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4400M Digital RO System
1.0 GENERAL INFORMATION
The 4400M - Digital Reverse Osmosis (RO) system produces up to 16.7 US gallons per minute
(64.4 litres per minute) of product water suitable for applications requiring biological and inorganic purity. The product water quality meets ISO 13959, ISO 11663 and ISO 26722
Standard requirements. More than 99% of all microorganisms, pyrogens, particulates, organics with a molecular weight greater than 300, and up to 95% of all dissolved inorganic contaminants from the feed water are removed.
The 4400M RO system is supplied on a skid consisting of a pump, RO element housings, manifolds, valves, pressure gauges, flow rotameters, a control panel and tubing. The system
skid and manifolds are shipped fully assembled, pre-piped and pre-wired. See APPENDIX A1 for
detailed description of the system components. The standard RO system is available in 208VAC
(60 Hz) 3-phase but it is also customized to 230, 380, 420, 460, 575 VAC 3-phase or 115/230
VAC single phase power supply. The system is offered with a choice of 2, 3, 4, 5, 6, 8, 9, 10 or 12
RO membrane elements to suit specific product flow requirements.
A NEMA 4-12 control panel consists of a digital controller, an electronic digital interface and display for setting and monitoring process control parameters. Optional control interfaces are provided with the RO system for:
Feeding product water to a Storage Tank or a Direct Feed line.
Diverting product water to the drain.
A Remote Alarm Panel.
A Remote PC Interface.
A Product 0.1 Cell Constant Conductivity/Temperature Sensor.
NOTE The 4400M system does not include external pre-treatment and posttreatment devices, piping and fittings to the point of use.
1.1
HOW DOES THE RO PROCESS WORK?
Reverse Osmosis (RO) is a cross flow membrane filtration process used for water purification. It removes both dissolved organics and salts using a mechanism different from ion exchange or activated carbon. The pressurized feed water flows across a membrane, with a portion of the feed permeating the membrane. The balance of the feed sweeps parallel to the surface of the membrane to exit the system without being filtered. The filtered stream is called the
“permeate”. The second stream is called the “concentrate” because it carries off the concentrated contaminants rejected by the membrane. Because the feed and concentrate flow parallel to the membrane instead of perpendicular to it, the process is called “cross flow
filtration”. Depending on the size of the pores engineered into the membrane, cross flow filters are effective in the classes of separation known as reverse osmosis, nano-filtration, ultra-
filtration and the more recent micro filtration.
MAN-4400MCOLD (rev.J) page 11 of 103
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Table of contents
- 2 INTENDED USE
- 7 SAFETY
- 7 DEFINITIONS
- 7 LABELS
- 8 SPECIFICATIONS
- 9 GENERAL PRECAUTIONS
- 11 GENERAL INFORMATION
- 11 WORK?
- 12 APPLICATIONS
- 14 INSTALLATION AND START-UP
- 14 SYSTEM
- 14 REQUIREMENTS
- 15 SYSTEM
- 16 START-UP
- 16 Electrical Hook-up Verification
- 16 Pre-Start-up Verification
- 17 Control Panel/Microprocessor Start-up
- 18 4400M System Start-up
- 19 Checking the RO Pump Rotation
- 20 Purging Air from the RO Pump
- 21 OPERATIONS AND MONITORING
- 21 OPERATIONS
- 22 CONTROLS
- 22 The Display Navigation
- 25 Set-Up Screen Descriptions
- 32 Set-Up Data Reference Table
- 32 Controller Options
- 33 PROCEDURES
- 34 System Start-up
- 34 Normal Operations
- 34 System Shut-down
- 35 PERFORMANCE
- 37 Effects of Pressure on Membrane Performance
- 38 Effects of Recovery on Membrane Performance
- 39 Effects of Temperature on Membrane Performance
- 41 MAINTENANCE
- 41 REQUIREMENTS
- 42 Scheduled Maintenance Log Sheet
- 44 PROCEDURES
- 44 Pre-filter Replacement Procedure
- 44 Solenoid Valve Seal Replacement Procedure
- 45 CLEANING
- 46 Dealing with a Hardness/Metal Oxide Fouling Problem
- 47 Dealing with a Colloids/Silica Fouling Problem
- 47 Dealing with an Aluminum/Polymer Fouling Problem
- 48 SANITIZATION
- 49 Clean-In-Place (CIP) Equipment Requirements
- 52 Cleaning/Sanitization Chemicals
- 53 Overview of Recommended Chemicals
- 57 Cleaning/Sanitization Procedure Using a CIP System Skid
- 60 Cleaning/Sanitization Procedure Using a Tank and RO Pump
- 62 Tank Decommissioning and Chemical Storage
- 62 Neutralizing Cleaning/Sanitization Solutions
- 63 Restarting RO System after Chemical Cleaning/Sanitization Procedures
- 64 Test Strips Overview
- 65 STORAGE
- 67 TROUBLESHOOTING
- 67 ALARMS/MESSAGES
- 68 DIAGNOSIS
- 69 System Test Matrix
- 70 WARRANTY
- 71 CONTACT INFORMATION
- 72 A1 4400M DIGITAL REVERSE OSMOSIS SYSTEM
- 73 COMPONENTS
- 78 A2 4400M CONTROL PANEL DISPLAY
- 79 A3 SET-UP MENU DISPLAY NAVIGATIONAL FLOW CHART
- 80 A4 ALARM LOG SHEET
- 81 A5 DEVICE MATERIALS OF CONSTRUCTION
- 82 A6 WATER SAMPLING PROCEDURE
- 83 A7 REQUIREMENTS FOR INSTALLATION OF EXTERNAL CONNECTIONS TO THE 4400M SYSTEM
- 83 REQUIREMENTS
- 86 A8 4400M RO TYPICAL FLOW RATES
- 88 A9 TABLE OF SYSTEM MONITORING PARAMETERS
- 90 A10 SITE ACCEPTANCE TEST (SAT) PROCEDURES
- 91 CHECKLIST
- 92 SETPOINTS
- 93 MATRIX
- 96 A11 SAMPLE PROCESS & INSTRUMENT DRAWING
- 97 A12 ELECTRICAL CONTROL INTERLOCKS FOR THE CONTROL PANEL
- 98 FEATURES
- 101 A13 SPARE PARTS LIST
- 103 CUSTOMER SYSTEM NOTES