Reverse Osmosis User’s Manual Model AT-500, AT-1000 AT-1000 Pictured
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Table of Contents INTRODUCTION ......................................................................................................... 4 SAFETY ....................................................................................................................... 4 FEED WATER AND OPERATION SPECIFICATIONS ................................................ 5 REJECTION, RECOVERY AND FLOW RATES.......................................................... 5 SYSTEM REQUIREMENTS AND OPERATION GUIDELINES .............
INTRODUCTION Your AT-Series system is a durable piece of equipment which, with proper care, will last for many years. This User’s Manual outlines installation, operation,, maintenance and troubleshooting details vital to the sustained performance of your system. The test results which are included with this User’s Manual indicate your system’s permeate (product) and concentrate (waste) ( test results.
DO NOT UNDER ANY CIRCUMSTANCE REMOVE ANY CAU UTION, WARNING, OR OTHER DESCRIPTIVE LABELS FROM THE SYSTEM. FEED WATER AND OPERATION SPECIFICATIONS Nothing has a greater effect on a reverse osmosis system than the feed water quality. quality NOTE: IT IS VERY IMPORTANT TO MEET THE MINIMUM FEED WATER REQUIREMENTS. FAILURE TO DO SO WILL CAUSE THE MEMBRANES TO FOUL AND VOID THE MANUFACTURER’S WARRANTY. OPERATING LIMITS NOTE: HIGHER TDS AND/OR LOWER TEMPERATURES WILL REDUCE THE SYSTEM’S PRODUCTION.
solids do not pass through the membrane. To calculate the % rejection, use the following formula: % Rejection = [(Feed TDS – Product TDS) / Feed TDS] x 100 Example: 98.5% = [(550-8.25)/550] x 100 NOTE: ALL TDS FIGURES MUST BE EXPRESSED IN THE SAME UNITS, TYPICALLY PARTS PER MILLION (PPM) OR MILLIGRAMS PER LITER (MG/L). AT-Series reverse osmosis systems are designed to reject up to 98.5% NaCl, unless computer projections have been provided or stated otherwise.
NOTE: FEED LINE MUST BE MINIMUM 1/2” INCH. PERMEATE (PRODUCT WATER) CONNECTION Locate the 3/8” tubing labeled permeate and attach to storage tank. tank. Ensure that the permeate water can flow freely with no backpressure. Backpressure can cause irreversible damage to the membrane elements. The 3/8” permeate line can be run to the holding tank with PVC fittings, or other FDA approved materials. materials. This is so the material being used does not di dissolve into the permeate water.
NOTE: IT’S RECOMMENDED RECOMMEND THAT A LICENSED ELECTRICIAN WIRE YOUR SYSTEM IN ACCORDANCE WITH LOCAL AND NATIONAL ELECTRICAL CODES (NEC). WARNING: TO REDUCE THE RISK OF ELECTRICAL SHOCK, THE INCOMING POWER SUPPLY MUST INCLUDE A PROTECTIVE EARTH GROUND. AT-Series systems are typically controlled with a liquid level switch in a storage tank. The liquid level switch turns the system on when the water level in the tank drops, and off when the tank is full.
HF1-STANDARD 9 AT – Series User’s Manual MKTF-205 06/12
HF4-OPTIONAL 10 AT – Series User’s Manual MKTF-205 06/12
NF3-OPTIONAL 11 AT – Series User’s Manual MKTF-205 06/12
NF4-OPTIONAL 12 AT – Series User’s Manual MKTF-205 06/12
AT-500, AT-1000 SYSTEM IDENTIFICATION FIGURE 1A NUMBER IDENTIFICATION 1. Solenoid Valve – Turns On/Off Feed Water 2. 5 Micron Sediment – Removes particulates 3. 10 Micron Carbon Block – Chlorine reduction 4. Pressure Gauge - Measures feed pressure 5. Pressure Gauge - Measures pressure after filters 6. Control Switch - Controls RO system 7. Recycle Valve – Recycles concentrate back to feed (if applicable) 8. Concentrate Valve – Controls flow of concentrate (waste) water to the drain 9.
FIGURE 1B FIGURE 1C 14 AT – Series User’s Manual MKTF-205 06/12
FIGURE 1D FIGURE 1E 15 AT – Series User’s Manual MKTF-205 06/12
FIGURE 1F Note: A portion of the frame has been removed to expose components.
AT-500 MEMBRANE FLOW DIAGRAM FIGURE 1G Note: Black arrows represent concentrate water and white arrows represent permeate water.
AT-1000 MEMBRANE FLOW DIAGRAM FIGURE 1H Note: Black arrows represent concentrate water and white arrows represent permeate water.
SYSTEM PURGING Carefully inspect your system before initial start-up. Check that all plumbing and electrical connections are not loose or have not come undone during shipment. A user’s manual, test results, and filter housing wrench will accompany your AT-Series reverse osmosis system. NOTE: LEAVE THE POWER TO THE SYSTEM OFF FOR THIS PROCEDURE. 1. 2. 3. 4. Redirect permeate water to the drain for this procedure. Fully open the concentrate valve #8 (counter clockwise).
INITIAL START-UP 1. 2. 3. 4. Keep the permeate water line to drain for this procedure. Fully open the concentrate valve #8 (counter clockwise). (Figure 1B, Page 14) Fully close the recycle valve # 7(clockwise)(if applicable). (Figure 1B, Page 14) Return position of the bypass white lever inline on the solenoid valve #1. (Figure 2, Page 19) 5.
DESIGN BASIS FOR AT-500 AND AT-1000 1000 WARNING: NEVER EXCEED THE MAXIMUM PRESSURE RATING OF YOUR SYSTEM.
OPERATING DO’s AND DON’Ts DO: Change the cartridge filters regularly Monitor the system and keep a daily log Run the system as much as possible on a continuous basis. Adjust the system recovery to the recommended value Always feed the pump with filtered water. DON’T Permit chlorine to enter or be present in the feed water. Shut down the system for extended periods. Close the throttle valve completely. Operate the system with insufficient feed flow. Operate the pump dry.
PRE-FILTER PRESSURE GAUGES These gauges measure the feed water pressure when it enters and exits the pre-filters. A pressure differential of 10 - 15 psi or more on the two pressure gauges indicates that the pre-filters require servicing. For example, if the inlet pressure is 40 psi, the filter should be changed when the outlet pressure is 30 psi or below. PERMEATE (PRODUCT) FLOW METER AND CONCENTRATE (WASTE) FLOW METER These flow meters indicate the flow rates of the permeate and concentrate water.
much colder feed water – may require 150 psi to produce the same amount of permeate. Never exceed 150 psi. Example: 98.5% = [(550-8.25)/550] x 100 % Rejection = (Feed TDS – Product TDS)/ (Feed TDS) x 100 ADJUSTING THE BYPASS VALVE Use a fat screw driver to increase or decrease the pressure to the bypass valve. To increase the pressure, turn the screw clockwise. To decrease the pressure, turn the screw counter clockwise.
MEMBRANE BRANE REMOVAL AND REPLACEMENT Replacing membranes in the pressure vessels is an easy process if you have the proper information and tools at hand. Please refer to the following instructions when removing and replacing membrane elements: WARNING: ALL PRESSURE GAUGES MUST READ ZERO BEFORE PROCEEDING. BEFORE ATTEMPTING, ATTEMPTING DISCONNECT THE POWER FROM THE SYSTEM AND BLEED ALL WATER PRESSURE FROM THE SYSTEM. 1. Remove the end caps from the top of the membrane housings.
WARNING: THE BRINE SEAL MUST BE IN THE SAME POSITION FOR EACH MEMBRANE ELEMENT HOUSING, SO MARK EACH HOUSING PRIOR TO REMOVING THE MEMBRANE ELEMENTS. THE BRINE SEAL IS A RUBBER SEAL THAT PROTRUDES ON ONE SIDE OF THE MEMBRANE AND IS S ALWAYS ON THE FEED SIDE OF THE MEMBRANE ELEMENT. 1. Remove one membrane element at a time from the membrane element housings, from the top of the housing. Long L nose pliers may be necessary to pull the old membrane element out of the membrane element housing. 2.
FIGURE 4 View from the back of AT-500, AT-1000 reverse osmosis system.
FLUSHING THE SYSTEM The system should be flushed weekly to remove sediment from the surface of the membranes. To manually flush the system, follow the preceding steps: 1. The system must be operating during the flush procedure. 2. Fully open the concentrate valve. (Figure 1B, Page 14) 3. Allow the system to run for 10 to 20 minutes. 4. After 10 to 20 minutes, close the concentrate valve to its previous setting. Ensure the proper concentrate flow rate is going to the drain. 5.
Preparing unit for shipment: 5. Disconnect the inlet, concentrate, pre-filter, and permeate plumbing. 6. Drain all water from the pre-filter cartridge housings by unscrewing the housings, removing the pre-filter cartridges, and drain the water from the housings. 7. Disconnect the tubing from the connectors on the permeate and concentrate inlets and outlets. 8. Fully open the concentrate valve. 9. Drain the flow meters. 10.
REVERSE OSMOSIS TROUBLESHOOTING SYMPTOMS Low Inlet Pressure Low Permeate Flow High permeate flow Poor permeate quality POSSIBLE CAUSES Low supply pressure Increase inlet pressure Cartridge filters plugged Change filters Solenoid valve malfunction Replace sol. valve and/or coil Motor may not be drawing correct current Concentrate valve might be damaged Use clamp-on amp meter to check the motor amp draw.
ABNORMAL PERMEATE FLOW Permeate flow should be within 20% of the rated production, after correcting the feed water temperatures above or below 77°F. Check your permeate flow meter to determine the permeate flow rate.
TEMPERATURE CORRECTION FACTORS FOR MEMBRANE Find the temperature correction factor (TCF) from the table below. Divide the rated permeate flow at 77°F by the temperature correction factor. The result is the permeate flow at the desired temperature.
If a system is rated to produce 5 gpm of permeate water @ 77˚ F, the same system will produce more water at a higher temperature. It will also produce less water at a lower temperature. Use the temperature correction table to obtain the correct flow. Example: 5 gpm @ 59˚ F (5÷1.42=3.52 gpm) 5 gpm @ 77˚ F (5÷1=5 gpm) 5 gpm @ 84˚ F (5÷0.89=5.62 gpm) SERVICE ASSISTANCE If service assistance is required, please complete the following process: Contact your local dealer or distributor.
OPERATION Company: ____________________ Date of StartUp: ___________________ ____________________ Date of Last Cleaning: ___________________ Location: Week Of: System Serial #: ____________________ ____________________ Date Time Hour of Operation Filter inlet pressure (psi) Filter outlet Pressure (psi) Concentrate Pressure (psi) Pump Discharge Pressure (psi) Feed Flow (gpm) Permeate Flow (gpm) Concentrate Flow (gpm) Recovery % Feed Temperature Feed TDS (ppm) Permeate TDS (ppm) Rejection % Feed PH
DRAWINGS FIGURE 5 35 AT – Series User’s Manual MKTF-205 06/12
Note: A portion of the frame has been removed to expose components.
FIGURE 7 37 AT – Series User’s Manual MKTF-205 06/12
FIGURE 8 38 AT – Series User’s Manual MKTF-205 06/12
AT-500 SYSTEM PART LIST Item No. Qty. Part No. Description 1……………2………..200901……GAUGE, BTM, NO FILL, 0-100PSI/BAR, 2” DIA 2……………1………..204913……VALVE, SOLENOID, N/C, UL, 110V, 1” FNPT 3……………1………..200635……CART, SEDIMENT, POLYPRO, 4.5”X10”, 5 MIC 4……………2………..203648……HOUSING, FILTER, BLK/BLU, 4.5”X10”, 1” FNPT 5……………1………..200662……CARTRIDGE, CARBON, BLOCK, 4.5”X10”, 10 MIC 6……………1………..200898……METER, FLOW, PM, 0-5GPM, 1/2” x 1/2” MNPT 7……………1………..200897……METER, FLOW, PM, 0-2GPM, 1/2” x 1/2” MNPT 8……………1………..
AT-1000 SYSTEM PART LIST Item No. Qty. Part No. Description 1……………2………..200901……GAUGE, BTM, NO FILL, 0-100PSI/BAR, 2” DIA 2……………1………..204913……VALVE, SOLENOID, N/C, UL, 110V, 1” FNPT 3……………1………..200635……CART, SEDIMENT, POLYPRO, 4.5”X10”, 5 MIC 4……………2………..203648……HOUSING, FILTER, BLK/BLU, 4.5”X10”, 1” FNPT 5……………1………..200662……CARTRIDGE, CARBON, BLOCK, 4.5”X10”, 10 MIC 6……………1………..200898……METER, FLOW, PM, 0-5GPM, 1/2” x 1/2” MNPT 7……………1………..200897……METER, FLOW, PM, 0-2GPM, 1/2” x 1/2” MNPT 8……………1………..
AT-500 FLOW DIAGRAM 41 AT – Series User’s Manual MKTF-205 06/12
AT-1000 FLOW DIAGRAM 42 AT – Series User’s Manual MKTF-205 06/12
110V ELECTRICAL SCHEMATIC 43 AT – Series User’s Manual MKTF-205 06/12
220V ELECTRICAL SCHEMATIC 44 AT – Series User’s Manual MKTF-205 06/12
AT – Series User’s Manual MKTF-205 06/12
