GE OSMONICS F-801 INTERNAL REVERSE OSMOSIS UNIT Operation and Maintenance Manual Revision E This Revision Supersedes P/n 12552 Rev.
F-801 INTERNAL REVERSE OSMOSIS UNIT Installation, Operation and Maintenance Manual TABLE OF CONTENTS CHAPTER ONE: GENERAL INFORMATION Section The Manual Safety Summary Applications Contraindications Environmental Considerations Theory of Operation Fluid Components Monitors and Controls Optional Equipment Specifications Inlet Water Requirements Flow Rates Electrical Requirements Membrane Performance Characteristics Environmental Requirements Disposal Electromagnetic Interference Service Assistance Return
CHAPTER FOUR: ROUTINE MAINTENANCE 4-1 Section Routine Maintenance of F-801 Internal RO System Daily / Per Treatment Maintenance Weekly Maintenance Monthly Maintenance Quarterly Maintenance Annual Maintenance Specific Maintenance Procedures and Instructions Motor Lubricant Procedure Leak Repair Pre-filter Replacement F-801 Cleaning Indications Pre-Cleaning Preparation Pre-Cleaning Procedure Cleaner Recirculation and Dwell Time Post-Cleaning Rinse Procedure BIOSAN Pre Cleaning Preparation BIOSAN Cleaning
CHAPTER FIVE: TROUBLESHOOTING 5-1 Table of Content RO Fails to Run RO Runs Intermittently Motor Runs Hot Low Pump Pressure Pressure Gauge Vibrates Erratically Excess Product Pressure (too high) Product Flow Too Low Product Flow Too High Membrane Product Pressure Too Low Leaks Low Percent Rejection Rejection Display Fluctuates TDS Value High RO Fails to Draw Disinfectant RO Pump Leaks 5-3 5-5 5-5 5-6 5-6 5-7 5-7 5-7 5-8 5-9 5-9 5-9 5-10 5-10 5-11 5-12 CHAPTER SIX: DRAWINGS 6-1 CHAPTER SEVEN: SPARE P
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F-801 Internal RO System by GE Osmonics F-801 Internal RO System CHAPTER ONE: GENERAL INFORMATION 12552e – 27 Feb 04 1-1 General Information
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F-801 Internal RO System by GE Osmonics 1.1 The Manual This manual has been prepared to provide the operator with information and instructions regarding the installation, use, maintenance and troubleshooting of the GE Osmonics F-801 Internal Reverse Osmosis System. CAUTION: When used as a medical device, Federal law restricts this device to sale by or on the order of a physician. Per CFR 801.109 (b)(1).
F-801 Internal RO System by GE Osmonics USE PROPER WATER AND DRAIN CONNECTIONS: Use proper water and drain connections to prevent contamination of the RO and danger to the patient. To ease confusion, the Quick Disconnect (QD) fittings have been colorcoded. Both the male and female fittings are colored. The color coding is; Green = FEED water, Red = WASTE water, White = PERMEATE (Product) water. SHOCK HAZARD: Connect this device to a proper ground connection in accordance with the National Electrical Code.
F-801 Internal RO System by GE Osmonics 1.5 Environmental Considerations Prior to the installation of the F-801 RO System, it will be necessary to provide utilities and create an environment suitable for the trouble free operation of the RO system and its accessories. POWER: The F-801 operates on 115 VAC single-phase power.
F-801 Internal RO System by GE Osmonics WATER PURITY: Plumbing materials can significantly contribute to the contamination of the water. Metallic pipes (with the exception of 316 stainless steel) must be eliminated once the purification process has begun. Schedule 40 or 80 PVC pipes, polypropylene, PVDF, and other FDA recommended materials are suitable for most grades of purified water. Care must also be exercised in the choice of a thread sealant.
F-801 Internal RO System by GE Osmonics 1.7 Fluid Components Pre-filter: From the feed water, the fluid path flows through the softener (optional) on through the carbon tank and then into the pre-filter, located in a blue housing mounted on the side of the hemodialysis unit. It is a cartridge type filter with a nominal filtration rating of five microns. Pressure Adjust Regulator: Used to adjust the product pressure. The pressure is displayed on the product pressure gauge, on the front of the RO.
F-801 Internal RO System by GE Osmonics Feed Port: The Feed Port is a green colored quick-disconnection port for the introduction of feed water to the RO. The port has a check valve that closes when there is no hose connected to the fitting. Product Port: The Product Port is a white colored quick-disconnection port for the output of purified product water. The port has a check valve that closes when there is no hose connected to the fitting.
F-801 Internal RO System by GE Osmonics 1.8 Monitors and Controls RO Power Switch: The RO Power Switch is mounted on the back of the remote monitor module. The switch is used to turn the F-801 RO unit on and off. Inlet Water Sensor: Monitors the quality of the inlet water. Inlet quality is compared to the outlet (product) water quality and is displayed as "percent rejection" on the front panel.
F-801 Internal RO System by GE Osmonics Dialyze/Flush Valve: The Dialyze/Flush Valve is a 1/4-turn ball valve. When in the dialyze mode, the valve is in the closed position. When the valve is turned at any point towards flush, the valve is open. The closer to the flush point, the more the valve is open. When in flush, the valve bypasses the waste flow tube. Percent Rejection Display: The Percent Rejection Display is a 5 LED array that indicates how the RO membranes are performing.
F-801 Internal RO System by GE Osmonics 1.9 Optional Equipment GE Osmonics offers a number of optional items to adapt the equipment to meet specific needs. Options are available to improve the quality of the feedwater to the RO. Frequently requested options are briefly described in the following paragraphs. If more information is needed, or if other options are desired, please consult the factory. Refer to Chapter xx for catalog part numbers.
F-801 Internal RO System by GE Osmonics 1.10 Specifications: 1.10.1 Input Water Requirements Minimum Maximum Input flow Rate 2.0 GPM N/A Temperature (water) 10°C (50°F) 32°C (90°F) NOTE: Operating at lower temperatures may make it impossible for the F-801 RO to produce adequate permeate for the dialysis machine. pH (operating) TF Membranes 5.5 10.5 pH w/chloramines present (operating) TF Membranes 5.5 8.5 pH (cleaning) TF Membranes 2.0 11.0 Pressure, dynamic 30 PSI 100 PSI 1.10.
F-801 Internal RO System by GE Osmonics 1.10.4 Membrane Performance Characteristics Salt rejection (TF Membranes): Test Solution: Conductivity: Operating Pressure: Product Back pressure: 1.10.5 95% minimum at initial testing at factory.
F-801 Internal RO System by GE Osmonics 1.13 Service Assistance If service assistance is required, please take the following steps: Consult the “Troubleshooting” section of this manual (Chapter Five). If the problem cannot be identified and corrected by any of the procedures found in that section, then... Contact your Facility Equipment Technician. If the technician is unable to help then… Call GE Osmonics Technical Service Department at (800) 633-3080 or (206) 395-2200.
F-801 Internal RO System by GE Osmonics 1.14 Return Goods Authorization (RGA) Procedure If you wish to return goods for, warranty evaluation and/or credit please have your original sales order, invoice and device serial number available when you call GE Osmonics. Call GE Osmonics at (800)-633-3080 and request Technical Service.
F-801 Internal RO System by GE Osmonics 1.15 Symbols and Abbreviations “RENALIN®” Refers to Peracetic Acid and Peroxide-based Compounds, such as Renalin®, Minncare™, Peracidin™ (20% peroxide, 4% Peracetic Acid) ASTM American Society for Testing and Materials AAMI Association for the Advancement of Medical Instrumentation CA Cellulose Acetate C Celsius CSA Canadian Standards Association cc Cubic Centimeters cf Cubic Foot (feet) cfu/ml.
F-801 Internal RO System by GE Osmonics ml.
F-801 Internal RO System by GE Osmonics NOTES: 12552e – 27 Feb 04 1 - 18 General Information
F-801 Internal RO System by GE Osmonics F-801 Internal RO System CHAPTER 2: INSTALLATION GUIDELINES AND INITIAL SYSTEM START-UP 12552e - 27 Feb 04 2-1 Installation Guidelines and Instructions
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F-801 Internal RO System by GE Osmonics 2.1 Installation Considerations 1. The RO unit requires 115 VAC power for operation and consumes 10 amps of current. 2. The RO unit requires nominally 1.6 GPM water at 30 PSI. Warmer feed water (up to 25°) will produce more permeate, and will consume more water. The water may also require some pretreatment to ensure maximum performance and suitability.
F-801 Internal RO System by GE Osmonics NOTE: There will be little or no flow through the product line at this time. 5. Make sure that the RO power switch is in the OFF position. Plug the power cord into a 115 VAC grounded outlet. Do not use an extension cord or an adapter. 6. Ensure the dialyze/flush valve is in the dialyze position. 7. Turn the RO power switch on and run the system for 30 minutes. Observe displays and note stabilization of rejection and TDS. 8.
F-801 Internal RO System by GE Osmonics 12. Perform the following checks: Pump pressure gauge: between 140 – 160 PSI Pre-filter pressure differential: Both above 30 PSI, no greater difference than 8 PSI above clean filter readings. Product pressure: between 35-40 PSI. Percent rejection: greater than 95%, continue to rinse if lower. TDS at normal for region. 13.
F-801 Internal RO System by GE Osmonics 4. Close the product valve on the F-801, and disconnect the product line from the inlet water line of the dialysis machine. Tape a sterile gauze around the opening of the inlet water line to the dialysis machine. 5. Hold the product line over the container and run product water for 60 seconds. 6. Aseptically remove the lid from the sample bottle and rinse the bottle twice with RO product water. 7.
F-801 Internal RO System by GE Osmonics NOTES: 12552e - 27 Feb 04 2-7 Installation Guidelines and Instructions
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F-801 Internal RO System by GE Osmonics F-801 Internal RO System CHAPTER 3: SYSTEM OPERATION 12552e – 27 Feb 04 3-1 System Operation
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F-801 Internal RO System by GE Osmonics 3.1 Daily Start-up WARNING: Verification of the absence of all sanitizers, cleaners, disinfectants and chlorine/chloramines must be performed before RO product water is used for any patient related uses. WARNING: Use of exhausted carbon in the presence of chlorine/chloramines will result in damage to the F-801 RO membrane and may cause serious patient injury. CAUTION: When moving the F-801 assembly, push only on the handle and in the direction of travel.
F-801 Internal RO System by GE Osmonics WARNING: Only the cold water supply should be used. If blending of hot and cold water is to occur, an appropriate temperature blend valve must be used, and the temperature of the incoming water supply must be continuously monitored, and not be allowed to rise above 30°C (86°F). Excessively high water temperature may cause severe patient injury or death. 6. Turn the F-801 RO unit ON.
F-801 Internal RO System by GE Osmonics NOTE: If the product pressure or product flow is insufficient, a low dialysate flow alarm will occur on the dialysis machine. Small adjustments to the product pressure may be made with the pressure adjust knob located inside the RO module on the feed water line. Read the percent rejection. It should display in the green region between 8595% rejection.
F-801 Internal RO System by GE Osmonics 3.2 Bicarbonate Container Filling RO water may be dispensed from the product line of the F-801 Internal RO system for use in filling bicarbonate jugs, drawing water samples, etc. 1. With the dialysis machine OFF and the F-801 ON and all tests and checks performed; a. Close the product valve on the product line. b. Disconnect the product line from the dialysis machine inlet water line.
F-801 Internal RO System by GE Osmonics NOTES: 12552e – 27 Feb 04 3-7 System Operation
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F-801 Internal RO System by GE Osmonics F-801 Internal RO System CHAPTER FOUR: ROUTINE MAINTENANCE 12552e – 27 Feb 04 4- 1 Routine Maintenance
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F-801 Internal RO System by GE Osmonics 4.1 Routine Maintenance of F-801 Internal RO System GE Osmonics RO systems have been designed to operate with a minimum of operator attention. Like all mechanical systems they will operate longer and with less trouble when operator maintenance is performed regularly. Operator maintenance on a GE Osmonics reverse osmosis system is limited to maintaining performance logs, cleaning and disinfection, replacement of damaged or failed parts and periodic lubrication.
F-801 Internal RO System by GE Osmonics 4. Observe and record the pre-filter inlet and outlet pressure gauges on the operation log. The difference in the pressure values will help measure the condition of the filter cartridge. When the pressure differential (delta P) increases 8 PSI above the clean, initial delta P, the cartridges need to be changed (or sooner if the pre-filter core appears soiled). Refer to section 4.2 for specific instructions on changing pre-filter. 5.
F-801 Internal RO System by GE Osmonics 4.1.2 1. Weekly Maintenance Observe, or measure, and record the waste and product flow rates on the operation log. Allow the water temperature to stabilize before attempting to record the results. This will help prevent errors due to fluctuating temperature. a. Waste flow 2000 ml/min (±10%) b. Product flow 1580 ml/min (150 PSI pump pressure and 25 C feed water temperature) with product line disconnected from dialysis machine and line open to atmosphere.
F-801 Internal RO System by GE Osmonics 4.1.4 Quarterly Maintenance 1. Clean the RO Membranes. Refer to the RO membrane cleaning procedure in this chapter. 2. Disinfect the RO machine. The RO should be disinfected after cleaning. Refer to the membrane disinfection procedure in this chapter. 3. Verify the TDS and percent rejection readings with an independent monitoring device every 3 months. 4. Check the quick-disconnect fittings and hoses.
F-801 Internal RO System by GE Osmonics 4.2 4.2.1 Specific Maintenance Procedures and Instructions Motor Lubricant Procedure NOTE: Only perform this procedure on motors that have plugs on each end of the motor and have instructions on the motor identification plate indicating the requirement. NOTE: During initial start-up and after performing motor lubrication procedure, a hot oily smell may be detected. This is normal and should fade away. 1.
F-801 Internal RO System by GE Osmonics 6. If the leak is still present, de-pressurize system again and tighten the fitting another quarter-turn. Check again for leaks. (Over tightening can crack the female fitting). 7. If the leak continues, it may be necessary to replace the male threaded fitting and/or the female threaded fitting.
F-801 Internal RO System by GE Osmonics 1. Prior to performing this maintenance on any tube fitting, release any pressure on the tubing system (i.e., turn off the pump, open a drain port, etc.). 2. Remove the red locking clip (if applicable). 3. Push the dark gray collar in towards the body of fitting (light gray). releases the ‘gripper’, which holds the tubing in place. 4. Hold the gray collar in while gently pulling the tube away from the fitting.
F-801 Internal RO System by GE Osmonics 4. Carefully remove the housing (bottom part) from its head. Empty the water and used pre-filter cartridge. 5. Inspect the central core of the used pre-filter for dirt or rust. If discoloration is present in the cartridge interior, the filter has been in service too long and should be replaced sooner, or at a delta pressure lower than 8 PSI. 6. Check the O-ring in the groove of the filter housing.
F-801 Internal RO System by GE Osmonics 4.3 F-801 Cleaning Indications Foulants such as minerals, silt and organic substances may collect on the RO membrane surface and cause the RO membrane to foul and diminish in its function. Many of these foulants are prevented by proper selection of pretreatment equipment, while others are treatable only with more sophisticated designs. Regardless of the foulant, it is essential to clean the membrane promptly once cleaning is indicated.
F-801 Internal RO System by GE Osmonics 4.3.1 Pre-Cleaning Preparation There are two types of cleaners available, a low pH cleaner (Calcium/Iron removal) and a high pH cleaner (Silt/Organics removal). GE Osmonics provides these cleaners in liquid form. The low pH cleaner attacks mineral scale deposits such as calcium, magnesium and iron build-up, and should be used first. The high pH cleaner will remove accumulated silt and organic matter from the RO membrane.
F-801 Internal RO System by GE Osmonics 4. Turn the RO on for five minutes and establish a pre-cleaning % rejection, TDS and pH record on the cleaning disinfect log sheet. 5. Prepare the cleaning solution by adding the amount of cleaner as specified on the labeling to two gallons of pretreated or RO product water. CAUTION: Water to be used must be chlorine free or damage to the RO membranes may result. 6. Turn the RO power switch off and close the product valve.
F-801 Internal RO System by GE Osmonics CAUTION: Check that there is waste flow within 10 seconds. If not, turn off the RO and verify that the disinfect-line is connected properly. CAUTION: Do not allow air or foam to be drawn into the RO system, as this will damage the pump. NOTE: The % rejection will fall below 85% and the TDS will rise considerably when the cleaner is re-circulated through the F-801 RO unit. NOTE: The cleaners will foam; this is normal.
F-801 Internal RO System by GE Osmonics 6. Ensure that the water supply to the RO unit is on. If it is partially closed, rotate the dialyze/flush valve to the full flush position. 7. Turn ON the F-801 RO unit and operate in the flush mode for 5-10 minutes. This will aid in rinsing the system quickly. CAUTION: Some pump noise (chattering) is normal in the flush position. Excessive pump noise (chattering) can be damaging to the pump.
F-801 Internal RO System by GE Osmonics 4.3.2 BIOSAN Pre-Cleaning Preparation BIOSAN is a liquid cleaner/descaler agent intended for use in removing mineral scale and organic biofilm and is a short-term storage solution for RO water systems. WARNING: The solution is a mild irritant to eyes and skin. It is recommended that gloves (latex/vinyl) and eye protection be worn when handling BIOSAN. Neither respiratory protection nor special ventilation are required.
F-801 Internal RO System by GE Osmonics 6. Prepare the cleaning solution by adding the amount of cleaner as specified on the labeling to two gallons of pretreated or RO product water. CAUTION: Water to be used must be chlorine free or damage to the RO membranes may result. 7. Turn the RO power switch off and close the product valve. WARNING: Label machine with appropriate warning signs such as "Do Not Use / Contains BIOSAN" to prevent use of the RO until it is properly rinsed. 8.
F-801 Internal RO System by GE Osmonics 3. Turn the Dialyze/Flush valve to the Flush position and operate RO for an additional 5-10 minutes. The Flush mode will allow the flow of cleaner only to the reject side of the RO membrane to flush particles away. Very little or no product water will be made. Pump pressure during this step should read approximately 40-80 PSI. CAUTION: Some pump noise (chattering) is normal in the flush position. Excessive pump noise (chattering) can be damaging to the pump.
F-801 Internal RO System by GE Osmonics 5. Open the product valve. 6. Ensure that the water supply to the RO unit is on. If it is partially closed, rotate the dialyze/flush valve to the full flush position. 7. Turn ON the F-801 RO unit and operate in the flush mode for 5-10 minutes. This will aid in rinsing the system quickly. CAUTION: Some pump noise (chattering) is normal in the flush position. Excessive pump noise (chattering) can be damaging to the pump.
F-801 Internal RO System by GE Osmonics 4.4 F-801 Disinfection Indications DETERMINATION OF MICROBIAL CULTURING AND DISINFECTION FREQUENCY IS THE RESPONSIBILITY OF THE OPERATING FACILITY. The following is recommended for critical applications where bacteria and endotoxins are a major concern, such as for Hemodialysis. Disinfection should occur when bacterial growth is above the limits set by the facility, or when over 200 CFU/ml (maximum AAMI standard) is detected.
F-801 Internal RO System by GE Osmonics Materials Required: • 200 ml. Formaldehyde, 37% • 1 gallon pre treated or RO water • Disinfect container with volume of 2 ½ gallon or more • formaldehyde test kit • product rinse line (extension hose) • “DO NOT USE” warning labels or signs (not provided by GE Osmonics) • cleaning / disinfect log sheets • most current log sheets for water quality comparison • proper protective body wear • sterile gauze and tape 4.4.1.
F-801 Internal RO System by GE Osmonics CAUTION: Formaldehyde or Formalin is usually provided in a clinical setting in a 37% solution. Check the labeling on the packaging to make certain this is the case. If the solution is other than 37%, the dilution will require adjustment. The end solution should not exceed 2.2%. Consult the Medical Director or Director of Nursing to determine the correct solution strength.
F-801 Internal RO System by GE Osmonics 4.4.1.3 Formaldehyde Post-Disinfection Rinse Procedure 1. After the dwell time, remove the waste hose and clear accessory flush line from the disinfect solution and place it in the drain with the appropriate air gap. Connect the feed line to the pre-filter outlet. 2. Connect the feed line to the water supply. Ensure that the water supply to the RO unit is ON. If it is partially closed, rotate the dialyze/flush valve to the full flush position. 3.
F-801 Internal RO System by GE Osmonics 4.4.2 Peracetic Acid/Peroxide-Based Compounds (Renalin®) Disinfection Procedure Renalin®, Minncare™, Peracidin™ and others are trade names for compounds based on Peracetic Acid and Hydrogen Peroxide compounds, and are common in dialysis facilities. The products referred to in this procedure typically have 20% hydrogen peroxide and 4% peroxacetic acid before dilution.
F-801 Internal RO System by GE Osmonics 4.4.2.1Renalin® Pre-Disinfection Preparation CAUTION: When ‘RENALIN®’ is to be used as a disinfectant, several preparatory steps are required by GE Osmonics as well as the membrane manufacturer. Failure to comply with these instructions, which incorporate instructions from the membrane manufacturer, will jeopardize the system performance and warranty. a. The system must be free of all incompatible materials. b. Clean the membranes with an acid such as 0.
F-801 Internal RO System by GE Osmonics 6. Connect the feed line (green QD) from the pre-filter outlet to the green fitting on the disinfect tank. 7. Connect the drain line (red QD) extension and connect the female portion to the red fitting on the disinfect tank. CAUTION: By connecting all the lines to the disinfect/cleaning tank, the system is set-up for recirculation. Never leave the unit unattended in the recirculation mode. 4.4.2.2Renalin® Disinfection and Dwell Time 1.
F-801 Internal RO System by GE Osmonics 3. Turn off the RO; do not operate the RO dry. CAUTION: Do not allow air to be drawn up into the RO unit as this will damage the pump. 4. Disconnect the drain line from the tank and re-attach the drain line extension. SECURE the drain line extension in the drain. Make sure the RED QD connector is fully joined and latched (listen for the ‘click’). 5. CLOSE the ‘Product Valve’.
F-801 Internal RO System by GE Osmonics 4.4.2.3Renalin® Post-Disinfection Rinse Procedure 1. After the dwell time, ensure that the drain line is in the drain with appropriate air gap, the feed line is connected to the pre-filter outlet, and that the clear accessory flush line is connected to the product line and placed in the drain receptacle with the appropriate air gap. 2. Open the product valve. 3. Connect the feed line to the water supply. Turn ON the water supply.
F-801 Internal RO System by GE Osmonics 4.5 Product Water Culture FREQUENCY: Once a month or more often, depending upon culture results, and unit protocol. We recommend before and after disinfection.
F-801 Internal RO System by GE Osmonics 4.5.1 Product Water Culture Procedure This procedure assumes the RO is connected to power and water, and is in operating condition. 1. Close the product valve and connect the extension hose to the product line. . Place the other end in a drain and open the product valve. 2. Turn on the RO unit. Allow the RO unit to run for 10-15 minutes. 3. Close the product valve on the product line and remove the extension hose. 4.
F-801 Internal RO System by GE Osmonics 4.6 System Storage This storage procedure has been established to store F-801 RO machines. It is not recommended that a unit be dormant longer than 24 hours without disinfectant. ROs that have been left unused for more than 24 hours risk the possibility of colonizing bacteria and exceeding acceptable limits. ROs to be stored should first be disinfected with one of the procedures in this chapter.
F-801 Internal RO System by GE Osmonics 4.6.2 BIOSAN Storage Procedure WARNING: It is recommended that gloves (latex/vinyl) and eye protection be worn when handling BIOSAN. 1. Follow the BIOSAN procedure in this chapter. 2. Do not rinse the RO out after BIOSAN has been circulated in the RO. 3. Disconnect the disinfect line, waste line, feed water line, power and product line. 4. Coil the hoses and power cord, and cover the RO with a large plastic bag to protect the RO from dust.
F-801 Internal RO System by GE Osmonics NOTES: 12552e – 27 Feb 04 4- 33 Routine Maintenance
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F-801 Internal RO System by GE Osmonics F-801 Internal RO System CHAPTER FIVE: TROUBLESHOOTING 12552e - 27 Feb 04 5- 1 Troubleshooting
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F-801 Internal RO System by GE Osmonics Table of Contents SECTION TITLE PAGE 5.1 RO Fails to Run 5-5 5.2 RO Runs Intermittently 5-5 5.3 Motor Runs Hot 5-6 5.4 Low Pump Pressure 5-6 5.5 Pressure Gauge Vibrates Erratically 5-7 5.6 Excess Product Pressure (too high) 5-7 5.7 Product Flow Too Low 5-7 5.8 Product Flow Too High 5-8 5.9 Membrane Product Pressure too Low 5-9 5.10 Leaks 5-9 5.11 Low Percent Rejection 5-9 5.12 Rejection Display Fluctuates 5-10 5.
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F-801 Internal RO System by GE Osmonics 5.1 RO Fails to Run 1. a. b. c. d. Power off. Check position of power switch. Check power cord (plugged in). Check outlet and circuit breaker/fuse panel for power with voltmeter. Check fuses in RO monitor panel. 2. Improper line voltage. a. Verify that line and equipment voltages are compatible. b. Check to make sure that combination of RO and other equipment that may be plugged into the same outlet are not overloading the circuit. 3.
F-801 Internal RO System by GE Osmonics 4. Pump inoperative a. Inspect pump and motor coupling for wear. b. Clean any debris or liquid from connection area. 5.3 Motor Runs Hot NOTE: Under normal conditions, the temperature of the motor may operate up to 40 C (104 F) above ambient (room) temperature. 1. a. b. c. d. e. Pump/motor binding. Remove pump head and try restarting motor. Inspect pump and motor coupling for wear. Clean any debris or liquid from connection area. See 5.4 Replace pump. a. b. c.
F-801 Internal RO System by GE Osmonics E. Flush valve is partly open a. Open and close valve and then measure and compare to original specifications. F. Pre-filter is plugged a. Replace pre-filter. 5.5 Pressure Gauge Vibrates Erratically 1. Air in gauge tubing. a. Loosen tube fitting at gauge to bleed air. 2. Obstruction in pressure gauge orifice. a. Remove obstruction. 3. Pump telegraphing (making noise) a. Inspect pump and motor coupling for wear. 4. Faulty gauge. a. Replace gauge. 5.
F-801 Internal RO System by GE Osmonics 4. Center tube of ROMA collapsed from operating at high temperatures. a. Correct temperature problem. b. Replace membrane. 5. a. b. c. d. 6. 5.8 Check softener pretreatment for brackish (high salt) water. Check inlet water for high conductivity. Check water softener for proper function. Regenerate softener. Check supply water for hardness and conductivity. Feed water fouling membrane (change in feed water). a. Check for change in feed water quality. b.
F-801 Internal RO System by GE Osmonics 5.9 Membrane Product Pressure Too Low 1. Product flow rate below specifications for temperature and pressure. a. Clean or replace membrane. 2. Flow demand exceeds flow capacity of membrane. a. Correct condition demanding excessive flows. b. Increase temperature of feed water and/or pump pressure (within operating limits). Continuously monitor temperature. 5.10 Leaks 1.
F-801 Internal RO System by GE Osmonics 6. Erroneous meter readout. a. Verify water quality with independent meter and check conductivity probe connection. b. Check all quick-disconnect connections. c. Replace inlet water sensor probe. d. Replace product water sensor probe (percent rejection). e. Replace monitor circuit board. 7. Membrane failure. a. Replace membrane. 8. Change in feed water TDS. a. Verify feed and product water quality with independent meter. b.
F-801 Internal RO System by GE Osmonics 4. Waste pressure too low. a. Adjust pump settings. 5. Product flow too high. a. See 5.8 6. Membrane scaled or fouled. a. Verify condition of pretreatment equipment. b. See membrane cleaning procedure in this manual. 7. a. b. c. d. e. f. Erroneous meter readout. Verify water quality with independent meter. See 5.12.7 TDS water probe wire disconnected or loose. Replace TDS water sensor probe. Replace thermistor. Replace monitor circuit board. 8.
F-801 Internal RO System by GE Osmonics 5.15 RO Pump Leaks 1. Tubing connection leaking. a. Tighten or reconnect tubing fitting. 2. Mechanical seal failure (leaks out vent hole). a. Replace pump.
F-801 Internal RO System by GE Osmonics NOTES: 12552e - 27 Feb 04 5- 13 Troubleshooting
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F-801 Internal RO System by GE Osmonics F-801 Internal RO System CHAPTER SIX: DRAWINGS 12552e – 27 Feb 04 6-1 Drawings
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F-801 Internal RO System by GE Osmonics REMOTE MONITOR MODULE PANEL F-801 RO and Cart Assembly (Component Layout) 12552e – 27 Feb 04 6-3 Drawings
F-801 Internal RO System by GE Osmonics PREFILTER CARBON TANK SHORT BACK PREFILTER CARBON TANK SOFTENER PREFILTER CARBON TANKS * A three tank option is available, please consult factory.
F-801 Internal RO System by GE Osmonics Assembly Instructions 1. Remove plugs from the tank head. 2. Install the input elbow, output nipple, and the sample valve in locations shown. Use Teflon tape and thread in approximately 3-5 turns.
F-801 Internal RO System by GE Osmonics 40571 ELBOW ADAPTER 40564 DUAL PORT 12104 FEED WATER FITTING 40569 40572 PRODUCT WATER FITTING 40570 40599A 2.
F-801 Internal RO System by GE Osmonics 60158 40704 40738 OUT IN *40095 *60370 *60240 *40605 *40095 F-801 RO (Pre-filter Assembly) 12552e – 27 Feb 04 6-7 Drawings
F-801 Internal RO System by GE Osmonics MANIFOLD ASSEMBLY 14731 MOTOR 30014 PUMP ASSEMBLY 12168−1 INPUT ASSEMBLY 12285−1 F-801 RO (Plumbing Module, Main Components) 12552e – 27 Feb 04 6-8 Drawings
F-801 Internal RO System by GE Osmonics 60360 30014 SEE DETAIL ’B’ 12285−1 (SEE DETAIL ’A’) 50003 12922 12168−1 40568 40569 1234489 40676 12131 50012 DETAIL ’A’ DETAIL ’B’ F-801 RO (Plumbing Module, Component Details) 12552e – 27 Feb 04 6-9 Drawings
F-801 Internal RO System by GE Osmonics 40576 (2X) 40564 PART OF ITEM 40947 40947 40561 40948 PART OF ITEM 40948 F-801 RO (Plumbing Module, Component Details) 12552e – 27 Feb 04 6 - 10 Drawings
F-801 Internal RO System by GE Osmonics 40564 40561 12922 40742 40677 14731 60002 60041 40569 41614 12130 50112 F-801 RO (Plumbing Module, Component Details) 12552e – 27 Feb 04 6 - 11 Drawings
F-801 Internal RO System by GE Osmonics F-801 RO (Plumbing Module, Tubing) 12552e – 27 Feb 04 6 - 12 Drawings
F-801 Internal RO System by GE Osmonics A (12") B (8") C (5 3/4") B (5 3/4") See Detail ’A’ on next sheet B (3 1/2") See Detail ’B’ on next sheet A (5") A (10") D (2") C (15 1/2") B (12 1/4") D (10") A (10") D (45") D (3 3/4") Item Letter A B C D LEGEND Description 3/8” Tubing, Translucent (Natural) 3/8” Tubing, White 1/4" Tubing, Translucent (Natural) 1/8” Tubing, White Part No.
F-801 Internal RO System by GE Osmonics 41036 40671 40254 40143 40077 40602 DETAIL ’A’ 40564 12288 DETAIL ’B’ F-801 RO (Plumbing Module, Component Details) 12552e – 27 Feb 04 6 - 14 Drawings
F-801 Internal RO System by GE Osmonics 60307 12110 40332 40584 SEE DETAIL ’A’ 20178 40602 12131 12201 40570 60051 40569 40564 40571 40218 12131 PLUS SIDE DETAIL ’A’ Note: The ‘plus side’ of the check valve (p/n 40584) should face towards the small manifold (p/n 12201).
F-801 Internal RO System by GE Osmonics 20177 12359 12329 12213 30026 12310 12324 12312 12315 F-801 RO (Monitor Module, Front Section) 12552e – 27 Feb 04 6 - 16 Drawings
F-801 Internal RO System by GE Osmonics 12776 30010 FUSE INSIDE (20012) 60002 20203 60041 12311 F-801 RO (Monitor Module, Back Section) 12552e – 27 Feb 04 6 - 17 Drawings
F-801 Internal RO System by GE Osmonics NOTE: ALL TUBING IS 3/8" I.D. BRAIDED HOSE UNLESS OTHERWISE NOTED. RO MEMBRANE PERMEATE TUBING (1/4" OD POLYETHYLENE TUBE) (65" LENGTH OF 60184) PREFILTER HOUSING ASSEMBLY (12197) ADAPTER, 3/8" HOSE TO 3/8" STEM (40672) GREEN MALE Q.D. (12886) GREEN FEMALE Q.D.
F-801 Internal RO System by GE Osmonics GREEN QUICK DISCONNECT RED QUICK DISCONNECT F−801 WATER SUPPLY HOSE. REMOVE FROM PREFILTER OUTLET PORT AND CONNECT TO DISINFECT TANK SUCTION PORT FITTING. F−801 WASTE−TO−DRAIN. DISCONNECT QUICK−CONNECT FITTING FROM REST OF HOSE, AND CONNECT TO DISINFECT F−801 PRODUCT−TO−USE HOSE. DISCONNECT QUICK−CONNECT FITTING FROM REST OF HOSE, AND CONNECT TO DISINFECT TANK.
12552e – 27 Feb 04 6 - 20 INPUT POWER 110/120 VAC, 60HZ FROM POWER CORD GREEN WHITE BLACK 10 A FUSE SLOW−BLOW RO PUMP POWER SWITCH PUMP MOTOR POWER SUPPLY F-801 Internal RO System by GE Osmonics F-801 RO (High Voltage Electrical, 60Hz) Drawings
F-801 Internal RO System by GE Osmonics RED RED GREEN RED GREEN RED BLUE YELLOW GREEN F-801 RO (Low Voltage Electrical) 12552e – 27 Feb 04 6 - 21 Drawings
WATER SUPPLY PREFILTER 12552e – 27 Feb 04 6 - 22 PRODUCT WATER QUALITY SENSOR (TDS) THERMISTOR EXCESS PRODUCT CHECK VALVE FEEDWATER SENSOR CARBON TANK STANDARD PRETREAT PRODUCT TO USE PRODUCT WATER QUALITY SENSOR (PERCENT REJECTION) PRESSURE REGULATOR PUMP PRESSURE GAUGE RO MEMBRANE HOUSING PRODUCT PRESSURE GAUGE RO PUMP WASTE FLUSH VALVE DRAIN FLUSH WASTE RESTRICTOR WASTE METERING ORIFICE F-801 Internal RO System by GE Osmonics F-801 RO (Plumbing Schematic) Drawings
F-801 Internal RO System by GE Osmonics TOOLS REQUIRED: 1. FLAT BLADE SCREWDRIVER. 2. 3/4" WRENCH OR EQUIVALENT. 3. TOWEL. PROCEDURE: 1. TURN OFF POWER AND WATER TO UNIT. 2. OPEN FRONT COVER AND EXPOSE PUMPHEAD. 3. REMOVE ACORN NUT. NOTE: DO NOT LOSE WASHER. 4. USE SCREWDRIVER AND TURN SCREW AS SHOWN. CLOCKWISE TO INCREASE PRESSURE, COUNTER CLOCKWISE TO DECREASE PRESSURE. EACH 90° ROTATION WILL CHANGE PRESSURE ABOUT 25 PSI. 5. REPLACE WASHER (IF IT CAME OFF) AND ACORN NUT. 6.
F-801 Internal RO System by GE Osmonics “Push-In” Fitting Instructions 12552e – 27 Feb 04 6 - 24 Drawings
F-801 Internal RO System by GE Osmonics NOTES: 12552e – 27 Feb 04 6 - 25 Drawings
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F-801 Internal RO System by GE Osmonics F-801 Internal RO System CHAPTER SEVEN: SPARE PARTS LIST 12552e – 27 Feb 04 7-1 Spare Parts List
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F-801 Internal RO System by GE Osmonics F-801 Internal RO System SPARE PARTS LIST NOTE: Part Numbers are subject to change and should be verified when ordering spare parts.
F-801 Internal RO System by GE Osmonics CATALOG NUMBER PARTS (cont.
F-801 Internal RO System by GE Osmonics CATALOG NUMBER PARTS (cont.
F-801 Internal RO System by GE Osmonics CLEANERS 14962 1228653 1228791 Membrane Cleaner, BIOSAN, 1 gal., liquid Cleaner, LIQUICLEAN 103™,1gal., Low pH, liquid Cleaner, LIQUICLEAN 511™,1gal.
F-801 Internal RO System by GE Osmonics NOTES: 12552e – 27 Feb 04 7-7 Spare Parts List
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Call (253) 395-2200 for additional information, (800) 633-3080 in the U.S., or visit www.osmonics.
