GE OSMONICS Z SERIES REVERSE OSMOSIS SYSTEM Operation and Maintenance Manual P/N: 1238339 REV.
Z SERIES REVERSE OSMOSIS SYSTEM Installation, Operation and Maintenance Manual TABLE OF CONTENTS CHAPTER ONE: Section 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.11.1 1.11.2 1.11.3 1.11.4 1.11.5 1.11.6 1.12 1.13 1.14 1.15 1.
CHAPTER THREE: Section 3.1 SYSTEM OPERATION Daily Start-Up Procedure 3-1 3-3 CHAPTER FOUR: Section 4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.3 4.3.1 4.3.1.1 4.3.1.2 4.3.1.3 4.4 4.4.1 4.4.1.1 4.4.1.2 4.4.
CHAPTER FIVE: TROUBLESHOOTING Table of Contents RO Fails to Run RO Runs Intermittently Motor Runs Hot Water Produced While RO is Off Low Waste Pressure Pressure Gauge Vibrates Erratically Excess Product Pressure Product Flow Too Low Product Flow Too High Poor Apparent Water Quality TDS Reading Too High RO Pump Leaks at Inlet End Leaks RO Fails to Draw Disinfectant Product Divert Controller and Valve Malfunction 5-1 5-3 5-5 5-6 5-6 5-7 5-7 5-7 5-8 5-8 5-9 5-9 5-10 5-10 5-10 5-11 5-11 CHAPTER SIX: DRAWING
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Z Series RO System by GE Osmonics Z Series RO System CHAPTER ONE: GENERAL INFORMATION 1238339b – 16Oct03 1-1 General Information
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Z Series 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 Z Series 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). The manual has been written in narrative form supplemented with schematics and drawings for clarification.
Z Series RO System by GE Osmonics USE PROPER POWER CONNECTIONS: Use proper wiring and connection methods to satisfy hospital electrical codes. DEVICE LABELING: Do not under any circumstances; remove any Caution, Warning or any other descriptive labels from the devices until the conditions warranting the label are eliminated. DO NOT OPERATE IN A FLAMMABLE ATMOSPHERE: To avoid fire or explosion, do not operate this device in an explosive environment or near flammable anesthetics. 1.
Z Series RO System by GE Osmonics WATER: Reverse osmosis systems require a reliable water source. Additionally, it is necessary to have adequate flow rates and pressure. The Z-Series RO is equipped with safety devices to shut down the unit when the pressure falls below 10 PSI. If flow rates drop below the required level the pressure will drop as well, causing the RO to shut down. It is important to run water at the design flow rate when testing water pressure rather than reading static pressure.
Z Series RO System by GE Osmonics 1.6 Theory of Operation The Z-Series RO is an open-frame mounted reverse osmosis unit which is fully monitored for pressure, percent rejection and output TDS. The unit includes prefiltration to remove gross particles capable of fouling membranes and damaging the highpressure pump. The RO pump provides the pressure required to drive water through the membranes at economical flow rates and improves the membrane's rejection performance.
Z Series RO System by GE Osmonics Inlet Water Sensor: The Inlet Water Sensor monitors the quality of the feed water. Input water quality is compared to the output (product) water and is displayed as "percent rejection" on the front panel. Disinfect Inlet Valve: The Disinfect Inlet Valve is a 1/4 turn ball valve which connects to the input water side of the pump. The valve is used whenever cleaners or disinfectants are introduced to the unit.
Z Series RO System by GE Osmonics Waste Recirculation Flow Meter: The Waste Recirculation Flow meter displays the amount of recycled waste water returned to the inlet of the high-pressure pump. The flow is displayed in a panel mounted flow meter. Automatic Flush: The Automatic Flush feature is intended to reduce the concentrations of suspended solids at the RO membrane surface, thereby reducing the accumulation of scale.
Z Series RO System by GE Osmonics Inlet Solenoid Valve: The Inlet Solenoid Valve is located on the riser pipe of the Z Series RO and serves to shut off the water supply to the RO system. It is actuated open when the power switch is placed in the ON position. Inlet Water Valve: The Inlet Water Valve is located after the inlet manifold and before the pre-filter. The valve allows manual shut off of the water supply to the unit. This valve is also used to shut off the water for pre-filter changes.
Z Series RO System by GE Osmonics Percent Rejection Display: The Percent Rejection Display is a 5 LED panel mounted array that indicates how the RO membranes are performing. The lights correspond to 99%, 95%, 90%, 85%, and >70% rejection. The 99% light, when illuminated, indicates a need to evaluate the RO system performance. CAUTION: RO units do not normally perform in excess of 99%; verify this reading with an independent meter and take corrective action if indicated.
Z Series RO System by GE Osmonics RO Interlock: The RO Interlock circuit, when activated, will not allow the RO unit to operate (run). An electric signal is sent from the RO unit control box (panel) to a normally open micro switch on the device. These devices are typically part of the pretreatment system. When the micro switch is closed, the signal returns to the RO unit control box activating the RO interlock circuit thus disabling RO operation.
Z Series RO System by GE Osmonics Product Divert System: The divert valve rotates open directing water to drain during RO system start-up and/or a high TDS alarm condition. The opening of the divert valve is communicated with the illumination of an indicator on the product divert controller. The open divert valve directs product water to drain and will remain open as long as an alarm condition exists and close after an approximate two-minute start-up delay or one-minute alarm removal delay. 1.
Z Series RO System by GE Osmonics Disinfect Alarm Monitor (DAM) The Disinfect Alarm Monitor reduces the possibility of patient and equipment exposure to disinfectants. The monitor provides a dependence requiring that Disinfect key switches, located on the RO Controller and RO Status Monitor, are purposely engaged prior to introducing disinfectants or cleaning agents into the loop piping. The key switch dependency ensures that disinfect operations are an intentional and deliberate act.
Z Series RO System by GE Osmonics Ultra Filters and Sub-micron Filters Ultra and Sub-micron filters are used to remove undesirable solids from the water. Normally these filters are used in the distribution loop to remove microorganisms and media fines. In some instances ultra filters are used in front of RO units to remove harmful colloids. In these circumstances the ultra filter is employed in a unit similar to an RO. Most frequently, filtration devices are used in the distribution plumbing.
Z Series RO System by GE Osmonics 1.11.2 1. Flow Rates Product flow rates based on the following conditions with product flow equal to waste flow: Operating Pressure: Product Pressure: pH: Feed Water Temperature: 200 - 250 PSI 1 PSI 6.5 77°F (25°C) GPM Product Flow Rate LPM GPD Z-9600 6.67 25.24 9,600 36,340 Z-12000 8.33 31.55 12,000 45,425 Z-14400 10 37.85 14,400 54,510 Z-6000 4.17 15.77 6,000 22,712 Z-8000 5.56 21.03 8,000 30,283 Z-10000 6.94 26.
Z Series RO System by GE Osmonics 1.11.4 Dimensions & Weights Dimensions Height Depth Width 74 inches 32.5 inches 29.75 inches Operating Weight Indirect Units Lbs. Direct Units Lbs. Z-9600 450 Z-6000 390 Z-12000 510 Z-8000 450 Z-14400 630 Z-10000 510 Z-12000 630 1.11.5 Membrane Performance Characteristics % Salt Rejection 95% Minimum Salt Rejection Operating Pressure Direct Feed 225 PSI ±10 PSI Indirect Feed 250 PSI ±10 PSI 1.11.
Z Series RO System by GE Osmonics 1.12 Disposal Disposal of this product or parts must be carried out according with local disposal codes. 1.13 Electromagnetic Interference This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with these instructions, may cause harmful interference to other devices in the vicinity. However, there is no guarantee that interference will not occur in a particular installation.
Z Series RO System by GE Osmonics 1.15 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. A representative will provide instructions and a return authorization number, which needs to be clearly written on the outside of the box used to ship your materials.
Z Series RO System by GE Osmonics 1.16 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.
Z Series RO System by GE Osmonics MNPT Male National Pipe Thread MSDS Material Safety Data Sheet Megohm/cm Million Ohms/Centimeter mw Molecular Weight NaCl Sodium Chloride N/A Not Applicable NPT National Pipe Thread NSF National Sanitation Foundation PA Polyamide P/N Part Number ppm Parts Per Million psi Pounds Per Square Inch PVC Polyvinyl Chloride QD Quick Disconnect RO Reverse Osmosis ROMA Reverse Osmosis Membrane Assembly SF Speed fit TB Terminal Barrier Strip (Main):
Z Series RO System by GE Osmonics NOTES: 1238339b – 16Oct03 1 - 21 General Information
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Z Series RO System by GE Osmonics Z Series RO System CHAPTER 2: INSTALLATION GUIDELINES AND INITIAL SYSTEM START-UP 1238339b – 16Oct03 2-1 Installation Guidelines and Instructions
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Z Series RO System by GE Osmonics 2.1 Installation Considerations 1. RO Unit: a. Location: The Z Series RO unit is free standing and should be situated with 2 feet of clearance on all sides. Locate away from any obstructions to provide room for access to the power cord and the water connections. b. Dimensions: Height – 74”; Width – 30”; Depth – 32.5” c. Weight: Between 390 and 630 pounds depending on the RO unit model. 2. Product Divert Controller: a.
Z Series RO System by GE Osmonics 2.2 Installation Procedures: 1. RO Unit: a. Connect the Z Series RO to the pre-treated feed water with sufficient diameter pipe (or hose) to ensure adequate flow of water. b. Connect the waste water line to the drain in accordance with the local plumbing code. c. Connect the product water line to the Product Divert Valve Assembly (RO Product Water Connection). d. Plug the power cord from the RO Controller into the appropriate outlet. 2. Product Divert: a.
Z Series RO System by GE Osmonics 4. Temperature Alarm: a. Connect the Temperature Alarm Monitor wires to the terminals in the RO control box. Refer to the electrical schematic in Chapter Six for connections. b. Install the Temperature Probe in the direct flow of the water in the run of a 1” or larger piping tee after the first piece of pre-treatment equipment. Refer to the installation drawing in Chapter Six for specific details. 5. Storage Tank Level Controls: a.
Z Series RO System by GE Osmonics 2.3 First Time Start-Up Procedures: 2.3.1 RO Unit WARNING: Any pre-treatment device supplying water to the RO must be ready for use. CAUTION: Check all wire connections to ensure they are secure or torque to their proper specification. Loose connections on high amperage wires can cause a potential hazard. 1. Connect the product output (prior to the Product Divert Valve Assembly) to drain. 2.
Z Series RO System by GE Osmonics 9. Adjust system pressure to 200 to 250 PSI depending on water consumption by rotating the pressure adjustment knob and pump output throttle valve. CAUTION: DO NOT adjust system pressure to more than 300 PSI. DO NOT close throttle valve completely or severe damage will occur to the pump. 10. Turn off the RO unit and reconnect the product line to the Product Divert Valve Assembly. WARNING: The RO unit must be disinfected prior to first use. (Reference section 4.
Z Series RO System by GE Osmonics 2.4 Product Water Analysis Procedure: In order to ensure that the RO is performing at or above AAMI (Association for the Advancement of Medical Instrumentation) Standards, it is necessary to perform an AAMI Water Quality Analysis test. New RO must be operated and rinsed to drain for at least two hours before taking a product water sample. This ensures the membranes are free of preservative or other contaminants that would invalidate the test.
Z Series RO System by GE Osmonics NOTES: 1238339b – 16Oct03 2-9 Installation Guidelines and Instructions
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Z Series RO System by GE Osmonics Z Series RO System CHAPTER 3: SYSTEM OPERATION 1238339b – 16Oct03 3-1 System Operation
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Z Series RO System by GE Osmonics 3.1 Daily Start-Up Procedure 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. NOTE: If optional remote monitoring or control equipment (i.e. RO Status Monitor, Disinfect Alarm Monitor…) is installed, refer to the appropriate manual for daily start-up conditions. 1. Ensure that all the valves in the water supply line to the RO are open.
Z Series RO System by GE Osmonics 9. The TDS monitor should stabilize within 2 to 5 minutes of start-up. The TDS during this time may be higher than the alarm set point. The audible alarm may be muted at this time by pressing the alarm mute switch. The alarm mute switch will silence the audible alarm for approximately 2 minutes. WARNING: A high TDS alarm condition requires immediate attention. 10. The absence of chlorine must be verified in the feed water after the pretreatment carbon tanks.
Z Series RO System by GE Osmonics NOTES: 1238339b – 16Oct03 3-5 System Operation
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Z Series RO System by GE Osmonics Z Series RO System CHAPTER FOUR: ROUTINE MAINTENANCE 1238339b – 16Oct03 4-1 Routine Maintenance
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Z Series RO System by GE Osmonics 4.1 Routine Maintenance of Z-Series RO System GE Osmonics Z-Series RO systems have been designed to operate with a minimum of operator attention. The RO system will operate longer and with less trouble when 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, periodic lubrication, and cartridge filter replacement.
Z Series RO System by GE Osmonics 5. 6. 7. 8. 9. 10. 11. Observe the supply and waste pressures and record values in the operation log. Allow water temperatures to stabilize before recording results to prevent errors due to fluctuating temperatures. Observe the waste and product flow rates and record values in the operation log. Allow water temperatures to stabilize before recording results to prevent errors due to fluctuating temperatures.
Z Series RO System by GE Osmonics 4.1.4 1. Semi-Annual Maintenance Lubricate motor and pump bearing frame if applicable (non-submersible motor only). Reference section 4.2.1, Pump Lubrication Procedure as necessary. 2. Re-torque the connection points on high amperage power and motor wires (Reference Technote 128). 3. Tighten the three screws inside the conduit elbow located on the outlet of the pump housing (submersible motor only).
Z Series RO System by GE Osmonics 4.2 Specific Maintenance Procedures and Instructions 4.2.1 Pump Lubrication Procedure NOTE: Submersible multi-stage centrifugal pumps do not require lubrication. 1. Use No. 2 Lithium grease (with molybdenum disulfide) as a lubricant (GE Osmonics P/N 50040). 2. Operate the RO for at least 15 minutes to bring the pump bearings to normal operating temperature. 3. Remove the plug from the pump bearing frame. 4.
Z Series RO System by GE Osmonics 3. With the RO unit operating normally, adjust the TDS alarm selector switch so that the TDS valve exceeds the TDS alarm set point and check the following; a. 4. With the RO unit operating in the condition listed above, adjust the TDS alarm selector switch so that the TDS value is lower than the TDS alarm set point and check the following; a. 5. 4.2.
Z Series RO System by GE Osmonics 4.2.4 Pre-Filter Cartridge Replacement Procedure NOTE: This procedure should be followed every thirty days or when the delta pressure increases by 10 PSI over a clean filter delta, whichever occurs first. 1. Close the inlet water supply valve. Pressures will drop to zero on the gauges and the RO pump will turn off automatically if the RO unit is operating. 2. Remove the pre-filter bowls by rotating to the left until it is free of the head. 3.
Z Series RO System by GE Osmonics 4.3 Z-Series Cleaning Indications WARNING: Some safety systems are disabled when the RO unit is operated with the Disinfect key switch. An operator should be present and monitoring the RO unit when operated in this manner. The following systems will not be operable: a. b. c. d. RO Interlock(s) Water Quality Monitoring Display Product Divert System Low Pressure Switch CAUTION: Water and solutions to be used must be chlorine free or damage to the RO membranes may result.
Z Series RO System by GE Osmonics There are a variety of indications for cleaning membranes. The most common is a reduced product flow rate. Remember that a reduction in inlet water temperature can also result in a reduced flow rate. Refer to Technote 113 "Temperature Correction Factors" to determine the reduction in flow that can be attributed to reduced water temperature. Clean the membranes whenever the temperature compensated flow rate drops by 10%.
Z Series RO System by GE Osmonics 4.3.1.1 1. Cleaning Procedure With the RO unit operating establish a pre-cleaning % rejection, TDS, and pH record on the cleaning disinfect log sheet. NOTE: If your RO system is equipped with a "submersible" high-pressure pump, the pump/motor housing must be purged of all air during the start-up procedure. Turn on the RO system and open the small valve on the top end of the pump/motor housing very slowly to purge. Air should be heard escaping to the atmosphere.
Z Series RO System by GE Osmonics 4.3.1.2 1. 2. 3. Post Cleaning Rinse Procedure Remove the RO waste and product lines from the cleaning tank and connect to drain. Turn on the RO unit. When the RO system is equipped with a Disinfect Alarm Monitor and RO Status Monitor post cleaning rinse operations may commence only when both disinfect key switches are activated, the RO unit power switch is turned on, and the alarm timer has expired.
Z Series RO System by GE Osmonics 13. 14. 15. Turn off the RO unit when the operating parameters (% Rejection, TDS, pH) have normalized. Reconnect the RO product line to the Product Divert Valve Assembly. Remove the “Do Not Use/Contains Cleaner” warning label. CAUTION: The RO should be disinfected after cleaning procedures are completed. 4.3.1.3 1.
Z Series RO System by GE Osmonics 9. Turn on the RO unit. When the RO system is equipped with a Disinfect Alarm Monitor and RO Status Monitor cleaning operations may commence only when both disinfect key switches are activated, the RO unit power switch is turned on, and the alarm timer has expired. If the Disinfect Alarm Monitor is not included in the RO system the Disinfect Start key switch can be turned ON to circulate the solution through the RO system.
Z Series RO System by GE Osmonics 4.4 Disinfection Procedure WARNING: Some safety systems are disabled when the RO unit is operated with the Disinfect key switch. An operator should be present and monitoring the RO unit when operated in this manner. The following systems will not be operable: a. b. c. d. RO Interlock(s) Water Quality Monitoring Display Product Divert System Low Pressure Switch CAUTION: Glutaraldehyde and Actril™ are not recommended disinfectants.
Z Series RO System by GE Osmonics 4.4.1 Formaldehyde Disinfection Preparation WARNING: Always wear rubber gloves, apron and facemask. Use proper ventilation during disinfection and rinse-out. A face respirator with an organic cartridge to remove formaldehyde fumes may be worn. DO NOT BREATHE FUMES OR ALLOW FORMALDEHYDE TO COME IN CONTACT WITH SKIN OR EYES. Follow all Material Safety Data Sheet (MSDS) precautions and OSHA Standards.
Z Series RO System by GE Osmonics 4.4.1.1 Formaldehyde Disinfection Procedure NOTE: If your RO system is equipped with a "submersible" high-pressure pump, the pump/motor housing must be purged of all air during the start-up procedure. Turn on the RO system and open the small valve on the top end of the pump/motor housing very slowly to purge. Air should be heard escaping to the atmosphere. Close the valve when water is seen flowing from this valve. 1. Turn off the RO unit power switch. 2.
Z Series RO System by GE Osmonics 9. Turn on the RO unit. When the RO system is equipped with a Disinfect Alarm Monitor and RO Status Monitor disinfect operations may commence only when both disinfect key switches are activated, the RO unit power switch is turned on, and the alarm timer has expired. If the Disinfect Alarm Monitor is not included in the RO system the Disinfect Start key switch can be turned ON to circulate the solution through the RO system.
Z Series RO System by GE Osmonics 17. Turn off the RO unit and pour the last amounts of cleaner into drain to protect the pump from running dry. RO systems equipped with a Disinfect Alarm Monitor will use the RO unit power switch to turn off the pump and stop circulation. RO systems without a Disinfect Alarm Monitor will use the Disinfect key switches to turn off the pump. 18. Rotate the Disinfect Inlet Valve to the closed position.
Z Series RO System by GE Osmonics 4.4.2 Peracetic Acid/Peroxide-Based (Renalin®) Disinfection Preparation WARNING: Always wear rubber gloves, apron and face mask. Use proper ventilation during disinfection and rinse out. A face respirator with an organic cartridge to remove fumes may be worn. DO NOT BREATHE FUMES OR ALLOW RENALIN / MINNCARE TO COME IN CONTACT WITH SKIN OR EYES. Follow all Material Safety Data Sheet (MSDS) precautions and OSHA Standards.
Z Series RO System by GE Osmonics CAUTION: ‘RENALIN®’ is corrosive to most metals other than stainless steel. Any brass components that will come into contact with the ‘RENALIN®’ must be replaced with suitable stainless or plastic materials prior to attempting disinfection. ‘RENALIN®’ type products contain oxidizing agents and are potentially damaging to thin film (polyamide) membranes. It is imperative that all the precautions and instructions are followed correctly.
Z Series RO System by GE Osmonics 4.4.2.1 Renalin® Disinfection Procedure NOTE: If your RO system is equipped with a "submersible" high-pressure pump, the pump/motor housing must be purged of all air during the start-up procedure. Turn on the RO system and open the small valve on the top end of the pump/motor housing very slowly to purge. Air should be heard escaping to the atmosphere. Close the valve when water is seen flowing from this valve. 1. 2. Turn off the RO unit power switch.
Z Series RO System by GE Osmonics 9. Turn on the RO unit. When the RO system is equipped with a Disinfect Alarm Monitor and RO Status Monitor disinfect operations may commence only when both disinfect key switches are activated, the RO unit power switch is turned on, and the alarm timer has expired. If the Disinfect Alarm Monitor is not included in the RO system the Disinfect Start key switch can be turned ON to circulate the solution through the RO system.
Z Series RO System by GE Osmonics 16. Rotate the Disinfect Inlet Valve to the closed position. Allow the disinfectant solution to remain in contact for 2-12 hours. CAUTION: Do not allow the Renalin® to dwell more than 12 hours, or the RO membranes will be permanently damaged. 4.4.2.2 Post Renalin® Disinfection Rinse Procedure 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Remove the Disinfect Inlet Valve disinfection line from disinfect tank and connect to drain. Ensure that the water supply to the RO unit is on.
Z Series RO System by GE Osmonics 4.5 Product Water Culture FREQUENCY: A product water culture should be taken once a month or more often, depending upon culture results, and unit protocol. GE Osmonics recommends this be performed before and after disinfection. RATIONALE: Performing a product water culture will help ensure that the microbial count of the product (RO) water falls within the AAMI Hemodialysis Water Standard.
Z Series RO System by GE Osmonics 4.6 System Storage It is not recommended that an RO unit be dormant longer than 24 hours without disinfectant. RO units that have been left unused for more than 24 hours risk the possibility of colonizing bacteria and exceeding acceptable limits. RO units to be stored should first be disinfected with one of the procedures in this chapter. CAUTION: ‘RENALIN®’ products (Renalin®, Minncare™, Peracidin™. etc.) are not acceptable disinfectants for storage of systems.
Z Series RO System by GE Osmonics 4.6.2 BIOSAN™ Storage Procedure WARNING: It is recommended that protective gloves and eye protection be worn when handling the BIOSAN™. Follow all Material Safety Data Sheet (MSDS) precautions and OSHA Standards. WARNING: Label machine with appropriate warning signs such as "Do Not Use / Contains Cleaner" to prevent use of the RO until it is properly rinsed. a. Disinfect and rinse the RO unit with an acceptable disinfectant solution. Reference section 4.
Z Series RO System by GE Osmonics NOTES: 1238339b – 16Oct03 4 - 28 Routine Maintenance
Z Series RO System by GE Osmonics Z Series RO System CHAPTER FIVE: TROUBLESHOOTING 1238339b – 16Oct03 5-1 Troubleshooting
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Z Series RO System by GE Osmonics Table of Contents SECTION PAGE 5.1 RO Fails to Run 5-5 5.2 RO Runs Intermittently 5-6 5.3 Motor Runs Hot 5-6 5.4 Water Produced While RO is Off 5-7 5.5 Low Waste Pressure 5-7 5.6 Pressure Gauge Vibrates Erratically 5-7 5.7 Excess Product Pressure 5-8 5.8 Product Flow Too Low 5-8 5.9 Product Flow Too High 5-9 5.10 Poor Apparent Water Quality 5-9 5.11 TDS Reading too High 5-10 5.12 RO Pump Leaks at Inlet End 5-10 5.13 Leaks 5-10 5.
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Z Series RO System by GE Osmonics 5.1 RO Fails to Run 1. Power Check position of power switch. Check position of service disconnect switch. Check outlet and circuit breaker/fuse panel for power. Check fuses in RO and at service disconnect. Replace fuse(s) as necessary. Line Voltage Verify the line and equipment voltages are compatible. Electrical Connections Ensure the power cord is connected to the appropriate outlet. Check all wiring connections to verify solid connection.
Z Series RO System by GE Osmonics 5.2 RO Runs Intermittently 1. Low Water Pressure (Static or Dynamic) Correct cause of low pressure by adjusting pressure regulator or installing a booster pump. Low Feed Water Flow Rate (Dynamic) Replace pre-filter cartridges. Check pretreatment devices. Check that water supply valves are open. Electrical Connection Ensure the power cord is connected to the appropriate outlet. Check all wiring connections to verify solid connection.
Z Series RO System by GE Osmonics 5.4 1. a. b. c. 2. a. 3. b. Water Produced While RO is Off Inlet Solenoid Valve Cycle valve off and on with power switch to clear obstruction. Remove valve and clear obstruction. Replace valve as necessary. RO By-Pass Valve (Indirect Feed Units only) Verify the bypass valve is not inoperative. Clean or replace valve as necessary. Product Return Check Valve (Direct Feed Units Only) Verify the check valve is not inoperative. Clean or replace valve as necessary. 5.5 1.
Z Series RO System by GE Osmonics 5.7 1. a. 2. a. b. 3. a. b. 5.8 1. a. 2. a. 3. a. b. 4. a. 5. a. b. c. d. Excess Product Pressure (Product Return Port Connected) Feed Water Pressure Too High Install pressure regulator if not already present and reduce pressure. Product Flow Rate Too High Decrease operating pressure by adjusting pump pressure regulator. Increase waste flow by adjusting waste flow valve.
Z Series RO System by GE Osmonics 5.9 Product Flow Too High 1. 2. Rejection Satisfactory A. Waste Pressure Too High a. Adjust pressure regulator. b. Waste flow too low. B. Feed Water Temperature Too High a. Adjust temperature blending valve. b. Correct plumbing error that allows the cold water to be heated. Rejection Unsatisfactory A. ROMA Internal Seals Damaged, Dirty, Or Dislodged a. Disassemble ROMA, clean and inspect “O” rings and seals. B. Membrane Hydrolyzed (Exposed To Oxidant) a.
Z Series RO System by GE Osmonics 5.11 1. a. 2. a. b. 3. a. 4. a. b. 5. a. b. c. d. e. 6. a. 7. a. b. TDS Reading Too High Waste Flow Too Low Open waste flow control valve. Waste Pressure Too Low Adjust waste flow control valve. Adjust waste pressure regulator. Product Flow Too High See 5.9 Membrane Scaled Or Fouled Verify condition of pretreatment equipment. See membrane cleaning procedure in this manual.
Z Series RO System by GE Osmonics 5.14 1. a. 2. a. 3. a. 4. a. b. 5. a. b. c. d. 6. a. RO Fails To Draw Disinfectant Disinfect Inlet Valve Closed Open valve. Housing On Submersible Pump Contains Air Purge air, see cleaning or disinfect procedure. Disinfect Line Kinked Or Plugged Clear disinfect line. Air Leak On Disinfect Draw Line Tighten fittings. Check O-ring in Disinfect Inlet Valve. Motor Fails To Turn On Disinfect key switch inoperative. Remote monitor (if equipped) key switch not turned. D.A.M.
Z Series RO System by GE Osmonics NOTES: 1238339b – 16Oct03 5 - 12 Troubleshooting
Z Series RO System by GE Osmonics Z Series RO System CHAPTER SIX: DRAWINGS 1238339b – 16Oct03 6-1 Drawings
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Z Series RO System by GE Osmonics AIR BLEED VALVE FLUID PANEL ASSEMBLY ASSEMBLY PRESSURE REGULATOR VALVE WASTE FLOW VALVE Z Series RO (Indirect Feed) (Component Layout) 1238339b – 16Oct03 6-3 Drawings
Z Series RO System by GE Osmonics HIGH−PRESSURE PUMP ASSEMBLY PRESSURE SWITCH PUMP PRESSURE ADJUSTING VALVE AUTO−FLUSH ASSEMBLY ROMA VALVE RO BYPASS VALVE INLET WATER SOLENOID PREFILTER ASSEMBLY DISINFECT VALVE Note: Part of the frame has been removed to expose components.
Z Series RO System by GE Osmonics FLUID PANEL ASSEMBLY CONTROLLER ASSEMBLY PRESSURE REGULATOR VALVE WASTE FLOW VALVE Z Series RO (Direct Feed) (Component Layout) 1238339b – 16Oct03 6-5 Drawings
Z Series RO System by GE Osmonics Note: Part of the frame has been removed to expose components.
Z Series RO System by GE Osmonics Z Series RO (Typical Indirect System Pretreat Diagram) 1238339b – 16Oct03 6-7 Drawings
1238339b – 16Oct03 2 & 13 CONDUCTOR 18 AWG NON−REPEATING MULTI−COLOR WIRE WITH 10FT WHIP, AND THE APPROPRIATE SIZE AND TYPE OF CONDUIT MEETING LOCAL CODES (TO BE SUPPLIED AND INSTALLED BY OTHERS) DISINFECT ALERT MONITOR (D.A.M.) RO STATUS MONITOR 6-8 5 3 4 2 1 RO WASTE RO UNIT ELECTRICAL RECEPTICAL BY OTHERS ELECTRICAL CONNECTION BY OTHERS FM FM DFS FS UV LAMP LOW LEVEL ALARM FM (TYP.
Z Series RO System by GE Osmonics Z Series RO (Typical Direct System Pretreat Diagram) 1238339b – 16Oct03 6-9 Drawings
1238339b – 16Oct03 2 & 13 CONDUCTOR 18 AWG NON−REPEATING MULTI−COLOR WIRE WITH 10FT WHIP, AND THE APPROPRIATE SIZE AND TYPE OF CONDUIT MEETING LOCAL CODES (TO BE SUPPLIED AND INSTALLED BY OTHERS) DISINFECT ALERT MONITOR (D.A.M.) RO STATUS MONITOR 6 - 10 DI CONNECTION VALVE 3 5 4 2 1 4x4 ELEC.
1238339b – 16Oct03 HEIGHT: 75" WIDTH: 30" DEPTH: 32.
Z Series RO System by GE Osmonics Z Series RO (Indirect Feed) (Flow Diagram) 1238339b – 16Oct03 6 - 12 Drawings
Z Series RO System by GE Osmonics Z Series RO (Direct Feed) (Flow Diagram) 1238339b – 16Oct03 6 - 13 Drawings
1 1 TB3−5B PRODUCT DIVERT A B 600 VAC FNQ−R 1/2 AMP F2 FUSE CHEM FEED TB2−8A TB3−3B 5 13 TR2 CR3 8 14 TB4−7B TB4−1B 4 (XFM 1) CONTROL CHASSIS 208/230/460 VAC PRIMARY (CHANGE JUMPER AS NEEDED) F1 FUSE A B 600 VAC FNQ−R 1/2 AMP INTERLOCK H4 H1 CONTROL DOOR (XP) X2 (−) 110 VAC SECONDARY X1 CONTROL BOX FUSES F1 AND F2 ARE MOUNTED ON TRANSFORMER XFM. 2) DRAWING SHOWN, POWER NOT APPLIED.
1238339b – 16Oct03 1 6 - 15 F2 FUSE L1 5 L2 TB3−5B CHEM FEED TB2−8A TB3−3B INTERLOCK 4 5 13 TR2 CR3 TB4−7B 8 14 (XFM 1) TB4−1B TO SINGLE PHASE MOTOR CONTROLLER MOTOR CONNECTION SW CR8 A B 600 VAC FNQ−R 1/2 AMP 9 1 CONTROL CHASSIS 208/230/460 VAC PRIMARY (CHANGE JUMPER AS NEEDED) F1 FUSE A B 600 VAC FNQ−R 1/2 AMP PRODUCT DIVERT H4 H1 CONTROL DOOR (XP) X2 (−) 110 VAC SECONDARY X1 CONTROL BOX FUSES F1 AND F2 ARE MOUNTED ON TRANSFORMER XFM.
Z Series RO System by GE Osmonics PRODUCT OUTPUT TO LOOP OR STORAGE TANK.
Z Series RO System by GE Osmonics OFF I O ON Z Series RO (Typical Controller) 1238339b – 16Oct03 6 - 17 Drawings
Z Series RO System by GE Osmonics CR1 CR2 CR3 CR4 4" CR6 CR7 6" A B A B TB4 TR2 TB1 TR1 9" T1 2 3 1 A LOAD + F3 B TB3 INPUT TB2 − A A F2 F1 XFM−2 B B XFM−1 Z Series RO (Relay Operation Detail) 1238339b – 16Oct03 6 - 18 Drawings
Z Series RO System by GE Osmonics 1 2 3 LOAD − INPUT + Z Series RO (Control Box Chassis Major Component Locations) 1238339b – 16Oct03 6 - 19 Drawings
Z Series RO System by GE Osmonics PRD DIVERT CHEM FEED RED/BLK ORANGE RED 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 BLACK RED BLK/WHT WHT/BLK WHITE BLACK RED/WHT BLUE BLU/BLK OR/BLK GRN/BLK 2 1 RO CONTROLLER TIMER TR2−5 TR2−8 BLACK RED 2 3 RO STATUS MONITOR OVER TEMP ALARM GROUND (GREEN) S1−2 (RED) S1−4 (BLK) COMMON (WHT) GROUND (GREEN) RED BLACK RED BLACK BLACK RED 1 2 3 4 5 6 HIGH FLOAT 1 HIGH FLOAT 2 LOW FLOAT 1 LOW FLOAT 2 LOW LOW FLOAT 2 LOW LOW FLOAT 1 10 9 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3
ALARM TH SEL KEY 1 2 3 4 5 6 7 8 9 10 1238339b – 16Oct03 KEY BLACK WHITE WHITE BROWN RED GREEN PURPLE BLUE BLACK YELLOW ORANGE 1 2 3 4 5 6 7 8 9 10 11 12 6 - 21 CONDUCTIVITY PROBE 5 4 3 2 1 WHITE HEAT SHRINK SHIELD GREEN BLACK RED 5 4 3 2 1 10K TH CON−PROBE CON12 12 11 10 9 8 7 6 5 4 3 2 1 ORANGE BLACK BROWN GREEN RED CR6−9 (GREY) CR7−12 (BROWN) CR6−12 (WHT) BLUE PURPLE BLACK YELLOW BLUE ORANGE RED WHT / YEL / BLK WHT / YEL / BLK KEY 6 5 4 3 2 1 %REJ PROBE TB−3 TB−1 TB−2 RO CONTROLLER TERM
Z Series RO System by GE Osmonics Z Series RO (Disinfect Alarm Monitor Wiring Connections) 1238339b – 16Oct03 6 - 22 Drawings
Z Series RO System by GE Osmonics Z Series RO (Fluid Panel) 1238339b – 16Oct03 6 - 23 Drawings
Z Series RO System by GE Osmonics 40674 40675 40396 12904 12905 12095 Z Series RO (Fluid Panel Assembly, Rear View) 1238339b – 16Oct03 6 - 24 Drawings
Z Series RO System by GE Osmonics 40640 40397 40080 40727 40087 Z Series RO (Pressure Regulator Assembly) 1238339b – 16Oct03 6 - 25 Drawings
Z Series RO System by GE Osmonics Z Series RO (Waste Flow Control Valve Assembly) 1238339b – 16Oct03 6 - 26 Drawings
Z Series RO System by GE Osmonics 1229990 123 5145 13 394 13 393 13 395 (TOP VIEW) 80350 * SEE BELOW 41309 41410 41409 41409 (ENDCAP AND ADAPTERS EXPL ODED VIEW) PAR T NO.
Z Series RO System by GE Osmonics "PUSH−IN" FITTNGS NOTE: FITTING IS NOT DESIGNED TO BE DISASSEMBLED. IF THE FITTING LEAKS, CHECK FOR IMPROPER TUBE INSERTION OR TUBE ROUTING THAT MAY CONTRIBUTE TO LEAKAGE. INTERNAL COMPONENT REPLACEMENTS ARE NOT AVAILABLE. PUSH TUBE INTO FITTING TO SECURE. "O" RING PROVIDES SEAL. COLLET HAS STAINLESS STEEL TEETH THAT GRIP TUBE. ATTACH LOCKING CLIP BETWEEN COLLET FLANGE AND FITTING BODY TO PREVENT ACCIDENTAL RELEASE OF TUBE.
Z Series RO System by GE Osmonics NORMAL RUN OVERRIDE AUTOMATIC SHUTDOWN FUNCTION OF THIS SAFETY DEVICE IS ELIMINATED WHEN SWITCH IS IN "OVERRIDE". R. O. UNIT OPERATING R. O. UNIT INTERLOCK USE OVERRIDE FUNCTION ONLY IN AN EMERGENCY. EXTREME DANGER TO PATIENTS AND EQUIPMENT WHEN IN OVERRIDE MODE.
Z Series RO System by GE Osmonics Over Temperature Probe (Probe Installation) 1238339b – 16Oct03 6 - 30 Drawings
Z Series RO System by GE Osmonics Over Temperature Alarm (Electrical Schematic, Reference Only) 1238339b – 16Oct03 6 - 31 Drawings
Z Series RO System by GE Osmonics 20036 20089 30080 20114 1 2 3 4 5 6 7 8 9 10 "CAUTION" RISK OF ELECTRIC SHOCK. DO NOT REMOVE COVER. REFER SERVICING TO QUALIFIED SERVICE PERSONNEL. 450016/C FRONT VIEW WITH COVER CLOSED 60362 41507 60627 30044 1236373 TO VALVE FRONT VIEW CONTROLLER ASSEMBLY 60362 30080 30044 20114 20089 20036 1236373 41507 60627 PART NO. STRAIN CLAMP, WATER TIGHT 8 PIN,SMALL POWER CORD WITH " HOSPITAL " PLUG, 8’ FUSE, 3AMP, SLO−BLO RELAY,24V,DPDT INDICATOR, 1/2".
Z Series RO System by GE Osmonics 1 40611 FROM RO PRODUCT 40169 41582 TO STORAGE TANK OR DIRECT TO LOOP WALL MOUNTING REFERENCE TO CONTROL BOX 40169 40926 60343 (2 PLS) 40386 40864 1228209 40863 3" DRAIN LINE NOTES: 1 A SPRING RETURN CHECK VALVE (MINIMUM 1/2 PSI) MUST BE INSTALLED DOWNSTREAM OF THE VALVE ASSEMBLY. 2) ALL THREADED PARTS TO BE WRAPPED WITH TEFLON TAPE. 60343 1228209 41582 40926 40864 40863 40386 40611 40169 PART NO.
Z Series RO System by GE Osmonics A PRODUCT DIVERT VALVE L1 B CR5 4 12 NO 1 9 8 1 5 CLOSE RED NEUTRAL WHITE OPEN BLACK 13 14 TB1 10 9 WHITE 8 7 6 5 BLACK A F1 B 3 AMP SLO BLO 4 3 2 1 GREEN 24V AC NEUTRAL BLACK 24V HOT RED TB4−1 (ON RO) TB4−7 (ON RO) 18−3 POWER CORD LEGEND: WIRING INSIDE ENCLOSURE WIRING OUTSIDE ENCLOSURE Product Divert (Product Divert Connection to RO Controller) 1238339b – 16Oct03 6 - 34 Drawings
Z Series RO System by GE Osmonics NOTES: 1238339b – 16Oct03 6 - 35 Drawings
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Z Series RO System by GE Osmonics Z Series RO System CHAPTER SEVEN: SPARE PARTS LIST 1238339b – 16Oct03 7-1 Spare Parts List
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Z Series RO System by GE Osmonics Z Series RO System SPARE PARTS LIST NOTE: Part Numbers are subject to change and should be verified when ordering spare parts. CATALOG NUMBER PARTS 12131* 1229615* 1229980 1230048 12310 12312 1234709 1234709 1234711 1234732 1235402 1235403 1236035 1236350 20007 20089 20120* 20127* 21144* 30080 30110 30118 30123 30147 40127 40170** 40171 40173 40396 40674* 40675* 40700* 1238339b – 16Oct03 DESCRIPTION Sensor Probe, Total Dissolved Solids, Feed, Product Fuse, 0.
Z Series RO System by GE Osmonics CATALOG NUMBER PARTS (continued) 30151 30150 30149 41582 40700 40863 40864 50040 40291 60240 60280 60341 60370 50092 Switch, Temperature Transducer, Temperature Temperature probe well, SS Valve, Ball, 1”, Electric Valve, Waste Flow QD, Female x 1” Hose Barb QD, Male x 1” NPT Grease Cartridge (non-submersible pump/motor only) Valve, sample (1/4” NPT x barb) Clamp, worm gear, 3/4” Clamp, worm gear, 5/8” Tube, 1/8” Hose, 3/8” Hose, 5/8” CLEANERS 14962 14963 1228792 1228791
Z Series RO System by GE Osmonics MOTORS/PUMPS 30196***** 30194***** 30203***** 30195***** 30193***** 30206***** 30207***** 14439***** 14440***** 30400**** 30399**** 30398**** 30401**** 30397**** 10327**** 10261**** 10251**** * ** *** **** ***** Motor only, 5HP, 1Ph, 230V~ Motor only, 5HP, 3Ph, 208V~ Motor only, 5HP, 3Ph, 230V~ Motor only, 5HP, 3Ph, 460V~ Motor only, 7.5HP, 3Ph, 208V~ Motor only, 7.5HP, 3Ph, 230V~ Motor only, 7.
Z Series RO System by GE Osmonics NOTES 1238339b – 16Oct03 7-6 Spare Parts List
Call (253) 395-2200 for additional information, (800) 633-3080 in the U.S., or visit www.gewater.
