Nelsen NRO 2540 Commercial Systems - Intec America

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Nelsen NRO 2540Commercial SystemsInstallation, Operation & Maintenance ManualIncluding NRO-22540-1400-WM

Table of ContentsSystem Specifications.Page 3Introduction.Page 4.Page 5.Page 6Feed Water RequirementsRO MembranesRecovery & Rejection.Page 7.Page 8System Requirements & Operation GuidelinesRO Start-Up.Page 10.Page 12.Page 13Operation & MaintenanceMembrane CleaningSpare Parts.Page 14.Page 15.Page 16TroubleshootingOperation LogWarrantyPage 72

System SpecificationsNelsen Commercial Reverse Osmosis System SpecificationsModel TypeModel Number:Production GPDMembranePermeate GPMFeed GPM**% Recovery w/RecyclePumpFLA 60HZ 1Ø 110/220FLA 60HZ 3Ø 230/460Circuit SizeInletPermeateConcentrateUnit Dims (DxWxH)Shipping Dims (DxWxH)Weight - PoundsFloor StandNRO-12540-7007002-1/2" x 40" (1).48GPM1.719-40%.5 HP7.1/3.4N/A20/10A3/4"3/8"3/8"27¼"x24"x54¾"Floor StandNRO-22540-140014002-1/2" x 40" (2).97GPM230-60%.75 HP10/5.0N/A20/10A3/4"3/8"3/8"27¼"x24"x54¾"Wall MountNRO-12540-700-WM7002-1/2" x 40" (1).48GPM1.719-40%.5 l MountNRO-22540-1400-WM14002-1/2" x 40" (2).97GPM230-60%.75 25½"x58"104 lbs.34"x25½"x58"118 lbs.48"x40¾"x29¼"106 lbs.48"x40¾"x29¼"120 lbs.** - Minimum pressure of 20 psi WARNING: Please carefully read the information contained in this Installation, Operation &Maintenance Manual (IO&M Manual) before starting or operating this reverse osmosis waterpurification system. Failure to do so, may void warranty, cause equipment damage, bodily injury orpotentially death. WARNING: This Reverse Osmosis System is designed and produced for the purification of wateronly. Do not use this equipment for any other purpose without express written authorization fromthe manufacturer. Failure to follow these guidelines may result in serious bodily injury or death. WARNING: The RO System should be shielded from the elements. Periodic rain and exposure toUV Rays will cause irreparable damage to the unit and will not be covered by warranty. Exposureto rain and high humidity environments may also cause damage to the pump motor and electroniccontrols. This damage will not be covered under warranty.3

Introductionto pass through to Point of Use (POU). Reverseosmosis is considered to be the finest filtrationprocess and was developed as a method for thedesalination of seawater, but was later accepted bymany manufacturing industries as a method of waterpurification. The process of reverse osmosis involvesforcing water molecules through a semi-permeablemembrane which is rolled up spirally around a hollowtube. High pressure exerted by the water, forces thewater through the membrane, separating it from theimpurities. This process removes unwanted particlesthat are as small as dissolved ions. The impurities areflushed to drain.Nelsen Corporation’s commercial reverse osmosisNRO systems produce high quality water. Thesystem is durable and with proper care will lastfor many years. Components are of the highestquality on our reverse osmosis systems. Thismanual outlines installation, operation, maintenanceand troubleshooting details vital to the sustainedperformance of your system.Reverse Osmosis WaterFiltration ProcessFIGURE 1Reverse Osmosis removes dissolved inorganicsolids (such as salt) from water. The membraneallows only the permeate water, not entratedSolutionWater diffuses through semi-permeablemembrane toward region of higherconcentration to equalize solution strength.Ultimate height difference columnis “osmotic” pressure.DiluteSolutionApplied pressure in excess of osmoticpressure reverses water flow direction,hence the term “Reverse Osmosis”.4

Feed Water RequirementsFeed water quality has a huge effect on theperformance of the reverse osmosis system. It isimportant to supply the reverse osmosis system withthe feed water quality shown below. Pretreatmentmay be required if the parameters below are not met.Failure to meet feed water requirements may foulmembranes, void the system warranty and effect thestated performance of the system.is predicted by the Langelier Saturation Index (LSI).The LSI should be zero or negative throughoutthe unit unless approved anti-scalents are used.Softening is the preferred method of controllinghardness scale.Carbon Filter - Used to remove chlorine andorganics from the feed water. Free chlorine will causerapid irreversible damage to the membranes.Table 2: Recommended Feed Water QualityThe residual free chlorine present in most municipalwater supplies will damage the thin film compositestructure of the membranes used in this unit. Carbonfiltration or sodium bisulfite injection should be usedto completely remove the free chlorine residual.HardnessFree ChlorineT.D.S.*Turbidity SDIPhIronSilicaHydrogen SulfideManganeseOrganicsPressure 1 grain0 ppm 2000 ppm 53-11 0.01 ppm 1 ppm0 ppm 0.05 ppm 1 ppm20 - 60 psi40 F - 80 FTemperature8 C - 27 C*If TDS exceeds 2000 ppm, consult factory.Chemical Injection - Typically used to feedantiscalant, coagulant, or bisulfite into the feed wateror to adjust the feed water pH.Prefilter Cartridge - Used to remove smallersuspended solids and trap any particles that may begenerated by the other pretreatment. The cartridge(s)should be replaced when the pressure drop acrossthe housing increases 5 - 10 psi over the cleancartridge pressure drop. The effect of suspendedsolids is measured by the silt density index (SDI)test. An SDI of five (5) or less is specified by mostmembrane manufacturers and three (3) or less isrecommended.The RO feed water must be pretreated in order toprevent membrane damage and/or fouling. Properpretreatment is essential for reliable operation of anyRO system.Pretreatment requirements vary depending on thequality of the feed water. Pretreatment equipmentis sold seperatly. The most common forms ofpretreatment are described below.Iron & Manganese - These foulants should beremoved to less than 0.1 ppm. Special media filtersand/or chemical treatment is commonly used.pH - The pH is often lowered to reduce the scalingMedia Filter - Used to remove large suspendedpotential.solids (sediment) from the feed water. Backwashingthe media removes the trapped particles. Backwashcan be initiated by time or differential pressure.Silica - Reported on the analysis as SiO2. Silicaforms a coating on membrane surfaces when theconcentration exceeds its solubility. Additionally, thesolubility is highly pH and temperature dependent.Silica fouling can be prevented with chemicalinjection and/or reducing the recovery.Water Softener - Used to remove calcium andmagnesium from the feed water in order to preventhardness scaling. The potential for hardness scaling5

Reverse Osmosis Membranes Reverse Osmosis Unit: Required for the productionof treated water, as per the daily requirements.Different capacities of the unit are availabledepending on the rate of production of purifiedwater. For example, a 1400 gallon-per-day systemproduces purified water at the rate of 58 gallonsper hour.Table 3: Typical Rejection Characteristicsof Reverse Osmosis miumMercuryBariumSeleniumCyanidePhosphateChloride Pretreatment Equipment: Filtration systems arenecessary and should be installed along with thereverse osmosis system, especially if the watercontains excessive mineral hardness. Storage Tank: Necessary for storage of permeatewater. The storage tank stores the permeatewater for later use. Re-pressurization System: Consists of a pumpand bladder tank, which pressurizes water fromstorage tank and supplies water where there is ademand. NOTES: NRO Commercial Tap WaterSystem Performance is based on 500 ppmTDS & 77ºF temperature. Higher TDSor lower temperatures could affectpermeate production.% 6%84-92%96-98%85-92%May vary based on membrane type, water pressure,temperature, pH & TDSFIGURE 2Diagram of a Reverse Osmosis Membrane6

Recovery & RejectionThe amount of total dissolved solids (TDS) rejectedby membrane is expressed as a percentage (%). Forexample, a 99.6% rejection rate means that 99.6%of total dissolved solids do not pass through themembrane. To calculate the % rejection, use thefollowing formula:Recovery is defined as the measure of the permeateflow to feed flow. A higher recovery rate means lessconcentrate going to the drain. A higher recoverycan also cause soluble salts to precipitate out of theconcentrate and onto the membrane surface.% Recovery Permeate flow rate 100Feed flow rate% Rejection ((Feed TDS – Permeate TDS) (FeedTDS)) 100Feed Flow Permeate Flow Concentrate FlowExample: If permeate flow is 10 GPM andExample: I f feed water has 1500 TDS and permeatewater has 20 TDS, thenFeed Flow 10 15 25 GPM% Recovery (1500 - 20) 100 98.7%1500concentrate flow is 15 GPM, then% Recovery (10/25) x 100 40%System Requirements & Operation GuidelinesElectrical ailure to do so may cause systemFdamage, property damage or bodily injuryincluding death.The pump used on the NRO system is pump & motorcombination. The motor is available is a 110/220,60 hertz single phase. Each NRO system is equippedwith a 6 foot electrical cord. NOTE: Nelsen Corporation recommendsthat a license electrician install your unitin accordance to local and national codes. WARNING: Ensure that all voltagesupplies match the equipment being used.Failure to do so may cause death or seriousinjury. Proper breaker ratings must beused according to applicable local codes.Electrical service should be installed bya qualified, licensed technician. Ensureall ground connections are properlymade to the complete system. All externalconnections to the RO System shouldbe dry contact only. Float switchesand pretreatment lockouts should notproduce voltage applied to the electroniccontrol box if so equipped. Ensure allelectrical connections to float switches andpretreatment equipment are completed.PlumbingThe high-pressure pump and membrane(s) requirea continuous flow of water with a minimum feedpressure of 20 PSI, not to exceed 105ºF. Run theconcentrate piping to an open drain, with an air gapand free of blockage.Pre-FiltrationNRO systems will filter most particles over 5microns in size. Change the cartridge every monthor when a 10 PSI pressure drop occurs. If prefilter becomes clogged and flow to pump becomesrestricted, cavitation in pump could occur.7

RO Start-Up Always maintain a sufficient flow of feedwater during operation Locate the permeate tubing Attach the permeate tubing to permeate outlet.Make sure the permeate water flows freely andthat there is no back-pressure. Back-pressure cancause damage to the membrane(s).PumpThe pump must never run dry. Operating the pumpwithout adequate feed water will damage the pump.Always supply pump with filtered water. Improperflow could cavitate the pump if it runs dry.MountingThe freestanding system should be bolted down incompliance to local regulation standards. CAUTION: The plumbing in the permeateline can contaminate the high qualitywater produced by the NRO system.Ensure that the components are compatiblewith the application. The pH of the ROpermeate water will normally be 1-2 pointslower than the feed water pH. A pH of 6.5or lower can be very aggressive to someplumbing materials, such as copper piping.InstallationThe NRO systems are free standing and require nospecial installation; however if placed on an unevenfloor, the system may vibrate. If this occurs, placethe system on a rubber mat to reduce the vibrations.Carefully inspect the system before start-up. Checkall plumbing and electrical connections. Connectionsmay have become loose during shipment. Locate the concentrate tubing. This can be foundafter the concentrate control valveStart-Up Membrane installation - some RO's do not havemembranes installed, if this is the case refer topage 10, Membrane Removal & Replacement Before installing the 5 micron prefilter cartridge tothe filter housing, do the following steps: Unscrew the housing, water may come out ofthe housing, so put a bucket under the area tocatch any water that comes out Inspect to see if any debris is inside of housing,if so rinse with water Lubricate the o-ring around groove ofhousing with food grade lubricant andreinstall onto housing Install the 5 micron cartridge provided, thenreattach the housing onto the cap and hand tighten,then bump tighten with the included wrench. Locate the feed water inlet on the prefilter housing Attach the feed inlet tubing to the feed watersource, located before the filter housing. Attach drain line to the concentrate outlet Run the concentrate line to the drain. Water shouldrun freely, without any obstructions or debris Make sure no back-pressure exists on theconcentrate line Check to make sure the electrical power supplymatches your NRO system power supply A level control switch located in a storage tanktypically controls NRO systems. The liquid levelswitch turns the system on when water level intank drops and off when tank is full. If the NROsystem is equipped with an electrical controlbox, the level control is connected to the levelcontrol connections in box. Do not exceed the levelcontrol’s power rating. Liquid Level Switches canbe obtained from original selling dealer. Two levelcontrols are standard.8

If a liquid level switch is used, install it at thistime and turn power to the NRO system on.Otherwise turn the systemon by plugging in the powerOcord. Allow system to runfor about 30 minutes, with PEthe concentrate controlNvalve fully open (counterCONCENTRATEclockwise) to purge air andCONTROL VALVEpreservatives fromthe system. After all preservatives are flushed out of thesystem, connect the permeate line to the storagetank or point of use. NOTE: If your system is equipped withOPENa permeate flush, refer to the NROController ROC2 Manual for importantstart-up procedures. Make sure no back pressure exists on permeateline. A check valve must be installed if backpressure is present. NRO permeate water that is being produced at thistime should be discarded to the drain for the first30 minutes of operation. Any impurities will beflushed from the system at this time Turn the concentrate control valve until thedesignated permeate flow is acquired. The exactoperating pressure may vary depending ontemperature and/or TDS of feed water. This flowrate is determined as followed: WARNING: This Reverse OsmosisGPM GPD/1440System has been preserved with eitherfood grade sodium metabisulfite or foodgrade glycol to protect from biologicalgrowth or freezing. The RO System shouldbe thoroughly flushed for one hour beforeuse of the product water. The concentrateand permeate outlets should be run to asuitable drain for flushing of the system.The system should be flushed at lowpressure with high flows. Locate the concentrate control valve andpressure gauge Turn the concentrate control valve until theindicated concentratepressure gauge reads 50CLPSI. Concentrate pressureOwill increase as valve isSclosed. Flush the systemEfor about 1 hour withCONCENTRATECONTROL VALVEconcentrate pressure at 50PSI to remove impuritiesfrom the system Check for leaks. All NRO systems are fullytested, prior to shipment, but leaks may occurduring transitEXAMPLE: 2800 GPD NRO should produce1.94 GPM Permeate water WARNING: Never exceed maximumpressure rating of your membrane orpressure vessel.NRO systems equipped with an multi-stage boosterpump feature a pump discharge throttle valve.(Throttle Valves are not available with a rotary vanepump and motor.) This valve adjusts RO desiredrecovery. Feed water entersthe system through anautomatic shut-off valve.Ensure that the valve openswhen the system turnson, allowing water to flowthrough the system andclosed when the systemturns off, stopping waterfrom flowing through thesystem. This saves waterand prevents prematureTHROTTLE VALVEfouling of theRO membranes.CLOSE9

Operation & MaintenanceCheck your feed water chemistry. Pre-treatment and/or reducing the system recovery may be required toreduce fouling and scaling on membranes.RO process causes concentration of impurities in theconcentrate stream to increase. These impuritiesmay precipitate (come out of solution) when theirconcentration reaches saturation levels.These gauges measure feed water pressure whenit enters and exits the prefilter housing. A pressuredifferential of 10% or more indicates the prefilterneeds to be replaced.Low Pressure SwitchThe low-pressure switch shuts off the system whenthe feed water pressure drops too low for the systemto function properly. This will prevent damage tothe pump. When pressure is restored, the systemwill restart automatically. If pressure fluctuation isnoticed, and system is cycling off and on repeatedly,turn the system off and ensure the proper feed flowand pressure are available into the system. NOTE: Precipitation can scaleor foul membranes.Permeate & ConcentrateFlow Meter(s)Prefilter Pressure GaugesCONCENTRATEPERMEATEThese flow meters indicateflow rates of permeate andconcentrate water. Whenadded together indicate thefeed water flow rate if thesystem is not equipped witha recycle flow meter.Membrane Removal & ReplacementMembrane changing can be an easy process ifyou have the proper tools and information on hand.Follow the below instructions when removing andreplacing membrane(s).Waste Recycle ValveThis valve allows youto recycle some of theconcentrate water back toRECYCLEthe feed line ahead of theVALVEpump. This will increasethe recovery rate of the RO.The amount of the wastewater recycled is limitedby the TDS of the feed water. The drawback of usingrecycle concentrate water is an increase of TDS inpermeate water. To increase the recycle rate, startwith the flowmeter recycle valve fully open. Note theflow rate shown on the concentrate flowmeter. Thisis the total concentrate flow. Slowly turn the recyclevalve clockwise until the concentrate flow comesdown to the specified rate. The difference betweenthe total concentrate flow and the adjusted flow isthe amount being recycled.NOTE: Always remove & replace the membrane in the direction of the FEEDflow. This protects the brine seal fromfolding over. The brine seal should alwaysbe on the FEED end of the pressure vessel. WARNING: Depressurize the systemuntil all pressure gauges read zero beforeproceeding. Before attempting, disconnectthe power from the system and bleed allwater pressure from the system. Remove the hoses and fittings from both ends ofthe pressure vessel Remove end caps from thepressure vessel. This is doneby removing the crescentwedge(s), using properlysized allen wrench10

Thread a nipple and tee into the concentrateport. The nipple must extend past the end of thepressure vessel. Apply slight force to remove endcaps. A “pickle fork” or ball joint separator canalso be used to apply upward force on the end cap.Place a rag or towel between the tool and the edgeof the vessel to prevent scarring and damage.Remove any fittings used to remove caps. After both ends are removed, membranes canbe removed from pressure vessel. Note whichside brine seal is on. All NRO RO unitshave flow indicator stickers on eachvessel. The stickers indicate directionof feed flow and position of brine seal.The membrane must be removed andinstalled according to the arrow decal.The line on the decal references theposition of the brine seal. WARNING: Do not pull membranesusing permeate tube, this may causedamage. CAUTION: Wear gloves for thefollowing steps in order not to contaminatethe membrane Replace the new membrane(s). Feed in directionof feed water flow. Failure to do so may damageor “roll” the brine seal. Make sure brine seal is onfeed end of pressure vessel. Replace any damaged brine seals or o-rings.Lubricate o-rings with food grade glycerin forproper lubricant. Re-install the end caps by gently twisting themwhile pushing onto vessel making sure to notpinch or damage any o-rings in the process.Make sure the outer diameter of the end cap isflush with the inner groove of the vessel. Replace crescent wedge(s) into the vesselgrooves & tighten screws. Reattach any fittings that may have beendisconnected in the process. Refer to start-up directions to start system. CAUTION: New or factory cleanedmembranes are shipped in a preservativesolution. Therefore the RO should beflushed at 50 PSI for 1 hour to remove thepreservative from the membrane. See startup directions. NOTE: Discard the permeate andconcentrate water during this operation.Cautionary Reminders Change the cartridge filters regularly Monitor the system and keep a daily log Run the system, as much as possible, ona continuous basis. Adjust the system recovery to therecommended value Always feed the pump with filteredwater. DO NOT permit chlorine to enter or bepresent in the feed water. DO NOT shut down the system forextended periods. DO NOT close the throttle valvecompletely. DO NOT operate the system withinsufficient feed flow. DO NOT operate the pump dry11

Membrane CleaningPeriodic cleaning of membranes can improve systemperformance. In normal conditions, mineral scale,biological matter, colloidal particles and organicsubstances can foul membranes.WARNING: Cleaning chemicals are dangerous and can cause injury anddamage. Read and comply with all safetyand disposal precautions. It is the user’sresponsibility to comply with all federal,state and local regulations that may apply.Inorganic anti-fouling cleaningUse an acid cleaning solution to remove inorganicsalts such as CaCO3, CaSO4, BaSO4 and metaloxides, such as iron from reverse osmosismembranes. Do not use sulfuric acid because itmay cause calcium sulfate to precipitate on themembranes. Recommended cleaning solutions forinorganic cleaning include: Solution of 0.2% hydrochloric acid (HCL) Solution of 0.5% phosphoric acid (H3PO4) Solution of 0.2% sulfamic acid Solution of 1.0% sodium hydrosulfiteOrganic anti-fouling cleaningUse alkaline cleaning solutions to remove silica,bio films and organic matter from membranes.Acceptable cleaning solutions for organic cleaninginclude: Solution of 0.1% sodium hydroxide (NaOH) Solution of 1.0% sodium triphosphate (STP), 1.0%trisodium phosphate (TSP) and 1.0% Na-EDTAThe pH of the solutions above should beapproximately 12 and temperature of the solutionless than 86 F.Membrane cleaning directionsTo set-up a cleaning station, follow these directions:1. Record the amount and TDS of the permeate withthe system set at normal operating pressure.2. Prepare approximately 15 gallons of inorganiccleaning solution (with a pH of approximately 2)in a polypropylene or fiberglass reinforced plastictank with a removable cover. Use RO water formake up water if possible.3. Connect a hose from the cleaning solution tankto the inlet of the pre-filter on the RO unit. Ensurethere is a flooded inlet to the pump or positivefeed pressure. It will be necessary to use a feedpump to generate enough pressure to overcomethe RO pressure switch. If a feed pump is notused, the pressure switch can be disconnectedas long as the RO pump is primed before useand sufficient flow is available to the pump. Theswitch must be reconnected after the cleaningprocess to ensure pump protection.4. F eed the permeate and the drain tubes back tothe cleaning solution tank so that the solutionwill recirculate during cleaning. Solution of 0.1% sodium hydroxide (NaOH) and0.1% of tetra-sodium salt of ethylene diaminetetraacetic acid (Na-EDTA)5. Turn on the reverse osmosis pump. Adjust theconcentrate control valve (drain restrictor) to aconcentrate pressure of 50 psi (3.5 bar). Run thepump for approximately thirty (30) minutes. Solution of 0.1% sodium hydroxide (NaOH) and0.05% sodium salt of dodecyl-sulfate (NaDDS)6. Turn the system off and reconnect to the feedwater supply.12

7. Turn the system on and flush at 50 psi (3.5 bar)for 15 minutes. Discard all of the permeate andconcentrate water.NOTE: The prefilter cartridge should be replaced before AND after the cleaning isdisinfection procedures.8. Adjust the system to normal operating pressureand record the amount and TDS of the permeatewater after the acid cleaning to assess anyimprovements in the system’s performance.1. Remove deposits on membranes and othersystem parts with an alkaline cleaner priorto disinfection.9. Repeat this procedure for organic cleaningsolution (with a pH from 11 to 12).10. Readjust the concentrate pressure to originaloperating pressure for normal operation. Afterthe cleaning procedure is complete, check theamount and TDS of the permeate to evaluate theeffectiveness of the cleaning process.DisinfectionHydrogen peroxide or renalin may be used fordisinfection. Procedures are identical to themembrane cleaning directions described above,with the following exceptions:Spare PartsSpare parts can be ordered through your originalselling dealer. Prefilter Elements Inlet Solenoid Valve Concentrate Flow Meter with Valve Hose Washers Pressure Gauges, 0-100 and 0-300 Pressure SwitchOptional: M

Nelsen Corporation's commercial reverse osmosis NRO systems produce high quality water. The system is durable and with proper care will last for many years. Components are of the highest . Water Softener - Used to remove calcium and magnesium from the feed water in order to prevent hardness scaling. The potential for hardness scaling

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