a couple of minutes as when the unit sits overnight or when unit is stopped during the day as there will be “TDS creep” as salts will migrate across the membranes when unit is sitting in standby mode.
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Page 13: Installation Requirements
Installation Requirements Section Header Section Header 3. Installation Requirements Note: Failure to properly pre-treat the water may result in reduced membrane life and premature membrane failure and is not covered under the limited warranty. Listed below are all the critical water specifi cation limits and the required pre-treatment regimens. Feed Water Limits and Recommended Pre-Treatment Approach Specifi cation Limit Recommended Pre-Treatment... -
Page 14: Additional Feed Water Pre-Treatment
The fi lmTec RO (Eco Pro-440i type) membranes are not tolerant towards free chlorine, and as such require a chlorine fi lter system to remove free chlorine from the feed water. Properly sized activated carbon fi lters (chlorine treated water) or catalytic carbon fi lters (chloramine treated water) supply the ability to remove the free chlorine from the feed water. A weekly check needs to be performed to ensure the carbon fi lter system is functioning properly and the level of free chlorine measures < 0.10 PPM during system operation. Membrane failure due to chlorine exposure occurs in less than 200 hours (8 days) when exposed to a 0.5 PPM level of free chlorine. Note: Running the system with a depleted or non-functioning chlorine fi lter will at once start to damage the RO membranes and avoid any warranty from the membrane manufacturer. -
Page 15: Water Supply
3.2.1 Water Supply The water supply must be able to supply a minimum of 25 GPM (Standard Flow)/35 GPM (High Flow) at 40-60 psi to the RO unit. The fl ow lines need to be sized to minimize pressure drops per accepted plumbing design guidelines. Normal operating feed fl ow will vary between 10 and 22 GPM depending on water temperature. At this condition, the feed water pressure does not exceed 70 psi. HF unit will vary between 15 and 35 GPM depending on the RO fl ow demand. If you are using a booster pump, set the booster pump to 60 psi. 3.2.2 Floor Drain All water drains and overfl ow lines must drain to the fl oor drain. The R.O. System plumbing is constructed to allow a visual indication of water fl owing to the drain to help diagnose proper system operation. The RO tank has a 2” female overfl ow plug... -
Page 16: Reverse Osmosis System Identification
3.4 Reverse Osmosis System Identification Note: See APPENDIX 1 for more R.O. System identifi cation. Air Supply Connection Human-Machine Interface Integrated Storage Tank Carbon Block Filters Grundfos VFD Pump Grundfos Re-Pressurization Pump Membranes Reject Out 1.5” Female NPT Municipal Water Inlet 1.5” Female NPT Spot-Free Outlet Connection Carbon Outlet to 1.0”... -
Page 17: Installation
Installation 4. Installation WARNING! DO NOT ATTEMPT TO REMOVE THE FILTER COVER IF THE PRESSURE IN THE HOUSING IS NOT ZERO. IF THE CAP IS REMOVED WHILE THE UNIT IS PRESSURIZED, THE CAP COULD CAUSE SERIOUS INJURY OR DEATH. •... - Page 18 Groove Nipple Line up and make connection Groove Coupling Carbon Block Outlet (PT2) fi g, 4 - 3 - Connecting carbon block assembly to RO unit Connect reject water to either reject tank or drain, with a 1.5” male NPT hose (fi g. 4 - 4). • fi g, 4 - 4 - Reject out connection Connect spot-free outlet to a wash Rain-bar with a 1.0” male NPT hose (fi g. 4 - 5). •...
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Page 19: Membrane Installation
4.1.1 RO Membrane Installation The membranes utilize an integrated locking jumper tube (Dupont iLEC) system which allows removal and replacement with- out removal of the membrane housing, hoses, or bottom caps. However, if the ceiling height does not permit the membrane to be removed while the housing is on the RO unit, the IPS split clamps will need to be removed in order to remove the feed hoses and membrane housings. -
Page 20: Electrical Installation
- 1) . This number should be referenced when requesting support on the R.O. System as this number links to both the controller software and hardware. innovateIT Serial # fi g. 4.1.2 - 1 - RO System serial # location Locate customer network interface (fi g. 4.1.2 - 2) - Page 21 Customer Network Interface RJ-45 CAT5 Shielded fi g. 4.1.1 - 2 - Customer network interface • Main Control Disconnect (DS1) is used to disconnect all power to the unit. Run customer supplied power (480VAC/3PH) to DS1 according to the system schematic (fi g, 4.1.1 - 3). • NOTE: Verify a Phase Rotation before making 480VAC connection to DS1 (L1= BRW, L2=ORG, L3=YEL) Customer Supply 480VAC/3PH fi g.
- Page 22 Production Pump BRK Transfer Pump BRK Power Supply BRK (CB2) (CB2) (CB3) Power Supply (PWS) 480VAC to 24VDC Main Disconnect (DS1) VPN Tosibox Re-Pressurization Pump Contactor PLC (I/O) E-STOP Contactor (ESR1) Circuit Relay (CR1-5) Transfer Pump 24V Components Fuse Overload Coil (OL1) Air Valve Manifold 24 VDC Terminal Strips PLC (I/O) Terminal Strips...
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Page 23: System Startup
System Startup 5. System Startup WARNING! 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. - Page 24 Air Valve Testing Page MANUAL Mode Button fi g. 5 - 1 - HMI Overview Screen 10. 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 (fi g. 5 - 2). fi g.
- Page 25 Priming Vent Plug fi g. 5 - 3 - Production Pump priming vent plug fi g. 5 - 4 - Transfer Pump priming vent plug 14. Loosen the Transfer (Re-Pressurization) Pump priming vent plug with a 10mm wrench until there is constant stream fl owing then tighten the Vent plug back in (fi g. 5 - 4).
- Page 26 17. To (Bump start) both Grundfos pumps (Transfer Pump and Production Pump), press Open (Pump ON) for a second, then press Close (Pump OFF) (fi g 5 - 7). fi g. 5 - 7 - Bump starting Production and Transfer Pumps 18. Repeat steps 10-14. This process will eliminate any air trapped in the pumps. 19.
- Page 27 24. Return to the OVERVIEW screen and place unit in AUTO mode by selecting START (fi g. 5 - 9). fi g. 5 - 9 - HMI Overview screen and Start button 25. Verify tank is fi lling. 26. Verify Reject water is fl owing to the reject. 27. The initial RO water produced by the unit will need to be dumped down the drain. During the fi rst 2 hours of RO production the water is high concentrate. 28.
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Page 28: Maintenance
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 fi lter. -
Page 29: Pressure Switches
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. - Page 30 fi g. 6.2 - 1 - Carbon fi lter 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 and pumps etc. • Verify there is no bad hose (bend, crink, bad connection and rips.
- Page 31 Free Chlorine Level RO Pump Date Water Temp (F) TDS Out (PPM) Feed Pressure (psi) Maintenance...
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Page 32: Troubleshooting
• If the water feed temperature is always low (40-50F), the water temperature drops below consult with innovateIT for a recommendation on a 77F. As the water reaches 40F, the cold-water membrane (DuPont XLE-440i membrane pump pressure required to generate... - Page 33 Problem Potential Causes Solution • Tank level sensor is disconnected or • Verify the connector pin (longer pin connect to GND), has failed drain tank and replace sensor if necessary • The PLC calibration screen which RO production cycle allows the system to function is set not starting as tank for an incorrect storage tank height drops...
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Page 34: Hmi Fault Codes
7.1 HMI Fault Codes Delay HMI Alarm Cause SENSOR 01 (FLOW METER) SIGNAL FAULT Signal could be high/low, or sensor disconnected SENSOR 02 (TANK LEVEL) SIGNAL FAULT Signal could be high/low, or sensor disconnected SENSOR 03 (PRODUCTION PUMP DISCHARGE Signal could be high/low, or sensor disconnected PRESSUERE) SIGNAL FAULT SENSOR 04 (CARBON FILTER INLET SENSOR) Signal could be high/low, or sensor disconnected... - Page 35 Delay HMI Alarm Cause Production tank over fl owed, valves may be stuck PRODUCTION TANK HAS OVERFILLED OR IS IN TROUBLE open EMERGENCY STOP HAS BEEN DEPRESSED E-Stop engaged PRODUCTION TANK WAS NOT SPANNED. DE- Fill the tank and set the span on the maintenance FAULT VALUE USED. screen - value should be around 2500 Carbon fi lter sensor see a -2psi difference, sensor CARBON FILTER INLET &...
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Page 36: Glossary Of Terms
Glossary of Terms 8. Glossary of Terms The following list includes terms and abbreviations used in this document. Reverse Osmosis - A water purifi cation technology that uses a semi-permeable membrane to remove dissolved • substances from the water. In reverse osmosis, an applied pressure is used to overcome osmotic pressure, forcing water molecules to pass through the membrane while all dissolved solids remain in the feed water side of the membrane. - Page 37 • TDS is measured in parts per million (PPM). The innovateIT RO system is designed to operate with feed water with TDS levels up to 1000 PPM which is much higher than general municipal water standards.
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Page 38: Appendix 1 - Ro System Identification
Appendix 1 - RO System Identification Section Header Main Shut Off Switch Air Supply Connection Human Machine Interface Integrated Storage Tank Emergency Stop Push Button Carbon Block Filters Grundfos VFD Pump Grundfos Re-Pressurization Pump Membranes Flow Meter Solenoid E Overfl ow Connection Emergency Municipal Water Fill Line From Carbon Filter Reject Out... - Page 39 Reject Line Reject Line Flow Switch Membrane Flush Line Carbon Pressure Inlet Transducer RO Water to Transfer Pump (Repress Pump) Carbon Pressure Outlet Solenoid D Transducer Reject Line Flow Switch RO Tank Drain Valve Appendix 1...
- Page 40 Solenoid B Solenoid C Solenoid A Appendix 1...
- Page 41 Production Pump BRK Transfer Pump BRK Power Supply BRK (CB2) (CB2) (CB3) Power Supply (PWS) 480VAC to 24VDC Main Disconnect (DS1) VPN Tosibox Re-Pressurization Pump Contactor PLC (I/O) E-STOP Contactor (ESR1) Circuit Relay (CR1-5) Transfer Pump 24V Components Fuse Overload Coil (OL1) Air Valve Manifold 24 VDC Terminal Strips PLC (I/O) Terminal Strips...
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Page 42: Appendix 2 - Electrical Schematic
Appendix 2 - Electrical Schematic Appendix 2... - Page 43 Appendix 2...
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- Page 45 Appendix 2...
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Page 48: Appendix 3 - Spare Parts
Appendix 3 - Spare Parts Section Header innovateIT Product Number Description EL-PS-WDR-120-24 POWER SUPPLY, AC-DC,24V,5A,200- OMRON-NXAD3204 OMRON ANALOG INPUT 4-20MA-4POI OMRON-NXDA3203 PLC, NX SERIES, ANALOG OUTPUT, 6203237 1A THERMAL MINI CIRCUIT BREAK EL-TRM-2966184 24VDC/AC VARIANT PLC RELAY MOD ELE-MS-OVRLD-LRD07 TESYS LRD THERMAL OVERLOAD REL... - Page 49 Product Number Description RC-TRAN-AV300P300 0-300 PSI PRESSURE TRANSDUCER RO-TRAN-AV300P005 0-5 PSI TANK LEVEL SENSOR RO-FLTR-15000600 1.25 INCH CARBON FILTER HEAD/BASE TEE RO-HS-11/2BKFRNTR200RL HOSE CLAMPS 1.5-INCH HOSE RO-MBRN-440I RO MEMBRANE RO-CBF-CAT-01230065 RO 3 MICRON CARBON FILTER RO-HSNG-80S30-1 RO MEMBRANE HOUSING...