Ep-160016 Manual

REVERSE OSMOSIS SYSTEM
INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL
Standard Photograph
The appearance of your equipment may differ.
JOB NAME: PROJECT PC21597

01-WALB-ALDI
MODEL: MRO-94K-8H REVERSE OSMOSIS UNIT

WITH MGT-600 3 TWIN ALT SOFTENER
P.O. NUMBER: 037858
JOB NUMBER: EP-160016
Marlo Incorporated: 2227 South Street • Racine, Wisconsin 53404 • 262.681.1300 • FAX 262.681.1318 • www.Marlo-Inc.com • info@ Marlo-Inc.com
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5-264
MRO-8 REVERSE OSMOSIS SYSTEM
INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
TABLE OF CONTENTS
Section 1
Operation Parameters & Projected Performance
Pretreatment Considerations
Basics of Chemical Pretreatment
Basics of Reverse Osmosis

Section 2
RO Major Component Identification
RO Installation
Section 3
Pre-Startup Checklist
Start-Up Procedures
Control Panel Operation
Section 4
Routine Maintenance
Record Keeping Requirements
Section 5
Troubleshooting
Membrane Cleaning Procedures
Section 6
Vendor Literature
Major Component I/O Manuals
Section 7
System General Arrangement Drawings
Electrical Enclosure Drawings
Wiring Diagrams
Section 8
Pretreatment
SECTION 1
Operation Parameters & Projected Performance
Pretreatment Considerations
Basics of Chemical Pretreatment
Basics of Reverse Osmosis

DESIGN PARAMETERS
Model: MRO-94K-8H
Membrane Array: 2:1:1
Membrane Housing Size: 8” Diameter x 4 Long

Material / Design Pressure: FRP / 300 PSI
Membrane Type: Brackish Toray TM720-370

Size: 8” x 40”
Quantity: (4) per Housing
Prefilter Cartridges (5 micron) 2.5" x 40"Long (5 required)
Power Supply Required 460 volts/ 60 hertz/ 3 phase (pump power)

120 volts/ 60 hertz/ 1 phase (control power)
RO Pump Motor HP 25
Permeate Flow Sensor K factor 2" 66.739

Concentrate/Reject Flow Sensor K factor 1-1/2" 117.85
RO SYSTEM FEEDWATER CHARACTERISTICS AND QUALITY REQUIREMENTS

Inlet feedwater temperature range: 55-80° F
Feedwater free chlorine content: < 0.1 ppm
Maximum feedwater turbidity: 1 NTU
Maximum Silt Density Index (SDI-15 minute): 4.0
Feedwater pH range: 4 - 11
Maximum RO concentrate LSI: 1.07
RO SYSTEM OPERATIONAL PARAMETERS

Inlet feedwater pressure range (at RO inlet valve): 30-100 PSIG
Maximum prefilter housing pressure drop: 20 PSIG
Low inlet pressure cut-out switch (factory set): 10 PSIG
Designed inlet feedwater flowrate: 87 GPM

Designed RO product flowrate: 65 GPM
Designed RO reject flowrate to drain: 22 GPM
Membrane feed pressure: 100-300 PSIG (Monitored only)

Membrane outlet pressure (concentrate): 100-300 PSIG (Monitored only)
Membrane cleaning frequency: At 10% system performance loss,

As determined by “normalized” data
RO SYSTEM PROJECTED PERFORMANCE:

Overall system TDS reduction (0 years): Normalized 97% TDS reduction
Minimum TDS reduction (0 years): Min. 95% TDS reduction
The RO system has been designed to operate on a carbon filtered, softened water supply that has been
sufficiently filtered to reduce the Total Dissolved Solids and particles to achieve the Turbidity and SDI
levels recommended above. The feedwater must be free of free chlorine and other oxidizing agents to
prevent irreversible damage to the RO membranes.
REVERSE OSMOSIS UNIT CHEMICAL FEED RECOMMENDED DOSAGES:
(Dosages may need adjustment under actual operating conditions.)
Pretreatment (if needed)
Sodium Bisulfite – Fed before the RO to remove chlorine from the water because
those substances are harmful to the RO elements. For every part of chlorine in the raw water, feed 3
parts of sodium bisulfite
Recommended Starting Dosage - 3-5 ppm
Antiscalant – Fed before the RO to reduce the scaling potential of the water on the RO elements.
Recommended Starting Dosage – 2-3 ppm

(this dosage will vary depending on which anti-scalant is used)
Post treatment (if needed)
Caustic – Fed after the RO to achieve the target pH level of 7
Recommended Starting Dosage - 1 ppm
Chlorine– Fed after the RO to achieve the target chlorine residual
Recommended Starting Dosage - 0.5 ppm
Note: These dosages are general guidelines only. Specific dosages are dependent on raw water quality.
Ref er to the actual chemical manuf acturer’s recommendations f or your specific installation.
INTRODUCTION
This manual contains important information about your unit, including information needed for
installation, operating, and maintenance procedures. These reverse osmosis systems have been
designed and engineered to provide high quality water when operated according to specifications. A
thorough understanding of the system and its operation is required for proper application. Review
this manual in detail before making any attempt to install or start the system. Abuse or tampering of
equipment by inexperienced operators can cause irreversible damage.
Process Description
Reference Drawings are located in section 4. Use the Process and Instrumentation Diagram as
guides to your understanding of the processes involved.
Pretreatment Depth Filters (If needed) – Raw water first flows through depth filters for high
quality filtration. The depth filters use a multilayer design where the filter bed uses successively
smaller media to provide efficient filtration at higher flow rates than single media filters. To maintain
clarity, the depth filter requires periodic backwashing to remove the filtered media from the filter bed.
Pretreatment Carbon Filters (If needed) – Raw water flows through carbon filters for chlorine
and organics removal. To maintain efficient absorbtion , the carbon filter requires periodic
backwashing to unpack the filter bed.
Pretreatment Water Softeners (If needed) – Chlorine free water flows through the water softener
to remove hardness which will foul the membranes. The softener is periodically regenerated with
salt to replenish the resin’s softening capacity.
Pretreatment Chemical Feed (If needed) – Raw water is chemically treated before it enters the
RO unit. Sodium bisulfite, if required, is fed to remove chlorine from the water
because those substances are harmful to the RO elements. Next, antiscalant chemical is fed to
reduce the potential the water has to scale the RO elements.
Reverse Osmosis System - The mixture of water and chemicals flows to the reverse osmosis
system. The RO system splits the water into two streams. The product stream (permeate) flows to
points of use, and the waste stream (concentrate) flows to drain. Control of the RO unit is
accomplished with the RO control panel.
Post-treatment Chemical Feed (If needed) – RO permeate water is chemically treated after the
RO unit. Chlorine is fed to prevent bacteria growth and caustic is fed to adjust the product water pH,
if required.
PRETREATMENT CONSIDERATIONS FOR REVERSE OSMOSIS
It is imperative that adequate consideration be given to the pretreatment needs of reverse osmosis
systems. Some pretreatment schemes are based on membrane considerations, such as dechlorination
for PA and TFC membranes or chlorination and pH adjustment for CA membranes. The major
pretreatment requirement for any RO is the control of membrane “fouling”. Fouling involves the
entrapment of material in the feed/brine path or deposition on the surface of the membrane. There are
four categories of fouling. Figure 1 depicts these foulants, possible sources, and possible pretreatment
techniques for these foulants.
Scaling by Salts:
Salts in the feedwater are usually concentrated by a factor of two to four times (50 – 75% conversion) in
the RO process. Solubility limits of some salts can be exceeded and they precipitate. The scaling
components of concern are calcium carbonate, calcium sulfate, silica, strontium sulfate, barium sulfate,
and calcium fluoride. Four basic pretreatment design approaches are used to control scale:
1. Reduce RO recovery to where salt concentrations are below solubility limits.

2. Alter the feed temperature to increase solubility limits.
3. Remove one of the ions responsible for the scale-forming compounds.
4. Add an antiscalant which inhibits precipitation of the scaling compound. The proper
antiscalant can increase the solubility by a factor of 2 to 5.
Calcium carbonate (line) scaling is a problem with most natural feedwater and is controlled by:
1. Softening which removes the calcium ion.

2. Acid feed which reduces the biocarbonate / carbonate ion level by converting it into carbon
dioxide.
3. The use of an antiscalant
The LSI (Langlier Saturation Index) is used to determine the lime-scaling tendency of a water and is
dependent on temperature, pH, alkalinity and calcium levels.
Calcium sulfate solubility limits are not usually exceeded when feedwater TDS is under 1,500 ppm and
recovery is 80% or less.
The solubility of reactive silica in waters is variable but is about 120 – 150 ppm at 20° C or greater, and 50
– 60 ppm at 10° C. When saturated, the silica can polymerize to form colloidal silica. Higher silica
solubility limits have been observed in RO systems but it is difficult to predict due to other factors, such as
pH, and the effects of other ions in solution. Evaluation on a case-by-case basis would be required to
determine silica scaling potential.
Metal Oxide Fouling:
Iron and manganese, when oxidized, can form insoluble precipitates that can foul a membrane. Iron
fouling is the most prevalent. Iron fouling can be avoided by:
1. Removal of the iron from the feedwater before it gets to the RO.
2. Preventing the oxidation of soluble ferrous iron into the insoluble ferric iron.
3. Operating at a lower pH while the iron is still soluble.
4. Adding a sequestering agent to keep the iron in solution.
Iron can be removed by manganese zeolite filtration, aeration followed by filtration, or by sodium zeolite
exchange of dissolved iron and manganese. Generally, 4 ppm of soluble iron can be tolerated in the
reject water if dissolved oxygen is 5 ppm or less.
Colloidal Fouling:
The coagulation of colloids, as they concentrate in an RO unit, can result in colloid fouling. Typically,
colloids range in the 0.2 to 1.0 micron size range and are: clays (aluminated silicates) found in raw
waters, iron colloids from the corrosion of carbon steel piping, and aluminum hydroxide resulting from
improper alum clarification. The SDI test method determines the fouling tendency of water due to
colloids. Normally, well waters have an SDI of less than three and present no colloids fouling problem.
Surface waters normally have SDI’s of greater than 5 and pretreatment must be considered. The SDI can
be reduced by such methods as:
1. Multimedia filtration – with or without upstream addition of polyelectrolyes

2. Ultrafiltration
3. Microfiltration
The characterization of colloids in the water, and the effectiveness of pretreatment, is difficult to predict
and may require on-site pilot work.
Biological Fouling:
Biological fouling is caused by the growth of microorganisms in the RO. CA membranes are susceptible
to biological degradation, so a residual chlorine level of 0.3 to 1.0 ppm is required. PA and TFC
membranes are resistant to biological attack. The formation of a bio-film on any membrane can severely
retard flux. It is controlled in CA membranes by using residual chlorine and, in PA or TFC membranes, by
periodic sodium bisulfite treatments. Preferably, all membranes should utilize adequate pretreatment and
correct operations for the RO that inhibit propagation of microorganisms.
Table 1:
RO FOULING
CATEGORY EXAMPLES SOURCES PRETREATMENT
Scaling Salts Calcium Carbonate Feedwater pH Adjustment (Improve Solubility)

Calcium Sulfate Antiscalant (Improve Solubility)
Barium Sulfate Softening (Remove Calcium Ion)
Strontium Sulfate Precipitation (Remove Silica)
Calcium Flouride Heat Exchangers
Silica
Metal Oxides Iron Feedwater, Oxidation followed by filtration

Manganese Corrosion, Use corrosion-proof materials
Aluminum Clarifiers
Coloids (SDI) Clay Surface Waters Coagulation / Flocculation

Silt (SDI 10 – 175), Clarifiers
Rust Corroding Pipes Multimedia Filters
Microfiltration
Ultrafiltration
Biological Bacteria Non-Chlorinated Feed, Chlorinate (Disinfect)

Off-Line RO’s Proper Off-Line Storage
Surface Waters
BASICS OF CHEMICAL PRETREATMENT
There are a number of chemicals that can be introduced into the RO feed to enhance the operation of the RO
system.
 Acids
 Caustic
 Dechlorination Chemicals
 Antiscalants and Dispersants
Acids
Acids, typically hydrochloric [HCl] or sulfuric [H2SO4], are fed to lower the feed pH.
Sulfuric acid is used more often than hydrochloric acid, based on a lower operating cost, reduced fuming
to the atmosphere which can corrode surrounding metal components, and a better membrane
rejection of the sulfate ion than the chloride ion. Technical grade sulfuric acid, with no other additives, is
suitable for use with a RO system. Sulfuric acid is commercially available as a 20% and 93% solution.
The 93% solution is also referred to as 66° Baume solution. Caution is required in diluting 93%
sulfuric acid, since the maximum heat of dilution of approximately 280°F occurs around 60%. It is critical
that the concentrated acid is added slowly to the top of dilution water that is being agitated to minimize
the buildup of heat and boiling of the makeup solution.
Hydrochloric acid is preferred when there is a concern for scaling by calcium sulfate, barium sulfate
or strontium sulfate. Sulfuric acid increases the sulfate ion level in the RO feed, which directly increases
the potential for sulfate-based scaling. Technical grade hydrochloric acid (with no additives) typically
is suitable for use with a RO system. Hydrochloric acid is typically available as a 30% to 37%
solution. It is sometimes referred to as muriatic acid.
The primary purpose for reducing the feed pH is to reduce the potential of calcium carbonate
scaling in the RO concentrate as measured by using the Langlier Saturation Index [LSI]. LSI is a
method of reporting the scaling or corrosive potential of low TDS brackish water based on the level of
saturation of calcium carbonate [CaCO3]. LSI is important in RO water chemistry in determining
whether a w ater will or will not form calcium carbonate scale. Water with a negat ive LSI is
considered corrosive to metal piping and will not form calcium carbonate scale. Water with a
positive LSI is not corrosive, but it will tend to form calcium carbonate scale.
The LSI value is calculated by subtracting the calculated pH of saturation of calcium carbonate from
the actual feed pH. Calcium carbonate solubility decreases with increasing temperature (as
evidenced by the liming of a tea kettle), higher pH, higher calcium concentration, and higher alkalinity
levels. The LSI value can be lowered by reducing pH by the injection of an acid (typically sulfuric or
hydrochloric) into the RO feed water. A recommended target LSI in the RO concentrate is negative 0.2
(which indicates that the concentrate is 0.2 pH units below the point of calcium carbonate saturation). A
negative 0.2 LSI allows for pH excursions in actual plant operation. A polymer-based antiscalant can
also be used to inhibit the precipitation of calcium carbonate. Some antiscalant suppliers have
reported the efficacy of their product up to a positive LSI value of 2.5 in the RO concentrate (though a
more conservative design LSI level is +1.8).
Caustics
Caustics, for a few process applications, can be i njected to increase the RO feed pH. Typically, the
only caustic injected is sodium hydroxide [NaOH] based on cost, availability and its solubility in water.
Most of the time the quality of the NaOH can be technical grade (and free of any additives). If
the technical grade NaOH is not clear in color (e.g. has a blackish tint), then a higher grade of NaOH
may be desirable such as rayon or nylon grade. NaOH is commercially available as 100% solid
flake or as 20% or 50% solution. Caution is required in storing 50% caustic since it can freeze at
temperatures just below 60°F (15.5°C), with a special concern for cold air drafts.
Caution is required in raising the feed pH as it can decrease the solubility of CaCO3, as measured by an
increasing LSI, iron and manganese.
The most common process application that uses a caustic feed involve 2nd pass RO systems. In a 2-
st
Pass RO, the permeate from a 1 pass RO becomes the feed to the 2nd pass. The 2nd pass RO
st
“polishes” the 1 pass permeate to quality levels as good as 4 megohm-cm. Caustic is introduced into
the 2nd pass feed for 4 reasons.
1. At a pH of 8.2 and higher, all carbon dioxide gas is converted into the bicarbonate
ion. The bicarbonate ion will be rejected by the RO. Carbon dioxide, being a gas, would
pass through the RO into the permeate stream unimpeded. The carbon dioxide would
become an undesirable load to downstream polishing mixed beds.
2. Certain TOC constituents are better rejected at a higher pH.
3. Silica rejection and solubility are higher at higher pH levels (particularly above a pH of 9).
4. Boron rejection is higher at higher pH levels (particularly above a pH of 9).
Dechlorination Chemicals
At no time should there be a Free Chlorine residual in the feed water. Even very low levels of
chlorine in the feed stream will result in irreparable oxidation damage of the membrane. Therefore,
operators should ensure that oxidant does not enter the RO system. The two most common
pretreatment methods for reducing chlorine levels are by absorption onto granular activated carbon
filter media or by the use of a chemical reducing agent such as sodium bisulfite.
Pressurized carbon filters are typically used on s mall systems (50 gpm to 100 gp m or less) due to
capital cost considerations. It is recommended that a premium grade of carbon is used that has been
acid-washed for the removal of heavy metals and hardness and has very low levels of carbon fines that
can foul the RO. Anytime new carbon media is installed, the carbon filter must be thoroughly rinsed
until all carbon fines are absent from the effluent (this can take a few hours to days). One cannot rely
on a 5-micron cartridge filter to protect the RO element from fouling due to carbon fines. The
advantages of a carbon filter are their ability to remove organics from the feedwater that could foul the
RO and t hat they are more reliable in treating all the feed water than a chemical feed system. The
disadvantage is that carbon filters are notorious for breeding bacteria that can result in a bi ological
fouling of the RO. Carbon filters have been known to see a doubling of viable bacteria counts in 24 hours,
with capital intensive and operator intensive periodic steam sanitization the only answer for controlling
microbial populations. Steam sanitization for critical applications (like USP W ater production
for the pharmaceutical industry) can be as frequent as 1 to 7 days.
Sodium Bisulfite [SBS] is the typical chlorine reducing agent of choice for larger RO systems. Note:
SBS should not be cobalt catalyzed. A SBS solution is made by dissolving solid sodium
metabisulfite into water and has a pH of 4.6 at 1.0% (by weight) solution strength. A 10% (by weight)
SBS solution will require the addition of 0.51 pounds of solid sodium metabisulfite into one gallon of
water. The sodium metabisulfite is commercially available at 97.5% to 99% purity and can be stored
safely up to six months in a dr y storage area. The SBS solution is not stable to air and r eacts with
oxygen as well as chlorine, therefore it is recommended that batches less than 2% by weight be used
within 3 to 7 days and batch solutions less than 10 % be used within 7 to 14 days. T heoretically,
1. 47 ppm of SBS (or 0. 70 ppm of sodi um met abi sulfite) will stoichiometrically neutralize 1.0
ppm of chlorine. Designers have been known to use a dosing rate of 1.8 ppm to 3.0 ppm of SBS per
1.0 ppm chlorine so as to include an industrial safety factor for brackish water RO systems. SBS
needs to be added far enough upstream of the RO elements to insure at least 20 seconds of reaction
time. Proper in-line mixing is required which preferably includes a static mixer.
Na2S2O5 (sodium metabisulfite) + H2O —> 2 NaHSO3 (sodium bisulfite)
NaHSO3 + HOCl —> NaHSO4 (sodium bisulfate) + HCl (hydrochloric acid)
NaHSO3 + Cl2 + H2O —> NaHSO4 + 2 HCl
The advantages of SBS dechlorination are that it is less capital intensive than carbon filters for large
systems, the reaction by-products are r eadily removed by t he RO, and re sidual SBS i s readily
removed by the RO.
The disadvantages of SBS c an be the need to handle and mix a small volume of chemical and an
increased risk in chlorine making it to the membranes if sufficient monitoring and c ontrols are not
designed into the dechlorination system. In a few cases where Sulfur Reducing Bacteria [SBRs] are
present in the feed supply, the bisulfite functions as a nutrient and enhances their growth. SBRs are
usually found in anaerobic (low oxygen content) shallow wells in regions such as Florida. Frequently
hydrogen sulfide (H2S) is also present as a by-product of the SBR metabolic process. Monitoring for
dechlorination can be p erformed by the use of an Available Free Chlorine monitor, monitoring for a
residual bisulfite concentration, or by an ORP meter. We recommend that the feed to the
RO/NF system is equipped with a O RP (Oxidation-Reduction Potential) meter. The feedwater
can then be c ontinuously monitored for the presence of oxidant. Except in wastewater
applications where chloramines are used, the ORP meter reading should always be below 300
mV. If it exceeds 300 mV, the plant operator should receive a warning that a dangerous level of oxidant
is getting to the membrane and should take action, such as adding or increasing the dose of SBS, to
reduce the oxidant concentration. If the ORP value reaches 350 m V, the plant should be shut down
until the oxidant concentration can be reduced to a safe value (ORP < 300 mV).
Antiscalants and Dispersants
There are a large number of chemical suppliers who supply a variety of proprietary antiscalants and
dispersants to improve the operation of RO and NF systems.
Antiscalants are a f amily of chemicals designed to inhibit the formation and pr ecipitation of
crystallized mineral salts that form scale. Most antiscalants are proprietary organic man-made
polymers (e.g. polyacrylic acids, carboxylic acids, polymaleic acids, organo-phosphates,
polyphosphates, phosphonates, anionic polymers, etc.). Molecular weight of these polymers can range
from 2,000 Dalton to 10,000 Dalton.
Antiscalant technology for RO systems initially was derived from chemistries used in cooling water
and boiler water applications. It should be dul y noted that the large number of different antiscalant
chemistries that have evolved have produced a wide variety of results and efficacy depending on the
application and organic polymer used.
Caution should be u sed in the use of antiscalants made of polyacrylic acid. They are susceptible to
the formation of a f oulant that settles on the membrane surface if there are high levels of iron. This
foulant will increase feed pressure requirements, but typically can be cleaned using a low pH cleaning.
Caution should also be used in the use of antiscalants that are anionic in nature (e.g. polyacrylic
acids) when a c ationic-based coagulant or filtering aid i s used in t he pretreatment. A very
viscous, sticky foulant can be produced that will increase feed pressure requirements, and it can be
very difficult to clean off.
An antiscalant that was popular in the early days of RO was sodium hexametaphosphate (SHMP), but its use
has been greatly reduced with the advent of proprietary antiscalants. SHMP has a number of limitations.
Batches of diluted SHMP has to made every 2 to 3 days due to hydrolysis by exposure to air, which
would dilute its efficacy and create a potential calcium phosphate scaling risk. SHMP has a reduced
protection to calcium carbonate scaling with a maximum LSI rating in the concentrate of +1.0.
Antiscalants retard the growth of crystalline salt structures in the RO feed and c oncentrate
streams, thereby allowing a c oncentration of sparingly soluble salts in excess of the normal
solubility limits. Antiscalants can be used to replace, or can be usedin conjunction with, acid feed to
control calcium carbonate scaling.
A number of factors can affect the rate of mineral scale formation. Lower temperatures reduce the
solubility of mineral scales (the exception here is calcium carbonate scale formation is enhanced when
temperature increases). The solubility of sparingly soluble salts increase with higher TDS levels (this is
due to the increased interference by all the ions in the seeding process of scale formation).
Most common mineral scalants of concern:
 Calcium carbonate [CaCO3]
 Calcium sulf ate [CaSO4]
 Strontium sulfate [SrSO4]
 Barium sulf ate [BaSO4]
Less common mineral scalants are:

 Calcium phosphate [CaPO4]
 Calcium fluoride [CaF2]
Dispersants are a family of organic man-made polymers designed to inhibit the agglomeration
and deposition of foulants onto the membrane surface. Dispersants are sometimes referred to as anti-
foulants. Foulants tend to be a softer, non-crystalline deposit. Dispersant chemicals frequently have
antiscalant properties. The efficacy of differing dispersants can vary for different foulants, so one
needs to know what foulant they are treating for.
Foulants treated by dispersants:

 Mi neral Scal es
 Metal Oxides and Hydroxides [iron, manganese, aluminum]
 Polymerized Silica
 Colloidal material [defined as very small particles that stays in an infinite suspension
and can be composed of clay, iron, aluminum, silica, sulfur and/or organic matter]
 Biological matter
Predicting the maximum solubility of super-saturated silica can be dif ficult. In particular, iron present
in the feed water can readily produce iron silicates and dramatically reduce the allowable concentration
of silica in the RO concentrate stream. Other major factors are pH and temperature. Predicting the
maximum levels of metals (e.g. iron, manganese, aluminum) can also be difficult. The soluble forms of the
metal ions allow for higher levels of saturation. The insoluble forms tend to act more like particles and
colloids.
Optimal dosing and al lowable maximum saturation levels of scalants and f oulants for
antiscalants/dispersants are best determined by the chemical supplier who utilizes a proprietary
software package.
Maintaining proper dosing levels of an antiscalant/dispersant is important. Under-dosing can ca u se

sc al i ng or f oul i ng. O v er-do si n g ca n ca u se a de po si t i o n of t he antiscalant/dispersant
onto the membrane, creating a fouling problem.
It is important that the antiscalant/dispersant be thoroughly flushed from the RO elements at shutdown,
as it can settle onto the membrane and c ause a f ouling problem. The injection of
antiscalant/dispersant should cease during low pressure flushes when the RO feed water is the source
of flush water.
The design of the antiscalant/dispersant injection system into the RO feed stream needs to make sure
that it is properly mixed before it enters the RO elements. The use of a s tatic mixer is the most
effective mixing method, but adds cost to a system. Most systems have the injection point just before the
RO feed cartridge filter(s) and rely on the cartridge filter residence time and RO feed pump agitation to
affect the mixing.
It is recommended that if there is an acid pH adj ustment of the RO feed water, the acid sho ul d b e
i nj ect e d up st re am and t h or ou ghl y m i x ed bef ore i t reach e s t h e antiscalant/dispersant
injection point. Concentrated pockets of low pH ac id may destroy the efficacy of the
antiscalant/dispersant.
The chemical metering pump used for the injection of antiscalant/dispersant should be adjusted to
maximize the frequency of injection. A suggested minimum stroking frequency is once every 5
seconds. Typical dosing rates of antiscalants/dispersants are 2 to 5 ppm. To achieve a reasonable
stroking frequency of the metering pump, a dilution of the antiscalant/dispersant may be required.
Antiscalants/dispersants are supplied as either a concentrated liquid or in a powder form. Dilution

water should be hardness-free and preferably be of RO permeate quality. Diluted
antiscalant/dispersants can become biologically fouled in the day tank depending on temperatures
and how much it has been diluted. A suggested residence time for a diluted solution is 7-10 days.
Normally, undiluted antiscalant/dispersant solutions do not suffer from biological fouling.
Another major issue in selecting an antiscalant/dispersant is the assurance that it is compatible with
the RO membrane being used. There are incompatible chemicals that can irreversibly foul or
damage a RO membrane. We rely on t he supplier of the chemical to have performed all RO
membrane compatibility and process efficacy tests.
Some recommended questions to ask chemical suppliers of antiscalants and dispersants are:
 Is it compatible with the RO membrane type in question?
 Is there an installation list of end-users with over 1000 hours of successful operation?
 Does it react adversely with any other constituents in the RO feed water (e.g. iron, heavy
metals, cationic polyelectrolytes, etc.)? What are the recommended dosing rates and
maximum dosing rates?
 What are the projected limits of solubility for individual scaling and fouling components?
 Are there any special discharge concerns?
 Is it suitable for potable water applications (if required)?
 Does the supplier offer other RO chemical feeds like antiscalant-compatible coagulants,
biocides and cleaning chemicals?
 Does the supplier offer off-site technical support services like membrane autopsies or
cleaning of elements?
Glossary
Alkalinity: Alkalinity is comprised primarily of carbon dioxide, bicarbonate, carbonate and hydroxides.
Naturally occurring alkalinity is the earth’s natural buffering system in that small doses of strong acids
(e.g. acid rain) react with alkalinity and result in relatively small changes in pH. Carbon dioxide and
bicarbonate are in a balance between the pH range of 4.4 and 8.2. At a pH of 4.4 or lower, all alkalinity
is in the form of carbon dioxide. At a pH o f 8.2, there is no c arbon dioxide and all alkalinity is
bicarbonate. Bicarbonate and carbonate are in a balance between the pH range of 8.2 and 9.6. At a
pH of 9.6, there is no c arbon dioxide or bicarbonate and all alkalinity is carbonate. As the pH
increases above 9.6, hydroxyl alkalinity due to the presence of the hydroxide ion starts to occur. Most
naturally occurring water sources have a pH bet ween 6 and 8.4, so the presence of hydroxides is the
result of man-made activity. Alkalinity, especially by boiler water chemists, can be r eported as M-
Alkalinity and P -Alkalinity. M-Alkalinity measures the Total Alkalinity in a w ater in terms of “ppm as
calcium carbonate” based on an acid titration to a pH of 4.2 using a Methyl orange indicator endpoint.
P-Alkalinity measures the amount of bicarbonate, carbonate and hydroxyl alkalinity based on an acid
titration to a pH of 8.2 using a Phenolphthalein pink indicator endpoint.
Barium (Ba): A divalent cation. The solubility of barium sulfate (BaSO4) is low and c an cause a RO
scaling problem in the back-end of a RO. Barium sulfate solubility is lower with increasing sulfate
levels and decreasing temperatures. Typically, barium can be found in some well waters, with typical
concentrations less than 0.05 ppm to 0.2 ppm. It is important that barium be measured with
instruments capable of 0.01 ppm (10 ppb) minimum detection levels. With saturation at 100%, super-
saturation up to 6000% is typical with an antiscalant.
Bicarbonate (HCO3): A monovalent anion. The solubility of calcium bicarbonate is low and can cause
a RO scaling problem in the back-end of a RO. Calcium bicarbonate solubility is measured using
LSI (Langlier Saturation Index) for brackish waters or the Stiff-Davis Index for seawaters and is lower
with increasing temperature and i ncreasing pH. Bicarbonate is one component of alkalinity and its
concentration is in a balance with carbon dioxide between the pH range of 4.4 and 8.2 and in a balance
with carbonate between the pH range of 8.2 and 9.6.
Calcium (Ca): A divalent cation. Calcium, along with magnesium, is a major component of hardness
in brackish water. The solubility of calcium sulfate (CaSO4)(gypsum) is typically limited to 230%
with the use of an antiscalant. The solubility of calcium carbonate is typically limited to a LS I
(Langlier Saturation Index) value of positive 1.8 to 2.5.
Carbon Dioxide (CO2): Carbon dioxide is a gas that when dissolved in water reacts with the water to
form weak carbonic acid (H2CO3). If a pure water was completely saturated with carbon dioxide, its
concentration would be about 1600 ppm and the pH would be about 4.0. A typical source for carbon
dioxide in natural waters is the result of a balance with bicarbonate alkalinity based on the pH of the
water. The concentration of carbon dioxide in water is typically indirectly determined by graphical
comparison to the bicarbonate concentration and pH. Carbon dioxide and the bicarbonate ion are
in a balance between the pH range of 4.4 and 8.2. The alkalinity is all carbon dioxide at pH 4.4 and is
all bicarbonate at pH 8.4. The RO design program calculates the carbon dioxide level based on the
bicarbonate level and pH of the water. Carbon dioxide, being a gas, is not rejected or concentrated by
a RO membrane, therefore its concentration will be the same in the feed, permeate and concentrate.
Acidifying the RO feed water will lower pH by converting bicarbonate to carbon dioxide.
Carbonate (CO3): A divalent anion. The solubility of calcium carbonate is low and c an cause a RO
scaling problem in the back-end of a RO. Calcium carbonate solubility is measured using LSI (Langlier
Saturation Index) for brackish waters or SDSI (Stiff-Davis Index) for seawaters and is lower with
increasing temperature and increasing pH. Carbonate is one component of alkalinity and its
concentration is in a balance with bicarbonate between the pH range of 8.2 and 9.6. At a pH of 9.6 and
higher, there is no carbon dioxide or bicarbonate, with all alkalinity being in the carbonate form.
Ionic Strength: The solubility of sparingly soluble salts increases with increasing feedTDS. To
account for this effect in calculating the solubility of a salt (e.g. calcium sulfate, barium sulfate, strontium
sulfate or SDSI), the Ionic Strength of a water is calculated. The Ionic Strength of each ion is derived by
taking the ppm concentration of each ion (as calcium carbonate) and multiplying each monovalent ion
by 1 x 10-5 and each divalent ion by 2 x 10-5. Summing the Ionic Strength of each ion then derives
the total Ionic Strength of the water.
Iron (Fe): Iron is a water contaminant that takes two major forms. The water-soluble form is known
as the ferrous state and has a + 2 valence state. In non-aerated well waters ferrous iron behaves
much like calcium or magnesium hardness in that it can be removed by softeners or its precipitation in
the back end of the RO system can be controlled by the use of a dispersant chemical in an RO feed
water. The water-insoluble form is known as the ferric state and has a + 3 v alence state.
Typically, RO manufacturers will recommend that combined iron levels be less than 0.05 ppm in the
RO feed. If all iron is in the soluble ferrous form, iron levels up to 0.5 ppm in the feed can be tolerated if
the pH is less than 7.0 (though an iron dispersant is recommended). The introduction of air into
water with soluble ferrous iron will result in the oxidation to insoluble ferric iron. Soluble iron can
be found in deep wells, but can be converted into the more troublesome insoluble iron by the
introduction of air by being placed in tanks or by leaky pump seals. Soluble iron can be treated with
dispersants or can be removed by iron filters, softeners or lime softening. Insoluble ferric iron oxides
or ferric hydroxides, being colloidal in nature, will foul the front end of the RO system. Sources of
insoluble iron are aerated well waters, surface sources, and i ron scale from unlined pipe and t anks.
Insoluble iron can be removed by iron filters, lime softening, softeners (with limits), ultrafiltration
(with limits) and multimedia filtration with polyelectrolyte feed (with limits). Precautions are required
with the use of potassium permanganate in manganese greensand iron filters in that potassium
permanganate is an ox idant that could damage any polyamide membrane. Precautions are also
required with a c ationic polyelectrolyte in that they can irreversibly foul a negat ively charged
polyamide membrane. Corrosion proof vessels and piping (e.g. FRP, PVC or stainless steels) are
recommended for all RO systems, RO pretreatment, and distribution piping coming to the RO system.
Iron as foulant will quickly increase RO feed pressure requirements and i ncrease permeate TDS. In
some cases, the presence of iron can create a bi o-fouling problem by being the energy source for iron-
reducing bacteria. Iron-reducing bacteria can cause the formation of a slimy biofilm that can plug the
RO feed path.
LSI (Langlier Saturation Index): LSI is a method of reporting the scaling or corrosive potential of low
TDS brackish water based on the level of saturation of calcium carbonate. LSI is important in RO water
chemistry in determining whether a water will or will not formcalcium carbonate scale. Water with a
negative LSI is considered corrosive to metal piping and will not form calcium carbonate scale.
Water with a positive LSI is not corrosive, but it will tend to form calcium carbonate scale. LSI is
important to RO chemists as a measurement of the scaling potential for calcium carbonate. The LSI
value is calculated by subtracting the calculated pH of saturation of calcium carbonate from the actual
feed pH. Calcium carbonate solubility decreases with increasing temperature (as evidenced by the
liming of a t eakettle), higher pH, higher calcium concentration, and higher alkalinity levels. The LSI
value can be lowered by reducing pH by the injection of an acid (typically sulfuric or hydrochloric) into
the RO feed water. A recommended target LSI in the RO concentrate is negative 0.2 (which indicates
that the concentrate is 0.2 pH units below the point of calcium carbonate saturation). A negative 0.2 LSI
allows for pH excursions in actual plant operation. A polymer-based antiscalant can also be used to
inhibit the precipitation of calcium carbonate. Some antiscalant suppliers have claimed the efficacy of
their product up t o a positive LSI value of 2.5 in the RO concentrate (though a m ore conservative
design LSI level is +1.8). Sodium h ex am etaphosphate, an i norganic antiscalant, was used in the early
days of RO but the maximum concentrate LSI was + 0.5 and it had to be made in short-lived batches
as the air easily oxidized it.
Magnesium (Mg): A divalent cation. Magnesium can account for about a third of the hardness in a
brackish water, but can have a concentration five times higher than calcium in sea water. The solubility
of magnesium salts is high and typically does not cause a scaling problem in RO systems.
Manganese (Mn): Manganese is a water contaminant present in both well and s urface waters, with
levels up to 3 ppm. Manganese, like iron, can be found in organic complexes in surface waters. In
oxygen-free water, it is soluble. In the oxidized state, it is insoluble and usually in the form of black
manganese dioxide (MnO2) precipitate. An alert level for potential manganese fouling in a RO aerated RO
feed waters is 0.05 ppm. Drinking water regulations limit manganese to 0.05 ppm due to its ability
to cause black stains. Dispersants used to control iron fouling can be us ed to help control
manganese fouling.
pH: The pH of the feed water measures the acidity or basicity. A pH of 7.0 is considered neutral. A pH
between 0.0 and 7.0 is acidic. A pH between 7.0 and 14.0 is basic. To the analytical chemist, pH is a
method of expressing hydrogen ion concentration in terms of the power of 10 with the pH value being
the negative logarithm of the hydrogen ion concentration. To the water chemist, pH is important in
defining the alkalinity equilibrium levels of carbon dioxide, bicarbonate, carbonate and hydroxide ions.
The concentrate pH is typically higher than the feed due to the higher concentration of
bicarbonate/carbonate ions relative to the concentration of carbon dioxide. The RODESIGN program
allows theuser to adjust the pH of the feed water using hydrochloric and sulfuric acid. Lowering the feed
pH with acid results in a lower LSI (Langlier Saturation Index) value, which reduces the scaling
potential for calcium carbonate. Feed and concentrate (reject) pH can also affect the solubility and
fouling potential of silica, aluminum, organics and oil. Variations in feed pH c an also affect the
rejection of ions. For example, fluoride, boron and s ilica rejection are lower when the pH bec omes
more acidic.
SDSI (Stiff Davis Saturation Index): SDSI, in similar fashion as LSI, is a method of reporting the
scaling or corrosion potential of high TDS seawater based on the level of saturation of calcium
carbonate. The primary difference between SDSI for high TDS seawater and LSI for low TDS
brackish water is the effect that increasing ionic strength has on increasing solubility. The solubility of
sparingly soluble salts increase with higher TDS and ionic strength, based on the theory that a denser ion
population interferes in the formation and/or precipitation of the sparingly soluble salt.
Silica (SiO2): Silica (silicon dioxide), in some cases, is an anion. The chemistry of silica is a complex
and somewhat unpredictable subject. In similar fashion as TOC reports the total concentration of
organics (as carbon) without detailing what the organic compounds are, silica reports the total
concentration of silicon (as silica) without detailing what the silicon compounds are. The “Total Silica”
content of water is composed of “Reactive Silica” and “Unreactive Silica”. Reactive silica (e.g.
silicates SiO4) is dissolved silica that is slightly ionized and has not been pol ymerized into a long
chain. Reactive silica is the form that RO and i on exchange chemists hope f or. Reactive silica is the
form of silica to be us ed in RO projection programs. Reactive silica, though it has anionic
characteristics, is not counted as an anion in terms of balancing a water analysis but it is counted as
a part of total TDS. Unreactive silica is polymerized or colloidal silica, acting more like a solid than a
dissolved ion. Silica, in the colloidal form, can be removed by a RO but it can cause colloidal fouling of
the front-end of a RO . Colloidal silica, with sizes as small as 0.008 micron can be m easured
empirically by the SDI (Silt Density Index) test, but only that portion that is larger than 0.45 micron or
larger. Particulate silica compounds (e.g. clays, silts and sand) are usually 1 micron or larger and can
be measured using the SDI test. Polymerized silica, which uses silicon dioxide as the building block,
exists in nature (e.g. quartzes and agates). Silica, in the polymerized form, also results from
exceeding the reactive silica saturation level. The solubility of reactive silica is typically limited to
200-300% with the use of a silica dispersant. Reactive silica solubility increases with increasing
temperature, increases at a pH less than 7.0 or more than 7.8, and decreases in the presence of iron
which acts as a catalyst in the polymerization of silica. Silica rejection is pH sensitive, with increasing
rejection at a more basic pH as the reactive silica exists more in the salt form than in the acidic form.
Strontium (Sr): A divalent cation. The solubility of strontium sulfate is low and can cause a RO
scaling problem in the back-end of a RO. Strontium sulfate solubility is lower with increasing sulfate
levels and decreasing temperatures. Typically, strontium can be found in some well waters where lead
ores are also present, with typical concentrations less than 15 ppm. With saturation at 100%, super-
saturation up to 800% is typical with an antiscalant.
Sulfate (SO4): A divalent anion. The solubility of calcium, barium and strontium sulfate is low and
can cause a RO scaling problem at the concentrate end of a R O. The solubility of these sparingly
soluble salts is lower with decreasing temperature. The recommended upper limit for sulfate in potable
water is 250 ppm based on taste issues.
Basics of RO and NF: Principle of Reverse Osmosis and

Nanofiltration
How Reverse The phenomenon of osmosis occurs when pure water flows from a dilute saline solution
Osmosis Works through a membrane into a higher concentrated saline solution.
The phenomenon of osmosis is illustrated in Figure 1.4. A semi-permeable membrane is

placed between two compartments. “Semi-permeable” means that the membrane is
permeable to some species, and not permeable to others. Assume that this membrane is
permeable to water, but not to salt. Then, place a salt solution in one compartment and pure
water in the other compartment. The membrane will allow water to permeate through it to
either side. But salt cannot pass through the membrane.
Figure 1.4 Overview of osmosis
Osmosis Reverse Osmosis

Water diffuses through a semi-permeable Applied pressure in excess of osmotic pressure
membrane toward region of higher concentration to reverses water flow direction. Hence the term
equalize solution strength. Ultimate height “reverse osmosis“.
difference between columns is “osmotic” pressure.
As a fundamental rule of nature, this system will try to reach equilibrium. That is, it will try to
reach the same concentration on both sides of the membrane. The only possible way to
reach equilibrium is for water to pass from the pure water compartment to the salt-
containing compartment, to dilute the salt solution.
Figure 1.4 also shows that osmosis can cause a rise in the height of the salt solution. This
height will increase until the pressure of the column of water (salt solution) is so high that
the force of this water column stops the water flow. The equilibrium point of this water
column height in terms of water pressure against the membrane is called osmotic pressure.
If a force is applied to this column of water, the direction of water flow through the
membrane can be reversed. This is the basis of the term reverse osmosis. Note that this
reversed flow produces a pure water from the salt solution, since the membrane is not
permeable to salt.
How Nanofiltration The nanofiltration membrane is not a complete barrier to dissolved salts. Depending on the
type of salt and the type of membrane, the salt permeability may be low or high. If the salt
Works
permeability is low, the osmotic pressure difference between the two compartments may
become almost as high as in reverse osmosis. On the other hand, a high salt permeability of t
membrane would not allow the salt concentrations in the two compartments to remain
very different. Therefore the osmotic pressure plays a minor role if the salt permeability is
high.
How to Use In practice, reverse osmosis and nanofiltration are applied as a crossflow filtration process.
Reverse Osmosis The simplified process is shown in Figure 1.5.
and Nanofiltration
in Practice Figure 1.5 Reverse osmosis process
With a high pressure pump, feed water is continuously pumped at elevated pressure to the
membrane system. Within the membrane system, the feed water will be split into a low-
saline and/or purified product, called permeate, and a high saline or concentrated brine,
called concentrate or reject. A flow regulating valve, called a concentrate valve, controls the
percentage of feedwater that is going to the concentrate stream and the permeate which will
be obtained from the feed.
The key terms used in the reverse osmosis / nanofiltration process are defined as follows.
Recovery - the percentage of membrane system feedwater that emerges from the system
as product water or “permeate”. Membrane system design is based on expected feedwater
quality and recovery is defined through initial adjustment of valves on the concentrate
stream. Recovery is often fixed at the highest level that maximizes permeate flow while
preventing precipitation of super-saturated salts within the membrane system.
Rejection - the percentage of solute concentration removed from system feedwater by the
membrane. In reverse osmosis, a high rejection of total dissolved solids (TDS) is important,
while in nanofiltration the solutes of interest are specific, e.g. low rejection for hardness and
high rejection for organic matter.
Passage - the opposite of “rejection”, passage is the percentage of dissolved constituents

(contaminants) in the feedwater allowed to pass through the membrane.
Permeate - the purified product water produced by a membrane system.

Flow - Feed flow is the rate of feedwater introduced to the membrane element or
membrane system, usually measured in gallons per minute (gpm) or cubic meters per hour
(m3/h). Concentrate flow is the rate of flow of non-permeated feedwater that exits the
membrane element or membrane system. This concentrate contains most of the dissolved
constituents originally carried into the element or into the system from the feed source. It is
usually measured in gallons per minute (gpm) or cubic meters per hour (m3/h).
Flux - the rate of permeate transported per unit of membrane area, usually measured in
gallons per square foot per day (gfd) or liters per square meter and hour (l/m2h).
Factors Affecting Permeate flux and salt rejection are the key performance parameters of a reverse osmosis
Reverse Osmosis or a nanofiltration process. Under specific reference conditions, flux and rejection are
and Nanofiltration intrinsic properties of membrane performance. The flux and rejection of a membrane system
Performance are mainly influenced by variable parameters including:
 pressure
 temperature
 recovery
 feed water salt concentration
The following graphs show the impact of each of those parameters when the other three
parameters are kept constant. In practice, there is normally an overlap of two or more
effects. Figure 1.6, Figure 1.7, Figure 1.8 and Figure 1.9 are qualitative examples of reverse
osmosis performance. In nanofiltration, the salt rejection is less depending on the operating
conditions.
Not to be neglected are several main factors which cannot be seen directly in membrane
performance. These are maintenance and operation of the plant as well as proper
pretreatment design. Consideration of these three ‘parameters’, which have very strong
impact on the performance of a reverse osmosis system, is a must for each OEM (original
equipment manufacturer) and end user of such a system.
Pressure With increasing effective feed pressure, the permeate TDS will decrease while the permeate
flux will increase as shown in Figure 1.6.
Temperature If the temperature increases and all other parameters are kept constant, the permeate flux
and the salt passage will increase (see Figure 1.7).
Recovery Recovery is the ratio of permeate flow to feed flow. In the case of increasing recovery, the
permeate flux will decrease and stop if the salt concentration reaches a value where the
osmotic pressure of the concentrate is as high as the applied feed pressure. The salt
rejection will drop with increasing recovery (see Figure 1.8).
Feedwater Salt Figure 1.9 shows the impact of the feedwater salt concentration on the permeate flux and
Concentration the salt rejection.
Figure 1.6 Performance vs. Figure 1.7 Performance vs. temperature

pressure
n
Salt Salt
Rejection Rejection
Permeate Permeate
Flux Flux
Pressure Temperature
Figure 1.8 Performance vs. recovery Figure 1.9 Performance vs. feedwater salt
concentration
Salt Salt
Rejection Rejection
Permeate Permeate
Flux Flux
Recovery Feed Concentration
Table 1.1 shows a summary of the impacts influencing reverse osmosis plant performance.
Table 1.1 Factors influencing reverse osmosis performance

Increasing Permeate Flow Salt Passage
Effective pressure  
Temperature  
Recovery  
Feed salt correction  
Increasing  Decreasing 
SECTION 2
RO Major Component Identification
RO Installation
MAJOR COMPONENTS
Reference Drawings are located in section 7. Use the Process and Instrumentation Diagram,
General Layout drawings, and RO Assembly Drawings as guides to your understanding of the
components involved.
System Automatic Inlet Valve (FV-1)

Feed water enters the RO system through a normally closed diaphragm valve. The valve is
controlled by an electric solenoid valve. When the system is off, a closed inlet valve prevents water
from flowing through the system at line pressure.
RO Pre-filter (F-1)
The pre-filter removes particles as small as 5 microns. The filter housing contains 5-micron
cartridges. To measure the pressure drop through the filters, there are two pressure gauges (PI-1
and PI-2) located before and after the pre-filter housing. Change the filter cartridges monthly or
when the pressure drop across the filters exceeds 15 psig.
Temperature Indicator (TI-1)

The temperature indicator (a function of the conductivity monitor) measures the temperature of the
feed water. On some units the water temperature is measured by the permeate conductivity cell.
Temperature has an effect on permeate production rate. The colder the water, the more pressure
is required to achieve the desired permeate flow.
Low Pressure Switch (PSL)

A low inlet pressure can cause permanent damage to the high-pressure pump. When a low-
pressure condition exists, the entire system will shut down. The low-pressure switch is set to shut
the system off at 10 psig. Once the unit is shut down due to low pressure, the operator must correct
the problem and manually restart the unit.
High Pressure Pump and Motor (P-1 and M-1)

The pump increases the water to a high operating pressure feeding the RO modules. Pressure
gauges before and after the pump (PI-2 and PI-3) indicate the pump feed pressure and the pump
discharge pressure. The pressure gauge (PI-3) monitors the performance of the pump.
Membrane Feed Throttling Valve (HCV-1)

The module feed pressure is controlled by a throttle valve located after the high-pressure pump
discharge. Pressure gauge PI-3 indicates the pump discharge pressure and pressure gauge PI-4
indicates membrane feed pressure.
RO Module (EH)
The RO housings each contain thin film composite spiral wound RO elements. Some of the feed
water permeates through the membrane and travels a spiral path to the product water collection
tube at the center of the cartridge. The remaining feed continues through the spiral layers, the
length of the cartridge. It then encounters the next cartridge in the vessel and the process is
repeated. The product from each cartridge exits from the common product tube in the membrane
vessel. Element housings are oriented in a cascade fashion called an "array". Waste water from the
first set of parallel housings becomes the feed water for the next set of parallel housings, and so on.
All housings share a common header to collect all the product water.
Membrane Concentrate Throttling Valve (HCV-2)

A control valve located on the membrane concentrate header aids in regulating the operating
pressure of the unit by providing back pressure to the modules. Pressure Gauge PI-5 indicates the
module concentrate pressure as water leaves the element housings.
Concentrate Flow Meter (FE-1)
A flow meter displays the concentrate flow rate leaving the system.
Concentrate Check Valve (CV-1)

When the RO unit is not operating, this check valve prevents reverse water flow to the modules.
Recirculation Water Control Valve (HCV-3) (OPTIONAL)

A control valve located on membrane concentrate header aids in recirculating water back to the
pump inlet to improve unit efficiency.
Recirculation Flow Meter (FE-3) (OPTIONAL)

A flow meter displays the recirculation flow rate.
Recirculation Check Valve (CV-3) (OPTIONAL)

This check valve prevents bypass of water flow to drain.
Product Water Conductivity Element (CE-1)

The conductivity element measures the amount of dissolved solids in the product stream and sends
a signal to the conductivity controller on the control panel.
Permeate Flow Meter (FE-2)

A flow meter displays the permeate flow rate leaving the system.
Pressure Gauge (PI-6)

This gauge measures the pressure leaving the product line.
Check Valve (CV-2)

The check valve ensures that there is no product backflow when the unit is off.
INSTALLATION
Reference Drawings are located in section 7. Use the Process and Instrumentation Diagram,
General Layout drawings, and RO Assembly Drawings as guides to your understanding of the
installation involved.
1. Equipment Location
For proper system operation and maintenance, the equipment needs an adequate amount of space:
a. Equipment Space – The RO system should be placed on a flat concrete surface. Figure
the space needed for each component based on the dimensions shown
in the general layout drawing. Those figures do not include"maintenance
space"
b. Maintenance Space - Provide at least 5 feet (1.5 meters) of space to the left and to the right of
the RO module housings and provide an approximate radius of 3 feet (0.9
meters) of space around the unit.
c. Piping - In addition, allow spacing for piping connections to and from each unit.
2. Equipment Leveling
The structural steel frame and the side supports are designed to carry the weight of the equipment and
distribute the operating weight over a large floor area. The floor area must be level so that the weight of
the skid is evenly distributed and supported. If the floor is uneven, grout beneath the steel skid.
Remove all crating from unit and remove the small parts boxes.
3. Equipment Anchoring and Bolting

There are anchoring holes arranged around the perimeter of the RO frame. The frame must be securely
anchored to the floor for safety.
4. Piping Installation
Remove the protective caps and plugs from the product outlet, concentrate outlet, and RO inlet.
It is recommended that the RO be placed near the electrical and water connections. The water inlet
and outlet connections should remain the same pipe size as the connection points on the RO (i.e. 2-
inch inlet connection on the RO should be connected to a 2-inch pipe supply). The water supply
pressure should be 30-50 psig at designed flowrate for proper operation. RO water is very aggressive.
Use non-corrosive pipe and valves in all external connections.
Connect a product line from the RO unit permeate outlet to the storage tank. A detachable spool piece
is strongly recommended to divert product water so that the product line can be run to drain during
initial start up and after membrane cleaning operations. This is so that any preservatives or
cleaning chemicals are thoroughly flushed out of the unit before being placed back into service. Prior
to securing this outlet to service or storage, it should be directed to a drain until the modules have been
thoroughly flushed, during initial start-up.
Notice: This reverse osmosis system is designed to send the permeate (product) to a non
pressurized storage tank. If the permeate is to be fed directly to the point of use, a
pressure relief valve must be installed in the product line.
The RO drain connection requires an “air gap” to prevent contamination of the RO with bacteria, etc.
In addition, the drain line should not be located higher than 10-feet above the RO system. If the drain
is located more than 10-feet above the unit, proper flushing of the membranes may not occur possibly
resulting in premature fouling and / or scaling..
5. Electrical Installation
Electrical Schematic Drawings are located in section 7.
A qualified electrician should do electrical connection. The electrical interconnections, field wiring, and
power requirements are shown on the electrical schematics contained in this manual. Confirm that the
power supply is compatible with the RO design and that sufficient amperage is available. The power
supply should be properly fused with a disconnect switch at the distribution panel.
On standard RO units, there are two electrical power connections that must be made. The first is the
control power which is 120V/60HZ/1PH. This can be wired to a standard 15 amp circuit. The second
connection is the RO pump power source. This is generally 460V/60HZ/3PH unless special your
unit requires special voltages. Refer to the specific wiring diagrams for your order found in section 7.
Notes:
A fused disconnect switch must be installed prior to the RO pump
motor starter. (All work must conform to local electrical codes.)
The direction of pump rotation should be checked at time of startup.

The system requires water in the unit to manually jog the pump.
Do not run the pump in dry condition.
Other electrical connections -

A. RO Start/Stop Signal – The RO unit requires a closed dry contact signal to run automatically.
If a float switch is used in a permeate storage tank, be sure it is a differential type that will
allow the tank water level to drop 1-2 feet before activating the RO. This will prevent the RO
unit from frequently starting and stopping.
B. Pretreatment Lockout Signal – If automatic pretreatment equipment is used, wire the

regeneration dry contact signal as shown in the electrical schematic.
C. Chemical Feeders (Anti Scalant or Bi-Sulfite) – If chemical pretreatment is used, wire the
chemical feed pumps and solution tank low level switches to the main control panel as shown
on the wiring diagram.
6. RO Membranes
The membranes are factory installed. If required, the membranes should be loaded in the direction of
flow. Follow membrane housing instructions and membrane loading instructions found in section 7.
7. Prefilter Cartridges
Make sure the water pressure is off. Open the prefilter cartridge housing and check if cartridges were
factory installed. If you need more cartridges, use 5 micron rating.
RO Storage Tank Float Level Switch Installation / Operation
Float Switch Installation
1. See reference drawing below.
2. Locate and drill hole through the RO storage tank sidewall for the 1/2” bulkhead fitting.
3. Attach the bulkhead, liquid-tight cordgrip, and float switch cable.
4. Wire the float switch to the RO control panel. On 3-wire (SPDT) float switches, only two of the wires
are normally used.
Common - White
Normally Open - Black
Normally Closed - Red
Note: Insulate unused wire because it can become electrically hot.
Float Switch Operation

1. The length of the cable inside the tank determines the on/off level. As the length
is increased, the on/off differential increases. Typical length is 12”.
2. Be sure to check the float switches for proper operation during
startup. Adjust the cable length as required to calibrate the water
levels.
DUAL TRANSFER PUMP SKID
INSTALLATION INSTRUCTIONS
1. Refer to general arrangement and electrical drawings for installation.
2. Do not reduce suction size piping on pump.
3. The pump control panel has HAND /OFF /AUTO selector switches for each
pump.
Recirculation Loop Applications

The panel is shipped with a test jumper wire on the AUTO control
circuit (See wiring diagrams). If the pumps are used in a recirculation loop
configuration and are meant to be always running, the jumper can be left in
place. The pumps will run continuously unless the water level in the storage
tank is low.
Direct Feed Applications

The customer MUST remove the jumper and wire in a start/stop dry contact
signal device to enable AUTO control. If this is not done, the pumps will run
continuously even if the process is not demanding water. This will deadhead
the pumps causing heat buildup and seal failure.
4. There is also a low level float switch input that MUST be wired in to prevent
the pumps from running dry.
5. A low tank level alarm dry contact is also provided for customer connection
to an alarm circuit.
6. Failure to wire in an AUTO control start/stop dry contact device or low level
float switch protection may cause permanent damage to pumps not covered
under warranty.
7. The HAND mode on the pumps is strictly for troubleshooting. Do not run the
pumps in HAND mode in normal operation because all safety interlocks are
disabled.
SECTION 3
Pre-Startup Checklist
Start-Up Procedures
Control Panel Operation

MRO-8H SERIES RO UNIT
QUICK START-UP INSTRUCTIONS
1. The membranes have been preloaded at the factory and are filled with preservative. Verify the 5
micron prefilter cartridge is installed in the prefilter housing.
2. Open the FV-1 auto inlet valve by depressing the “Force inlet valve open” key on the Panelview
Startup screen.
3. Open HCV-1 feed throttle valve, HCV-2 concentrate (reject) throttle valve, and HCV-3 recycle
throttle valve half way.
4. The inlet and suction pressure gauges should indicate line pressure and water should be flowing
through the unit to drain. Allow the unit to flush for 10 minutes to purge the air and preservative
solution from the membranes. After 10 minutes, close the FV-1 auto inlet valve by depressing
the“Force inlet valve open” key on the Panelview Startup screen.
5. Apply the 3PH high voltage pump power, and check for correct pump rotation by starting the high
pressure pump and looking at the motor fan. Depress the “Bump RO pump”Power key on the
Startup screen to start the pump. If rotation is not correct, have an electrician disconnect power
and re-wire the power leads.
6. Follow the detailed PLC controls instructions to run the RO unit. Reference the design parameter
specifications page in Section 1 for the recommended design flowrates for your model.
- Adjust HCV-1 feed throttle valve to match the Permeate flowrate design specifications
- Adjust HCV-2 concentrate throttle valve to match the Concentrate Reject flowrate design specs.
- Adjust HCV-3 recycle throttle valve to match the Recycle flowrate design specifications
(Note: some models do not require a HCV-3 recycle valve)
- Warning: Adjust valves carefully. Do not exceed 300psi membrane feed pressure
PERMEATE
SV-1 CONCENTRATE
FV-1 AUTO FLOW
SOLENOID FLOW SENSOR
INLET VALVE SENSOR
VALVE
LOW
PRESSURE
SWITCH
FV-2 AUTO FLUSH
VALVE
MEMBRANE
CONCENTRATE
PRESSURE
HCV-2
CONCENTRATE
THROTTLE
VALVE
HCV-3 RECYCLE
THROTTLE VALVE
MEMBRANE FEED
PRESSURE
HCV-1 RO HIGH 5 MICRON
MEMBRANE FEED RECYCLE PRESSURE PUMP PREFILTER
THROTTLE VALVE FLOWMETER
START-UP / OPERATION
General Guidelines
Before starting up the RO unit, make sure the pretreatment section is working in accordance with the
specifications. If the pretreatment involves changing of the chemical characteristics of the feed water
(i.e. chemical pre-treatment), then a full water analysis must be made. In addition, the absence of
chlorine, turbidity and SDI of the water entering the RO must be determined.
Check the correct setting of all the high pressure control valves (approx. ½ way).
Check the pipe connections and valves for leaks. Tighten connection where necessary.
Do Not operate pressure vessel with permeate port pressure in excess of 100 psig. Gradually increase
feed pressure and feed flow to RO elements. It is important to pay attention in order not to cause any
damage with over feeding or hydraulic shock loading to RO elements during start-up and cleaning.
Make sure the prefilter cartridge housing is loaded with filter cartridges.
No attempts should be made to operate the system before thoroughly reading this manual. It is also
recommended that the operator utilize the system flow diagrams to follow the flows of feed, reject, and
product water through the plant. All valves and instrumentation should also be located and identified
before attempting operation.
Chemical Handling
Operation of the RO system necessitates the handling of a variety of chemicals. All of the chemicals are
safe when properly handled. However, severe injury could result from misuse of water treatment
chemicals. For a complete guide to proper handling of each specific chemical, the chemical manufacturer
or supplier should be consulted.
Cautions
a. Do not operate the RO system unless the pretreatment system is properly functioning. Operation
without the pretreatment system will result in irreversible fouling of the RO membranes.
b. Several alarm circuits have been provided in the system to protect various components of the system.
Operation of the system while the alarm circuits have been circumvented could result in damage to
those components for which the alarm circuits provide protection.
c. The pretreatment system and all low pressure piping have been designed for a maximum operating
pressure of 100 psi. This pressure should not be exceeded.
d. The maximum feed water temperature of 100F should not be exceeded.
e. The feed water to the RO system must be CHLORINE FREE. Chlorine will cause irreversible damage
to the RO modules
f. Dry operation or operation of any of the pumps in the system against a closed discharge or closed inlet
should be avoided, since severe damage to the pump could result.
g. Operating the system at any length of time with a closed reject line will cause severe damage to the ‘
modules.
h. If the unit is to be shut down for more than two days, the unit must be operated for at least 30 minutes
each day, or the RO modules should be treated with a biocide to control bacteria growth.
i. This unit is capable of producing water of highest quality which can be contaminated by corrosion
products, bacteria, or other impurities originating in the plumbing system beyond this unit. Therefore, it
shall be the responsibility of the purchaser to install a suitably designed plumbing system and
appropriate disinfection compatible with the intended use of the water.
j. The RO modules must be protected from extremes of temperature. The maximum operating
temperature is 100F. The modules must also be protected from freezing. Do not store them below
32F
INITIAL START-UP
EQUIPMENT
The initial system start-up is typically performed just after the element loading. The material needed for
element loading is listed below. For start-up, the following is also recommended.
 Safety glasses when working with chemicals

 Thermometer
 pH meter
 Conductivity meter (range: from permeate to brine conductivity)
 3 or 4 clean plastic bottles (with plugs) for each pressure vessel for samples
 Analysis equipment for
 Total hardness
 Calcium
 Alkalinity
 Chloride
 Sulfate
 Iron
 Silica
 Free Chlorine
 Redox potential
PRE-START-UP CHECK
After having loaded the elements into the pressure vessels and before starting up the RO unit, make sure
that the whole pretreatment section is working in accordance with the specifications. If the pretreatment
involved changing of the chemical characteristics of the raw water, then a full analysis of the water
entering the Ro unit must be made. Furthermore, absence of chlorine, turbidity and SDI must be
determined.
The raw water intake must be stable with respect to:
 Flow
 SDI
 Turbidity
 Temperature
 pH
 Conductivity
 Bacteria (standard plate count)
The following checks of the pretreatment system and the RO unit are recommended for the initial start-up
(results to be included in the start-up report)
PRE-START-UP CHECKLIST
 Corrosion resistant materials of construction are used for all equipment including piping and wetted
parts of pumps
 All piping and equipment is compatible with designed pressure
 All piping and equipment is compatible with designed pH range (cleaning)
 All piping and equipment is protected against galvanic corrosion
 Media filters are backwashed and rinsed
 New/clean cartridge filter is installed directly upstream of the high pressure pump
 If chlorine is used, provisions exist to ensure comp… removal prior to the membranes
 Planned instrumentation allows proper operation and monitoring of the pretreatment and RO system
 Planned instrumentation is installed
 Instrumentation is calibrated
 Pressure relief protection is installed and correctly set (if provided)
 Provisions exist for preventing the product pressure from exceeding the feed brine pressure more
than 0.3 bar (5psi) at any time
 Interlocks, time delay relays and alarms are properly set
 Provisions exist for sampling feed, permeate and reject streams from each array and the total plant
permeate stream.
 Pressure vessels are properly piped both for operation and cleaning mode
 Pressure vessels are secured to the rack or frame
 Precautions as given in Section 7, Assembly and Loading of Pressure Vessels, are taken
 Membranes are protected from temperature extremes (freezing, direct sunlight, heater exhaust, etc.)
 Pumps are ready for operation (lubricated, proper rotation)
 Fittings are tight
 Permeate line is open
 Permeate flow is directed to drain
 Reject flow control valve is in open position
 Feed flow valve is throttled and/or pump by-pass valve is partly open to limit feed flow to less than
50% of operating feed flow
START-UP SEQUENCE
Proper start-up of reverse osmosis (RO) water treatment systems is essential to prepare the membranes
for operating service and to prevent membrane damage due to overfeeding or hydraulic shock. Following
the proper start-up sequence also helps ensure that system operating parameters conform to design
specifications so that system water quality and productivity goals can be achieved. Measurement of initial
system performance is an important part of the start-up process. Documented results of this evaluation
senire as benchmarks against which ongoing system operating performance can be measured.
The parameters necessary for the operation of your RO unit are listed in
the Specifications in Section 1. If you operate outside these parameters, the manufacturer
cannot be responsible for any potential, irreversible damage that might occur.
Before initiating system start-up procedures, membrane pretreatment, loading of the membrane
elements, instrument calibration, and other system checks should be completed. Following is the
recommended RO system start-up sequence.
TYPICAL START-UP SEQUENCE
a) Before initiating the start-up sequence, thoroughly rinse the pretreatment section to flush out debris
and other contaminants without letting the feed enter the elements.
b) Check all valves to ensure that settings are correct. The feed pressure control and concentrate
control valves should be fully open.
c) Use low pressure water at a low flow rate to flush the air out of the elements and pressure vessels.
Flush at a gauge pressure of a (30 to 60 psi). A permeate and concentrate flows should be
directed to an approved waste collection drain during flushing.
d) During the flushing operation, check all pipe connections and valves for leaks. Tighten connections
where necessary
e) After the system has been flushed for a minimum of 30 minutes, close the feed pressure control
valve.
f) Ensure that the concentrate control valve is open.
g) Slowly crack open the feed pressure control valve (feed pressure should be less than 60 psi)
h) Start the high pressure pump Allow the pump to run for two seconds to check for proper rotation. If
rotation is not correct, have an electrician disconnect power and re-wire the power leads.
i) Slowly open the HCV-1 feed pressure control valve, increasing the feed pressure and feed flow rate
to the membrane elements until the design concentrate flow is reached. The feed pressure
increase to the elements should be less than (10psi) per second. Continue to send all permeate
and concentrate flows to an approved waste collection drain. The HCV-3 recycle flow rate should
be set to the proper flow rate by adjusting the recycle valve.
j) Slowly close the HCV-2 concentrate control valve until the ratio of permeate flow to concentrate
flow approaches, but does not exceed, the design ration (recovery). Continue to check the system
pressure to ensure that it does not exceed the upper design limit.
k) Repeat steps “i” and “j” until the design permeate and concentrate flows are obtained.
Optimum performance will result from the minimum operating pressure required to produce
the required product flow under constant system conversion rate. Operating at constant
conversion is critical to assure proper RO operation. In addition, proper operation will prevent
scaling of the RO membranes.
l) Calculate the system recovery and compare it to the system’s design value.
m) Check chemical additions of acid, scale inhibitor, and sodium metabisulfite (if used). Measure
feedwater pH
n) Check the Langelier Saturation Index (LSI) or the Stiff & Davis Stability Index (S & DSI) of the
concentrate by measuring pH, conductivity, calcium hardness, and alkalinity levels and then making
the necessary calculations.
o) Allow the system to run for one hour
p) Take the first reading of all operating parameters
q) Read the permeate conductivity from each pressure vessel and identify any vessels that do not
conform to performance expectations (e.g., vessels with leaking O-rings or other evidence of
malfunction)
r) After 24 to 48 hours of operation, read all plant performance data such as feed pressure, differential
pressure, temperature flows, recovery and conductivity readings (please refer to Section 5, Record
Keeping). At the same time draw samples of feedwater, concentrate, and combined system
permeate and analyze sample constituents
s) Compare system performance to design values
t) Confirm proper operation of mechanical and instrumental safety devices
u) Switch the permeate flow from drain to the normal operating position
v) Lock the system into automatic operation
w) Use the initial system performance information obtained in steps “p” through “r” as a reference for
evaluating future system performance. Measure system performance regularly during the first
week of operation to ensure proper performance during this critical initial stage.
RO SYSTEM: CONTROLLER and STARTERS
DESCRIPTION AND OPERATION
NOTE: Reference main control panel (MCP) wiring diagrams and MCC wiring diagrams
in section four of this manual.
READ AND UNDERSTAND THE ENTIRE MANUAL BEFORE ATTEMPTING TO START
THIS SYSTEM. VERIFY PUMP ROTATION BEFORE RUNNING PUMPS
Abbreviations:
MCP=Main Control Panel
MCC= Motor Starter Panel
SECTION A: INTRODUCTION:
The RO contains the main PLC with operator interface (OIT). The PLC controls the operation
of the RO. The OIT allows local monitoring and operator intervention with the PLC. The RO will
normally run when the permeate tank is low and will shut off when the permeate tank is high.
The RO has two modes of operation, service and flush. During service the RO produces
quality water to the permeate tank. In a flush mode the membranes are flushed and the water
is sent to a waste system or drain.
SECTION B: RO INTERCONNECT WIRING SUMMARY

Reference the wiring diagrams for details.
Wire power to the MCC and MCP of the RO. Two power drops are required one 3 phase high voltage drop
normally 460 V (check wiring diagram) to the RO Motor Starter MCC1 and 120v to the RO MCP.
Reference Interconnect Wiring Diagram B1331133-09-01 for field interconnect wiring diagram.
SECTION C: MCP SELECTOR SWITCHES (SS), LIGHTS (LT) AND PUSHBUTTONS (PB):
SS3 RO System Clean/Shutdown/Auto Selector Switch- This is a maintained three position selector switch.
Auto- in this position the RO will be in the proper mode for operation. This is the normal position
of the switch.
Shutdown- in this position the RO will be forced to shutdown. This position could be used to
perform any maintenance on the RO. Upon transition from auto to shutdown the RO will flush first
before shutting down.
Clean- in this position the cleaning pump will be enabled in order to clean the RO. There is a short
10 second delay before the cleaning pump is enabled
1
SECTION C: MCP SELECTOR SWITCHES (SS), LIGHTS (LT) AND
PUSHBUTTONS (PB) cont’d
PUSHBUTTONS (PB)
PB-1 Alarm Acknowledge/Silence – PB is a momentary pushbutton. This pushbutton is used to

acknowledge or silence the alarm horn.
Note: To force the system out of a flush prematurely, hold the pushbutton in for approximately 7-8
seconds until the flush light goes out. This will be useful during startup.
LIGHTS (LT)
LT-3 RO Fault/Alarm, Light- This light is red and will be lit steady when any of the following faults
occur. A fault will normally cause the RO to flush and then shutdown. A fault or alarm will
cause an alarm banner to appear on the OIT and cause the horn to sound. A fault will
cause the light to be steady and an alarm will cause the light to flash. A fault is more
serious than an alarm.
Standard Faults-
RO Inlet Low Pressure
Pump Failure
High Permeate Conductivity
Maximum number of pump restarts due to low pressure
RO Pump P1 In Hand select and there is low pressure
Optional Faults-
Antiscalant Tank Low Level
SBS Tank Low Level
ORP out of Range
pH out of Range
High Membrane Feed Pressure
Standard Alarms-
RO Pump P1 Maximum Time In Hand select
Inlet Valve Forced Open too long
Optional Alarms-
Permeate Tank High Level
Permeate Tank Low Level
Low Control Air Pressure
2
SECTION D: MCP INSTRUMENTS
LOW PRESSURE SWITCH PSL -This pressure switch is located along the bottom of the MCP. It senses
pressure to the RO pump suction inlet. When pressure goes below the setpoint the
switch will open and signal the PLC that pressure is low. After 2 minutes of a continuous
low pressure loss of signal the RO will fault alarm and shutdown. The setpoint of this
switch is adjustable. The range of the setpoint 0-30psi.Initial setpoint=10 psi
INLET SOLENOID VALVE SV-1- This solenoid is located along the bottom of the MCP. It is energized to open
the inlet feed valve. It allows pressure to vent from the top of the inlet diaphragm valve
which causes the in-line water pressure to the diaphragm to open the valve. When the
PLC commands the valve to shut the solenoid is de-energized which forces water
pressure from the solenoid to pressurize the top of the diaphragm to close the inlet feed
valve.
OPERATOR INTERFACE- An operator interface is provided to show data on the RO system. It also allows
changes to various presets in the program. Details on this are listed later in this
document.
3
SECTION E: RO MCC-1 SELECTOR SWITCHES AND LIGHTS:
RO PRESSURE PUMP P1 SELECTOR SWITCH SS1
Hand, Off, Auto This is a 3 position maintained switch, it controls the

operation of the RO pressure pump
Auto - When in this position the pump will be controlled automatically by

the PLC.
Off When in this position the pump will be forced off.
Hand When in this position the pump is still under PLC control but there are not
as many conditions required in order for it to run.
The pump can only be in this position for a maximum of 5
minutes. There is a short delay before the pump will turn on. RO mode
select on the MCP must be in the "auto" position in order for the
pump to turn on. After this 5 minute period the pump will turn off and
the horn will sound. To reset this interval, turn the selector SS1 to off and
then back to the "hand" position. The pump will turn off in this position if
low pressure or high pressure (optional) is sensed. To reset the pump
due to a low or high pressure fault turn the pump selector switch back to
off and then to hand again. The fault reset button can also be used to
reset the fault.
NOTE: The normal position for this selector switch is AUTO. If it is

desired to turn the pump off it is recommended that the RO auto,
shutdown, clean selector on the front of the MCP be placed in shutdown
position instead of placing the pump selector to the off position. The light
on the selector switch is powered off the pumps contactor’s auxiliary
contact. When the pump is running and the contactor is in then the light
will turn on.
WARNING: IT IS NOT RECOMMENDED TO RUN THE PUMP IN HAND WITHOUT HAVING AN OPERATOR
THERE TO MONITOR THE RO SYSTEM.
RO PRESSURE PUMP P1 OVERLOAD SETTING- Located on the bottom of the pumps contactor is the
adjustable overload relay. There is a small dial on this overload. The dial needs to be set
to the full load amp (FLA) draw of the pump. This value is on the pump motors
nameplate. It was set at the factory but should be rechecked before starting.
NOTE: CONNECTION TIGHTENING- VERIFY ALL WIRE CONNECTIONS IN THE MCC ARE TIGHT.SHIPPING
MAY HAVE CAUSED TERMINALS TO LOOSEN. A LOOSE CONNECTION CAN
CAUSE FUSES TO BLOW OR PROBLEMS WITH THE MOTOR.
4
SECTION G: RO FAULT SHUTDOWN AND ALARMS:
-FAULTS WILL SHUTDOWN THE RO, SOUND THE HORN, CAUSE AN ALARM BANNER AND
LIGHT THE FAULT LIGHT.
SHUTDOWN FAULTS: THE FOLLOWING CONDITIONS WILL CAUSE THE RO TO SHUTDOWN. SOME
FAULTS WILL CAUSE THE RO TO FLUSH AND THEN SHUTDOWN. OTHER FAULTS WILL
JUST SHUTDOWN THE RO WITHOUT A FLUSH. THE FAULT RESET SWITCH MUST BE
USED TO RESTART THE RO. THE FAULT RESET SWITCH IS NOT ACTIVE IF THE RO IS IN A
FLUSH OR THE ALARM HORN IS ON. ON ANY FAULT, THE HORN MUST BE SILENCED
FIRST AND THEN THE RO SHOULD BE ALLOWED TO FLUSH AND SHUTDOWN OR JUST
SHUTDOWN WITHOUT A FLUSH.
ALARM BANNER- ANY FAULT WILL GENERATE AN ALARM BANNER. AN ALARM BANNER IS A
MESSAGE OF THE FAULT THAT WILL POP UP ON THE OPERATOR INTERFACE (OIT). ALL
FAULTS ARE RECORDED ON THE ALARM HISTORY SCREEN.
STANDARD FAULTS
1. HIGH CONDUCTIVITY (PERMEATE) FAULT- The RO has to be in service (RO pump running) to recognize
conductivity. The RO will delay for a short period (10 seconds internal delay) before it recognizes
high conductivity.
.The alarm will not go off after this delay. The RO will stay in service with high conductivity for a
maximum adjustable time. This time is adjustable and was preset at one minute. If the conductivity
is still high after this 1 minute period the RO will alarm, flush, and then shutdown. Use the alarm
silence pushbutton to silence the horn. If the conductivity goes below setpoint before the 1 minute
period is up there will be no alarm and the RO will stay in service.
After the RO flushes and shuts down use the Fault Reset Button on the main screen to restart the
RO.
2. LOW PRESSURE TO RO PUMP INLET FAULT:-If the RO is in service and low pressure is sensed there will
be a delay and then the pump will turn off. There will be no alarm at this point. The RO inlet valve
will stay open and the RO will wait until it senses ok pressure (not low).If the pressure during this
period goes above setpoint the RO will go back to RUN mode.
If the pressure stays below setpoint for a period of 2 minutes the RO will alarm, flush and
shutdown. Use the alarm silence pushbutton to silence the horn. After the RO is done flushing due
to the low pressure fault use the fault reset button to restart the RO. Low pressure is active when
the pump selector switch is in hand or auto. An indicator on the main screen will flash "LOW IN
PSI" when the pressure switch is below setpoint in flush or service. Check that all valves feeding
the RO are open and operating properly. Check feed pressure to RO.
3. MAXIMUM NUMBER OF RESTARTS DUE TO LOW PRESSURE EXCEEDED FAULT-Once low pressure is
sensed the RO pump will turn off and the inlet feed valve will stay open. A 2 minute counter is
started at this point The RO will attempt to restart due to low pressure only 5 times during this 2
minute period. If the number of restarts has exceeded 5 then the low pressure light will be lit and
the horn will sound. The RO will shutdown. Use the fault reset switch to restart the RO. Check that
all valves feeding the RO are open and operating properly. Check feed pressure to RO.
5
SECTION G: RO FAULT SHUTDOWN AND ALARMS:
STANDARD FAULTS CON'T D
.
4. PUMP HAS FAILED TO START FAULT: If the pump fails to start when it is commanded to, this alarm will
occur. Most likely it is a tripped overload. Turn the pump selector switch to off. Turn off power to the
MCC and reset the overload.
Check that the overload is set to the FLA rating given on the motor nameplate. Return power to the
RO. Check that the correct voltage is present in the MCC. Use the fault reset button to reset the
RO.
OPTIONAL FAULTS
1. ORP OUT OF RANGE- If the RO is in service or flushing the controller will monitor the ORP. IF the ORP goes
out of range the RO will fault without a flush. Use the fault reset to restart the RO. The RO will flush
and then go back to service. If the ORP goes out of range during flush the RO will end the flush
cycle and fault. Use the fault reset button to restart the RO. Check the chemical feed of the SBS
system for dosing problems.
2. pH OUT OF RANGE- If the RO is in service or flushing the controller will monitor the pH. IF the pH goes out of
range the RO will fault without a flush. Use the fault reset to restart the RO. The RO will flush and
then go back to service. If the pH goes out of range during flush the RO will end the flush cycle and
fault. Use the fault reset button to restart the RO. Check the chemical feed of the acid system for
dosing problems.
3. ANTISCALANT TANK LEVEL IS LOW- If the RO pump is running and the level in the antiscalant tank goes
low this fault will cause the RO to fault, flush and then shutdown. Use the fault reset button to
restart the RO after filling the antiscalant tank.
4. SBS TANK LEVEL IS LOW- If the RO pump is running or the RO is in a flush and the level in the SBS tank
goes low this fault will cause the RO to fault and then shutdown. Use the fault reset button to
restart the RO after filling the SBS tank.
5. HIGH MEMBRANE FEED PRESSURE- When the membrane feed pressure exceeds a preset limit this fault
will occur. The RO will fault, flush and shutdown. Check manual valve positions downstream of the
RO pump. Press the fault reset button to restart the RO. The RO will flush and then try to restart.
6
SECTION G: RO FAULT SHUTDOWN AND ALARMS: cont’d
STANDARD ALARMS:
1. RO PUMP P1 IN HAND POSITION MAXIMUM TIME ALARM: If the pumps hand off auto selector switch is in
hand for more than 5 minutes while the pump is running the pump will be forced off and the horn
will sound. To reset this time period turn the pumps hand off auto selector switch to off and then on
again.
2. INLET FEED VALVE FV1 FORCED OPEN TOO LONG: If the inlet feed valve is forced open too long this
alarm will occur. Disengage the force on the valve. This is on the run hours screen.
OPTIONAL ALARMS:
1. PERMEATE TANK HIGH LEVEL- this is only applicable if the level signal is analog and not discreet
2. PERMEATE TANK LOW LEVEL- this is only applicable if the level signal is analog and not discreet
3. LOW CONTROL AIR PRESURE- this occurs when the control air pressure decreases below a certain preset.
This pressure controls the automatic valves so it is critical to maintain 80-100psi
SECTION H: MCP RO SEQUENCE OF OPERATION AND MCC

MISCELLANEOUS
RO SEQUENCE OF OPERATION- Normally the RO starts and stops based on level in the permeate
storage tank. When the level is low the RO will run. When the level is high the RO will stop. When the RO
stops based on high level the RO will not restart until the level goes low again. There are many faults that
can shut the RO down. These faults need to be resolved and then use the fault reset selector switch or
button to restart the RO.
START UP SEQUENCE DUE TO LEVEL START OR SELECTOR SWITCH SS3 TRANSITION FROM
SHUTDOWN TO AUTO
1. RO inlet feed valve is opened
2. RO flush valve opens and RO flushes.
4. After the flush is done the inlet valve remains open and after a short delay the RO pump turns on.
7
SECTION H: MCP RO SEQUENCE OF OPERATION AND MCC
MISCELLANEOUS cont’d
SHUTDOWN SEQUENCE DUE TO HIGH LEVEL
1. With the pump on and RO running, the RO pump will turn off and the RO will flush. After this flush the
RO will shutdown.
MISCELLANEOUS
Delays - There are many delays programmed into the system. It is normal for the system to delay before things
happen. Typically the inlet valve will open and then delay before the RO pump turns on or the flush valve
opens
BUMPING PUMPS TO VERIFY CORRECT ROTATION
Motor Rotation and Overloads-Before running the pumps verify proper rotation by bumping the pumps.
Go to the start up screen and press the appropriate pump bump button to turn on the pump for one
second.
Inlet Feed Valve Override- overriding (to open) the inlet feed valve- On the startup screen is a
maintained button to force the inlet feed valve open. This can be used to flood the RO before turning on
the RO pump. Remember to unforce the valve when finished.
Normal Switch Positions- Under normal operation the following switch positions should be maintained.
1. RO System Selector on MCP should be in "auto"
2. RO Pump Selector Switch For P1 on the RO MCC1 should be in the "auto" position.
SECTION I. R.O. OPERATIONAL MODES

SERVICE- RO service is the same as RO running. The inlet feed valve FV-1 is open and the RO
pump(s) is on.
FLUSH- The unit will flush the first pass under the following main events:
NOTE: The R.O. will also flush under other conditions not listed below since there are many
different combinations to all the selector switches and other items relating to the functioning of
the R.O.The following are the main events under which the R.O. will flush:
1. High Level Shutdown.

2. Low pressure restart fail.
3. High conductivity shutdown (after one minute of being in service with high conductivity)
4. After a fault shutdown and the alarm reset is used.
5. Transition of RO System Selector Switch
8
SECTION J. STARTING CONDITIONS FOR PROPER OPERATION:
After the R.O. has been pressurized and ready for start up the following selector switches should be in
their listed states in order to start the unit and avoid starting problems.
RO MCC1- Pump selector P1 selector switch should be on Auto.

MCP- RO System selector should be set to Auto
All manual valves for RO in service should be open.
All air should be vented from the system.
Chemical Feed tanks Full (if applicable)
Pumps bumped to verify correct rotation
The inlet feed valve should be not be in its forced state-see the start up screen to unforce this valve.
9
SECTION K. OPERATOR INTERFACE (OIT)
General Information:
The OIT is located on the MCP on the RO skid. It allows the user to monitor, choose and
change detailed data in regards to the RO. The OIT communicates with the Programmable
logic controller via a cable. This is a touch screen monitor.
Numeric Entry Button- All numeric entry button have a red border with a checkered yellow
background. The number displayed is the current value for that preset. If a change in data is
necessary, touch the desired button on the screen. A small keypad will pop up. Enter in the
desired value using this keypad. Press the enter key. (long arrow key) There is a minimum
and maximum value that can be entered. If the value entered is out of range a small banner
will pop up indicating this.
10
SYSTEM MAIN SCREEN
This is the main system screen and displays the status of the RO. The number of options will
determine how the screen looks. As options are added more information will be available on
the screen.
1ST Line- Displays the status of the RO system. This can be any of the following:
1. RUN- The RO system is in auto and RO pressure pump(s) are running producing permeate
water.
2. Flush- The RO is being flushed
3. Fault - The RO has or will shut down due to a fault in the RO operation
4. Cleaning Mode- The RO has been selected to be cleaned and RO pump P1 is in
auto.
5. Shutdown- The RO is shutdown due to any of the following: P1 is not running in auto
or RO is in a forced shutdown, the RO is shut down due to high level in the permeate
tank.
6. Low Pressure Retry- the RO is trying to automatically restart itself after sensing low
inlet pressure to the pump P1. It will keep the inlet feed valve open and wait for the
pressure to rise in order for the RO to restart itself.
If after two continuous minutes of low pressure the RO will fault.
7. Transition- The RO is transitioning from one mode to another-e.g. from flush to
service, open feed valve and then delay to turn on P1 etc.
8. RO Lockout
Fault Reset Button This button is only used when there is a fault due an RO problem. A fault
is represented by a steady red light on the front of the panel. An alarm is a flashing red light on
the front of the panel.
On a fault that results in an automatic flush, the operator should wait until after the flush to use
this button. The button is not active in a flush. Once this button is pressed the system will try
and restart again. This button is not active if the R.O. is flushing or if the horn is still on
Standard Data Displays-

Permeate Conductivity- the permeate conductivity is shown here in micro Siemens. The text
"conductivity" will flash when the conductivity is above setpoint
Permeate Flow- the permeate flow is shown here in gpm.
Concentrate Flow- the concentrate flow is shown here in gpm
Inlet Valve Open/Close Indication
Flush Time Left- if the RO is in flush mode then the minutes left in this step will be displayed
and along with the text ”flush time left”. This is located in the lower left hand corner of the
screen
LOW INLET PSI-This text indicator is located in the upper right hand corner of the screen. The
text "Low Inlet PSI" will appear and flash if the RO pump is running or the RO is in a flush if the
pressure switch is below its setpoint. The display will be blank otherwise.
11
SYSTEM MAIN SCREEN cont'd
Recovery – A continuously updated calculation showing the relationship between the total
feed water flow into the RO and permeate flow produced by the RO. The ideal recovery
operating percentage is between 60-70%.
Optional Data Displays-
ORP- the ORP of the inlet water in millivolts will be displayed.
pH- the pH of the inlet water will be displayed here.
Tank Level- if the level signal is analog and not discreet (float switches) the level will shown.
SCREEN CHANGE BUTTON- THIS IS LOCATED ON EVERY SCREEN EXCEPT THE SCREEN LIST
SCREEN. IT CAN BE USED TO GO TO THE SCREEN LIST SELECTOR TO CHANGE TO A
DIFFERENT SCREEN.
12
SCREEN SELECTOR SCREEN
This screen allows the user to go to a different screen. Press the button of the screen you want
to go to. The three buttons in the middle may or may not be displayed depending on the
options used.
Time and date- the current time and date are shown. This is only used for the time/date stamp
on any fault or alarm. If time or date is not correct go to the configuration and change. See
configuration screen on next page.
13
SCREEN START UP
This screen can be used at startup to bump pumps and force the inlet feed valve open to flood
the RO.
Bump RO Pump Button- press this button momentarily to bump the RO pump to verify rotation.
Bump CIP Pump Button- if equipped with the CIP option use this button to bump the CIP pump
to verify correct rotation.
Force Inlet Valve Open- this is a two position maintained button that can be used to force the
inlet feed valve open.
Note- remember to leave the valve unforced when finished. If this button is left in the
forced position for more than 5 minutes an alarm will occur.
14
SCREEN RO SET UP FOR EXTERNAL SIGNAL OPTIONS
This screen is used to enable or disable different options that can be used with the RO.
The RO was already setup with the correct options. In case any are added after shipment this is the way to add
options.
These options require the installation of the appropriate sensors in order to communicate with the PLC. Consult
the factory for these details.
Permeate Tank Level Signal- the standard level signal is a SPDT level float switch. If an analog level transmitter
is used the analog level signal needs to be enabled.
Note: a discreet and analog signal can't be used at the same time.
Enable Disable ORP- use this button to enable or disable the ORP option.
Enable Disable pH- use this button to enable or disable the pH option.
Press to test ALM LT- Press this button to test the alarm light on the front of the MCP.
Notes: \
If the option is enabled the alarms for that device will be active even though there may not be a sensor
attached yet.
Do not enable the option until the sensor installation and wiring is complete.
If the option is not enabled it will not have its related screen or go to screen button show up.
15
CONFIGURATION CHOICE SCREEN-
Use the button in the upper right hand corner to go to the configuration screen.
This button allows access to various setup parameters of the panelview. The only item that may need to be
adjusted is the time and date. The time and date is only used for the alarm history records.
16
CONDUCTIVITY SETPOINTS SCREEN
Use this screen to change and view the following presets:
Permeate Conductivity Fault Setpoint in microsiemens (uS)
Conductivity Delay- this is the amount of time the RO will be allowed to run in service before a high conductivity
fault will occur. This is adjustable in minutes.
Conductivity Max Analog- this is the real world value that represents the 20ma value for conductivity. This value
must match the transmitter or the conductivity display will not be accurate. This value was preset at the
factory and shouldn't need to be adjusted.
17
ALARM HISTORY SCREEN AND ALARM BANNER SCREEN
The alarm history screen displays the date and time of any fault or alarm. Next to the date will be the actual alarm
message.
ALARM BANNER- When a fault or alarm occurs the alarm message will pop up over the current screen. Use the
acknowledge button to clear the banner.
18
FLOW TOTALS AND RO PUMP RUN HOURS SCREEN
RUN HOURS-This display records the number of hours the RO has been in service based on the pump running.
Use the reset button to reset the hours.
PERMEATE TOTAL GALLONS- this records the total permeate gallons and is only reset via the total reset button
to the right of the display.
CONCENTRATE TOTAL GALLONS- this records the total concentrate gallons and is only reset via the total reset
button to the right of the display.
19
PRESETS 1 SCREEN
This screen allows entry of various parameters as shown below:
Flush Time In Minutes
Permeate K factor- this is the pulses per gallons that the permeate flow sensor will send to the controller to
calculate flow. This value is determined by the pipe size, type and fitting. This was preset at the factory and
should not need to be changed.
Concentrate K factor- this is the pulses per gallons that the concentrate flow sensor will send to the controller to
calculate flow. This value is determined by the pipe size, type and fitting. This was preset at the factory and
should not need to be changed
Low Inlet PSI- this is the delay in seconds that the controller will allow the pump to run after the low pressure
signal or switch is below the preset.
Delay Pump On-this is the delay after the inlet valve is opened and the unit is not in a flush before the pump will
be enabled. This delay is in seconds.
Inlet PSI OK Delay- the RO pump will be enabled after the inlet pressure is ok for this many seconds.
Hours In High Level Stop. Start Flush- this is the amount of hours in a high level shutdown state before the RO
will flush and then go back into a high level shutdown condition.
HRS LEFT- the amount of hours that remain before a flush is initiated due to high level.
Permeate Flow Average (AVG) - Use this field to stabilize the permeate flow reading that is displayed on the
MAIN screen. This time entry is in seconds.
Concentrate Flow Average (AVG) - Use this field to stabilize the concentrate flow reading that is displayed on the
MAIN screen. This time entry is in seconds.
20
OPTIONAL SCREEN LEVEL SETPOINTS SCREEN
This screen will only be displayed if the Analog Level option is enabled on the RO setup screen.
This screen is optional and is only used when the permeate tank level signal is analog, not discreet. Discreet is
when there are float switches used in the tank to signal the RO to start and stop. Analog is a continuous
modulating signal that is usually transmitted by a pressure transducer or ultrasonic transmitter.
RO Stop Setpoint- this is the level at which the RO will stop. It will not turn back on again until it reaches the RO
start setpoint.
RO Start Setpoint- this is the level at which the RO will turn on. It will normally run until the level reaches the RO
stop setpoint.
Level Max Analog- this value should equal the scaled 20 ma value of the transmitter.
Level Min Analog this value should equal the scaled 4 ma value of the transmitter.
Leve1 Adjustment- use this as a multiplier in order to fine tune the level display. Normally this should be 1.
High Level Alarm- this is the level at which a high level alarm will occur.
Low Level Alarm- this is the level at which a low level alarm will occur.
21
OPTIONAL SCREEN ORP SETPOINTS SCREEN
This screen will only be displayed if the ORP option is enabled on the RO setup screen.
ORP High/Low Fault Setpoint in millivolts
ORP Delay- this is the amount of time the RO will be allowed to run in service or flush before an ORP out of range
fault will occur. This is adjustable in seconds.
ORP Max Analog- this is the real world value that represents the 20ma value for high ORP. This value must
match the transmitter or the ORP display will not be accurate.
ORP Min Analog- this is the real world value that represents the 4ma value for low ORP. This value must match
the transmitter or the ORP display will not be accurate
22
OPTIONAL SCREEN pH SETPOINTS SCREEN
This screen will only be displayed if the pH option is enabled on the RO setup screen
ph High/Low Fault Setpoint
pH Delay- this is the amount of time the RO will be allowed to run in service or flush before a pH out of range fault
will occur. This is adjustable in seconds.
pH Max Analog- this is the real world value that represents the 20ma value for high pH. This value must match
the transmitter or the pH display will not be accurate.
23
CHEMICAL FEED OPTIONS
There are three level switch options for chemical feed systems.
Acid Tank Low Level- this input was jumped. If this level needs to be acted upon when it’s low then wire a
normally open level switch to this input. A low level will cause an alarm and fault the RO when it is in flush or
service.
SBS Tank Low Level- this input was jumped. If this level needs to be acted upon when it’s low then wire a
normally open level switch to this input. A low level will cause an alarm and fault the RO when it is in flush or
service.
Antiscalant Tank Low Level- this input was jumped. If this level needs to be acted upon when it’s low then wire a
normally open level switch to this input. A low level will cause an alarm and fault the RO when it is in service.
CHEMICAL FEED PUMP CONTROL- if the system was ordered with chemical feed pump control there will
receptacles provided to turn on and off the chemical feed pump. There maybe one or two pumps that normally
need to be controlled.
Antiscalant- the receptacle for antiscalant will be marked and it will be energized whenever the RO pump is on.
SBS- the receptacle for SBS will be marked and it will be energized whenever the RO pump is on or the RO is in
a flush.
Receptacle GFI- if the receptacle GFI has tripped there will be a yellow LED that lights up. Press the receptacle
reset button to clear this.
24
CONTROLS CONTINUED: OPERATOR INTERFACE SCREENS
SCREEN SAVER- AFTER A PERIOD OF 10-15 MINUTES WITHOUT ANY ACTIVITY ON THE SCREEN THE
OIT WILL DISPLAY A SCREENSAVER. Touch the screen to go back to a normal display.
MISCELLANEOUS-
Dry Alarm Contact- there is an auxiliary alarm dry contact between terminals 9 and 10 in the RO MCP. This
contact will close upon an alarm.
25
SECTION 4
Routine Maintenance
Record Keeping Requirements

MAINTENANCE / DAILY TESTING PROCEDURES
PREFILTER ELEMENT REPLACEMENT

The RO unit uses 5-micron prefilter elements. Change the elements when the pressure gauges on
the inlet and outlet of the prefilter indicate a difference of 15 psi.
To change the elements:

a. Shut off RO system and all pumps.
b. Turn off main supply valve.
c. Open vent valve, release the housing pressure, and open drain valve.
d. Remove top of filter housing, wing nut and plate.
e. Discard elements from the prefilter housing.
f. Install new elements in the prefilter housing.
g. Re-assemble the prefilter housing.
h. Turn on manual supply valve, vent the air.
i. Turn the RO unit on and examine prefilter for leaks.
PUMP MAINTENANCE INSTRUCTIONS

The pump requires periodic lubrication. Refer to the manufacturer’s
recommended maintenance schedule in the pump installation/operation
manual found in section 7.
DAILY MAINTENANCE CHECK LIST

- Verify Pre-filter Pressure Differential.
- Check chemical level of all chemical feeders solution tanks and fill
tanks as needed.
- Determine Fouling Index Test Results (SDI).
- Record all information on RO System Daily Log.
- Run unit for 15 minutes every day if not in use (to control bacterial
growth by rinsing out stagnant water).
RECORD KEEPING per shift, unless otherwise stated  Calibration of all gauges and
(see Table 2 for an example). meters based on manufacturer’s
recommendations as to method
Introduction
and frequency but no less frequent
 Date, time and hours of than once every three months.
In order to be able to follow the
operation.
performance of the RO unit, it is
 Any unusual incidents, for example,
necessary that all relevant data are
 Pressure drop per cartridge upsets in SDI, pH and pressure and
collected, recorded and kept on file.
and per array. shutdowns.
Apart from keeping track of the
performance, the logsheets are also
 Feed permeate and  Complete water analysis of the
valuable tools for troubleshooting,
concentrate pressure of each feed, permeate and concentrate
and are needed in the cases of
array. streams and the raw water at start-
warranty claims.
up and every week thereafter.
 Conductivity of the feed,
This chapter is for general guidance
permeate and concentrate The water analysis shall include:
only and must not be used in place
streams for each array.
of the operating manual for a
Permeate conductivity of each  Calcium
particular plant. Site-dependent
pressure vessel weekly.
factors prevent specific  Magnesium
recommendations for all record
 TDS of feed, permeate and  Sodium
keeping. Thus, only the more
concentrate streams for each
general record keeping is covered  Potassium
array. The TDS is calculated
here.
from the water analysis. It can  Strontium
also be calculated from the
 Barium
Start-Up Report conductivity (at 25C) EC25 and
an appropriate K factor:  Iron (total, dissolved and
ferrous)
 Provide a complete description TDS = K EC25
 Aluminum (total and
of the RO plant. This can be
dissolved)
done using a flow diagram and The K factor has to be
equipment, instrumentation, and determined for each specific  Sulfate
material list to show water stream. Typical K factors are
5)  Chloride
source, pretreatment system, RO shown in Table 2 .
configuration and posttreatment  Nitrate
system.  pH of the feed , permeate and
 Fluoride
concentrate streams.
 Give results of checking  Phosphate (total)
according to check list (Section  Silt Density Index (SDI) or
 Silica (dissolved)
6.2.2). turbidity of the RO feed stream,
or both.  Conductivity
 Provide calibration curves of all
 pH
gauges and meters based on  Water temperature of the feed
manufacturers’ stream.  TOC
recommendations
 Langelier Saturation Index
 Record initial performance of RO (LSI) of the concentrate stream Table 1: Factors for Estimating
and pretreatment system as from the last array (for
TDS from Conductivity
provided below. concentrate streams < 10,000
mg/l TDS).
Water EC251(mS/m) K
 Stiff and Davis Stability Index
RO Operating Data (S&DSI) of the concentrate Permeate 0.1 – 1 0.50
stream from the last array (for 30 – 80 0.55
The following data must be concentrate streams > 10,000 Sea water 4,500-6,000 0.70
recorded and logged into an mg/l). Concentrate 6 500-8 500 0 75
appropriate logsheet at least once
1
EC25 does not include the conductivity caused by
dissolved CO2 (see 10.4 page 3)
standard (reference) conditions
by the following calculations:
RO Performance
 Ps
Normalization A. Normalized Permeate Flow
Pfs -– Ps - fcs TCFs
2
The performance of an RO system is Qs = x x Qo (1)
influenced by the feed water  Po TCFo
composition, feed pressure, Pfo -– Po - fco
temperature and recovery. For 2
example, a feed temperature drop of
4 C will cause a permeate flow
decrease of about 10%. This, with Pf = feed pressure
however, is a normal phenomenon.
P
In order to distinguish between such = one half device pressure drop
normal phenomena and real 2
performance changes, the measured Pp = product pressure
permeate flow and salt passage have
to be normalized, that means fc = osmotic pressure of the feed-concentrate
compared to a given reference mixture
performance while the influences of
operating parameters are taken into TCF = temperature correction factor
account. The reference performance Q = product flow
may be the designed performance or
the measured initial performance. subscript s = standard condition
subscript o = operating condition
Normalization with reference to the
designed (or warranted) system
performance is useful to verify that the The temperature correction factor follows the formula:
plant gives the specified (or
warranted) performance. TCF = EXP [2640 x {1 / 298 – 1 / (273 +T)}]; T  25 C
Normalization with reference to the = EXP [3480 x {1 / 298 – 1 / (273 +T)}]; T  25 C

initial system performance is useful to
show up any performance changes where T= temperature as C
between day one and the actual date.
As standard conditions, we take either the design valvues or the conditions
This procedure is strongly at initial performance as given in the start-up report, so that a fixed
recommended, because it allows an reference point is available.
early identification of potential
problems (e.g. scaling or fouling) For the osmotic pressure, different formulas are available in the literature. A
when the normalized data are valid and practical short approximation is:
recorded daily. Corrective measures
are much more promising when taken Cfc x (T + 320)
early.  fc = bar for Cfc < 20000
mg/l
A computer program called FTNORM 491000
is available for normalizing operating and
data and graphing Reg parameters (0.0117 x Cfc) – 34 T + 320
including normalized permeate flow  fc = x bar for Cfc > 20000
and salt passage as well as pressure mg/l
drop. This program is available from 14.23 345
Dow field sellers as Form No.
60900163 and requires Excel
software. Alternatively, the measured
plant performance at operating
conditions can be transferred to
INSTALLATION,
SubstitutingOPERATION, AND
these values in MAINTENANCE
equations (1) gives: MANUAL
25 – 1.5 – 1 – 2.5 0.67

Qs = x x 127
28 – 2 – 2 – 2.7 0.54
3
= 148 m /h normalized flow (652 gpm)
Compared to the start-up conditions, the plant has lost 1.6% capacity. This
is very good for a period of 3 months. Cleaning is not yet necessary.
The normalized permeate TDS is given by:
28 – 2 – 2 – 2.72 + 0.06 3670

Qps = x x 127
25 – 1.5 – 1 – 2.5 – 0.05 4052
= 77 mg/l
Compared to the initial 83 mg/l, the salt rejecxtion has slightly improved.
Such behavior is typical for the initial phase.
INSTALLATION,
Values OPERATION, AND MAINTENANCE MANUAL
after 3 months.
Feed water analysis in mg/l
Ca: 200 HCO3: 152

Mg: 80 SO4: 530
Na: 480 Cl: 850
Temp.: 10 C (50 F)
Pressure: 28 bar (406 psi) Pressure drop: 4 bar (58 psi)
3
Flow: 127 m /h (600 gpm) permeate pressure: 2 bar (29 psi)
Recovery: 72% Permeate TDS: 80 mg/l
For the standard conditions we have

P fs = 25 bar (363 psi)
P s
= 1.5 bar (181.5 psi)
2
C fs = 1986 mg/l
1
In
1 – 0.75
C fcs = 1986 x = 3671 mg/l
0.75
fcs = 2.5 bar (36.3 psi)
TCFs = EXP {3480 x {1 / 298 – 1 / (273 + 15)}] = 0.67
For the operating conditions we have
P fo = 28 bar (406 psi)
P o
= 2 bar (29 psi)
2
C fo = 2292 mg/l
1
In
1 – 0.72
C fco = 2292 x = 4052 mg/l
0.72
fco = 2.72 bar (39.4 psi)
TCFo = EXP {3480 x {1 / 298 – 1 / (273 + 10)}] = 0.54

C fc can be calculated from following approximation:
1
In
(1 – Y)
C fc = C f x
Y
product flow
where Y = recovery ratio =
feed flow
C f = TDS feed mg/l
B. The Normalized Permeate TDS is calculated from:
 Po
P fo - - P po - fco + po
2 C fcs
C ps = C po x (2)
 Ps C fco
P fs - - P ps - fcs + ps
2
Terms not yet defined under A are:
C p = product concentration as ion in mg/l
p = osmotic pressure of the permeate in bar
Example
Values of Start – Up:
Feed water analysis in mg/l
Ca: 200 HCO3: 152

Mg: 61 SO4: 552
Na: 388 Cl: 633
Temp.: 15 C (59 F)
Pressure: 363 bar Pressure drop: 3 bar (43.5 psi)
3
Flow: 150 m /h (660 gpm) Permeate pressure: 1 bar (14.5 psi)
Recovery: 75 % Permeate TDS: 83 mg/l
Pretreatment Operating Data
Since the RO system performance depends largely on the proper operation of the pretreatment, the
operating characteristics of the pretreatment equipment should be recorded. Specific recommendations
for all record keeping cannot be given, because pretreatment is site dependent. Typically, the following
items must be recorded:
 Total residual chlorine concentration in the RO feed (daily – unless known to be completely
absent).
 Discharge pressure of any well or booster pumps (twice a day).
 Pressure drop of all filters (twice a day).
 Consumption of acid and any other chemicals (daily – if used).
 Calibration of all gauges and meters based on manufacturers’ recommendations as to method and
frequency but no less frequent than once every 3 months.
 Any unusual incidents, for example, upsets and shutdowns as they occur.
Maintenance Log
 Record routine maintenance.
 Record mechanical failures and replacements.
 Record any change of membrane element locations with element serial numbers.
 Record replacements or additions of RO devices.
 Record calibration of all gauges and meters.
 Record replacement or additions of pretreatment equipment, for example cartridge filters and
include date, brand name and nominal rating.
 Record all cleanings of RO membranes. Include date, duration of cleaning, cleaning agent(s) and
concentration, solution pH, temperature during cleaning, flow rate and pressure (for cleaning
procedures see Section 7)
Correction Factors For Temperature (TCF) To Get Effect On

Permeate Rate For All Membrane Types
Temperature Correction Factors
35° F / 1.7° C = 0.53 77° F / 25.0° C = 1.00
40° F / 4.4° C = 0.56 80° F / 26.7° C = 1.04
45° F / 7.2° C = 0.62 85° F / 29.4° C = 1.10
50° F / 10.0° C = 0.68 90° F / 32.2° C = 1.17
55° F / 12.8° C = 0.73 95° F / 35.0° C = 1.23
60° F / 15.6° C = 0.78 100° F / 37.8° C = 1.30
65° F / 18.3° C = 0.85 105° F / 40.5° C = 1.39
70° F / 21.1° C = 0.90 110° F / 43.3° C = 1.45
75° F / 23.9° C = 0.97 115° F / 46.1° C = 1.51

Conversion Table
mg/L Total Dissolved Specific Specific Grains

Sodium Solids as Conductance Resistance per Gallon
Chloride mg/L CaCo2 (MicroSlemens/cm) Ohms/cm Sodium Chloride
0.05 0.043 0.105 9,523.800 0.0029
0.1 0.085 0.212 4,716.980 0.0060
0.2 0.170 0.424 3,558.490 0.012
0.3 0.255 0.637 1,569.850 0.018
0.4 0.340 0.848 1,179.240 0.023
0.5 0.425 1.06 943.396 0.029
0.6 0.510 1.273 785.545 0.035
0.7 0.595 1.985 673.400 0.041
0.8 0.680 1.696 589.622 0.047
0.9 0.765 1.908 524.109 0.053
1 0.85 2.12 471.698 0.06

2 1.70 4.24 235.849 0.12
3 2.55 6.37 156.985 0.18
4 3.40 8.48 117.924 0.23
5 4.25 10.6 94.339 0.29
6 5.10 12.73 78.554 0.35
7 5.95 14.85 67.340 0.41
8 6.80 16.96 58.962 0.47
9 7.65 19.08 52.410 0.53
10 8.5 21.2 47.169 0.58

20 17.0 42.4 23.584 1.17
30 25.5 63.7 15.698 1.75
40 34.0 84.8 11.792 2.34
50 42.5 106.0 9.433 2.92
60 51.0 127.3 7.855 3.51
70 59.5 148.5 6.734 4.09
80 68.0 169.6 5.896 4.68
90 76.5 190.8 5.241 5.26
100 85 212 4.716 5.85

200 170 410 2.439 11.70
300 255 610 1.639 17.5
400 340 812 1.231 23.4
500 425 1,008 992 29.2
600 510 1,206 829 35.1
700 595 1,410 709 40.9
800 680 1,605 623 46.8
900 765 1,806 553 52.6
1,000 850 2,000 500 58.5

2,000 1700 3,830 261 117
3,000 2550 5,670 176 175
4,000 3400 7,500 133 234
5,000 4250 9,240 108 292
6,000 5100 10,950 91 351
7,000 5950 12,650 79 409
8,000 6800 14,340 69 468
9,000 4650 16,000 62 526
10,000 8500 17,600 56 585
Daily Log
Marlo Job number _______________ Projected Permeate Flow Rate * _________
Model Number __________________ Projected Concentrate Flow Rate * _________
UOM
Date / Time
GPG
Feed Water Hardness /PPM
Feed Water Chlorine PPM

µs /
Feed Water Conductivity - (CF) PPM
Feed Water PH
Feed Water Temperature C or F
Feed Water Inlet Pressure PSI
RO Prefilter - (pp) PSI

YES/N
Filter Change O
Pump Suction - (sp) PSI
RO Pump Discharge PSI
Membrane Feed (**NOT TO EXCEED 300 PSI**) PSI
Interstage (If Applicable) PSI
Interstage 1 (If Applicable) PSI
RO Concentrate PSI
Membrane Perm Flush (If Applicable) PSI
Permeate Flow Rate - Qp GPM
Reject/Concentrate Flow Rate (GPM) Qr GPM
Recycle Flow Rate (If Applicable) GPM
Feed Flow Rate - Qf (Qr + Qp = Qf) GPM
Recovery Rate = (Qp/Qf) X 100 %

µs /
Permeate Conductivity PPM
Overall Rejection = (1-(Qp/ Qf)) x 100 = % %

* = Performance Data in Section 1 of manual
Notes: When prefilter pressure and suction pressure are greater then 20 psi = Change prefilter
Symbols : Q = Flow Rate C = Conductivity pp = prefilter pressure sp = suction pressure
This is a template. Make copies as needed.
*Symbols: Q – Flow Rate: C-Conductivity
Reference the Troubleshooting Guide in your Instruction Manual where trends or differences are noted.
Daily Log
Marlo Job number _______________ Projected Permeate Flow Rate * _________
Model Number __________________ Projected Concentrate Flow Rate * _________
UOM
Date / Time
GPG
Feed Water Hardness /PPM
Feed Water Chlorine PPM

µs /
Feed Water Conductivity - (CF) PPM
Feed Water PH
Feed Water Temperature C or F
Feed Water Inlet Pressure PSI
RO Prefilter - (pp) PSI

YES/N
Filter Change O
Pump Suction - (sp) PSI
RO Pump Discharge PSI
Membrane Feed (**NOT TO EXCEED 300 PSI**) PSI
Interstage (If Applicable) PSI
RO Concentrate PSI
Membrane Perm Flush (If Applicable) PSI
Permeate Flow Rate - Qp GPM
Reject/Concentrate Flow Rate (GPM) Qr GPM
Recycle Flow Rate (If Applicable) GPM
Feed Flow Rate - Qf (Qr + Qp = Qf) GPM
Recovery Rate = (Qp/Qf) X 100 %

µs /
Permeate Conductivity PPM
Overall Rejection = (1-(Qp/ Qf)) x 100 = % %

* = Performance Data in Section 1 of manual
Notes: When prefilter pressure and suction pressure are greater then 20 psi = Change prefilter
Symbols : Q = Flow Rate C = Conductivity pp = prefilter pressure sp = suction pressure
This is a template. Make copies as needed.
*Symbols: Q – Flow Rate: C-Conductivity
Reference the Troubleshooting Guide in your Instruction Manual where trends or
differences are note
SECTION 5
Troubleshooting
Membrane Cleaning Procedures

TROUBLESHOOTING YOUR RO
Summary: There can be many reasons why a RO system suffers a loss in performance, and is unable to
produce the proper quantity and/or quality of permeate water. Similar to a doctor attempting to make a
diagnosis, you must identify as many symptoms as possible before you can derive an educated guess as
to what the disease is.
INTRODUCTION
The focus of this paper is how to troubleshoot an RO on-site. Many of the techniques assume the
equipment has been designed with instrumentation and sampling points to allow troubleshooting and for
on-site cleanings, which is common for “industrial quality” systems, but not necessarily for “residential or
light commercial” equipment. The capital cost for small RO to include troubleshooting instruments and
sample valves is prohibitive for their market niches, relative to the minimal cost of replacing RO elements
on a more frequent basis. As RO systems reach a certain size (say 15 gpm or larger), the cost of
replacing RO elements on a frequent basis becomes prohibitive versus the initial capital cost of adding
instruments, sample valves and on-site cleaning equipment.
HOW TO AVOID TROUBLE

The best way to stay out of trouble with an RO is to avoid it initially. A few RO design tips are:
 Design the RO system with access to a c omplete water analysis. I f there are seasonal variations
(which are common for surface sources) or varying sources (which are common with municipal
sources), get all the analyses you can and be sure they are recent.
 Perform 15 minute SDI (Silt Density Index) tests. This on-site testing helps to determine the potential
for colloidal silt fouling.
 Invest in the appropriate pretreatment. I f you want to sleep well at night, make sure the system
design has adequate pretreatment to the RO.
 Design the RO flux rate conservatively, especially if the potential for fouling exists. A RO with a clean
well water source can be designed more aggressively than one f or a s urface water source. A
reduced rate of permeate water flow for a given area of membrane reduces the convective deposition
of foulants at the membrane surface. Fluxes for surface waters should range from 8 t o 14 g fd
(gallons per square foot per day) and 14 to 16 gfd for well sources.
 Design the RO recovery rate conservatively. A conservative per cent recovery of the feed water
minimizes the concentration of foulants.
 Maximize the cross flow velocity in the elements. A conservative design maximizes the cross-flow
velocity of the feed and concentrate streams. A higher cross-flow velocity reduces the concentration
of salts and foulants at the membrane surface by increasing their diffusion back into bulk feed stream
above the membrane surface.
 Select the right membrane for the application. Sometimes a neutrally charged CAB (cellulose acetate
blend) or LFC (Low Fouling Composite) RO element is a bet ter choice than a negat ively charged
CPA (Composite PolyAmide) RO element for difficult surface or waste water sources.
IDENTIFYING A PROBLEM
Verify that you really have an RO system upset or fouling. Changes in system operating parameters do
have an e ffect on per formance. For instance, an increase in feed TDS (total dissolved solids) will
increase feed pressure requirements by approximately 1 ps ig for every 100 ppm TDS increase due t o
increased osmotic pressure and it will also increase permeate conductivity since the RO will always reject
a fixed percentage of the salts. A 10º F increase in feed water temperature will increase the feed pump
pressure requirement by 15%. An increase in the per cent recovery of the system will increase the reject
TDS which in turn will increase permeate conductivity. (Concentrate TDS due t o concentration of the
feed water is 2 times higher at 90% r ecovery). Finally, a r eduction in the permeate flow will result in
higher conductivity if the same recovery is maintained because the passage of salts through the
membrane is independent of the passage of water through the membrane, which results in less permeate
water to dilute the salts that have passed through.
It is recommended that you “normalize” your logged operating data to determine if you have a pr oblem
with your system. “Normalization” computer programs, such as RODATA, graphically represent
normalized permeate flow, per cent salt rejection and feed-to-reject pressure drop. T hese normalized
parameters are calculated by comparing a par ticular day’s operations to the first day of operation.
Adjustments are made for changes in major operating variables such as temperature, feed TDS,
recovery, and pr essures. I n this way, performance declines unrelated to operating parameters can be
identified and treated.
Questions to ask yourself…

Loss in performance is generally divided into two categories: loss of flow, and loss of rejection. The
following lists of questions help to identify possible root causes for either of these problems.
Loss of Flow
Attributable to fouling, these questions can help pinpoint the problem. Certain foulants impact the front
end of the system while others impact the back end of the system. Use the RO Troubleshooting Matrix
(at the end of this document) to help determine the nature of the foulant.
 Did you shut down the RO system properly? The reject water from the service operation should be
flushed out of the system upon shutdown. If not, inorganic foulants can precipitate onto the surface of
the membrane. The best flush water source is RO permeate.
 Did you store the RO system properly? I mproperly stored systems (especially under warm
conditions) can produce a severe biofilm problem.
 If you acidify to lower feed pH or add scale inhibitor for the control of calcium carbonate (lime) scale,
are you meeting your target pH or SI concentration? If not, you may need to do an acid clean.
 Has your pressure drop between the feed and reject lines increased greater than 15%? Increasing
pressure drop indicates that fouling of the feed path and restriction flow over the membrane surface is
occurring. M onitoring pressure drops across stages gives you the advantage of determining if the
fouling is limited to a particular stage, which can help identify the potential foulant.
 Has your pressure drop between the feed and per meate lines increased greater than 15%. This
would indicate that you are fouling the surface of the membrane, and it’s time to clean.
 Are the cartridge filters fouling? I nspect the RO feed cartridge filter for foulants as this is relatively
easy.
Loss of Rejection
Loss of rejection displays itself as a higher permeate conductivity. It may be due either to fouling,
degradation of the membrane surface, or an o-ring leak. The following questions can help you pinpoint
the source of this problem. Verify that the permeate conductivity has not increased greater than 15%.
 Do all the vessels in a stage have nearly the same conductivity? Measure permeate quality by stage
and by pressure vessel if possible. O ne vessel having a significantly higher permeate conductivity
probably has a faulty o-ring, a disconnect, or a damaged membrane.
 Have your composite membranes been ex posed to chlorine or other strong oxidant? The exposure
may have damaged the membranes.
 Have your cellulose acetate membranes been ex posed to non-acidified water during shut-down, or
been allowed to soak in non-acidified water? The exposure may have damaged the membranes.
 Is the instrumentation accurate? Verify that all of your instruments are calibrated properly.
 Do the elements look discolored or damaged? I nspect the RO elements for foulants or physical
damage.
 How do the actual conductivity and temperature of the feedwater compare to the design criteria? If
the actual feedwater has higher TDS or is warmer than the design, this may account for the
discrepancy. Sample and obtain detailed water analyses of the RO feed, concentrate and permeate.
Compare the results of the analyses to the RO design projections of the element manufacturer.
 Can there be times when the permeate pressure exceeds the feed pressure? If the permeate is
pumped to an elevated position, and there are no check valves on the permeate line, at shut down,
the permeate pressure can exceed the feed pressure. This can cause the membrane envelopes to
expand and rupture.
 In seawater systems, are you flushing with permeate water at shut-down? Due to the high difference
in osmotic pressure between the feed/concentrate water and t he permeate, permeate water can
actually be pull ed back across the membrane. T his can result in “blistering” of the membrane
surface, and lead to leakage.
 Are your o-rings in good condition? O-rings can flatten or crack with age. The result is that leaks can
develop. Replacement of o-rings periodically is a good, cost-effective preventive maintenance step.
If you still think there is a problem…
 Once you have ruled out any mechanical failures as the source of your RO problem, then you need to
determine what your suspected foulant or foulants are and perform a cleaning or series of cleanings.
 The cleaning solution can be c ollected and an alyzed for the foulants removed, color change or pH
change. The effectiveness of the cleaning can be verified by placing the RO back into Service.
 If you don’t know what your foulants are and don’t want to experiment on s ite as to what cleaning
solution(s) are required and what the proper cleaning procedures should be, there are companies
who specialize in the supply of proprietary cleaning chemicals and of f-site evaluations of RO
elements. These services can be invaluable, especially the first time around in cleaning a RO.
 If all else fails in determining what fouled the RO element, a destructive autopsy can be performed.
The RO element is cut open and unrolled with analytical tests run on the membrane and the foulant to
determine the problem.
CLEAN IN PLACE TANK INSTRUCTIONS
1. Turn RO unit off.

Refer to the general arrangement drawing and the P&ID.
2. The CIP tank and hoses can be stored else ware when not needed.
3. Place CIP tank near the RO and connect the flexible quick connect hoses from
the tank to the RO unit following the connection points labeled CC-XX. The hose
connection points have the same number designation between the tank and RO
(CC-1A connects to CC-1B, CC-2A connects to CC-2B, etc)
CIP QUICK
CONNECT
HOSES
CIP HOSE
CONNECTIONS
(CC-XX)
4. To clean the entire array,

Connect hose between CIP tank CC-1B to RO skid CC-1A.
Connect hose between CIP conn CC-5A to CIP conn CC-5B.
Target cleaning flowrate 40 gpm
To clean the 1st stage membrane vessel only,
Connect hose between CIP tank CC-3B to RO skid CC-6.
Connect hose between CIP conn CC-5A to CIP conn CC-5B.
To clean the 2nd and 3rd stage membrane vessels only,

Connect hose between CIP conn CC-5A to CIP conn CC-6.
5. Prepare cleaning solution following instructions on proceeding pages.
6. Close all RO unit manual throttling valves (HCV-1, HCV-2, HCV-3 ).
7. To mix cleaning solution, activate the CIP pump and open mix valve HCV-4.
After mixing, close valve HCV-4 and only open all CIP isolation valves with hoses
connected.
8. Recirculate the cleaning solution through the membranes following the

proceeding instructions. Regulate the flowrate by adjusting valve HCV-5. After
cleaning, reset all valves to original position and run RO unit. Divert all permeate
to drain for 30 minutes after cleaning to remove any residual cleaning solution.
Cleaning Procedures for Composite

Polyamide RO Membrane Elements
This bulletin provides general information about the most typical foulants which
may affect the performance of Composite Polyamide Reverse Osmosis (RO)
membrane elements, and procedures for the removal of these foulants. The
information in this bulletin applies to both 4-inch and 8-inch diameter RO
membrane elements.
The surface of the RO membrane is subject to fouling by foreign materials which

may be present in the feed water. Examples are:
• Calcium carbonate scale

• Sulfate scale of calcium, barium or strontium
• hydrates of metal oxides (iron, manganese, copper, nickel, aluminum, etc.)
• Polymerized silica scale
• Inorganic colloidal deposits
• Mixed inorganic/organic colloidal deposits
• NOM organic material (Natural Organic Matter)
• Man-made organic compounds (e.g. antiscalant/dispersants, cationic
polyelectrolytes)
• Biological (bacterial bioslime, algae, mold, or fungi)
The term fouling used here includes the build up/ deposition of all kinds of layers on
the surface of the membrane, including scale formation.
Note: The Composite Polyamide type of RO membrane elements may not be

exposed to chlorinated water under any circumstances. Any such exposure may
cause irreparable damage to the membrane. Absolute care must be taken following
any disinfection of piping or equipment or the preparation of cleaning or storage
solutions to ensure that no trace of chlorine is present in the feedwater to the RO
membrane elements. If there is any doubt about the presence of chlorine, perform
chemical testing. Neutralize any chlorine residual with a sodium bisulfite solution,
and ensure adequate mixing and contact time to accomplish complete dechlorination.
Dosing rate is 1.8 to 3.0 ppm sodium bisulfite per 1.0 ppm of free chlorine.
Note: The use of cationic surfactant should be avoided in cleaning solutions,

since irreversible fouling of the membrane elements may occur.
The nature and rapidity of fouling depends on a number of factors, including:
• quality of the feedwater

• system recovery rate
• element flux
Typically, fouling is progressive, and if not controlled early, will impair the RO
membrane element performance in a relatively short time. Cleaning is
recommended when
• RO shows evidence of fouling
• Prior to a long-term shutdown.
It is not recommended to clean the elements unless the data indicates there is
fouling occurring. If there is no fouling occurring, do not clean!
Fouling characteristics that signal the need to clean are:

• A 10-15% decrease in normalized permeate flow.
• A 10-15% increase in normalized permeate quality.
• A 10-15% increase in normalized pressure drop, as measured between
the feed and concentrate headers.
If your facility does not normalize operating data, the site measured values for flows
and pressure can be applied instead of normalized values, providing there are no
major changes in critical operating parameters. The operating parameters which
must remain constant are: feed pressure, permeate back-pressure, recovery,
temperature, and feed TDS. If these operating parameters do fluctuate, it is highly
recommended that data be normalized to determine if fouling is occurring or if the
RO is actually operating normally based on the change in a critical operating
parameter.
Monitoring overall plant performance on a regular basis is an essential step in

recognizing when membrane elements are becoming fouled. Performance is
affected progressively and in varying degrees, depending on the nature of the
foulants. The following table provides a summary of the expected effects that
common foulants have on membrane performance.
Cleaning Frequency
RO cleaning frequency due to fouling will vary by site. It may vary from every 6-12
weeks on a high fouling water to 6 –12 months (or longer) on low fouling waters. If
cleaning is required more than once a month, then a re-evaluation of
the pretreatment stage is justified, with a view to serious improvement and/or a re-
design of the RO operation. If the cleaning frequency is every one to three months,
you may want to focus on improving the operation of your existing equipment, fine
tuning chemical dosage ect.
When to Clean. It is important to clean the membranes before they become heavily
fouled. Allowing the elements to become heavily fouled can impair the effectiveness
of the cleaning chemical. Heavy fouling can prevent full penetration of the foulant
layer by the cleaner, and impede flushing of the foulant from the elements. If
normalized membrane performance drops more than 30 to 50% before cleaning, it
may be impossible to fully restore the performance to baseline conditions.
Permeate Flush
One RO design feature that is commonly over-looked in reducing RO cleaning
frequency is the use of RO permeate water for flushing foulants from the system.
Soaking the RO elements during standby with permeate can help dissolve scale and
loosen precipitates, thereby helping to reduce the frequency of chemical cleaning.
Nature of Foulants
The type of foulant present can and does vary from location to location.
Frequently more than one foulant is present, necessitating both a low pH and high
pH cleaning regimen. Table 1 shows the most usual foulants and types of
membrane damage and their results on RO operation,
Type of Foulant/ Probable Pressure Feed Salt
Problem Location Drop Pressure Passage
Metal Oxide Fouling
(e.g. Fe,Mn,Cu,Ni,Zn) 1st stage lead Rapid Rapid Rapid
elements increase increase Increase
Colloidal Fouling
(organic and/or inorganic
complexes) 1st stage/ lead Gradual Gradual Slight
elements increase increase increase
Mineral Scaling (e.g. Ca,
Mg, Ba, Sr) Last stage/ Moderate Slight Marked
tail elements increase increase increase
Polymerized Silica
Last stage/ Normal to Increased Normal to
tail elements increased increased
Biological Fouling
Any stage, Marked Marked Normal to
usually lead All increase increase increased
Organic Fouling stages Gradual Increased Decrease
(dissolved NOM) d
Increase
Antiscalant Fouling
2nd stage Normal to Increased Normal to
most severe increased increased
Oxidant damage (e.g
Cl2, Ozone,KmnO4) 1st stage Normal to Decreased Increased
most severe decreased
Hydrolysis damage (out
of range pH) All stages Normal to Decreased Increased
decreased
Abrasion damage
(carbon fines, etc) 1st stage Normal to Decreased Increased
most severe decreased
O-ring leaks (at
interconnectors or Random Normal to Normal to Increased
adapters) (typically at decreased decreased
feed adapter)
Glue line leaks
1st stage Increasse
(due to perm pressure > Normal to Normal to
d
feed pressure in service most severe decreased decreased
or standby)
Glue line leaks

(due to closed Tail element Increased Increased Increased
permeate valve while of a stage (based on (based on
cleaning or flushing) prior fouling prior fouling
and high and high
delta P delta P
Note: Pressure Drop is defined as the Feed pressure minus the Concentrate
pressure
Table 1 Types of foulant, and their usual symptoms
Foulant types and effective cleaners
Calcium Carbonate Scale: Calcium carbonate is a mineral scale that may be

deposited from almost any feedwater if there is a failure in the antiscalant/dispersant
addition system or in the acid injection pH control system. An early detection of
calcium carbonate scaling is essential to prevent damage caused by the crystals on
the active membrane layers. Calcium carbonate scale detected early can be
removed by lowering the feedwater pH to between 3.0 and
5.0 for one or two hours. Longer resident accumulations of calcium carbonate
scale can be removed by a low pH cleaning with a citric acid solution.
Calcium, Barium & Strontium Sulfate Scale: Sulfate scale is a much “harder”
mineral scale than calcium carbonate and is therefore more difficult to remove.
Sulfate scale may be deposited if there is a failure in the antiscalant/dispersant
feed system or if there is an over feed of sulfuric acid in pH adjustment. Early
detection of the resulting sulfate scaling is essential to prevent damage caused by
the crystals on the active membrane layers. Barium and strontium sulfate scales
are particularly difficult to remove as they are insoluble in almost all cleaning
solutions. Special care should be taken to prevent their formation.
Calcium Phosphate Scale: This scale is particularly common in municipal

wastewaters and water supplies which may contain high levels of phosphate.
This scale can generally be removed with acidic pH cleaners.
Metal Oxide/Hydroxide Foulants: Typical metal oxide and metal hydroxide

foulants are iron, zinc, manganese, copper, aluminum, etc. They can be the result
of corrosion products from unlined pipes and tanks; from oxidation of the soluble
metal ion with air, chlorine, ozone, potassium permanganate; or from a
pretreatment filter system upset that utilizes iron or aluminum based coagulant
aids. Can generally be removed with low pH cleaners
Polymerized Silica Coating: A silica gel coating resulting from the super-
saturation and polymerization of soluble silica can be very difficult to remove. It
should be noted that this type of silica fouling is different from silica-based colloidal
foulants, which may be associated with either metal hydroxides or organic matter.
Polymerized silica scale can be very difficult to remove by traditional chemical
cleaning methods.
Colloidal Foulants: Colloids are inorganic or mixed inorganic/organic based

particles that are suspended in water and will not settle out due to gravity.
Colloidal matter typically contains one or more of the following major components:
iron, aluminum, silica, sulfur, or organic matter. High pH cleaners are generally
more effective against this type of foulant
Dissolved NOM/ Organic Foulants: The sources of dissolved NOM (Natural

Organic Matter) foulants are typically derived from the decomposition of vegetative
material into surface waters or shallow wells. The chemistry of organic foulants is
very complex, with the major organic components being either humic acid or fulvic
acid. Dissolved NOMs can quickly foul RO membranes by being absorbed onto the
membrane surface. Once absorption has occurred, then a slower fouling process of
gel or cake formation begins. It should be noted that the mechanism of fouling with
dissolved NOM should not be confused with the mechanism of fouling created by
NOM organic material that is bound with colloidal particles. High pH cleaners are
generally more effective against this type of foulant. Please note that wastewaters
may contain a range of naturally occurring and man-made organic compounds.
Should any of these compounds chemically bond to the membrane, cleaning regimes
may be ineffective in removing the foulant.
Microbiological Deposits: Organic-based deposits resulting from bacterial slimes,

fungi, molds, etc. can be difficult to remove, particularly if the feed path is plugged.
Plugging of the feed path makes it difficult to introduce and distribute the cleaning
solutions. To inhibit additional growth, it is important to clean and sanitize not only
the RO system, but also the pretreatment, piping, dead-legs, etc. High pH cleaners
in association with biocide treatments are most effective against this type of
problem.
Selection and Use of Cleaning Chemicals
There are a number of factors involved in the selection of a suitable cleaning

chemical (or chemicals) and proper cleaning protocol. At the time of the first
cleaning, it is recommended to contact:
• Manufacturer of the equipment,

• RO element manufacturer,
• RO specialty chemical and service supplier.
Proper identification of the foulant is essential to prescibe the correct cleaners to

most effectively remove the foulant.
Once the suspected foulant(s) are identified, one or more cleaning chemicals will be
recommended. These cleaning chemical(s) can be:
• Generic (typically technical grade, available from local chemical supply

companies )
• Private-labeled proprietary chemicals.
Independent RO service companies are available who can determine the proper
chemicals and cleaning protocol for your situation by testing a fouled element at
their facility. For difficult situations, this is a recommended option.
It is not unusual to use a number of different cleaning chemicals in a specific

sequence to achieve the optimum cleaning. As foulants may be laid down in
discrete “layers”, the sequence of cleaning can be important.
Typically, a low pH cleaning is first used to remove foulants (such as mineral scale),
followed by a high pH cleaning to remove organic material. This is not always the
case - there are instances where a high pH cleaning may used first to remove
foulants like oil or biological matter, followed by a low pH cleaning. The optimum
sequence can usually only be determined by conducting tests.
Some cleaning solutions are “combination” agents, and may have detergents added
to aid in the removal of heavy biological and organic debris, while others have a
chelating agent like EDTA added to aid in the removal of colloidal, organic and
biological material, as well as sulfate scale. Advice on the best use of such cleaners
is best obtained directly from the manufacturer of the speciality cleaners.
There is no objection to the use of speciality cleaners, providing it has been

adequately demonstrated that the cleaner will not damage the membrane.
General Precautions in Cleaning Chemical Selection and Usage
• If using a proprietary chemical, be sure the chemical has been qualified for
use with the membrane by the chemical supplier. The chemical supplier’s
instructions should not be in conflict with recommended cleaning
parameters and limits.
• Use the mildest cleaning regimen. This includes the cleaning parameters
of pH, temperature, and contact time. This will optimize the useful life of
the membrane.
• Clean at the recommended target temperatures to optimize cleaning
efficiency and membrane life.
• Use the minimal amount of chemical contact time to optimize membrane
life.
• Be prudent in the adjustment of pH at the low and high pH range to extend
the useful life of the membrane. A “gentle” pH range is 4 to 10, while the
harshest is 2 to 12.
• Typically, the most effective cleaning sequence is low pH followed by high
pH solutions. One known exception is oil-fouled membranes should not
use a low pH clean first as the oil will coagulate.
• Cleaning and flushing flows should be in the same direction as the normal
feed flow to avoid potential telescoping and element damage.
• When cleaning a multi-stage RO, the most effective cleaning plan is to

clean one bank/stage at a time so cleaning flow velocities can be
optimized and foulants from upstream stages will not pass through to
downstream stages.
• Flushing detergents with higher pH permeate can reduce any foaming
problems.
• Verify that proper disposal requirements for the cleaning solution are
followed.
•
 If the system has been fouled biologically, consider the extra step of
introducing a sanitizing biocide chemical after a successful cleaning.
Biocides can be introduced
o immediately after cleaning,
o periodically (e.g. once a week),
o continuously during service.
• Ensure that the biocide is compatible with the membrane, does not
create any health risks, is effective in controlling biological activity,
and is not cost prohibitive before going this route.
• Safety Considerations
o Be sure all hoses and piping can handle the temperatures, pressures
and pH which will be encountered during a cleaning.
o Always add chemicals slowly to an agitated batch of make-up water.
o Always wear safety glasses and appropriate protective gear when
working with chemicals.
o Don’t mix concentrated acids with caustic solutions.
st
o Thoroughly rinse the 1 cleaning solution from the RO system before
introducing the next solution.
pH and Temperature Limits for Cleaning
Membrane Type 45 C (113 F) 35 C (95 F) 30 C (86 F)

Brackish 2-10 2-11.5 2-12
Low Pressure
Brackish 2-10 2-11.5 2-12
Seawater 2-10 2-11 2-12
Note: The above cleaning parameters denote the maximum temperature limits for a
corresponding range of pH. Cleaning operations performed at the extremes may
result in a more effective cleaning, but can shorten the useful life of the membrane
due to hydrolysis.effects. To optimize the useful life of a membrane, it is
recommended to use the least harsh cleaning solutions necessary and to minimize
the contact time whenever possible.
Cleaning and Flushing Flow Rates per RO Pressure Tube

(differential Pressures are not to exceed 60 psi (4 bar) across any tube.)
Element Diameter GPM

4-inches 6 to 10 gpm 8-inches 24 to 40 gpm
Elements should be cleaned at the highest flow rate possible without exceeding 60
psi differential pressure limit. Exceeding the limit can result in mechanical damage
to the elements.
Cleaning Solution Volume Requirement per RO Element

(This volume does not include additional volumes required for piping, filters, etc. or
the initial 20% of volume dumped to drain.)
Element Normal Heavy Normal Heavy Fouling
Size Fouling Fouling Fouling
(Gallons) (Gallons) (Liters) (Liters)
4 x 40 in. 2.5 5 9.5 19

8 x 40 in. 9 18 34 68
Cleaning Tank sizing

Required volume of cleaning solution can be estimated as follows:
1. Cleaning solution requirement per element (see above) x number of
elements to be cleaned
Plus
2. Swept volume of connecting pipework to and from cleaning skid
Plus
3. Extra 20% of (1+2) above for first part of cleaning solution sent to drain
RO Cleaning Skid
The successful cleaning of an RO on-site requires a well designed RO cleaning
skid. See Figure 1 for a typical arrangement. The skid may or may not be hard
piped to the RO skid and may use flexible hose for connections to the RO skid. For
a multi-stage RO, it is recommended that each bank/array be cleaned one stage at
a time to optimize cross-flow cleaning velocity.
Cleaning Procedures
The source water for chemical solution make-up and rinsing should be clean RO
permeate or DI water and be free of hardness, transition metals (e.g. iron), and
chlorine..
RO Cleaning Tank:
This tank needs to be sized properly to accommodate the displacement of water in
the hose, piping, and RO elements. (see above).The tank should be designed to:
• Allow 100 % drainage

• easy access for chemical introduction and mixing
• recirculation line from the RO Cleaning Pump,
• proper venting, overflow,
• return line located near the bottom to minimize foam formation when using
a surfactant.
RO Cleaning Pump: This pump needs to be sized to develop the proper cross-flow
velocity to scrub the membrane clean. The maximum recommended pressure is 60
psi (4 bar) at the inlet to the pressure vessels to minimize the production of permeate
during cleaning and so reduce the convective re-deposition of foulant back on the
membrane surface. The table above gives the recommended flow rate ranges for
each pressure tube.
RO Cleaning Cartridge Filter:

Normally 5 to 10-micron and is designed to remove foulants that have been
displaced from the cleaning process. Filter must be located upstream of the RO
elements.
RO Tank Heater or Cooler: The maximum design temperature for cleaning is

113° F (45° C). It should be noted that heat is generated and imparted by the
RO Cleaning Pump during recirculation which can act as a heater,
RO Tank Mixer: This component is recommended for optimal mixing of chemical,

though some designers rely solely on the slow introduction of chemical while
maintaining a recirculation through the RO Cleaning Pump back to the tank.
Instrumentation: Cleaning system instrumentation should be included to monitor

flow, temperature, pressure, and tank level.
Sample Points: Sample valves should be located to allow pH and TDS

measurements off the RO Cleaning Pump discharge and the concentrate side
recirculation return line.
Permeate Return Line:

A small amount of the cleaning solution can permeate through the membranes,
therefore a permeate-side return line back to the RO Cleaning Tank is required.
Important: The permeate line and any permeate valves must always be open to
atmospheric pressure during the cleaning and flushing steps or damage to RO
elements can occur. If the permeate line is closed, the permeate pressure can build
up and become higher than the feed-side pressure of the tail elements. This can
result in excessive permeate back-pressure which can damage the membrane glue
lines in the tail elements.
RO Membrane Element Cleaning and Flushing Procedures
The RO membrane elements can be cleaned in place in the pressure tubes by

recirculating the cleaning solution across the high-pressure side of the membrane
at low pressure and relatively high flow. A cleaning unit is needed to accomplish
this task. See fig 1 for general arrangement.
RO cleaning procedures may vary dependent on the situation. The time required to
clean a stage is from 4 to 8 hours. A general procedure for cleaning the RO
membrane elements is as follows:
1. Perform a low pressure flush at 60 psi (4 bar) or less of the pressure tubes by
pumping clean water from the cleaning tank (or equivalent source) through the
pressure tubes to drain for several minutes. Flush water should be clean water of
RO permeate or DI quality and be free of hardness, transition metals, and
chlorine.
2. Mix a fresh batch of the selected cleaning solution in the cleaning tank. The
dilution water should be clean water of RO permeate or DI quality and be free of
hardness, transition metals, and chlorine. The temperature and pH should be
adjusted to their target levels.
3. Start recirculation. Initially send the displaced water from the system to drain
so y cleaning chemical is not diluted. Then divert the first 20%of the returned
cleaning solution ( the most highly fouled cleaning solution) to drain before
allowing the remaining cleaning solution to recirculate back into the RO Cleaning
Tank. For the first 5 minutes, slowly throttle the flow rate to 1/3 of the maximum
design flow rate. This is to minimize the potential plugging of the feed path with
a large amount of dislodged foulant.. For the second 5 minutes, increase the
flow rate to 2/3 of the maximum design flow rate, and then increase the flow rate
to the maximum design flow rate. If required, readjust the pH back to the target
when it changes more than 0.5 pH units. Circulate the cleaning solution through
the pressure tubes for approximately one hour or as required.
4. An optional soak and recirculation sequence can be used, if required. The

soak time can be from 1 to 8 hours depending on the manufacturer’s
recommendations. Caution should be used to maintain the proper

temperature and pH.
5. Upon completion of the chemical cleaning step, a low pressure cleaning rinse
with clean water (RO permeate or DI quality and free of hardness, transition
metals, and chlorine) is required to remove all traces of chemical from the
Cleaning Skid and the RO Skid. Drain and flush the cleaning tank; then
completely refill the Cleaning Tank with clean water for the Cleaning Rinse. Rinse
the pressure tubes by pumping all of the rinse water from the Cleaning Tank
through the pressure tubes to drain. A second cleaning can be started at this
point, if required.
6. Once the RO system is fully rinsed of cleaning chemical with clean water from
the Cleaning Tank, a final low pressure clean-up flush can be performed using
pretreated feedwater.The permeate line should remain open to drain. Feed
pressure should be less than 60 psi (4bar). This final flush continues until the
flush water flows clean and is free of any foam or residues of cleaning agents.
This usually takes 15 to 60 minutes. The operator should sample the flush water
going to the drain for detergent removal and lack of foaming by using a clear
flask and shaking it. A conductivity meter can be used to test for removal of
cleaning chemicals. The flush water to drain should be within 10-20% of the
feedwater conductivity.A pH meter can also be used to compare the flush water
to drain to the feed pH.
7. Once all the stages of a train are cleaned and the chemicals flushed out, the
RO can be restarted and placed into a Service Rinse. The RO permeate should
be diverted to drain until it meets the quality requirements of the process (e.g.
conductivity, pH, etc.). It is not unusual to take a period from a few hours to a few
days for the RO permeate quality to fully stabilize, especially after high pH or
very low pH cleanings..
DATA Monitoring
Good monitoring of the performance of a system can alert the user to possible fouling before the
situation becomes severe. The practice of entering operational data several times a week into a
normalization program can provide the means to track performance over time. Symptoms of fouling
would include one or all of the following conditions:
 Normalized water flow has decreased by 10-15% from start-up (reference) conditions.
 Delta P, or pressure drop over a stage or the system, has increased by 10-15%.
 Salt rejection has decreased (ie permeate TDS has increased) significantly over time.
Note that it is important to use normalized data. Normalized data corrects for temperature effects on
system performance. For instance, if the temperature drops, it is expected to require more pressure to
achieve the same flow. Loss of flow due solely to a reduction in temperature does not mean the system
is fouled.
Cleaning System Specifications

The following diagram gives the basic parts of an RO cleaning skid. Cleaning solution is pumped from a
storage tank through a cartridge filter to the RO array. Solution is then recycled back to the tank. The
volume of solution should be adequate to fill the volume of the vessels, filters and piping. The diagram
below shows no instrumentation, however, it may be advisable to add a low level switch to the tank to
prevent the pump from running dry. Additionally, a temperature controller and heater/cooler unit may be
added to maintain solution at the optimum temperature range.
Per meate
return
Chem i cal
Mix Ret urn Cartridge
RO Array
Filter
CI P PUMP
CIP Tank
Concentrate
return
Figure 1: Typical Cleaning skid arrangement

SECTION 6
Vendor Literature
Major Component I/O Manuals

GRUNDFOS INSTRUCTIONS
CR, CRI, CRN, CRT

Installation and Operating Instructions
Please leave these instructions with

the pump for future reference
LCPTL003_CR I&O_0705a.indd 1 12/8/2005 10:26:11 AM

SAFETY WARNING
Electrical Work
All electrical work should be performed by a qualified electrician in
accordance with the latest edition of the National Electrical Code,
local codes and regulations.
Shock Hazard
A faulty motor or wiring can cause electrical shock that could be fatal,
whether touched directly or conducted through standing water. For this
reason, proper grounding of the pump to the power supply’s grounding
terminal is required for safe installation and operation.
In all installations, the above-ground metal plumbing should be
connected to the power supply ground as described in Article 250-80
of the National Electrical Code.
Nameplate Data
Type key
CR, CRI, CRN 1s, 1, 3, 5, 10, 15, and 20
CR 3 -10 A FGJ A E HQQE 1 Type designation
Example
1 2 Model, material number,
Type range:
2 production number
CR, CRI, CRN 3 Head in feet at nominal flow
3 4
4 Nominal motor HP
Rated flow rate in [m³/h] (x 5=GPM) 5 6 5 Head at zero flow
Number of impellers 7 8 6 Rated RPM
Code for pump version 9 10 7 Nominal flow
Code for pipe connection 11 8 Rated frequency
9 Maximum pressure and
Code for materials maximum fluid temperature
Code for rubber parts 10 Direction of rotation
11 Production country
Code for shaft seal
CRT 2, 4, 8 and 16
Example CRT 16 - 30 /2 U G A AUUE
Type range:
CRT
Rated flow rate in [m³/h] (x 5=GPM)
Number of stages x 10
Number of impellers (used only Q GPM H FEET RPM
if the pump has fewer impellers
than stages) P HP N PSI °F max
Code for pump version

Code for pipe connection
Code for materials Model Key
Code for shaft seal and
rubber parts
CR, CRN 32, 45, 64, and 90

Example CR 32 -2 -1 U G A E KUHE
Type range:
CR, CRN
Rated flow rate in [m³/h] (x 5=GPM)
Number of impellers
Number of reduced diameter impellers
Code for pump version
Code for pipe connection
Code for materials
Code for rubber pump parts
Code for shaft seal

Codes
Example
Pump version
U FGJ A E HQQE
A *Basic version pump
U *NEMA version pump
B Oversize motor,
one flange size bigger HQQE
Shaft seal
F CR pump for high A O-ring seal with fixed driver
temperatures (Cool-Top™)
B Rubber bellows seal
H Horizontal version
D O-ring seal, balanced
HS High pressure pump with
over-synchronous speed and E Cartridge seal with O-ring
reversed direction of rotation H Balanced cartridge seal with O-ring
I Different pressure rating K Cartridge shaft seal with
K Low NPSH metal bellows
M Magnetic drive O Double seal, back to back
P Undersize motor P Double seal, tandem
R Horizontal version with R O-ring seal with reduced face
bearing bracket X Special version
SF High pressure pump with
reversed chamber stack and B Carbon, synthetic
direction of rotation resin-impregnated
T Oversize motor, H Cemented tungsten carbide,
two flange sizes bigger embedded hybrid
X **Special version Q Silicon carbide
Pipe connection U Cemented tungsten carbide
A Oval flange
B NPT thread E EPDM
C Clamp coupling F FXM (Flouraz®)
CA FlexiClamp K FFKM (Kalrez®)
CX TriClamp V FKM (Viton®)
F DIN flange
G ANSI flange
* In August 2003 the NEMA pump code was
J JIS flange discontinued for all material numbers created
N Changed diameter of ports by GRUNDFOS manufacturing companies in
O Externally threaded, union North America. The NEMA version pump code
P PJE coupling will still remain in effect for existing material
X Special version numbers. NEMA version pumps built in North
Materials America after this change will have either an
A Basic version A or U as the pump version code depending on
D Carbon-graphite filled PTFE
(bearings) the date the material number was created.
G Stainless steel parts of 316 SS ** If a pump incorporates more than two pump
GI Base plate and flanges of versions, the code for the pump version is X.
316 SS
I Stainless steel parts of 304 SS
X also indicates special pump versions not
II Base plate and flange of 304 SS listed above.
K Bronze (bearings)
S SiC bearing ring + PTFE neck
ring (only CR, CRN 32 to 90)
T Titanium
X Special version
Code for rubber parts

E EPDM
F FXM (Flouraz®)
K FFKM (Kalrez®)
V FKM (Viton®)

Pre-installation Checklist
1. Confirm you have the right pump
Read the pump nameplate to make sure it is the one you ordered.
CR — Centrifugal pump with standard cast iron and 304 stainless steel construction
CRI — Centrifugal pump; all parts in contact with water are 304 stainless steel construction
CRN — Centrifugal pump; all parts in contact with water are 316 stainless steel construction
CRT — Centrifugal pump; all parts in contact with water are titanium construction
CRE — Centrifugal pump with a Grundfos MLE VFD motor attached
2. Check the condition of the pump

The shipping carton your pump came in is specially designed around your pump during production to prevent damage. As a
precaution, the pump should remain in the carton until you are ready to install it. Examine the pump for any damage that may have
occurred during shipping. Examine any other parts of the shipment as well for any visible damage.
If the pump is shipped as a complete unit (motor attached to pump end), the position of the coupling (that connects the pump shaft
to the motor shaft) is set at factory specifications. No adjustment is required. If the unit is delivered as a pump end only, follow the
adjustment procedures on pages 11 - 12.
Pump without Motor (CR(I)(N) 1s, 1, 3, 5, 10, 15, and 20 Only): If you purchased a pump without a motor, the shaft seal has been set by
the factory. Do not loosen the three set screws on the shaft seal when attaching the motor.
Pump without Motor (CR(N) 32, 45, 64 & 90 Only): If you purchased a pump without a motor, you must install the seal. The seal is
protected in its own sub boxing within the pump packaging crate. To protect the shaft and bearings during shipment, a shaft holder
protective device is used. This device must be removed prior to installation of the seal. Read the seal installation instructions which
are included in the pump package.
3. Verify electrical requirements

Verification of the electrical supply should be made to be certain the voltage, phase and frequency match that of the pump motor.
The proper operating voltage and other electrical information can be found on the motor nameplate. These motors are designed
to run on ±10% of the nameplate-rated voltage. For dual-voltage motors, the motor should be internally connected to operate on
the voltage closest to the 10% rating, i.e., a 208 voltage motor wired per the 208 volt connection diagram. The wiring connection
diagram can be found on either a plate attached to the motor or on a diagram inside the terminal box cover. If voltage variations are
larger than ±10%, do not operate the pump.
4. Is the application correct for this pump?

Compare the pump’s nameplate data or its performance curve with the application in which you plan to install it. Will it perform the
way you want it to perform? Also, make sure the application falls within the following limits:
Type Designed to pump...
CR Hot and chilled water, boiler feed, condensate return, glycols and solar thermal fluids.
CRI/CRN Deionized, demineralized and distilled water. Brackish water and other liquids unsuitable for
contact with iron or copper alloys. (Consult manufacturer for specific liquid compatibilities.)
CRN-SF High pressure washdown, reverse osmosis, or other high pressure applications.
CRT Salt water, chloride based fluids and fluids approved for titanium.
Operating Conditions
Pump Fluid Temperatures
CR(I)(N) 1s, 3, 5, 10, 15, and 20 -4 to +248°F (-20 to +120°C)

*CR(N) 32, 45, 64, and 90 -22 TO +248°F (-30 TO +120°C)
CRT 2, 4, 8, 16 -4 to +248°F (-20 to +120°C)
CRN-SF -4 to +221°F (-15 to +105°C)
with Cool-Top™ up to +356°F (+180°C)
All motors are designed for continuous duty in +104°F (+40°C) ambient air conditions. For higher ambient temperature conditions
consult Grundfos.
* xUBE Shaft Seals are recommended for temperatures above +200°F. Pumps with hybrid shaft seals can only operate up to
+200°F (+90°C). Pumps with xUUE shaft seals can be operated down to -40°F (-40°C) (where “x” is the seal type).

Pre-installation Checklist (continued)
Minimum Inlet Pressures Maximum Operating Pressures
All CR, CRI, CRN NPSHR + 2 feet at 250°F (194°F for CRN-SF)
CRN-SF 29 psi (2 bar)
50 Hz 60 Hz Max.
Maximum Inlet Pressures Pump Type/Connection Stages Stages psi /bar
50 Hz 60 Hz Max. CR, CRI, CRN 1s
Pump Type/Connection Stages Stages psi /bar Oval flange 1 to 23 1 to 17 232 / 16
CR, CRI, CRN 1s 2 to 36 2 to 36 145 / 10 FGJ, PJE 1 to 36 1 to 27 362 / 25
27 217 / 15 CR, CRI, CRN 1
CR, CRI, CRN 1 2 to 36 2 to 36 145 / 10 Oval flange 1 to 23 1 to 17 232 / 16
27 217 / 15 FGJ, PJE 1 to 36 1 to 27 362 / 25
CR, CRI, CRN 3 2 to 29 2 to 15 145 / 10 CR, CRI, CRN 3
31 to 36 17 to 25 217 / 15 Oval flange 1 to 23 1 to 17 232 / 16
CR, CRI, CRN 5 3 to 16 2 to 9 145 / 10 FGJ, PJE 1 to 36 1 to 27 362 / 25
18 to 36 10 to 24 217 / 15 CR, CRI, CRN 5
CR, CRI, CRN 10 1 to 6 1 to 5 116 / 8 Oval flange 1 to 22 1 to 16 232 / 16
7 to 22 6 to 18 145 / 10 FGJ, PJE 1 to 36 1 to 24 362 / 25
CR, CRI, CRN 15 1 to 3 1 to 2 116 / 8 CR, CRI, CRN 10
4 to 17 3 to 12 145 / 10 Oval flange 1 to 10 145 / 10
CR, CRI, CRN 20 1 to 3 1 116 / 8 Oval flange 1 to 16 232 / 16
4 to 17 2 to 10 145 / 10 FGJ, GJ, PJE 1 to 16 1 to 10 232 / 16
CR, CRN 32 1-1 to 4 1-1 to 2 58 / 4 FGJ, GJ, PJE 17 to 22 12 to 17 362 / 25
5-2 to 10 3-2 to 6 145 / 10 CR, CRI, CRN 15
11 to 14 7-2 to 11-2 217 / 15 Oval flange 1 to 7 1 to 5 145 / 10
FGJ, GJ, PJE 1 to 10 1 to 8 232 / 16
CR, CRN 45 1-1 to 2 1-1 to 1 58 / 4
FGJ, GJ, PJE 12 to 17 9 to 12 362 / 25
3-2 to 5 2-2 to 3 145 / 10
CR, CRI, CRN 20
6-2 to 13-2 4-2 to 8-1 217 / 15
Oval flange 1 to 7 1 to 5 145 / 10
CR, CRN 64 1-1 to 2-2 1-1 58 / 4
FGJ, GJ, PJE 1 to 10 1 to 7 232 / 16
2-1 to 4-2 1 to 2-1 145 / 10
FGJ, GJ, PJE 12 to 17 8 to 10 362 / 25
4-1 to 8-1 2 to 5-2 217 / 15
CR, CRN 32 1-1 to 7 1-1 to 5 232 / 16
CR, CRN 90 1-1 to 1 58 / 4
8-2 to 12 6-2 to 8 362 / 25
2-2 to 3-2 1-1 to 1 145 / 10
13-2 to 14 9-2 to 11-2 580 / 40
3 to 6 2-2 to 4-1 217 / 15
CR, CRN 45 1-1 to 5 1-1 to 4-2 232 / 16
CRT 2 2 to 11 2 to 6 145 / 10 6-2 to 9 4-1 to 6 362 / 25
13 to 26 7 to 18 217 / 15
10-2 to 13-2 7-2 to 8-1 580 / 40
CRT 4 1 to 12 1 to 7 145 / 10 CR, CRN 64 1-1 to 5 1-1 to 3 232 / 16
14 to 22 8 to 16 217 / 15 6-2 to 8-1 4-2 to 5-2 362 / 25
CRT 8 1 to 20 1 to 16 145 / 10 CR, CRN 90 1-1 to 4 1-1 to 3 232 / 16
CRT 16 2 to 16 2 to 10 145 / 10 5-2 to 6 4-2 to 4-1 362 / 25
CRN-SF all all 72 / 5* CRT 2 2 to 26 2 to 18 305 / 21
362 / 25** CRT 4 1 to 22 1 to 16 305 / 21
* while pump is off or during start-up CRT 8 1 to 12 1 to 8 232 / 16
** during operation 14 to 20 10 to 16 362 / 25
CRT 16 1 to 8 1 to 8 232 / 16
10 to 16 10 to 12 362 / 25
Consult Grundfos for other working conditions.

Select pump location
The pump should be located in a dry, well-ventilated area which is not subject to freezing or extreme variation in temperature. Care must be taken
to ensure the pump is mounted at least 6 inches (150 mm) clear of any obstruction or hot surfaces. The motor requires an adequate air supply
to prevent overheating and adequate vertical space to remove the motor for repair. For open systems requiring suction lift the pump should be
located as close to the water source as possible to reduce piping losses.
Foundation
Concrete or similar foundation material should be used to provide a secure, stable
mounting base for the pump. Bolt hole center line dimensions for the various pump
types are given in Figure 1, page 6. Secure the pump to the foundation using all four
bolts and shim pump base to assure the pump is vertical and all four pads on the base are
properly supported. Uneven surfaces can result in pump base breakage when mounting
bolts are tightened.
The pump can be installed vertically or horizontally (see drawing at right). Ensure that
an adequate supply of cool air reaches the motor cooling fan. The motor must never fall
below the horizontal plane.
Arrows on the pump base show the direction of flow of liquid through the pump.
To minimize possible noise from the pump, it is advisable to fit expansion joints on
either side of the pump and anti-vibration mountings between the foundation and the pump.
Isolating valves should be fitted either side of the pump to avoid draining the system if the pump needs to be cleaned, repaired or replaced.

Pipework
Figure 1: Bolt Hole Centers
CR(I)(N) 1s, 1, 3, 5 & CRT 2, 4
NOTE: The CR, CRI, CRN pumps are shipped with covered suction and discharge.
8 11/16" (220mm) Max The covers must be removed before the final pipe flange to pump connections
7 1/16" (180mm)
are made.
Recommended installation torques
Max
3 15/16" (100mm)
Recommended Recommended
15/16" (150mm)
(4) 1/2" HOLES Model
(13mm) foundation torque (ft.- lbs) flange torque (ft.- lbs)
CR, CRI, CRN 1s/1/3/5, CRT 2/4 30 37 - 44
5
CR, CRI, CRN 10/15/20, CRT 8/16 37 44 - 52
CR, CRN 32/45/64/90 32 52 - 59
CR(I)(N) 10, 15, 20 & CRT 8, 16 CR(N)(X) 2, 4,
10 1/16" (256mm) Max. 8 1/4" (210mm)
8 1/2" (215mm) 7 1/16" (180mm)

Flooded Suction Suction Lift*
(150mm) Max
7 7/8" (200mm) Max
Figure 2 Figure 3
5 1/8" (130mm)
3 15/16" (100mm)
(4) 1/2" HOLES (4) 1/2" HOLES
(13mm) (13mm)
15/16"
5
CR(N) 32
11 3/4" (298mm)
9 7/16" (240mm)
(170mm)
(226mm)
(4) 9/16" HOLES

(14mm)
* CRN-SF pumps cannot be used for suction lift. The suction
11/16"
7/8"
pipe should have a fitting on it for priming.

8
6
Suction pipe
CR(N) 45, 64 The suction pipe should be adequately sized and run as straight and short as possible to keep friction
13" (331mm) losses to a minimum (minimum of four pipe diameters straight run prior to the suction flange). Avoid using
10 1/2" (266mm) unnecessary fittings, valves or accessory items. Butterfly or gate valves should only be used in the suction
line when it is necessary to isolate a pump because of a flooded suction condition. This would occur if the
water source is above the pump. See Figures 2 and 3. Flush piping prior to pump installation to remove loose
(251mm)
7 1/2" (190mm)
(4) 9/16" HOLES

debris.
(14mm)
7/8"
Minimum suction pipe sizes

9
The following recommended suction pipe sizes are the smallest sizes which should be used with any
CR(N) 90
specific CR pump type. The suction pipe size should be verified with each installation to ensure good
13 3/4" (348mm)
pipe practices are being observed and excess friction losses are not encountered. High temperatures may
require larger diameter pipes to reduce friction and improve NPHSA.
11" (280mm)
CR(I)(N) 1s, 1, 3, CRT 2 1” Nominal diameter sch 40 pipe

CR(I)(N) 5, CRT 4 1 1/4” Nominal diameter sch 40 pipe
10 5/16" (261mm)
7 7/8" (199mm)
(4) 9/16" HOLES

CR(I)(N) 10, 15, 20, CRT 8, 16 2” Nominal diameter sch 40 pipe
(14mm)
CR(N) 32 2 1/2” Nominal diameter sch 40 pipe
CR(N) 45 3” Nominal diameter sch 40 pipe
Discharge piping
It is suggested that a check valve and isolation valve be installed in the discharge pipe. Pipe, valves and
fittings should be at least the same diameter as the discharge pipe or sized in accordance with good piping
practices to reduce excessive fluid velocities and pipe friction losses. Pipe, valves and fittings must have a
pressure rating equal to or greater than the maximum system pressure. Before the pump is installed it is
recommended that the discharge piping be pressure checked to at least the maximum pressure the pump
is capable of generating or as required by codes or local regulations.
Whenever possible, avoid high pressure loss fittings, such as elbows or branch tees directly on either side of
the pump. The piping should be adequately supported to reduce thermal and mechanical stresses on the
pump. Good installation practice recommends the system be thoroughly cleaned and flushed of all foreign
materials and sediment prior to pump installation. Furthermore, the pump should never be installed at
the lowest point of the system due to the natural accumulation of dirt and sediment. If there is excessive
sediment or suspended particles present, it is advised a strainer or filter be used. Grundfos recommends
that pressure gauges be installed on inlet and discharge flanges or in pipes to check pump and system
performance.


NOTE: To avoid problems with waterhammer, fast closing valves must not be used in CRN-SF applications.
Table A
Minimum Continuous Duty Flow Rates for CR(I)(N)(T)
min°F to 176°F at 210°F at 248°F at 356°F
Pump Type
min°C to 80°C at 99°C at 120°C at 180°C
CR, CRI, CRN 1s 0.5 0.7 1.2 1.2*
CR, CRI, CRN 1 0.9 1.3 2.3 2.3*
CR, CRI, CRN 3 1.6 2.4 4.0 4.0*
CR, CRI, CRN 5 3.0 4.5 7.5 7.5*
CR, CRI, CRN 10 5.5 8.3 14 14*
CR, CRI, CRN 15 9.5 14 24 24*
CR, CRI, CRN 20 11 17 28 28*
CR, CRN 32 14 21 35 35*
CR, CRN 45 22 33 55 55*
CR, CRN 64 34 51 85 85*
CR, CRN 90 44 66 110 110*
CRT 2 1.3 2.0 3.3 N/A
CRT 4 3.0 4.5 7.5 N/A
CRT 8 4.0 6.0 10 N/A
CRT 16 8.0 12 20 N/A
Grundfos Cool-Top is only available in the following pump types.
*
Pump Type CR 1s CR 1 CR 3 CR 5 CR 10 CR 15 CR 20 CR 32 CR 45 CR 64 CR 90
Standard (CR) • • • •
I Version (CRI) • • • • • • •
N Version (CRN) • • • • • • • • • • •
Check valves
A check valve may be required on the discharge side of the pump to prevent the pump’s inlet pressure from being exceeded. For example,
if a pump with no check valve is stopped because there is no demand on the system (all valves are closed), the high system pressure on the
discharge side of the pump will “find” its way back to the inlet of the pump. If the system pressure is greater than the pump’s maximum inlet
pressure rating, the limits of the pump will be exceeded and a check valve needs to be fitted on the discharge side of the pump to prevent this
condition. This is especially critical for CRN-SF applications because of the very high discharge pressures involved. As a result, most CRN-SF installations
require a check valve on the discharge piping.
Bypass
A bypass should be installed in the discharge pipe if there is any possibility the pump may operate against a closed valve in the discharge line. Flow
through the pump is required to ensure adequate cooling and lubrication of the pump is maintained. See Table A for minimum flow rates. Elbows
should be a minimum of 12” from the orifice discharge to prevent erosion.
Temperature rise
It may sometimes be necessary to stop the flow through a pump during operation. At Time for Temperature
Pump Rise of 18° F (10°C)
shut-off, the power to the pump is transferred to the pumped liquid as head, causing Type
Seconds Minutes
a temperature rise in the liquid. The result is risk of excess heating of and consequent
damage to the pump. The risk depends on the temperature of the pumped liquid and CR 1s, 1, 3 210 3.5
for how long the pump is operating without flow. (See temperature rise chart.) CR 5 240 4.0
CR 10 210 3.5
Conditions/Reservations CR 15 150 2.5
The listed times are subject to the following conditions/reservations:
CR 20 120 2.0
• No exchange of heat with the surroundings.
Btu kJ CR 32, 45, 64, 90 60 1.0
• The pumped liquid is water with a specific heat of 1.0 lb.°F (4.18 kg°C ).
• Pump parts (chambers, impellers and shaft) have the same thermal capacity as water.
• The water in the base and the pump head is not included.
These reservations should give sufficient safety margin against excessive temperature rise.
The maximum temperature must not exceed the pump maximum rating.

Electrical
WARNING
THE SAFE OPERATION OF THIS PUMP REQUIRES THAT IT BE GROUNDED IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE AND LOCAL
GOVERNING CODES OR REGULATIONS. CONNECT THE GROUND WIRE TO THE GROUNDING SCREW IN THE TERMINAL BOX AND THEN TO
THE ACCEPTABLE GROUNDING POINT.
All electrical work should be performed by a qualified electrician in accordance with the latest edition of the National Electrical Code, local codes
and regulations.
Motor
Grundfos CR pumps are supplied with heavy-duty 2-pole (3600 RPM nominal), ODP or TEFC, NEMA C frame motors selected to our rigid
specifications. Motors with other enclosure types and for other voltages and frequencies are available on a special-order basis. CRN-SF pumps
are supplied with an IEC (metric) type motor with a reverse thrust bearing. If you are replacing the pumping unit, but are using a motor
previously used on another CR pump, be sure to read the “Motor Replacement” section on page 11 for proper adjustment of the coupling height.
Position of Terminal Box Figure 4

The motor terminal box can be turned to any of four positions in 90° steps. To rotate the terminal Motor Terminal Box Positions
box, remove the four bolts securing the motor to the pump but do not remove the shaft coupling; (Top View)
turn the motor to the desired location; replace and securely tighten the four bolts. See Figure 4.
Field Wiring
Wire sizes should be based on the current carrying properties of a conductor as required by the
latest edition of the National Electrical Code or local regulations. Direct on line (D.O.L.) starting
is approved due to the extremely fast run-up time of the motor and the low moment of inertia
of pump and motor. If D.O.L. starting is not acceptable and reduced starting current is required,
an auto transformer, resistant starter or soft start should be used. It is suggested that a fused
disconnect be used for each pump where service and standby pumps are installed.
Motor Protection
1. Single-Phase Motors:
With the exception of 10 HP motors which require external protection, single-phase CR pumps are equipped with multi-voltage, squirrel-cage
induction motors with built-in thermal protection.
2. Three-Phase Motors
CR pumps with three-phase motors must be used with the proper size and type of motor-starter to ensure the motor is protected against
damage from low voltage, phase failure, current imbalance and overloads. A properly sized starter with manual reset and ambient-
compensated extra quick trip in all three legs should be used. The overload should be sized and adjusted to the full-load current rating of the motor.
Under no circumstances should the overloads be set to a higher value than the full load current shown on the motor nameplate. This will void the
warranty. Overloads for auto transformers and resistant starters should be sized in accordance with the recommendations of the manufacturer.
Three phase MLE motors (CRE-Pumps) require only fuses as a circuit breaker. They do not require a motor starter. Check for phase imbalance
(worksheet is provided on page 17).
NOTE: Standard allowable phase imbalance difference is 5%.
3. CRN-SF
The CRN-SF is typically operated in series with a feed pump. Because the maximum allowable inlet pressure of the CRN-SF increases from 73
psi (when pump is off and during start-up) to 365 psi (during operation), a control device must be used to start the CRN-SF pump one second
before the feed pump starts. Similarly, the CRN-SF must stop one second after the feed pump stops.

Starting the Pump the First Time
Figure 5a
Priming
To prime the pump in a closed system or an open system where the water source is
above the pump, close the pump isolation valve(s) and open the priming plug on the Priming Vent Plug
CR(I)(N) 1s, 1, 3, 5, 10, 15, 20
pump head. See Figures 5a, 5b, and 5d. Gradually open the isolation valve in the suction CRT 2, 4, 8, 16
line until a steady stream of airless water runs out the priming port. Close the plug and Figure 5c
securely tighten. Completely open the isolation valves. For pumps with Cool-Top, see Suction Discharge
page 14.
In open systems where the water level is below the pump inlet, the suction pipe and pump must
be filled and vented of air before starting the pump. Close the discharge isolation valve and remove Drain Plug
the priming plug. Pour water through the priming hole until the suction pipe and pump are com-
pletely filled with water. If the suction pipe does not slope downward from the pump toward
the water level, the air must be purged while being filled. Replace the priming plug and securely tighten.
1. Switch power off.
2. Check to make sure the pump has been filled and vented.
3. Remove the coupling guard and rotate the pump shaft by hand to be certain it turns freely.
4. Verify that the electrical connections are in accordance with the wiring diagram on the motor. Figure 5b
5. Switch the power on and observe the direction of rotation. When viewed from the top, the pump
should rotate counter-clockwise (clockwise for CRN-SF).
6. To reverse the direction of rotation, first switch OFF the supply power.
7. On three-phase motors, interchange any two power leads at the load side of the starter.
On single-phase motors, see connection diagram on nameplate. Change wiring as required.
8. Switch on the power and again check for proper motor rotation. Once rotation has been
verified, switch off power again. Do not attempt to reinstall the coupling guards with the
motor energized. Replace the coupling guard if the rotation is correct. After guards are in
place the power can be reapplied.
Note - CR, CRI, CRN 1s to 5: For these pumps, it is advisable to open the bypass valve (Figure 5c)
during start-up. The bypass valve connects the suction and discharge sides of the pump, thus
making the filling procedure easier. When the operation is stable, the bypass valve must be closed.
NOTE: Motors should not be run unloaded or uncoupled from

the pump at any time; damage to the motor bearings will occur.

REMINDER: Do not start the pump before priming or venting the pump
(Figure 5d). Never operate the pump dry.
Operating Parameters Figure 5d

CR multi-stage centrifugal pumps installed in accordance with these instructions and
sized for correct performance will operate efficiently and provide years of service. The pumps are water-lubricated and do not require
any external lubrication or inspection. The motors may require periodic lubrication as noted in the following Maintenance Section.
Under no circumstances should the pump be operated for any prolonged periods of time without flow through the pump. This can result in motor
and pump damage due to overheating. A properly sized relief valve should be installed to allow sufficient water to circulate through the pump to
provide adequate cooling and lubrication of the pump bearings and seals.
Pump Cycling
Pump cycling should be checked to ensure the pump is not starting more than:
20 times per hour on 1/3 to 5 HP models
15 times per hour on 7 1/2 to 15 HP models
10 times per hour on 20 to 60 HP models
Rapid cycling is a major cause of premature motor failure due to increased heat build-up in the motor. If necessary, adjust controls to reduce the
frequency of starts and stops.
Boiler-feed installations
If the pump is being used as a boiler-feed pump, make sure the pump is capable of supplying sufficient water throughout its entire evaporation and
pressure ranges. Where modulating control valves are used, a bypass around the pump must be installed to ensure pump lubrication (see “Minimum
Continuous Duty Flow Rates”).
Freeze Protection
If the pump is installed in an area where freezing could occur, the pump and system should be drained during freezing temperatures to avoid
damage. To drain the pump, close the isolation valves, remove the priming plug and drain plug at the base of the pump. Do not replace the plugs
until the pump is to be used again. Always replace the drain plug with the original or exact replacement. Do not replace with a standard plug. Internal
recirculation will occur, reducing the output pressure and flow.

Motor Inspection
Inspect the motor at regular intervals, approximately every 500 hours of operation or every three months, whichever occurs first. Keep the motor
clean and the ventilation openings clear. The following steps should be performed at each inspection:
WARNING:
DO NOT TOUCH ELECTRICAL CONNECTIONS BEFORE YOU FIRST ENSURE THAT POWER HAS BEEN DISCONNECTED. ELECTRICAL SHOCK CAN
CAUSE SERIOUS OR FATAL INJURY. ONLY QUALIFED PERSONNEL SHOULD ATTEMPT INSTALLATION, OPERATION, AND MAINTENANCE OF THIS
EQUIPMENT.
1. Check that the motor is clean. Check that the interior and exterior of the motor is free of dirt, oil, grease, water, etc. Oily vapor, paper,
pulp, textile lint, etc. can accumulate and block motor ventilation. If the motor is not properly ventilated, overheating can occur and
cause early motor failure.
2. Use an Ohmmeter (“Megger”) periodically to ensure that the integrity of the winding insulation has been maintained. Record the
Ohmmeter readings. Immediately investigate any significant drop in insulation resistance.
3. Check all electrical connectors to be sure that they are tight.
Motor Lubrication
Electric motors are pre-lubricated at the factory and do not require additional lubrication at start-up. Motors without external grease fittings have
sealed bearings that cannot be re-lubricated. Motors with grease fittings should only be lubricated with approved types of grease. Do not over-
grease the bearings. Over greasing will cause increased bearing heat and can result in bearing/motor failure. Do not mix petroleum grease and
silicon grease in motor bearings.
Bearing grease will lose its lubricating ability over time, not suddenly. The lubricating ability of a grease (over time) depends primarily on the type of
grease, the size of the bearings, the speed at which the bearings operate and the severity of the operating conditions. Good results can be obtained
if the following recommendations are used in your maintenance program. It should also be noted that pumps with more stages, pumps running to
the left of the performance curve, certain pump ranges may have higher thrust loads. Pumps with high thrust loads should be greased according to
the next service interval level.
If pump is fitted with a bearing flange that requires grease, see the stickers on either the bearing flange or coupling guards for proper grease type
and greasing schedule.
Ambient
Severity Temperature Atmospheric Approved Types
Environment
of Service (Maximum) Contamination of Grease
Standard +104°F (+40°C) Clean, little corrosion Grundfos ML motors are greased
for life or will have the grease
Severe +122°F (+50°C) Moderate dirt, corrosion type on the nameplate. Baldor
>+122°F (+50°C) Severe dirt, abrasive motors are greased with Polyrex
Extreme EM (Exxon Mobile).
or Class H insulation dust, corrosion
Motor Lubrication Schedule (for Motors with Grease Nipples)

New motors that have been stored for a year or more should be regreased.
Standard Severe Extreme Weight of Volume of

NEMA/(IEC) Service Service Service Grease to Add Grease to Add
Frame Size Interval Interval Interval Oz./(Grams) 3
In /(Teaspoons)
Up through 210 (132) 5500 hrs. 2750 hrs. 550 hrs. 0.30 (8.4) 0.6 (2)
Over 210 through 280 (180) 3600 hrs. 1800 hrs. 360 hrs. 0.61 (17.4)* 1.2 (3.9)*
Over 280 up through 360 (225) 2200 hrs. 1100 hrs. 220 hrs. 0.81 (23.1)* 1.5 (5.2)*
Over 360 (225) 2200 hrs. 1100 hrs. 220 hrs. 2.12 (60.0)* 4.1 (13.4)*
*The grease outlet plug MUST be removed before adding new grease.
Procedure
CAUTION:
TO AVOID DAMAGE TO MOTOR BEARINGS, GREASE MUST BE KEPT FREE OF DIRT. FOR AN EXTREMELY DIRTY ENVIRONMENT, CONTACT
GRUNDFOS, THE MOTOR MANUFACTURER OR AN AUTHORIZED SERVICE CENTER FOR ADDITIONAL INFORMATION. MiXING DISSIMILAR
GREASE IS NOT RECOMMENDED.
1. Clean all grease fittings. If the motor does not have grease fittings, the bearing is sealed and cannot be greased externally.
2. If the motor is equipped with a grease outlet plug, remove it. This will allow the old grease to be displaced by the new grease.
3. If the motor is stopped, add the recommended amount of grease. If the motor is to be greased while running, a slightly greater
quantity of grease will have to be added.
NOTE: If new grease does not appear at the shaft hole or grease outlet plug, the outlet passage may be blocked. At the next service
interval the bearings must be repacked.
Add grease SLOWLY taking approximately one minute until new grease appears at the shaft hole in the endplate or grease outlet plug.
Never add more than 1-1/2 times the amount of grease shown in the lubrication schedule.
4. For motors equipped with a grease outlet plug, let the motor run for 20 minutes before replacing the plug.
10

Preventative Maintenance
At regular intervals depending on the conditions and time of operation, the following checks should be made:
1. Pump meets required performance and is operating smoothly and quietly.
2. There are no leaks, particularly at the shaft seal.
3. The motor is not overheating.
4. Remove and clean all strainers or filters in the system.
5. Verify the tripping of the motor overload protection.
6. Check the operation of all controls. Check unit control cycling twice and adjust, if necessary.
7. If the pump is not operated for unusually long periods, the unit should be maintained in accordance with these instructions. In addition,
if the pump is not drained, the pump shaft should be manually rotated or run for short periods of time at monthly intervals.
8. To extend the pump life in severe duty applications, consider performing one of the following actions:
- Drain the pump after each use.
- Flush the pump , through system, with water or other fluid that is compatible with the pump materials and process liquid.
- Disassemble the pump liquid components and thoroughly rinse or wash them with water or other fluid that is compatible with the
pump materials and process liquid.
If the pump fails to operate or there is a loss of performance, refer to the Troubleshooting Section on pages 15 - 16.
Motor Replacement
If the motor is damaged due to bearing failure, burning or electrical failure, the following instruc-
tions detail how to remove the motor for replacement. It must be emphasized that motors used on
Figure 6
CR pumps are specifically selected to our rigid specifications. Replacement motors must be of the CRT 2, 4, 8, and 16
same frame size, should be equipped with the same or better bearings and have the same service
factor. Failure to follow these recommendations may result in premature motor failure.
Disassembly
1. Turn off and lock out power supply. The power supply wiring can not be safely
disconnected from the motor wires.
2. Remove the coupling guards.
CR 1s, 1, 3, 5, 10, 15, and 20: do not loosen the three shaft seal securing allen screws.
3. Using the proper metric Allen wrench, loosen the four cap screws in the coupling. • Note the clearance
Completely remove coupling halves. On CR1s-CR20, the shaft pin can be left in the pump below the coupling
shaft. CR(N)32, 45, 64 and 90 do not have a shaft pin. • Raise the coupling
higher, as far as it
4. With the correct size wrench, loosen and remove the four bolts which hold the motor will go.
to the pump end. • Lower it halfway back
down (1/2 the distance
5. Lift the motor straight up until the shaft has cleared the motor stool. you just raised it).
• Tighten screws
(see torque specifica-
tions below)
Assembly
1. Remove key from motor shaft, if present, and discard.
2. Thoroughly clean the surfaces of the motor and pump end mounting flange. The motor and shaft must be clean of all oil/grease and
other contaminants where the coupling attaches. Set the motor on the pump end.
3. Place the terminal box in the desired position by rotating the motor.
4. Insert the mounting bolts, then diagonally and evenly tighten. For 3/8” bolts (1/2 to 2 HP), torque to 17 ft.-lbs., for 1/2” bolts (3 to 40 HP)
torque to 30 ft.-lbs., and for 5/8” bolts (50 - 60 HP) torque to 59 ft.-lbs.
5. CR 1s, 1, 3, and 5:
Insert shaft pin into shaft hole. Reinstall the coupling halves onto shaft and shaft pin. Reinstall the coupling screws and leave loose.
Check that the gaps on either side of the coupling are even, and that the motor shaft keyway is centered in the coupling half, as shown
in Figure 6a, page 12. Tighten the screws to the correct torque.
CR 10, 15 and 20:
Insert shaft pin into shaft hole. Insert plastic shaft seal spacer beneath shaft seal collar. Reinstall the coupling halves onto shaft and
shaft pin. Reinstall the coupling screws and leave loose. Check that the gaps on either side of the coupling are even and that the motor shaft
key way is centered in the coupling half, as shown in Figure 6a, page 12. Tighten the screws to the correct torque. Remove plastic shaft seal
spacer and hang it on inside of coupling guard.
CRT 2, 4, 8 and 16:
Reinstall coupling halves. Make sure the shaft pin is located in the pump shaft. Put the cap screws loosely back into the coupling halves.
Using a large screwdriver, raise the pump shaft by placing the tip of the screwdriver under the coupling and carefully elevating the
coupling to its highest point (see Figure 6). Note: the shaft can only be raised approximately 0.20 inches (5mm). Now lower the shaft half
way back down the distance you just raised it and tighten the coupling screws (finger tight) while keeping the coupling separation equal on
both sides. When the screws are tight enough to keep the couplings in place, then torque the screws evenly in a criss-cross pattern.
11

CR(N) 32, 45, 64 & CR90: Torque Specifications
Place the plastic adjustment fork under the cartridge seal collar (see Figure 7). CR(I)(N) 1s, 1, 3, 5, 10, 15, and 20
CRT 2, 4, 8, and 16
Fit the coupling on the shaft so that the top of the pump shaft is flush with the bottom
of the clearance chamber in the coupling (see Figure 8). Coupling Min. Torque
Bolt Size Specifications
Lubricate the coupling screws with an anti-seize and lubricating compound. Tighten
M6 . . . . . . . . . . . . 10 ft-lbs.
the coupling screws (finger tight) while keeping the coupling separation equal on both
sides and the motor shaft keyway centered in the coupling half as shown in Figure 6a. M8 . . . . . . . . . . . . 23 ft-lbs.
M10. . . . . . . . . . . 46 ft-lbs.
When the screws are tight enough to keep the couplings in place,
CORRECT
then torque the screws evenly in a crisscross pattern.
Figure 6a
Torque coupling screws to 62 ft.-lbs. Remove the adjustment fork Top
from under the cartridge seal collar and replace it to the storage View All CR(I)(N)(X)(T)
location (see Figure 9). Keyway Keyway
Gap between coupling
6. Check to see that the gaps between the coupling halves are equal.
Loosen and readjust, if necessary.
7. Be certain the pump shaft can be rotated by hand. If the shaft cannot be rotated or it
binds, disassemble and check for misalignment.
8. Prime the pump.
9. Follow the wiring diagram on the motor label for the correct motor wiring combina-
tion which matches your supply voltage. Once this has been confirmed, reconnect
the power supply wiring to the motor.
CORRECT NOT CORRECT
10. Check the direction of rotation, by bump-starting the motor. Rotation must be left
to right (counter-clockwise) when looking directly at the coupling.
11. Shut off the power, then re-install the coupling guards. After the coupling guards have Figure 7
been installed the power can be turned back on.
CR(N) 32, 45, 64, 90
Parts List
For each CR pump model Grundfos offers an extensive Parts List and diagram of part used in
that pump and is recommended to have on hand for future maintenance. In addition, the list-
ings also provide information about prepackaged Service Kits for those pump components most
likely to exhibit wear over time, as well as the complete Impeller Stack needed to replace the
“guts” of each model. These Parts Lists are available separately from the Grundfos literature
warehouse or as a set with extensive service instructions in the Grundfos CR Service Manuals
(for a small charge).
Left, prepackaged impeller stacks

ready for immediate installation; Figure 8
right, prepackaged flange kits.
Spare Parts NOTE: To avoid damaging the coupling halves,

Grundfos offers an extensive list of spare parts. For a current list of these parts, refer to: “All ensure that no portion of the keyway on the
Product Spare Parts/Service Kits” Price List, Form # L-SK-SL-002. motor shaft lies within the gap between the
two coupling halves.
Figure 9
12

WARNING:
WHEN WORKING WITH ELECTRICAL CIRCUITS, USE CAUTION TO AVOID ELECTRICAL SHOCK. IT IS RECOMMENDED THAT
RUBBER GLOVES AND BOOTS BE WORN, AND METAL TERMINAL BOXES AND MOTORS ARE GROUNDED BEFORE ANY WORK
IS DONE. FOR YOUR PROTECTION, ALWAYS DISCONNECT THE PUMP FROM ITS POWER BEFORE HANDLING.
Preliminary tests
Supply How to measure What it means
voltage Use a voltmeter, (set to the proper scale) When the motor is under load, the
measure the voltage at the pump terminal voltage should be within ±10% of the
box or starter. nameplate voltage. Larger voltage varia-
tion may cause winding damage.
On single-phase units, measure between
power leads L1 and L2 (or L1 and N for 115 Large variations in the voltage
volt units). On three-phase units, measure indicate a poor electrical supply and the
between: pump should not be operated until these
variations have been corrected.
• Power leads L1 and L2
If the voltage constantly remains high or
• Power leads L2 and L3
low, the motor should be changed to the
• Power leads L3 and L1 correct supply voltage.
Current How to Measure What it Means

measurement Use an ammeter, (set on the proper scale) to If the amp draw exceeds the listed service
measure the current on each power lead at factor amps (SFA) or if the current imbal-
the terminal box or starter. See the motor ance is greater than 5% between each leg
nameplate for amp draw information. on three-phase units, check the following:
Current should be measured when the pump 1. Burned contacts on motor starter.
is operating at constant discharge pressure. 2. Loose terminals in starter or terminal
box or possible wire defect.
3. Too high or too low supply voltage.
4. Motor windings are shorted or
grounded. Check winding and insula-
tion resistances.
5. Pump is damaged causing a motor
overload.
Insulation How to Measure What it Means

Resistance Turn off power and disconnect the sup- Motors of all HP, voltage, phase and cycle
ply power leads in the pump terminal box. duties have the same value of insulation
Using an ohm or mega ohm meter, set the resistance. Resistance values for new motors
scale selector to Rx 100K and zero adjust the must exceed 1,000,000 ohms. If they do not,
meter. motor should be repaired or replaced.
Measure and record the resistance between
each of the terminals and ground.
13

Startup for Cool-Top (from page 9)
Start-up
Note: Do not start the pump until it has been filled with liquid and vented.
Pay attention to the direction of the vent hole and take care to ensure that the escaping liquid does not cause injury to persons
or damage to the motor or other components.
In hot-liquid installations, special attention should be paid to the risk of injury caused by scalding hot liquid.
It is recommended to connect a drain pipe to the ½" air vent in order to lead the hot water/steam to a safe place.
Step Action
1
Note: The air-cooled top should only be started up with cold liquid.
Close the isolation valve on the discharge side and open the isolat-
ion valve on the suction side of the pump.
TM02 4151 5001

Open Closed
Remove the priming plug from the pump head (1) and slowly fill
the pump with liquid.
When the pump is completely filled with liquid, replace the priming
TM02 4152 1503
plug and tighten securely.
Remove the priming plug from the air-cooled chamber (2) and
slowly fill the chamber with liquid.
When the chamber is completely filled with liquid, replace the prim-
TM02 4153 1503
ing plug and tighten securely.
Open
. the isolation valve on the discharge side of the pump.
Valve may have to be partially closed when pump is started
TMo2 5907 4002
Open if no back pressure is present (i.e. boiler not up to pressure).

Open
5
TM01 1406 3702 / TM01 1405 4497
Start the pump and check the direction of rotation.

See the correct direction of rotation of the pump on the motor fan
cover.
If the direction of rotation is wrong, interchange any two of the in-
coming supply wires.
After 3 to 5 minutes, the air vent has been filled with liquid.
Note: During start-up of a cold pump with hot liquid, it is normal
that a few drops of liquid are leaking from the sleeve.
14

Diagnosing specific problems
Problem Possible cause Remedy
The pump does not run 1. No power at motor. Check for voltage at motor terminal box. If no voltage at motor,
check feeder panel for tripped circuits and reset circuit.
2. Fuses are blown or circuit Turn off power and remove fuses. Check for continuity with
breakers are tripped. ohmmeter. Replace blown fuses or reset circuit breaker. If new
fuses blow or circuit breaker trips, the electrical installation,
motor and wires must be checked.
3. Motor starter overloads are Check for voltage on line and load side of starter. Replace burned
burned or have tripped out. heaters or reset. Inspect starter for other damage. If heater trips
again, check the supply voltage and starter holding coil.
4. Starter does not energize. Energize control circuit and check for voltage at the holding coil.
If no voltage, check control circuit fuses. If voltage, check hold-
ing coil for shorts. Replace bad coil.
5. Defective controls. Check all safety and pressure switches for operation. Inspect
contacts in control devices. Replace worn or defective parts or
controls.
6. Motor is defective. Turn off power and disconnect wiring. Measure the lead to lead
resistances with ohmmeter (RX-1). Measure lead to ground
values with ohmmeter (RX-100K). Record measured values.
If an open or grounded winding is found, remove motor and
repair or replace.
7. Defective capacitor. Turn off power and discharge capacitor. Check with ohmmeter
(Single-phase motors) (RX-100K). When the meter is connected to the capacitor, the
needle should jump towards 0 ohms and slowly drift back to
infinity ( ). Replace if defective.
8. Pump is bound. Turn off power and manually rotate pump shaft. If shaft
does not rotate easily, check coupling setting and adjust as
necessary. If shaft rotation is still tight, remove pump and
inspect. Disassemble and repair.
1. Wrong rotation Check wiring for proper connections. Correct wiring.

The pump runs but at
2. Pump is not primed or is Turn pump off, close isolation valve(s), remove priming plug.
reduced capacity or airbound. Check fluid level. Refill the pump, replace plug and start the
does not deliver water pump. Long suction lines must be filled before starting the
pump.
3. Strainers, check or foot valves Remove strainer, screen or valve and inspect. Clean and replace.
are clogged. Reprime pump.
4. Suction lift too large. Install compound pressure gauge at the suction side of the
pump. Start pump and compare reading to performance data.
Reduce suction lift by lowering pump, increase suction line
size or removing high friction loss devices.
5. Suction and/or discharge Pump runs backwards when turned off. Air in suction pipe.
piping leaks. Suction pipe, valves and fittings must be airtight. Repair any
leaks and retighten all loose fittings.
6. Pump worn. Install pressure gauge, start pump, gradually close the
discharge valve and read pressure at shutoff. Convert
measured pressure (in PSI) to head (in feet): (Measured PSI x
2.31 ft./PSI = _____ ft.). Refer to the specific pump curve for
shutoff head for that pump model. If head is close to curve,
pump is probably OK. If not, remove pump and inspect.
7. Pump impeller or guide vane Disassemble and inspect pump passageways. Remove any
is clogged. foreign materials found.
15

Diagnosing specific problems
Problem Possible cause Remedy
The pump runs but at 8. Incorrect drain plug installed. If the proper drain plug is replaced with a standard plug,
reduced capacity or water will recirculate internally. Replace with proper plug.
does not deliver water 9. Improper coupling setting. Check/reset the coupling, see page 11 - 12.
(continued)
Pump cycles too much 1. Pressure switch is not Check pressure setting on switch and operation. Check
properly adjusted or is voltage across closed contacts. Readjust switch or replace
defective. if defective.
2. Level control is not properly Check setting and operation. Readjust setting (refer to level
set or is defective. control manufacturer’s data). Replace if defective.
3. Insufficient air charging or Pump air into tank or diaphragm chamber. Check dia-
leaking tank or piping. phragm for leak. Check tank and piping for leaks with soap
and water solution. Check air to water volume. Repair as
necessary.
4. Tank is too small. Check tank size and air volume in tank. Tank volume
should be approximately 10 gallons for each gpm of pump
capacity. The normal air volume is 2/3 of the total tank
volume at the pump cut-in pressure. Replace tank with one
of correct size.
5. Pump is oversized. Install pressure gauges on or near pump suction and

discharge ports. Start and run pump under normal
conditions, record gauge readings. Convert PSI to feet
(Measured PSI x 2.31 ft./PSI = _______ ft.) Refer to the
specific pump curve for that model, ensure that total head
is sufficient to limit pump delivery within its design flow
range. Throttle pump discharge flow if necessary.
Fuses blow or circuit breakers 1. Low voltage. Check voltage at starter panel and motor. If voltage var-
ies more than ±10%, contact power company. Check wire
or overload relays trip sizing.
2. Motor overloads are set Cycle pump and measure amperage. Increase heater size
too low. or adjust trip setting to a maximum of motor nameplate
(full load) current.
3. Three-phase current is Check current draw on each lead to the motor. Must be
imbalanced. within ±5%. If not, check motor and wiring. Rotating all
leads may eliminate this problem.
4. Motor is shorted or Turn off power and disconnect wiring. Measure the lead-
grounded. to-lead resistance with an ohmmeter (RX-1). Measure
lead-to-ground values with an ohmmeter (RX-100K) or a
megaohm meter. Record values. If an open or grounded
winding is found, remove the motor, repair and/or replace.
5. Wiring or connections Check proper wiring and loose terminals. Tighten loose
are faulty. terminals. Replace damaged wire.
6. Pump is bound. Turn off power and manually rotate pump shaft. If shaft
does not rotate easily, check coupling setting and adjust as
necessary. If shaft rotation is still tight, remove pump and
inspect. Disassemble and repair.
7. Defective capacitor Turn off power and discharge capacitor. Check with ohm-
(single-phase motors). meter (RX-100K). When the meter is connected to the
capacitor, the needle should jump towards 0 ohms and
slowly drift back to infinity ( ). Replace if defective.
8. Motor overloads at higher Use a thermometer to check the ambient temperature near
ambient temperature than the overloads and motor. Record these values. If ambient
motor. temperature at motor is lower than at overloads, especially
where temperature at overloads is above +104°F (+40°C),
ambient-compensated heaters should replace standard
heaters.
16

Three Phase Motors
Below is a worksheet for calculating current unbalance on a three-phase hookup. Use the
calculations below as a guide.
EXPLANATION & EXAMPLES
Here is an example of current readings

at maximum pump loads on each leg of Hookup 1
T1 = 51 Amps
a three-wire hookup. You must make
T2 = 46 Amps
calculations for all three hookups. NOTE:
T3 = 53 Amps
To begin, add up all three readings for Current unbalance should not exceed
TOTAL = 150 Amps
hookup number 1, 2, and 3. 5% at service factor load or 10% at
rated input load. If the unbalance
Hookup 1 cannot be corrected by rolling leads,
Divide the total by three to obtain the average. 50 Amps the source of the unbalance must be
3 150 Amps located and corrected. If, on the three
possible hookups, the leg farthest
Hookup 1 from the average stays on the same
Calculate the greatest current difference from 50 Amps power lead, most of the unbalance
the average. – 46 Amps is coming from the power source.
4 Amps However, if the reading farthest from
the averages moves with the same
Divide this difference by the average to motor lead, the primary source of
obtain the percentage of unbalance. Hookup 1 unbalance is on the “motor side” of
.08 or 8% the starter. In this instance, consider
50 4.00 Amps a damaged cable, leaking splice, poor
In this case, the current unblanace for
hookup number 1 is 8%. connection, or faulty motor winding.
FIGURE HERE
Hookup 1 Hookup 2 Hookup 3
L1 to T1 = ____ Amps L1 to T3 = ____ Amps L1 to T2 = ____ Amps
TOTAL = ____ Amps TOTAL = ____ Amps TOTAL = ____ Amps

_______ Amps _______ Amps _______ Amps
3 _______ Amps 3 _______ Amps 3 _______ Amps

____ Amps ____ Amps ____ Amps
– ____ Amps – ____ Amps – ____ Amps
____ Amps ____ Amps ____ Amps

____ or ____% ____ or ____% ____ or ____%
____ ____ Amps ____ ____ Amps ____ ____ Amps
17

Being responsible is our foundation
Thinking ahead makes it possible
Innovation is the essence
LIMITED WARRANTY
Products manufactured by (GRUNDFOS) GRUNDFOS PUMPS CORPORATION are warranted to

the original user only to be free of defects in material and workmanship for a period of
24 months from date of installation, but not more than 30 months from date of manufac-
ture. GRUNDFOS’ liability under this warranty shall be limited to repairing or replacing at
GRUNDFOS’ option, without charge, F.O.B. GRUNDFOS’ factory or authorized service station, any
product of GRUNDFOS’ manufacture. GRUNDFOS will not be liable for any costs of removal, instal-
lation, transportation, or any other charges which may arise in connection with a warranty claim.
Products which are sold but not manufactured by GRUNDFOS are subject to the warranty provided
by the manufacturer of said products and not by GRUNDFOS’ warranty. GRUNDFOS will not be liable
for damage or wear to products caused by abnormal operating conditions, accident, abuse, misuse,
unauthorized alteration or repair, or if the product was not installed in accordance with GRUNDFOS’
printed installation and operating instructions.
To obtain service under this warranty, the defective product must be returned to the
distributor or dealer of GRUNDFOS’ products from which it was purchased together with
proof of purchase and installation date, failure date, and supporting installation data. Unless
otherwise provided, the distributor or dealer will contact GRUNDFOS or an authorized service sta-
tion for instructions. Any defective product to be returned to GRUNDFOS or a service station must
be sent freight prepaid; documentation supporting the warranty claim and/or a Return Material
Authorization must be included if so instructed.
GRUNDFOS WILL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES,

LOSSES, OR EXPENSES ARISING FROM INSTALLATION, USE, OR ANY OTHER CAUSES. THERE
ARE NO EXPRESS OR IMPLIED WARRANTIES, INCLUDING MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE, WHICH EXTEND BEYOND THOSE WARRANTIES DESCRIBED OR REFERRED TO
ABOVE.
Some jurisdictions do not allow the exclusion or limitation of incidental or consequential

damages and some jurisdictions do not allow limitations on how long implied warranties
may last. Therefore, the above limitations or exclusions may not apply to you. This warranty
gives you specific legal rights and you may also have other rights which vary from jurisdiction
to jurisdiction.
L-CP-TL-003 12/05 (US)

Subject to alterations
GRUNDFOS Pumps Corporation GRUNDFOS Canada Inc. Bombas GRUNDFOS de Mexico S.A. de C.V.
17100 West 118th Terrace 2941 Brighton Road Boulevard TLC #15, Parque Stiva Aeropuerto
Olathe, Kansas 66061 Oakville, Ontario L6H 6C9 Canada Apodaca, N.L. 66600 Mexico
Telephone: 913 227 3400 Telephone: 905 829 9533 Telephone: 52 81 8144 4000
Fax: 913 227 3500 Fax: 905 829 9512 Fax: 52 81 8144 4010
www.grundfos.com

Models 3U / 3UB
End Suction Centrifugal
Operating Instructions, Installation & Maintenance Manual
EBARA Fluid Handling EBARA International Corporation

EBARA End Suction Centrifugal 3U / 3UB
Operating, Installation, and Maintenance
Contents
Section Page
Safety Specifications and Installation 3
3U / 3UB Selection Chart 5
3U / 3UB Specifications 6
3U / 3UB Type 1 Sectional View and Parts List 7
3U(B) 65 Type 3 Sectional View and Parts List 8
Installation Instructions 9
Maintenance and Service 10
3U / 3UB Assembly – 3HP - 15HP 11
Troubleshooting Checklist and Maintenance Information 13
WARNING
IMPORTANT SAFETY INSTRUCTIONS
Rules for Safe Installation and Operation
1. Read these rules and instructions carefully. Failure to follow them could cause serious bodily injury and/or property damage.
2. Check your local codes before installing. You must comply with their rules
3. For maximum safety, this product should be connected to a grounded circuit equipped with a ground fault interrupter device.
4. Before installing this product, have the electrical circuit checked by an electrician to make sure it is properly grounded.
5. Before installing or servicing your pump, BE CERTAIN pump power source is disconnected.
6. Make sure the line voltage and frequency of the electrical current supply agrees with the motor wiring. If motor is dual voltage
type, BE SURE it is wired correctly for your power supply.
7. Complete pump and piping system MUST be protected against below freezing temperature. Failure to do so could cause severe
damage and voids the Warranty.
8. Avoid system pressures that may exceed one and a half times the operating point selected from the pump performance curve.
9. Do not run your pump dry. If it is, there will be damage to the pump seal.
Installation
PACKAGE CONTENTS
1. Be sure all parts have been furnished and that nothing has been damaged in shipment.
2. The catalog lists all parts included with package. A packing list packed with pump, also lists contents.
3. OPEN PACKAGES AND MAKE THIS CHECK BEFORE GOING ON JOB.
PIPING – Pipes must line up and not be forced into position by unions. Piping should be independently supported near the
pump so that no strain will be placed on the pump casing. Where any noise is objectionable, pump should be insulated from
the piping with rubber connections. Always keep pipe size as large as possible and use a minimum of fittings to reduce
friction losses.
SUCTION PIPING – Suction pipe should be direct and as short as possible. It should be at least one size larger than suction
inlet tapping and should have a minimum of elbows and fittings (5 to 6 pipe diameters of straight pipe before inlet is recommended).
The piping should be laid out so that it slopes upward to pump without dips or high points so that air pockets are eliminated.
The highest point in the suction piping should be the pump inlet except where liquid flows to the pump inlet under pressure.
The suction pipe must be tight and free of air leaks or pump will not operate properly.
EBARA Fluid Handling

www.pumpsebara.com 3
(t) 803 327-5005 • (f) 803 327-5097 rev. 01/07
Rules for Safe Installation and Operation (continued)
DISCHARGE PIPING – Discharge piping should never be smaller than pump tapping and should preferably be one size
larger. A gate valve should always be installed in discharge line for throttling if capacity is not correct. To protect the pump
from water hammer and to prevent backflow, a check valve should be installed in the discharge line between the pump and
gate valve.
ELECTRICAL CONNECTIONS – Be sure motor wiring is connected for voltage being used. Unit should be connected to a
separate circuit. A fused disconnect switch or circuit breaker must be used in this circuit. Wire of sufficient size should be
used to keep voltage drop to a maximum of 5%.
Single phase motors have built-in overload protection. Flexible metallic conduit should be used to protect the motor leads.
PRIMING – The pump must be primed before starting. The pump casing and suction piping must be filled with water before
starting motor. When water is poured into pump to prime, remove all air before starting motor.
STARTING – When the pump is up to operating speed, open the discharge valve to obtain desired capacity or pressure. Do
not allow the pump to run for long periods with the discharge valve tightly closed. If the pump runs for an extended period of
time without liquid being discharged, the liquid in the pump case can get extremely hot.
ROTATION – All single phase motors are single rotation and leave factory with proper rotation. Three phase motors should
be checked to ensure proper rotation
FREEZING – Care should be taken to prevent the pump from freezing during cold weather. It may be necessary, when there
is any possibility of this, to drain the pump casing when not in operation. Drain by removing the pipe plug in the bottom of the
casing.
ROTARY SEAL – PRO STEEL pumps are fitted only with rotary seal. This seal is recommended for LIQUIDS free from abrasives.
LOCATION OF UNIT – The pump should be installed as near to the liquid source as is practical so that the static suction
head (vertical distance from the center line of the pump to water level) is maximized, and so that a short, direct suction pipe
may be used. The capacity of a centrifugal pump is reduced when the unit is operated under a high suction lift. The piping
should be as free from turns and bends as possible, as elbows and fittings greatly increase friction loss. Place the unit so that
it is readily accessible for service and maintenance and on a solid foundation, which provides a rigid and vibration-free sup-
port. Protect the pump against flooding and excess moisture.

(t) 803 327-5005 • (f) 803 327-5097 rev. 01/07
Model 3U / 3UB Selection chart Synchronous Speed 3450 RPM

3
M /MIN
0.1 0.2 0.3 0.4 0.5 0.6 0.8 1.0 1.5
Ft
100M
300
*40-200B-15HP 80
32-200-1-10HP 8
200 60
*40-200A- 9
32-200- 15HP
7½HP 7 6 50
150
TOTAL HEAD
32-160B-5HP 40
*50-160-1
40-160-1- 15HP
10HP 5
32-160A-5HP 50-160-
100 10HP 30
40-160-
7½HP
80 50-125-1
10HP
40-125B- 4
5HP 20
60
32-125-3HP 3
50 15
50-125
40-125A- 7½HP 2
40
5HP
1
10
30
20 30 40 50 60 80 100 150 200 300 400 600 700
CAPACITY IN GPM
*Three phase motor only

1. 3U65-125-7.5HP
2. 3U65-125-10HP
3. 3U65-160-10HP
4. 3U65-160-15HP*
5. 3U65-160-20HP*
6. 3U65-160-25HP*
7. 3U65-200-20HP*
8. 3U65-200-25HP*
9. 3U65-200-30HP*

(t) 803 327-5005 • (f) 803 327-5097 rev. 01/07
Specifications
Standard Optional
Size
Suction 3U32 – 2'' ANSI Equivalent Companion Flange kit
(150 lb. ANSI R.F. equivalent) 3U40 – 21/2'' ANSI Equivalent 150 Lb. ANSI, Female NPT
3U50 – 21/2'' ANSI Equivalent
3UB65 – 3'' ANSI Equivalent
Discharge 3U32 – 11/4'' ANSI Equivalent
(150 lb. ANSI R.F. equivalent) 3U40 – 11/2'' ANSI Equivalent
3U50 – 2'' ANSI Equivalent
3UB65 – 21/2'' ANSI Equivalent
Range of HP 3U – 3 HP to 15 HP
3UB – 71/2 HP to 30 HP
Range of Performance
Capacity 13 to 750 GPM at 3450 RPM
Head 33 to 250 feet at 3450 RPM
Liquid handled
Type of liquid Clean water
Temperature 212°F (100°C) Max. 250°F (121°C) with optional
high temperature seal
Max. working pressure 230 PSI (15 Bar)
Materials 3U 3UB
Casing 304L Stainless Steel 304L Stainless Steel
Impeller (closed type) 304L Stainless Steel Bronze Stainless steel option for 3UB models
Shaft Sleeve 304L Stainless Steel 304L Stainless Steel
Bracket Cast iron Cast iron
Shaft Seal Mechanical Seal – Type 21
Seal Material Carbon/Ceramic/Viton Consult factory for additional
Carbon/Ceramic/Buna optional seal availability
Hot water – Carbon/Ni-Resist/Viton, 250°F (121°C) max.
Direction of Rotation Clockwise when viewed from motor end
Motor
Type NEMA JM, TC, TSC Frame
Speed 60 Hz, 3450 RPM (2 poles) 4 pole – consult factory as noted
Bearing Ball Bearing
Single Phase TEFC – 3 HP
ODP – 3 HP to 10 HP
Three Phase TEFC – 3 HP to 30 HP Explosion proof – consult factory
ODP – 3 HP to 30 HP for availability
208-230/460V Washdown duty – consult factory
Motor Protection Overload protection must be provided for availability
Standard Accessories Suction and Discharge Flange Gasket
Motor support

(t) 803 327-5005 • (f) 803 327-5097 rev. 01/07
Sectional view – 3U / 3UB Type 1
039
011
117-3 800
111 041
115
021 129
135-1
001 125
018
117-2
117-1
212
Part No. Part Name Material No. for 1 Unit

001 Casing 304L Stainless 1
011 Casing cover 304L Stainless 1
018 Bracket Cast Iron 1
021 Impeller (3U) 304L Stainless 1
021 Impeller (3UB) Bronze 1
039 Key 304L Stainless 1
041 Shaft sleeve 304L Stainless 1
111 Mechanical seal – 1
115 O-Ring Viton 1
117-1 Gasket Nylon 1
125 Impeller Bolt 304L Stainless 1
160 Motor support (not shown) Steel 1 set
212 Plug 304L Stainless 1
800 Motor – 1
Suction Flange Gasket Viton 1
Discharge Flange Gasket Viton 1

(t) 803 327-5005 • (f) 803 327-5097 rev. 01/07
Sectional view – Model 3U 65 Type 3
3U 65-160/20
3U 65-160/25
3U 65-200/20
3U 65-200/25
3U 65-200/30

003 Motor bracket Cast iron 1
003A Adapter ring Cast iron 1
006 Coupling Steel / Stainless steel 1
007 Impeller Bronze/optional Stainless Steel 1
011 Mechanical seal 1
012 Motor 1
025 Drain plug 304L Stainless 1
026 O-ring Viton 1
034 Impeller nut Stainless / Nylon 1
040 Flange Gasket EPDM 2
042 Motor support Steel 2
042A Casing support (65-160 25HP only) Steel 2
044 Coupling guard Stainless Steel 2
234 Lip seal 304L Stainless 1

(t) 803 327-5005 • (f) 803 327-5097 rev. 01/07
3U / 3UB Installation Instructions
Mounting the Assembly

Do not operate the pump unless the assembly is securely and properly mounted.
Misalignment of the motor/pump assembly or not having the assembly reasonably level may cause pump vibration,
noisy operation, fluid leaks, or air leaks and air locks in the suction pipe.
1. Place the motor/pump assembly in its intended operating position.
2. Level the pump through the centerline of the motor/pump assembly suction port.
Initial Operation WARNING

Initialcertain
Make Operation
the motor is not connected to a power source until the motor is properly assembled and mounted.
Make certain
Serious the injury
personal motor oris damage
not connected
to the to a power source
motor/pump until the
assembly motor
could is ifproperly
occur the motorassembled andimproperly.
is activated mounted.
Serious personal injury or damage to the motor/pump assembly could occur if the motor is activated improperly.
Only certified electricians should make electrical connections.
1. Prime the pump by adding fluid to the volute case through the top plug.To properly prime the pump, venting
1. may
Prime
bethe pump by adding fluid to the volute case through the top plug.To properly prime the pump, venting
required.
may be required.
2. Check the nameplate on the motor to determine the correct wiring procedure for your intended power source
2. and
Check themotor
if the nameplate
is singleonorthe motor
three to determine
phase. the motor
Connect the correct
towiring procedure
a power source by forfollowing
your intended power
the wiring procedure
source
on and if the
the motor's motor is single or three phase. Connect the motor to a power source by following the wiring
nameplate.
procedure on the motor's nameplate.
Note:
a. Single phase motors are typically dual voltage. In some cases, three phase motors are tri-voltage. Check the
nameplate and follow the proper wiring procedure for the voltage you are using. Improperly wiring the motor
could result in damage to the motor.
b. Three phase motors require a control box. Install overload protection to help prevent motor damage.
c. Depending on the wiring, three phase motors may start in reverse. Interchange any two power leads to
change the starting direction and pump rotation.
• Always follow correct operating procedures.
• Always disconnect the motor/pump assembly from all power sources before servicing the pump or motor.
• Periodically check all power connections, bolts, screws, and the motor's mounting.
• Failure to properly follow assembly and operating instructions could result in damage to the pump and motor.
• Failure to properly install the impeller and impeller nut could result in damage to the pump and could cause
serious personal injury.

(t) 803 327-5005 • (f) 803 327-5097 rev. 01/07
Maintenance
Service
Keep ventilation openings clear of extraneous objects which may hinder free flow of air thru motor. Motor bearings are lubricated
during manufacture. Additional lubrication is not required during their normal lifetime.
CAUTION
Draining
The pump and piping should always be protected against freezing temperatures. If there is any danger of freezing, the unit
should be drained. To drain the pump, remove the drain plug at the bottom of the volute, and remove the priming plug to
vent the pump. Drain all piping.
Disassembly Instructions
All pumping parts can be removed from case without disturbing the piping.
WARNING
POWER SUPPLY – Open the power supply switch contacts and remove fuses. Disconnect the electrical wiring from the motor.
VOLUTE CASE
(a) Drain pump case by removing drain plugs.
(b) Remove the bolts securing volute case to pump bracket.
(c) Pry volute case from casing cover with a screwdriver.
IMPELLER
(a) Hold the motor shaft with a screwdriver in the shaft end slot. Grasp and turn the impeller counterclockwise (as viewed
from pump end).
SEAL
(a) Remove the rotating part of the seal by pulling it off the shaft.
(b) The stationary seat can be pressed from the casing cover.
CHECK LIST FOR EXAMINATION OF PUMP PARTS

IMPELLER - Replace the impeller if any vane is broken, excessive erosion shows, or if labyrinth surfaces are worn. Impeller
cap screw, washer and lockwasher should be replaced if damaged.
MECHANICAL SEAL - Seal face, O-ring and sealing members should be free of burrs and dirt. Complete seal assembly
should be replaced if not in perfect condition.
SHAFT- Shaft sleeve surface under seal or packing must be clean, smooth and without any grooves. It should be replaced if
necessary.
VOLUTE AND SEAL/PACKING PLATE LABYRINTH SURFACES (Wear Rings)- If worn, replace the necessary part. If fur-
nished with pressed in wear rings, only the rings need be replaced.
GASKETS - Volute, suction pipe and discharge pipe gaskets should be checked for damage. Replace if necessary.
NOTE
If replacement parts are ordered, please furnish the following information to your EBARA distributor:
1. Reference Numbers
2. Description of Pump Part
3. EBARA Model Number and Serial Number on the Nameplate.

(t) 803 327-5005 • (f) 803 327-5097 rev. 01/07
3U / 3UB Assembly Instructions

Position the pump on its end with the shaft up. The work surface should be level, capable of supporting the motor.
WARNING
Make certain the motor is not connected to a power source. Do not install or assemble the pump on a motor
connected to a power source. Serious injury could occur if the motor activates during pump assembly.
Assembling the Pump – Models 3HP - 15HP (see page 7 for sectional view)
1. Position a Nylon gasket (117-3) over the motor shaft.
2. Carefully press the rotating seal assembly onto the shaft sleeve (041). The smooth face of the
rotating ring must make good contact with the seal seat and the seal retainer must seal against the shaft sleeve.
Note: Seal faces should be wiped clean with non-oil based solvent or alcohol.
3. Using finger pressure only, insert the seal seat into the casing cover (011). Press the seal until it evenly
bottoms out in the seal cavity.
4. Position the cast iron motor bracket (018) over the shaft. Fasten the bracket to the motor, tightening bolts
using a cross-tightening pattern. (Tighten the bolts to the factory recommended torque specifications of 8 ft. lbs.)
Overtightening may cause stripping of threads.
5. Carefully position the casing cover (011) and seal over the shaft. Be careful not to damage the stationary
seal seat.
6. Slide the stainless steel shaft sleeve, with rotating assembly, over the motor shaft.
7. Position the O-ring (115) around the casing cover (011). Do not cut, nick, or damage the O-ring during the
installation.
8. Install the impeller shaft key (3/16" x 3/16" x 1 3/16").
9. Place the seal spring assembly over the rotating piece of the seal in position to receive the impeller.
10. Place a Nylon gasket (117-2) on top of spring retainer.
11. Firmly press the impeller (021) into position by aligning the slot over the shaft key. Press the impeller down
the shaft until it bottoms and seats squarely against the Teflon gasket (117-2) and shaft sleeve (041).
12. Place a Nylon gasket (117-1) over the impeller hub and into the impeller eye. Install the impeller bolt (125) to
secure the impeller to the shaft. Do not overtighten the shaft bolt. (Use a thread compound or cement to
secure the shaft bolt and prevent it from working loose.)
13. Tighten the impeller bolt. (Tighten the bolts to the factory recommended torque specifications of 11 ft. lbs.)
14. Install the pump volute (001) over the seal plate. Rotate the volute to align with the bolt holes and secure it
with the bolts, washers, and nuts. Cross-tighten the bolts to the factory recommended torque specifications
(8 ft. lbs.).
15. With a socket wrench, rotate impeller to check for alignment. If rubbing against casing, loosen bolts on
casing and retighten.

(t) 803 327-5005 • (f) 803 327-5097 rev. 01/07
1. Apply a coat of anti-seize lubricant to the inside of the coupling (005).
2. Insure that key is installed in motor shaft keyway, slide coupling (005) onto shaft. (Tip: To ease the installation
of the coupling tighten the set screw on the side of the coupling. Tightening this screw will cause the coupling
to open slightly allowing for easier installation. After the coupling is in place be sure to loosen the set screw
to release the pressure and allow the coupling to close down on the motor shaft.)
3. Secure the coupling to the motor shaft by tightening the socket head bolts in the side of the coupling. Torque
to 11ft. lbs.
4. Fasten the adapter ring (003A) to the motor using a cross tightening pattern.
5. Fasten the motor bracket (003) to the adapter ring.
6. Apply a thin coat of non-petroleum based lubricant (i.e. dish soap) to the stationary seal seat in the casing
cover (004), using finger pressure only press the stationary seal into the seal seat. Wipe the seal face clean
with alcohol and a soft cloth.
7. Position the o-ring ( 026 ) around the casing cover.
8. Using hand pressure or a rubber mallet, press fit the casing cover ( 004 ) onto the motor bracket (003).
9. Apply a thin coat of non-petroleum based lubricant (i.e. dish soap) to the inside of the rubber boot on the
rotating seal. Slide the seal onto the coupling pushing it gently until it contacts the stationary seal that was
installed in step 6. Place the spring and spring retainer over the coupling and onto the rotating seal.
10. Place the stainless steel lip seal (234) onto the spring retainer insuring that the raised surface of the lip seal
seats into the spring retainer.
11. Install the impeller shaft key (032) into the coupling shaft.
12. Slide impeller (007) over the key and shaft.
13. Tighten the impeller nut (034) to secure the impeller in place. Tighten to 11 ft.lbs
14. Install Casing (001). Take care to align the bolt holes. Cross tighten the bolts to 8 ft. lbs.
15. With a socket wrench, rotate impeller to check for proper casing alignment. If rubbing against casing occurs
loosen casing bolts and retighten taking care to cross-tighten and use equal torque.
16. Install motor support (042) or casing support (042A) as required.

(t) 803 327-5005 • (f) 803 327-5097 rev. 01/07
Troubleshooting
TROUBLE POSSIBLE CAUSE TROUBLESHOOTING
Pump does not run. Faulty connection of power supply circuit. Check power supply circuit.
Wrong wiring of control circuit. Correct control circuit.
Bound shaft Remove cause of obstruction.
Mechanical seal faces stuck together Release seal by turning shaft.
Faulty motor Repair or replace motor.
Damage to bearing Repair or replace any damaged bearing.
Pump does not pump water. Considerable voltage drop. Correct rotation direction.
Inadequate quantity. Rotation direction reversed. Re-prime the pump.
Lack of priming. Re-examine the plan.
High discharge head. Re-examine the plan.
Large piping loss. Clear foot valve suction.
Clogged foot valve. Check and repair suction piping.
Leakage from suction piping. Re-install as per our instructions.
Too high suction lift. Foot valve in ample immersion.
Low water level.
Overcurrent Considerable fluctuation of power supply Throttle flow rate at outlet.
voltage. Replace any damage bearing.
Considerable voltage drop.
Low head and overflow rate.
Damaged bearing.
Pump vibrates, excessive operating Beyond rated capacity. Reduce flow rate.
noise Cavitation. Consult distributor
Improper piping. Secure piping again.
Damaged bearing. Replace any damaged bearing.
Foreign matter clogging cooling fan. Remove foreign matter.
Pressurizing application. Too limited pressure switch setting. Replace pressure switch to wider range.
Pump starts and soon stops Check and repair leaks.
Pump does not stop Leakage in system. Reduce max pressure setting to the
Too high pressure setting. lower in pressure switch.
MAINTENANCE:
The pump does not require special maintenance.
The following rules must be observed for safe operation:
If the pump is not going to be used for a long period, the pump should be drained of water and flushed with clean water.
Where the pump is exposed to freezing temperatures, it should always be left drained when not in use.
*All specifications subject to change without notice.

(t) 803 327-5005 • (f) 803 327-5097 rev. 01/07

(t) 803 327-5005 • (f) 803 327-5097 rev. 01/07
Contact your dealer or supplier
for more information about other EBARA products

1651 Cedar Line Drive • Rock Hill, SC 29730
(t) 803 327 5005 • (f) 803 327 5097
www.pumpsebara.com
© 2005 EBARA International Corporation EFH 3U_3UB0107
Models 3U / 3UB
End Suction Centrifugal
Operating Instructions, Installation & Maintenance Manual
EBARA Fluid Handling EBARA International Corporation

Contents
Section Page
Safety Specifications and Installation 3
3U / 3UB Selection Chart 5
3U / 3UB Specifications 6
3U / 3UB Type 1 Sectional View and Parts List 7
3U(B) 65 Type 3 Sectional View and Parts List 8
Installation Instructions 9
Maintenance and Service 10
Troubleshooting Checklist and Maintenance Information 13
WARNING
IMPORTANT SAFETY INSTRUCTIONS
Rules for Safe Installation and Operation
1. Read these rules and instructions carefully. Failure to follow them could cause serious bodily injury and/or property damage.
2. Check your local codes before installing. You must comply with their rules
3. For maximum safety, this product should be connected to a grounded circuit equipped with a ground fault interrupter device.
4. Before installing this product, have the electrical circuit checked by an electrician to make sure it is properly grounded.
5. Before installing or servicing your pump, BE CERTAIN pump power source is disconnected.
6. Make sure the line voltage and frequency of the electrical current supply agrees with the motor wiring. If motor is dual voltage
type, BE SURE it is wired correctly for your power supply.
7. Complete pump and piping system MUST be protected against below freezing temperature. Failure to do so could cause severe
damage and voids the Warranty.
8. Avoid system pressures that may exceed one and a half times the operating point selected from the pump performance curve.
9. Do not run your pump dry. If it is, there will be damage to the pump seal.
Installation
PACKAGE CONTENTS
1. Be sure all parts have been furnished and that nothing has been damaged in shipment.
2. The catalog lists all parts included with package. A packing list packed with pump, also lists contents.
3. OPEN PACKAGES AND MAKE THIS CHECK BEFORE GOING ON JOB.
PIPING – Pipes must line up and not be forced into position by unions. Piping should be independently supported near the
pump so that no strain will be placed on the pump casing. Where any noise is objectionable, pump should be insulated from
the piping with rubber connections. Always keep pipe size as large as possible and use a minimum of fittings to reduce
friction losses.
SUCTION PIPING – Suction pipe should be direct and as short as possible. It should be at least one size larger than suction
inlet tapping and should have a minimum of elbows and fittings (5 to 6 pipe diameters of straight pipe before inlet is recommended).
The piping should be laid out so that it slopes upward to pump without dips or high points so that air pockets are eliminated.
The highest point in the suction piping should be the pump inlet except where liquid flows to the pump inlet under pressure.
The suction pipe must be tight and free of air leaks or pump will not operate properly.

(t) 803 327-5005 • (f) 803 327-5097 rev. 01/07
Rules for Safe Installation and Operation (continued)
DISCHARGE PIPING – Discharge piping should never be smaller than pump tapping and should preferably be one size
larger. A gate valve should always be installed in discharge line for throttling if capacity is not correct. To protect the pump
from water hammer and to prevent backflow, a check valve should be installed in the discharge line between the pump and
gate valve.
ELECTRICAL CONNECTIONS – Be sure motor wiring is connected for voltage being used. Unit should be connected to a
separate circuit. A fused disconnect switch or circuit breaker must be used in this circuit. Wire of sufficient size should be
used to keep voltage drop to a maximum of 5%.
Single phase motors have built-in overload protection. Flexible metallic conduit should be used to protect the motor leads.
PRIMING – The pump must be primed before starting. The pump casing and suction piping must be filled with water before
starting motor. When water is poured into pump to prime, remove all air before starting motor.
STARTING – When the pump is up to operating speed, open the discharge valve to obtain desired capacity or pressure. Do
not allow the pump to run for long periods with the discharge valve tightly closed. If the pump runs for an extended period of
time without liquid being discharged, the liquid in the pump case can get extremely hot.
ROTATION – All single phase motors are single rotation and leave factory with proper rotation. Three phase motors should
be checked to ensure proper rotation
FREEZING – Care should be taken to prevent the pump from freezing during cold weather. It may be necessary, when there
is any possibility of this, to drain the pump casing when not in operation. Drain by removing the pipe plug in the bottom of the
casing.
ROTARY SEAL – PRO STEEL pumps are fitted only with rotary seal. This seal is recommended for LIQUIDS free from abrasives.
LOCATION OF UNIT – The pump should be installed as near to the liquid source as is practical so that the static suction
head (vertical distance from the center line of the pump to water level) is maximized, and so that a short, direct suction pipe
may be used. The capacity of a centrifugal pump is reduced when the unit is operated under a high suction lift. The piping
should be as free from turns and bends as possible, as elbows and fittings greatly increase friction loss. Place the unit so that
it is readily accessible for service and maintenance and on a solid foundation, which provides a rigid and vibration-free sup-
port. Protect the pump against flooding and excess moisture.

(t) 803 327-5005 • (f) 803 327-5097 rev. 01/07
Model 3U / 3UB Selection chart Synchronous Speed 3450 RPM

3
M /MIN
0.1 0.2 0.3 0.4 0.5 0.6 0.8 1.0 1.5
Ft
100M
300
*40-200B-15HP 80
32-200-1-10HP 8
200 60
*40-200A- 9
32-200- 15HP
7½HP 7 6 50
150
TOTAL HEAD
32-160B-5HP 40
*50-160-1
40-160-1- 15HP
10HP 5
32-160A-5HP 50-160-
100 10HP 30
40-160-
7½HP
80 50-125-1
10HP
40-125B- 4
5HP 20
60
32-125-3HP 3
50 15
50-125
40-125A- 7½HP 2
40
5HP
1
10
30
20 30 40 50 60 80 100 150 200 300 400 600 700
CAPACITY IN GPM
*Three phase motor only

1. 3U65-125-7.5HP
2. 3U65-125-10HP
3. 3U65-160-10HP
4. 3U65-160-15HP*
5. 3U65-160-20HP*
6. 3U65-160-25HP*
7. 3U65-200-20HP*
8. 3U65-200-25HP*
9. 3U65-200-30HP*

(t) 803 327-5005 • (f) 803 327-5097 rev. 01/07
Specifications
Standard Optional
Size
Suction 3U32 – 2'' ANSI Equivalent Companion Flange kit
(150 lb. ANSI R.F. equivalent) 3U40 – 21/2'' ANSI Equivalent 150 Lb. ANSI, Female NPT
3U50 – 21/2'' ANSI Equivalent
3UB65 – 3'' ANSI Equivalent
Discharge 3U32 – 11/4'' ANSI Equivalent
(150 lb. ANSI R.F. equivalent) 3U40 – 11/2'' ANSI Equivalent
3U50 – 2'' ANSI Equivalent
3UB65 – 21/2'' ANSI Equivalent
Range of HP 3U – 3 HP to 15 HP
3UB – 71/2 HP to 30 HP
Range of Performance
Capacity 13 to 750 GPM at 3450 RPM
Head 33 to 250 feet at 3450 RPM
Liquid handled
Type of liquid Clean water
Temperature 212°F (100°C) Max. 250°F (121°C) with optional
high temperature seal
Max. working pressure 230 PSI (15 Bar)
Materials 3U 3UB
Casing 304L Stainless Steel 304L Stainless Steel
Impeller (closed type) 304L Stainless Steel Bronze Stainless steel option for 3UB models
Shaft Sleeve 304L Stainless Steel 304L Stainless Steel
Bracket Cast iron Cast iron
Shaft Seal Mechanical Seal – Type 21
Seal Material Carbon/Ceramic/Viton Consult factory for additional
Carbon/Ceramic/Buna optional seal availability
Hot water – Carbon/Ni-Resist/Viton, 250°F (121°C) max.
Direction of Rotation Clockwise when viewed from motor end
Motor
Type NEMA JM, TC, TSC Frame
Speed 60 Hz, 3450 RPM (2 poles) 4 pole – consult factory as noted
Bearing Ball Bearing
Single Phase TEFC – 3 HP
ODP – 3 HP to 10 HP
Three Phase TEFC – 3 HP to 30 HP Explosion proof – consult factory
ODP – 3 HP to 30 HP for availability
208-230/460V Washdown duty – consult factory
Motor Protection Overload protection must be provided for availability
Standard Accessories Suction and Discharge Flange Gasket
Motor support

(t) 803 327-5005 • (f) 803 327-5097 rev. 01/07
Sectional view – 3U / 3UB Type 1
039
011
117-3 800
111 041
115
021 129
135-1
001 125
018
117-2
117-1
212

018 Bracket Cast Iron 1
021 Impeller (3U) 304L Stainless 1
021 Impeller (3UB) Bronze 1
041 Shaft sleeve 304L Stainless 1
111 Mechanical seal – 1
115 O-Ring Viton 1
125 Impeller Bolt 304L Stainless 1
160 Motor support (not shown) Steel 1 set
212 Plug 304L Stainless 1
800 Motor – 1
Suction Flange Gasket Viton 1
Discharge Flange Gasket Viton 1

(t) 803 327-5005 • (f) 803 327-5097 rev. 01/07
Sectional view – Model 3U 65 Type 3
3U 65-160/20
3U 65-160/25
3U 65-200/20
3U 65-200/25
3U 65-200/30

003 Motor bracket Cast iron 1
003A Adapter ring Cast iron 1
006 Coupling Steel / Stainless steel 1
007 Impeller Bronze/optional Stainless Steel 1
011 Mechanical seal 1
012 Motor 1
025 Drain plug 304L Stainless 1
026 O-ring Viton 1
034 Impeller nut Stainless / Nylon 1
042 Motor support Steel 2
042A Casing support (65-160 25HP only) Steel 2
044 Coupling guard Stainless Steel 2
234 Lip seal 304L Stainless 1

(t) 803 327-5005 • (f) 803 327-5097 rev. 01/07
3U / 3UB Installation Instructions
Mounting the Assembly

Do not operate the pump unless the assembly is securely and properly mounted.
Misalignment of the motor/pump assembly or not having the assembly reasonably level may cause pump vibration,
noisy operation, fluid leaks, or air leaks and air locks in the suction pipe.
1. Place the motor/pump assembly in its intended operating position.
2. Level the pump through the centerline of the motor/pump assembly suction port.
Initial Operation WARNING

Initialcertain
Make Operation
the motor is not connected to a power source until the motor is properly assembled and mounted.
Make certain
Serious the injury
personal motor oris damage
not connected
to the to a power source
motor/pump until the
assembly motor
could is ifproperly
occur the motorassembled andimproperly.
is activated mounted.
Serious personal injury or damage to the motor/pump assembly could occur if the motor is activated improperly.
1. Prime the pump by adding fluid to the volute case through the top plug.To properly prime the pump, venting
1. may
Prime
bethe pump by adding fluid to the volute case through the top plug.To properly prime the pump, venting
required.
may be required.
2. Check the nameplate on the motor to determine the correct wiring procedure for your intended power source
2. and
Check themotor
if the nameplate
is singleonorthe motor
three to determine
phase. the motor
Connect the correct
towiring procedure
a power source by forfollowing
your intended power
the wiring procedure
source
on and if the
the motor's motor is single or three phase. Connect the motor to a power source by following the wiring
nameplate.
procedure on the motor's nameplate.
Note:
a. Single phase motors are typically dual voltage. In some cases, three phase motors are tri-voltage. Check the
nameplate and follow the proper wiring procedure for the voltage you are using. Improperly wiring the motor
could result in damage to the motor.
b. Three phase motors require a control box. Install overload protection to help prevent motor damage.
c. Depending on the wiring, three phase motors may start in reverse. Interchange any two power leads to
change the starting direction and pump rotation.
• Always follow correct operating procedures.
• Always disconnect the motor/pump assembly from all power sources before servicing the pump or motor.
• Periodically check all power connections, bolts, screws, and the motor's mounting.
• Failure to properly follow assembly and operating instructions could result in damage to the pump and motor.
• Failure to properly install the impeller and impeller nut could result in damage to the pump and could cause
serious personal injury.

(t) 803 327-5005 • (f) 803 327-5097 rev. 01/07
Maintenance
Service
Keep ventilation openings clear of extraneous objects which may hinder free flow of air thru motor. Motor bearings are lubricated
during manufacture. Additional lubrication is not required during their normal lifetime.
CAUTION
Draining
The pump and piping should always be protected against freezing temperatures. If there is any danger of freezing, the unit
should be drained. To drain the pump, remove the drain plug at the bottom of the volute, and remove the priming plug to
vent the pump. Drain all piping.
Disassembly Instructions
All pumping parts can be removed from case without disturbing the piping.
WARNING
POWER SUPPLY – Open the power supply switch contacts and remove fuses. Disconnect the electrical wiring from the motor.
VOLUTE CASE
(a) Drain pump case by removing drain plugs.
(b) Remove the bolts securing volute case to pump bracket.
(c) Pry volute case from casing cover with a screwdriver.
IMPELLER
(a) Hold the motor shaft with a screwdriver in the shaft end slot. Grasp and turn the impeller counterclockwise (as viewed
from pump end).
SEAL
(a) Remove the rotating part of the seal by pulling it off the shaft.
(b) The stationary seat can be pressed from the casing cover.
CHECK LIST FOR EXAMINATION OF PUMP PARTS

IMPELLER - Replace the impeller if any vane is broken, excessive erosion shows, or if labyrinth surfaces are worn. Impeller
cap screw, washer and lockwasher should be replaced if damaged.
MECHANICAL SEAL - Seal face, O-ring and sealing members should be free of burrs and dirt. Complete seal assembly
should be replaced if not in perfect condition.
SHAFT- Shaft sleeve surface under seal or packing must be clean, smooth and without any grooves. It should be replaced if
necessary.
VOLUTE AND SEAL/PACKING PLATE LABYRINTH SURFACES (Wear Rings)- If worn, replace the necessary part. If fur-
nished with pressed in wear rings, only the rings need be replaced.
GASKETS - Volute, suction pipe and discharge pipe gaskets should be checked for damage. Replace if necessary.
NOTE
If replacement parts are ordered, please furnish the following information to your EBARA distributor:
1. Reference Numbers
2. Description of Pump Part
3. EBARA Model Number and Serial Number on the Nameplate.

(t) 803 327-5005 • (f) 803 327-5097 rev. 01/07
3U / 3UB Assembly Instructions

Position the pump on its end with the shaft up. The work surface should be level, capable of supporting the motor.
WARNING
Make certain the motor is not connected to a power source. Do not install or assemble the pump on a motor
connected to a power source. Serious injury could occur if the motor activates during pump assembly.
1. Position a Nylon gasket (117-3) over the motor shaft.
2. Carefully press the rotating seal assembly onto the shaft sleeve (041). The smooth face of the
rotating ring must make good contact with the seal seat and the seal retainer must seal against the shaft sleeve.
Note: Seal faces should be wiped clean with non-oil based solvent or alcohol.
3. Using finger pressure only, insert the seal seat into the casing cover (011). Press the seal until it evenly
bottoms out in the seal cavity.
4. Position the cast iron motor bracket (018) over the shaft. Fasten the bracket to the motor, tightening bolts
using a cross-tightening pattern. (Tighten the bolts to the factory recommended torque specifications of 8 ft. lbs.)
Overtightening may cause stripping of threads.
5. Carefully position the casing cover (011) and seal over the shaft. Be careful not to damage the stationary
seal seat.
6. Slide the stainless steel shaft sleeve, with rotating assembly, over the motor shaft.
7. Position the O-ring (115) around the casing cover (011). Do not cut, nick, or damage the O-ring during the
installation.
8. Install the impeller shaft key (3/16" x 3/16" x 1 3/16").
9. Place the seal spring assembly over the rotating piece of the seal in position to receive the impeller.
10. Place a Nylon gasket (117-2) on top of spring retainer.
11. Firmly press the impeller (021) into position by aligning the slot over the shaft key. Press the impeller down
the shaft until it bottoms and seats squarely against the Teflon gasket (117-2) and shaft sleeve (041).
12. Place a Nylon gasket (117-1) over the impeller hub and into the impeller eye. Install the impeller bolt (125) to
secure the impeller to the shaft. Do not overtighten the shaft bolt. (Use a thread compound or cement to
secure the shaft bolt and prevent it from working loose.)
13. Tighten the impeller bolt. (Tighten the bolts to the factory recommended torque specifications of 11 ft. lbs.)
14. Install the pump volute (001) over the seal plate. Rotate the volute to align with the bolt holes and secure it
with the bolts, washers, and nuts. Cross-tighten the bolts to the factory recommended torque specifications
(8 ft. lbs.).
15. With a socket wrench, rotate impeller to check for alignment. If rubbing against casing, loosen bolts on
casing and retighten.

(t) 803 327-5005 • (f) 803 327-5097 rev. 01/07
1. Apply a coat of anti-seize lubricant to the inside of the coupling (005).
2. Insure that key is installed in motor shaft keyway, slide coupling (005) onto shaft. (Tip: To ease the installation
of the coupling tighten the set screw on the side of the coupling. Tightening this screw will cause the coupling
to open slightly allowing for easier installation. After the coupling is in place be sure to loosen the set screw
to release the pressure and allow the coupling to close down on the motor shaft.)
3. Secure the coupling to the motor shaft by tightening the socket head bolts in the side of the coupling. Torque
to 11ft. lbs.
4. Fasten the adapter ring (003A) to the motor using a cross tightening pattern.
5. Fasten the motor bracket (003) to the adapter ring.
6. Apply a thin coat of non-petroleum based lubricant (i.e. dish soap) to the stationary seal seat in the casing
cover (004), using finger pressure only press the stationary seal into the seal seat. Wipe the seal face clean
with alcohol and a soft cloth.
7. Position the o-ring ( 026 ) around the casing cover.
8. Using hand pressure or a rubber mallet, press fit the casing cover ( 004 ) onto the motor bracket (003).
9. Apply a thin coat of non-petroleum based lubricant (i.e. dish soap) to the inside of the rubber boot on the
rotating seal. Slide the seal onto the coupling pushing it gently until it contacts the stationary seal that was
installed in step 6. Place the spring and spring retainer over the coupling and onto the rotating seal.
10. Place the stainless steel lip seal (234) onto the spring retainer insuring that the raised surface of the lip seal
seats into the spring retainer.
11. Install the impeller shaft key (032) into the coupling shaft.
12. Slide impeller (007) over the key and shaft.
13. Tighten the impeller nut (034) to secure the impeller in place. Tighten to 11 ft.lbs
14. Install Casing (001). Take care to align the bolt holes. Cross tighten the bolts to 8 ft. lbs.
15. With a socket wrench, rotate impeller to check for proper casing alignment. If rubbing against casing occurs
loosen casing bolts and retighten taking care to cross-tighten and use equal torque.
16. Install motor support (042) or casing support (042A) as required.

(t) 803 327-5005 • (f) 803 327-5097 rev. 01/07
Troubleshooting
TROUBLE POSSIBLE CAUSE TROUBLESHOOTING
Pump does not run. Faulty connection of power supply circuit. Check power supply circuit.
Wrong wiring of control circuit. Correct control circuit.
Bound shaft Remove cause of obstruction.
Mechanical seal faces stuck together Release seal by turning shaft.
Faulty motor Repair or replace motor.
Damage to bearing Repair or replace any damaged bearing.
Pump does not pump water. Considerable voltage drop. Correct rotation direction.
Inadequate quantity. Rotation direction reversed. Re-prime the pump.
Lack of priming. Re-examine the plan.
High discharge head. Re-examine the plan.
Large piping loss. Clear foot valve suction.
Clogged foot valve. Check and repair suction piping.
Leakage from suction piping. Re-install as per our instructions.
Too high suction lift. Foot valve in ample immersion.
Low water level.
Overcurrent Considerable fluctuation of power supply Throttle flow rate at outlet.
voltage. Replace any damage bearing.
Considerable voltage drop.
Low head and overflow rate.
Damaged bearing.
Pump vibrates, excessive operating Beyond rated capacity. Reduce flow rate.
noise Cavitation. Consult distributor
Improper piping. Secure piping again.
Damaged bearing. Replace any damaged bearing.
Foreign matter clogging cooling fan. Remove foreign matter.
Pressurizing application. Too limited pressure switch setting. Replace pressure switch to wider range.
Pump starts and soon stops Check and repair leaks.
Pump does not stop Leakage in system. Reduce max pressure setting to the
Too high pressure setting. lower in pressure switch.
MAINTENANCE:
The pump does not require special maintenance.
The following rules must be observed for safe operation:
If the pump is not going to be used for a long period, the pump should be drained of water and flushed with clean water.
Where the pump is exposed to freezing temperatures, it should always be left drained when not in use.
*All specifications subject to change without notice.

(t) 803 327-5005 • (f) 803 327-5097 rev. 01/07

(t) 803 327-5005 • (f) 803 327-5097 rev. 01/07
Contact your dealer or supplier
for more information about other EBARA products

1651 Cedar Line Drive • Rock Hill, SC 29730
(t) 803 327 5005 • (f) 803 327 5097
www.pumpsebara.com
© 2005 EBARA International Corporation EFH 3U_3UB0107
Electronic Metering Pumps
Series C, C PLUS, A PLUS, E, E-DC, E PLUS and HV
Installation
Operation
Maintenance
Instruction
READ ALL WARNINGS CAREFULLY

BEFORE INSTALLING
TABLE OF CONTENTS
Page
1.0 SAFETY INSTRUCTIONS .................................................................................. 3

1.1 General Safety Considerations .................................................................. 3
1.2 Safety Operating Procedures ..................................................................... 3
2.0 UNPACKING THE PUMP ................................................................................... 6
3.0 INTRODUCTION ................................................................................................ 6

3.1 Principle of Operation ................................................................................ 6
3.2 Materials of Construction .......................................................................... 6
4.0. INSTALLATION ................................................................................................. 7

4.1 Mounting................................................................................................... 7
4.2 Piping ....................................................................................................... 9
4.3 Wiring ...................................................................................................... 10
4.4 Well Pump System Installation ................................................................. 10
5.0 START UP AND OPERATION ........................................................................... 11

5.1 Power ...................................................................................................... 11
5.2 Priming ...................................................................................................... 11
5.3 Capacity Control ....................................................................................... 13
5.3.1 Stroke Frequency Adjustment ...................................................... 13
5.3.2 Stroke Length Adjustment ............................................................ 13
5.3.3 Controlling Procedure ................................................................... 13
5.4 Control Panel Symbols ............................................................................. 14
5.5 Operation By External Input Signals ......................................................... 15
5.5.1 Stop Functions ............................................................................. 15
5.5.2 External Pacing Function .............................................................. 15
5.5.3 4-20mA DC Input Function ........................................................... 16
6.0. MAINTENANCE ............................................................................................... 17

6.1 Routine Maintenance ............................................................................... 17
6.2 Disassembly and Assembly Diaphragm Removal .................................... 18
6.3 Diaphragm Replacement ........................................................................... 18
6.4 Valve Replacement .................................................................................... 19
7.0 TROUBLESHOOTING ....................................................................................... 20
8.0. POLICIES AND PROCEDURES ......................................................................... 23

8.1 Manufacturer's Product Warranty ............................................................ 23
8.2 European Technical File Location ............................................................. 23
8.3 Returns ..................................................................................................... 24
8.4 Credits ...................................................................................................... 24
2
1.0 SAFETY INSTRUCTIONS
When using chemical feed pumps, basic safety pre-

cautions should always be followed to reduce risk of
fire, electric shock, and personal injury. Failure to
follow these instructions could result in death or
serious injury.
READ ALL INSTRUCTIONS
1.1 GENERAL SAFETY CONSIDERATIONS
• Always wear protective clothing including gloves and safety goggles when
working on or near chemical metering pumps.
• Inspect tubing regularly when replenishing chemical solution for cracking or

deterioration and replace as necessary. (Always wear protective clothing and
safety glasses when inspecting tubing.)
• When pump is exposed to direct sunlight use U.V. resistant tubing.
• Follow directions and warnings provided with the chemicals from the chemical
manufacturer. User is responsible for determining chemical compatibility with
chemical feed pump.
• Secure chemicals and metering pumps, making them inaccessible to children and
pets.
• Make sure the voltage on the chemical metering pump matches the voltage at the
installation site.
• Do not cut plug or the ground lug off of the electrical cord – consult a licensed
electrician for proper installation.
• Pump is NOT to be used to handle flammable liquids.
1.2 SAFETY OPERATING PROCEDURES
Each Electronic Metering Pump has been tested to meet prescribed specifications and
safety standards.
Proper care in handling, installation and operation will help in ensuring a trouble free
installation.
3
Please read all these cautionary notes prior to installation and start-up of your
metering pump.
Important: Pump must be installed and used with supplied back pressure/injection
valve. Failure to do so could result in excessive pump output.
• Handle the pump with care. Dropping or heavy impact causes not only external
damage to the pump, but also to electrical parts inside.
• Install the pump in a place where the ambient temperature does not exceed 104°F
(40°C). The pump is water resistant and dust proof by construction and can be
use outdoors, however do not operate the pump submerged. To avoid high
internal pump temperatures, do not operate in direct sunlight.
Solenoid housing, head and pump housing may be hot to touch

160oF (70oC).
• Install the pump in a place convenient for its future maintenance and inspection,
and then secure it to prevent vibration.
• Protective caps must be removed prior to installing tubing onto valve assemblies.
Use tubing of specified size. Connect the tubing to the suction side securely to
prevent the entrance of outside air. Make sure that there is no liquid leakage on
the discharge side.
• Be careful to check that the voltage of the installation matches voltage indicated
on the pump data label. Most pump models are equipped with a three-prong plug.
Always be sure the pump is grounded. To disconnect, do not pull wire but grip
the plug with fingers and pull out. Do not use the receptacle in common with heavy
electrical equipment, which generates surge voltage. It can cause failure of the
electronic circuit inside the pump.
• Tampering with electrical devices can be potentially hazardous. Always place

chemicals and pump installation well out of the reach of children.
• Never repair or move the metering pump while operating. Always disconnect
electrical power. For safety, always wear protective clothing (protective gloves
and safety glasses) when working on or near chemical metering pumps.
• An air bleed valve is available for most models with tubing connections. Air
purges should be performed when the pump-chamber contains no fluid at the time
of start-up. As a safety measure, connect the return tubing to the air bleed valve
and bypass fluid back to storage tank or a suitable drain.
• For accurate volume output, the pump must be calibrated under typical operating
conditions.
4
• Chemicals used may be dangerous and should be used carefully and according
to warnings on the label. Follow the directions given with each type of chemical.
Do not assume chemicals are the same because they look alike. Always store
chemicals in a safe location away from children and others. We cannot be
responsible for the misuse of chemicals being fed by the pump. Always have the
material safety data sheet (MSDS) available for any fluid being pumped.
• All pumps are pretested with water before shipment. Remove head and dry
thoroughly if you are pumping a material that will react with water, (i.e. sulfuric
acid, polymers). Valve seats, ball checks, gaskets, and diaphragm should also be
dried. Before placing pump into service, extreme care should be taken to follow
this procedure.
• Valve cartridges are stamped to indicate fluid flow direction. Always install so
that markings read from top to bottom, with the arrow pointing in the direction of
flow.
• When metering hazardous material DO NOT use plastic tubing, strictly use proper
rigid pipe. Consult supplier for special adapters or valve assemblies.
• Pump is NOT to be used to handle or meter flammable liquids or materials.
• Standard white discharge tubing is not recommended for installations exposed

to direct sunlight. Consult supplier for special black tubing.
• Factory will not be held responsible for improper installation of pump, or

plumbing. All cautions are to be read thoroughly prior to hookup and plumbing.
For all installations a professional plumber should be consulted. Always adhere
to local plumbing codes and requirements.
• When using pump with pressurized systems, make sure the pressure of the system
does not exceed the maximum pressure rating on the pump data label. Be sure to
depressurize system prior to hook up or disconnecting a metering pump.
• Electronic power modules are equipped with automatic reset thermal overload
devices and may reset unexpectedly.
5
2.0 UNPACKING THE PUMP
Check all equipment for completeness against the order and for any evidence of shipping
damage. Shortages or damages should be reported immediately to the carrier and to the
seller of the equipment.
The carton should Contain:
-Metering Pump
-Clear Flexible Suction Tubing*
-Stiff White Discharge Tubing*
-Foot valve/Strainer Assembly
-Backpressure Injection
Valve Assembly
-Manual
-Bleed Valve Assembly*
-Strainer Weight*
FIGURE 1
*Items may or may not be included depending on model.
Make sure that all items have been removed from the shipping carton before it is discarded.
3.0 INTRODUCTION
These installation, operation and maintenance instructions cover your electronic metering
pump. Refer to the pump data label to determine the actual model.
3.1 PRINCIPLE OF OPERATION
Diaphragm metering pumps are used to dispense chemicals or fluids. This is

achieved by an electromagnetic drive mechanism (solenoid), which is connected to
a diaphragm. When the solenoid is pulsed by the control circuit it displaces the
diaphragm, which, through the use of check valves, moves the fluid out the
discharge under pressure. When the solenoid is de-energized it returns the
diaphragm and pulls more fluid into the pump head and the cycle repeats.
The pump stroke rate is controlled by an internal circuit and is changed by turning
the rate knob. The mechanical stroke length is controlled by the stroke length
knob. Some models do not allow stroke rate control and do not have the stroke
rate knob.
3.2 MATERIALS OF CONSTRUCTION
The wetted materials (those parts that contact the solution being pumped)
available for construction are FPP (glass filled polypropylene), PVC, SAN,
Hypalon, Viton, Teflon, 316 Stainless Steel, PVDF, Ceramic and Alloy C. These
materials are very resistant to most chemicals. However, there are some chemicals,
such as strong acids or organic solvents, which cause deterioration of some
elastomer and plastic parts, such as the diaphragm, valve seats, or head.
6
3.2 MATERIALS OF CONSTRUCTION cont'd.
Consult a Chemical Resistance Guide or Supplier for information on chemical

compatibility.
Various manufacturers of plastics, elastomers and pumping equipment publish

guidelines that aid in the selection of wetted materials for pumping commercially
available chemicals and chemical compounds. Two factors must always be
considered when using an elastomer or plastic part to pump chemicals. They are:
• The temperature of service: Higher temperatures increase the effect of chemi-

cals on wetted materials. The increase varies with the material and the chemical
being used. A material quite stable at room temperature might be affected at
higher temperatures.
• Material choice: Materials with similar properties may differ greatly from one
another in performance when exposed to certain chemicals.
4.0 INSTALLATION
The metering pump should be located in an area that allows convenient connections
to both the chemical storage tank and the point of injection. The pump is water
resistant and dust proof by construction and can be used outdoors, however, do not
operate submerged. Avoid continuous temperatures in excess of 104°F (40°C). To
do otherwise could result in damage to the pump.
4.1 MOUNTING
Typical mounting arrangements are shown in Figures 3, 4, and 5.
Important: Injection point must be higher than the top of the solution supply
tank to prohibit gravity feeding, unless suitable backpressure is
always present at the injection point. Installation of an antisiphon
valve will prohibit gravity feeding.
• ALL HIGH VISCOSITY PUMPS (SERIES HV) REQUIRE FLOODED

SUCTION.
• For wall or shelf mounting refer to Figure 3. Connect suction tubing to suction
valve of chemical pump. Suction valve is the lower valve. Tubing should be
long enough so that the foot valve/strainer assembly hangs about 1-2 inches
(2-5 cm) above the bottom of chemical tank. To keep chemical from being
contaminated, the tank should have a cover.
7
• Flooded suction mounting (installing the pump at the base of the chemical
storage tank, Figure 4) is the most trouble free type of installation and is
recommended for very low output requirements. Since the suction tubing is
filled with chemical, priming is accomplished quickly and the chance of losing
prime is reduced.
To mount pump, drill four holes of .25” (6 mm) diameter in the shelf as shown in
the dimension drawing (Figure 2). Attach pump securely using four #10 (M5) bolts
and nuts.
• The pump can be mounted on

top of a solution tank as shown
in Figure 5. Install chemical pump
on the cover. Insert suction tub-
ing through the center hole and
cut tubing so foot valve/strainer
hangs about 1 or 2 inches (2-5
cm) above the bottom of the tank.
Mount the chemical pump rig-
idly by drilling four .25” (6 mm)
holes and using four #10 (M5) FIGURE 2
screws and nuts.
• USE AN ANTI-SIPHON VALVE IN THE DISCHARGE LINE whenever the

fluid pressure in the discharge line is below atmospheric pressure. This can
occur if the injection point is on the suction side of a water pump or against
a "negative" head such as when feeding down into a well.
FIG. 3 FIG. 4
FIG. 5
8
4.2 PIPING
• Use provided tubing of specified size for connection. Connect tubing securely
to prevent leakage of chemical and the entrance of air. Since plastic nuts are
used for fittings, they should not be tightened excessively (i.e. hand tighten
only). NPT suction and discharge valves must NOT be over tightened. Hold
fitting in place while adding piping and fittings. NPT suction and discharge
valves should only be tightened 25 to 35 in. lbs. (4.5-6.3 kg/cm).
• If the air bleed valve assembly is being used, a return line (tubing) should be
securely connected and routed back to the storage tank. To avoid possible
injury from chemicals do not attempt to prime using a bleed valve without
installing a return line.
• When pump is shelf mounted or top mounted on tank, suction tubing should
be kept as short as possible.
• To maintain metering performance, a backpressure/injection valve is provided.
The spring in the standard injection valve typically adds 17 - 20 PSI (1.17 - 1.38
BAR) to the line pressure, with the exception of the H8 pump, which adds 8 - 10
PSI (.55 - .69 BAR). The injection valve must be installed in the discharge line.
Best practice is to install the injection valve at the point of chemical injection.
• If the discharge tubing is going to be exposed to direct sunlight, black tubing
should be used instead of the standard white translucent tubing supplied with
each pump. To obtain, contact supplier.
• To prevent clogging or check valve malfunction always install a strainer
assembly to the end of the suction tubing (Figure 5). This foot valve/strainer
assembly should always be installed 1 to 2 inches (2-5 cm) above the bottom
of the chemical tank. This will help prevent clogging the strainer with any solids
that may settle on the tank bottom. The chemical tank and foot valve/strainer
should be cleaned regularly, to ensure continuous trouble free operation. If
the chemical being pumped regularly precipitates out of solution or does not
dissolve easily or completely (e.g. calcium hydroxide), a mixer should be used
in the chemical tank. These are readily available in many motor configurations
and mounting. To obtain, contact supplier.
• A flooded suction (tank liquid level always at a higher
elevation than the pump) is recommended when pumping
solutions such as sodium hypochlorite (NaOCl),
hydrogen peroxide (H2O2), etc., which are likely to
produce air bubbles. Maintaining a low liquid temperature
will also help eliminate this problem.
• Pipe corrosion can result if dilution at the injection point
does not occur rapidly. This problem is easily prevented
by observing this simple rule: install injection fitting so
that the end is in the center of the flow stream of the line
being treated. Trim injector tip as required. See Figure
6. Note: Extended injection assemblies are available for
large water lines. Consult your supplier for more
information. FIGURE 6
9
4.3 WIRING
• —Risk of electrical shock. This pump is supplied with a

three-prong grounding type power plug. To reduce risk of electric shock,
connect only to a properly grounded, grounding type receptacle.
• The metering pump should be wired to an electrical source, which conforms

to those on the pump data label. Applying higher voltage than the pump is
rated for will damage the internal circuit.
• In the electronic circuit of the control unit, measures for surge voltage are
made by means of surge absorbing elements and high voltage semiconduc-
tors. Nevertheless, excessive surge voltage may cause failure in some areas.
Therefore, the receptacle should not be used in common with heavy electrical
equipment, which generates high voltage. If this is unavoidable however,
measures should be taken by (a) the installation of a surge-absorbing element
(varistor of min. surge resistance 2000A) to the power supply connection of
the pump, or (b) the installation of a noise suppression transformer.
• Signal input to the external pulse signal input terminals ([EXTERNAL], [STOP])
must be a no-voltage signal from relay-contacts etc. and the input of other
signals is prohibited. (In the case of relay contacts, 100 ohms or below when
ON and 1-meg ohms or above when OFF). The pulse duration of the input signal
must be 10 milliseconds or over and the frequency of the input signal must not
exceed 125 times per minute. Signal cord is provided with the pump.
4.4 WELL PUMP SYSTEM INSTALLATION
Ensure that the metering pump voltage matches

the voltage of the well pump. Typical well pump
electrical circuits are shown in Figure 8. All elec-
tric wiring should be installed in accordance to
local codes by a licensed electrician.
Install the backpressure/injection (Figure 7) on
the discharge side of the metering pump into a
FIGURE 7
tee which is installed into the water line going to
the pressure tank.
Pumps carrying the "ETL Sanitation" (tested to NSF Standard-50) marks are listed for
swimming pools, spas and hot tubs, and when proper materials are selected, are capable
of handling but not linited to the following chemical solutions:
12% ALUMINUM SULPHATE, 5% SODIUM CARBONATE,
2% CALCIUM HYPOCHLORITE, 10% SODIUM HYDROXIDE,
12.5% SODIUM HYPOCHLORITE, 10% HYDROCHLORIC ACID
10
FIGURE 8
5.0 START UP AND OPERATION

5.1 POWER
All metering pumps are available in 115 and 230 volts at 50/60 Hertz, single phase.
In addition, certain models are available in 12 volt DC. Prior to start-up always
check to insure that the pump voltage/frequency/phase matches that of the power
supply.
If pump is fitted with a PVC pump head (7th position of model

number is “V” or "W". Note: PVC is gray, not black), uniformly
hand tighten the four head screws before use, 18-22 in. lbs.
(3.2 -3.9 kg/cm). Periodically tighten after installation.
5.2 PRIMING
When working on or around a chemical metering pump instal-

lation, protective clothing and gloves and safety glasses should
be worn at all times.
All pumps are tested with water. If the chemical to be pumped

reacts when mixed with water (e.g. sulfuric acid, polymer) the
pump head should be removed and dried thoroughly along with
the diaphragm and valve seats.
11
• Turn on the power to the pump. The green LED (not available on all mod-
els) will light up and flash off each time the pump strokes.
• Adjust the stroke rate knob to the 100% setting mark (for more information
see Section 5.3, Capacity Control).
• Adjust the stroke length knob to the 100% setting mark if applicable (for
more information see Section 5.3, Capacity Controls).
• If the discharge line is connected directly to a pressurized system it should

be temporarily bypassed during priming of the pump. A bleed valve will
simplify this operation by allowing easy bypass of the discharge fluid. Air
must be purged from the pumphead before the pump will operate against
pressure. (See Figure 9)
Air Bleed Operation:

• While pump is running, turn adjustment knob
counterclockwise.
• Run with valve open until a solid stream of fluid
comes out of the bypass tubing with no air
bubbles.
• Close air bleed valve by turning adjustment
FIGURE 9
screw clockwise.
• Chemical should reach the pump head after a few minutes of operation. If
not, remove the discharge fitting and moisten the discharge valve area (ball
check and valve seats) with a few drops of chemical being fed to the meter-
ing pump. For safety, always use protective clothing and gloves, wear safety
glasses and use a proper container to hold the chemical.
• If the pump continues not to prime, refer to Section 7.0, Troubleshooting, of

these instructions.
• Once the pump has been primed and is pumping the chemical through the
head, turn off the power, reconnect the discharge tubing (if it had been
removed) and immediately clean any spilled chemical that is on the pump
housing or head.
• Turn the power on once more and adjust the pump flow to the desired rate
(see Section 5.3.3, Controlling Procedure).
• Always check the calibration of the pump after start-up. It’s best to calibrate
the pump under your typical use conditions.
12
5.3 CAPACITY CONTROL
Capacity can be controlled by means of the stroke length adjusting knob and/or
stroke rate adjusting knob (except model C pumps). Control knobs provide coarse
adjustment; use a calibration column for accurate calibration. Contact your pump
supplier for proper calibration equipment.
5.3.1 Stroke Frequency Adjustment (E, E-DC, E Plus, HV, A Plus & C Plus only)
• Stroke frequency can be controlled

from 10 to 100% (12 to 125 strokes per
minute) by means of the electronic
circuit.
• Stroke frequency can be set by means

of the stroke rate adjusting knob even
while the pump is in operation. (See
Figure 10)
5.3.2 Stroke Length Adjustment
• Stroke length can be controlled within

0 to 100% of the diaphragm displace-
ment. It should be controlled within 20
to 100% for practical use.
• Stroke length can be set by means of

the stroke length adjusting knob while
the pump is in operation. Do not turn FIGURE 10
the knob while the pump is stopped.
5.3.3 Controlling Procedure
Proper set points for stoke length and stroke frequency should be determined
after consideration of the pump and characteristics of the fluid. The following
procedure is recommended from the viewpoint of pump performance. Note:
The closer the stroke length is to 100%, the better the pump performance
will be.
• Set the stroke length to 100% then adjust the stroke frequency for
coarse capacity control.
• Measure the capacity.
• When the measured capacity is less than the required value,
increase the stroke frequency and measure the capacity again.
• Then, adjust the stroke length for fine capacity control.
• Finally, measure the capacity and make sure that the required value
is obtained.
13
5.3.3 Controlling Procedure cont'd.
Example Selected Model = LPD4

Set Stroke Length = 100%
Set Stroke Rate = 100%
Output Capacity = 21 gallons per day (GPD)*
(Rated Pressure)
Desired Flow = 15 GPD

Adjust Stroke Rate to 80%
Output Capacity = 0.80 x 21 = 16.8 GPD*
Stroke Length Setting = 15 x 100 = 90% approximate

16.8
Thus to obtain the desired flow, stroke length is set at 90% and stroke rate
is set at 80% i.e. output capacity = 0.90 x 0.80 x 21 = 15.12 GPD*
*IMPORTANT!
Check these values by measurement. Output capacity is higher when
feeding against less than rated pressure
5.4 CONTROL PANEL SYMBOLS
The pumps come with universally accepted symbols, the following is pro-
vided for your convenience.
FIGURE 11
14
5.5 OPERATION BY EXTERNAL INPUT SIGNALS (Options):
The pump can be controlled by three types of input signals. All are fully isolated
from AC input and from earth ground. The input socket connections are located
at the bottom of the control panel face and the signal cords are provided with the
pump. Remove rubber plugs to access plug sockets.
5.5.1 STOP FUNCTION (E Plus, HV, A Plus, C Plus & C only)
Operation of the pump can be stopped by an external signal input. When

the external signal is input to the terminal marked which is provided at the
bottom of the control panel, the lamp (red) lights up and operation of the
pump is stopped. The stop function overrides both manual settings and
external input.
Operation of more than one pump from the same contact closure
will damage the pump circuits. When such operation is required,
the pump circuits must be electrically isolated from one another
by means of a multicontact control relay or similar means.
• The input signal must be in the form of closure of a mechanical relay or

other mechanical switching device, or solid-state relay or other solid-
state switching device. Voltage signals are prohibited. The switching
resistance of either mechanical or solid-state devices must be 100 ohms
or below when ON and 1 megohm or above when OFF. If any type of
solid-state device is employed, it must be installed with the proper
polarity, if required for the device; and leakage current must not exceed
200 microamperes to prevent false triggering in the OFF state.
The stop function is commonly used in conjunction with a tank float switch.
The float switch contacts are normally open but when the tank level falls past
a certain point the contacts close and the pump stops.
5.5.2 EXTERNAL PACING FUNCTION (E Plus, HV, A Plus, C Plus & C only)
The pump's stroke rate can be controlled by an external signal input. When
the input signal line is connected and the EXTERNAL /OFF /MANUAL
switch is in the external position and a contact signal is input to the terminal
marked , the pump makes one discharge stroke.
Operation of more than one pump from the same contact closure
will damage the pump circuits. When such operation is required,
the pump circuits must be electrically isolated from one another
by means of a multicontact control relay or similar means.
15
• When the “ON” signal pulse is input, the pump operates one stroke
and the fluid is discharged. In addition, the pump can be operated
continuously at a rate of up to 125 strokes/min. by repeated input of
“ON” and “OFF” signals.
• After receiving an input signal, the pump generates the necessary
power pulse to actuate the solenoid. The external signal input is
debounced by the pump circuit. The pump will not stroke in response
to a spurious or erratic input signal that follows at a rate greater than
125 spm. If the external signal rate exceeds 125 spm, the pump will
stroke at half the external signal rate to prevent overdosing and to
protect the pump from overheating.
• The input signal must be in the form of closure of a mechanical relay,
other mechanical switching device, or of a solid-state switching
device. Voltage signals are prohibited. The switching resistance of
either mechanical or solid-state devices must be 100 ohms or below
when ON and 1 megohm or above when OFF. If any type of solid-state
device is employed, it must be installed with proper polarity, if required
for the device; and leakage current must not exceed 200 microamperes
to prevent false triggering in the OFF state.
• Cycle rate of the input signal should not exceed 125 times per minute.
• Typical wiring is shown at right
for use with switch closure
flowmeters. (Figure 12)
• 10 millisecond contact time re-
quired for each “ON” input sig-
nal. FIGURE 12
5.5.3 4-20mA DC INPUT FUNCTION (E Plus only)
The pump’s stroke rate can also be controlled by a 4-20 mA DC signal to the
terminal marked [4-20 mA].
• For the 4-20 mA input to have any effect on the pump output rate, the
AUTO/OFF/MANUAL switch must be in the AUTO position.
• The 4-20 mA input signal affects the pump’s outputs as per the graph
below:
FIGURE 13
16
5.5.3 4-20mA DC INPUT FUNCTION cont'd.
• The signal cord polarity is:

Black = Common
White = Positive
Wrong polarity can result in excess flow.
Signal input impedance is 124 ohms.
Remove cap from pump socket labeled 4-20 mA, use polarized cord supplied
with pump to connect control circuit to pump. Plug cord into pump socket
labeled 4-20 mA.
6.0 MAINTENANCE
Before performing any maintenance or repairs on chemical
metering pumps, be sure to disconnect all electrical connec-
tions, insure that all pressure valves are shut off and pressure
in the pump and lines has been bled off.
Always wear protective clothing, gloves and safety glasses when

performing any maintenance or repairs on chemical metering
pumps.
6.1 ROUTINE MAINTENANCE
• Routinely check the physical operating condition of the pump. Look for the
presence of any abnormal noise, excessive vibration, low flow and pressure
output or high temperatures [when running constantly at maximum stroke
rate, the pump housing temperature can be up to 160°F (70°C)].
• For optimum performance, cartridge valves should be changed every 6-12
months. Depending on the application, more frequent changes may be
required. Actual operating experience is the best guide in this situation.
• Repeated short-term deterioration of valve seats and balls usually indicates
a need to review the suitability of wetted materials selected for the applica-
tion. Contact the supplier for guidance.
• Check for leaks around fitting or as a result of deteriorating tubing e.g. when
standard white translucent discharge tubing is exposed to direct sunlight.
Take appropriate action to correct leak by tightening fittings or replacing
components.
• Keep the pump free of dirt and debris as this provides insulation and can lead
to excessive pump temperatures.
17
• If the pump has been out of service for a month or longer, clear the pump head
valve assemblies by pumping fresh water for approximately 30 minutes. If
the pump does not operate normally after this “purging run”, replace
cartridge valve assemblies.
6.2 DISASSEMBLY AND ASSEMBLY

DIAPHRAGM REMOVAL
Flush pump head and valve assemblies out by running pump with water or other
suitable neutralizing solution. Wash outside of pump if chemical has dripped on
pump. Set stroke length knob of pump to 0% and unplug pump.
Depressurize the system and disconnect tubing or piping from the pump. Remove
the four pump head screws and then remove the pump head assembly.
Remove the diaphragm by grasping it at the outer edge and turning it counter
clockwise until it unscrews from the electronic power module (EPM). Don’t lose
the deflector plate or diaphragm shims which are behind the diaphragm, they are
needed for re-assembly. Note shim quantity may be from 0 to 2.
Inspect diaphragm, if it is intended to be used again look for indications of the

Teflon face being overstretched, (localized white areas) or the elastomer on the
back of the diaphragm being worn. Excessive amounts of either condition require
diaphragm replacement.
6.3 DIAPHRAGM REPLACEMENT
• When replacing the diaphragm, it is

always a good idea to replace the valve
cartridges and other worn parts. A kit
is available from your supplier with all
parts necessary to completely rebuild
your pump’s wet end. All your sup-
plier needs to know is the “KOPkit
No.” on your pump’s data label to
supply this kit.
• Set pump stroke length at 50% and FIGURE 14

unplug the pump.
• If you kept the shims from the original diaphragm or know the original
quantity you can avoid the next step for shimming the diaphragm.
18
6.3 DIAPHRAGM REPLACEMENT cont'd.
• Apply grease to areas of the diaphragm that contact the deflection plate.
• Slide the diaphragm deflection plate onto the back of the diaphragm stud,
radius side towards the diaphragm. Next slide two shims onto the diaphragm
threaded stud and screw the diaphragm into the EPM unit. Refer to Figure
14. Turn diaphragm clockwise until deflection plate and shims are tight against
solenoid shaft and the diaphragm stops turning. If there is a gap between the
adaptor and diaphragm, repeat the procedure removing one shim each time
until the diaphragm just touches the adaptor or is slightly recessed.
• If not already done, adjust stroke length to 50%. Place the pump head onto
the adaptor with valve flow arrows pointing up and install and tighten pump
head screws. Tighten screws until pump head pulls up against adaptor.
NOTE: Adjust stroke length only when pump is running!
• Adjust stroke length back to 100% for easier priming and place pump back into
service.
6.4 VALVE REPLACEMENT
• Flush pump to clean any chemical from pump head.

• Unplug pump, release system pressure, and disconnect tubing or piping.
• Unscrew valve cartridges and discard. Also remove o-rings down inside the
pump head.
• Install new valve cartridges with stamped letters reading from top to bottom,
and the arrow pointing in the direction of flow. Hand tighten only, do not use
wrenches or pliers. This is especially important when the pump head is made
of SAN material.
• Reconnect tubing or piping and reinstall the pump.

• Check for leaks around newly installed fittings.
19
7.0 TROUBLESHOOTING
PROBLEM PROBABLE CAUSE REM EDY
1. Leak in suction side of 1. Examine suction tubing. If

pump. worn at the end , cut
approximately one inch (2.5
cm) off and reconnect.
2. Valve seats not sealing. 2. Clean valve seats if dirty or

replace with alternate material
if deterioration is noted.
3. Low setting on pump. 3. When pumping against

pressure, the dial should be
set above 20% capacity for a
reliable feed rate.
4. Low suction level. 4. Solution must be above foot

valve strainer.
5. Diaphragm ruptured. 5. Replace diaphragm as shown

in 6.0 "Maintenance Section".
Check for pressure above
rated maximum at the injection
point. NOTE: Chemical
incompatibility with diaphragm
FAILURE TO
material can cause diaphragm
PUM P rupture and leakage around
the pump head.
6. Pump head cracked or 6. Replace pump head as shown

broken. in 6.0 "Maintenance Section".
Make sure fittings are hand
tight only. Using pliers and
wrench can crack pump head.
Also, chemical incompatibility
can cause cracking and
subsequent leakage.
7. Pump head contains air or 7. Bleed pump head, see 5.0

chlorine gas. "Start- up and Operation".
8. Breakdown or disconnection 8. Connect wiring properly.

of wiring. Check fuse or circuit breaker.
9. Voltage drop. 9. Take measures after

investigation of cause.
10. Malfunction of electronic 10. Contact supplier.

control board.
20
7.0 TROUBLESHOOTING cont'd.
1. Pump setting too low. 1. Adjust to higher setting

(pump must be operating to
adjust stroke length knob).
Clean injection parts with

LOSS OF 2. Scale at injection point. 2. 8% muriatic acid or
CHEM ICAL undiluted vinegar. (Also,
RESIDUAL see Maintenance Section).
Refill the tank with solution

3. Solution container allowed 3. and prime. (See Start- up
to run dry and Operation Section).
1. Pump setting too high. 1. Lower pump setting (pump

must be operting to adjust
stroke length knob).
2. Chemical in solution tank 2. Dilute chemical solution.

too rich. NOTE: For chemical that
reacts with water, it may be
TOO M UCH
necessary to purchase a
CHEM ICAL more dilute grade of chemical
direct from chemical supplier.
3. Siphoning of chemical into 3. Test for suction or vacuum at

well or main line. the injection point. If suction
exists, install an antisiphon
valve.
1. Worn tube ends. 1. Cut off end of tubing (about

LEAKAGE 1 in/2.5 cm) and then
reconnect as before.
AT TUBING
CONNECTIONS 2. Chemical attack. 2. Consult your seller for
alternate material.
1. Loose fittings. 1. Tighten hand tight. Replace

gasket if hand tightening does
not stop leakage.
LEAKAGE AT
2. Broken or twisted gasket. 2. Check gaskets and replace if
FITTING broken or damaged.
3. Chemical attack. 3. Consult your pump supplier

for alternate material.
21
7.0 TROUBLESHOOTING cont'd.

1. Dirty check valve. 1. Remove and replace or clean
off any scale or sediment.
2. Ball checks not seating or not 2. Check seat and ball checks for
sealing properly. chips, clean gently. If deformity
or deterioration is noted,
replace part with proper
material. Resulting crystals can
hold check valves open,
PUM P LOSES therefore, the valves must be
PRIM E disassembled and cleaned.
3. Solution container allowed to run 3. Refill the tank with solution and
dry. prime. See 5.0 (Start- Up and
Operation Section).
4. Chemical Outgassing. 4. Bleed gas, use flooded suction

and maintain chemical at room
temperature (approx. 20oF) to
minimize outgassing.
1. Too much pressure at discharge. 1. Turn off all pressure valves,

relieve system pressure then
loosen outlet tubing connection
at discharge point. Remove
discharge valve cartridge.
Dampen ball check and valve
seats with a few drops of solu-
tion. Set pump dial to maximum
rate. When pump is primed,
reconnect all tubing connectors.
2. Check valves not sealing. 2. Disassemble, clean & check for

deterioration, damage or swelling.
Reassemble and wet the valve
PUM P WILL assembly, then prime. See 5.0
NOT PRIM E (Start- Up & Operting Section).
3. Output dials not set at maximum. 3. Always prime pump with output
dial set at maximum rated
capacity.
4. Suction lift height too much. 4. Decrease suction lift or pull

Maximum 5 ft (1.5 m) vacuum on pump discharge
until pump is primed.
5. Pump equipped with spring loaded 5. Loosen discharge valve to aid in

high viscosity valves. priming, take necessary safety
precautions for spills, or apply
vacuum to pump discharge.
22
8.0 POLICIES AND PROCEDURES
8.1 MANUFACTURERS PRODUCT WARRANTY
The manufacturer warrants its equipment of its manufacture to be free of defects

in material or workmanship Liability under this policy extends for eighteen (18)
months from the date of purchase or one (1) year from date of installation or
whichever comes first. The manufacturer’s liability is limited to repair or replace-
ment of any device or part, which is returned, prepaid, to the factory and which
is proven defective upon examination. This warranty does not include installation
or repair cost and in no event shall the manufacturer’s liability exceed its selling
price of such part.
The manufacturer disclaims all liability for damage to its products through
improper installation, maintenance, use or attempts to operate such products
beyond their functional capacity, intentionally or otherwise, or any unauthorized
repair. Replaceable elastomeric parts are expendable and are not covered by any
warranty either expressed or implied. The manufacturer is not responsible for
consequential or other damages, injuries or expense incurred through use of its
products.
The above warranty is in lieu of any other warranty, either expressed or implied.
The manufacturer makes no warranty of fitness or merchantability. No agent of
ours is authorized to make any warranty other than the above.
For warranty and service matters within the European Union, contact the seller
first or:
Pulsafeeder Europe
Marssteden 68
7547 AD Enschede
The Netherlands
8.2 EUROPEAN TECHNICAL FILE LOCATION
P.O. Box 91
Washington
NE371YH
United Kingdom
23
8.3 RETURNS
The Customer Service Department will issue a Return Authorization (RA) number
for all returns. The following information will be required:
1. Billing and a ship-to address.

2. Model and serial number.
3. Contact name and phone number.
4. Reason for return.
5. Purchase order (where applicable).
6. RA number on outside of the carton.
All material must be returned freight prepaid. All merchandise must be properly
packaged and free of any corrosive, toxic or otherwise hazardous chemical. All
items returned must reference Return Authorization.
8.4 CREDITS
No equipment will be accepted beyond six months after date of shipment from the
factory. Only unused and undamaged equipment will be accepted for return to
stock. All credits are based on acceptance of materials as new and unused by our
inspection personnel. A restocking fee will apply. All equipment returned for
credit must have a RA number and be returned freight prepaid.
L9408900-000
G03
Wave Cyber (Shanghai) Co., Ltd.
8” Side Port Membrane Housing User’s Guide
If you want to get more information of Wave Cyber Products, please visit our website
http://www.wave-cyber.com
Page 1
WAVE CYBER MPV SERIES - SIDEPORT
OPERATION AND MAINTENANCE GUIDE
WAVE-8-150-P WAVE-8-300-P WAVE-8-450-P WAVE-8-600-P WAVE-8-1000-P
.150 .300 .450 .600 1000

.PSI .PSI .PSI .PSI .PSI
DANGER - High Pressure Device

This vessel may cause loss of life, severe bodily harm, and/or property damage if
not correctly installed, operated and maintained. Read and understand all guidelines
given before attempting to open, service or operate this vessel.
Failure to follow these guidelines and observe every precaution may result in
malfunction and could result in explosive head failure.
Misuse, incorrect assembly or use of damaged or corroded components can result

in explosive release of the end closure.
We recommend that only qualified mechanics, experienced in servicing high

pressure hydraulic systems, open, close and service this vessel.
This section is a guide to proper operation and maintenance of Wave Cyber

pressure vessel series. Good industrial practice must be used in applying this
information to assure safe vessel use. These guidelines are not intended to relieve the
user from full responsibility for correct operation and maintenance of the vessels.
For technical specifications and dimensions, refer to the Engineering Drawing of

each specific model.
The information in all sections must be carefully followed for the vessel to
provide the safe, long service life for which it is designed.
Page 2
CONTENTS
SECTION 1 OPERATION / MAINTENANCE GUIDE ……………………… 4
SECTION 2 PIPING CONNECTIONS……………………………………….. 5
SECTION 3 ELASTICITY AND MOUNTING REQUIREMENTS………… 6
SECTION 4 INSTALLATION GUIDE……………………………………… 7

MOUNTING SHELL………………………………….. 7
ELEMENT LOADING ………………………………… 9
MOUNTING HEAD ASSEMBLY…………………… 11
REMOVING HEAD ASSEMBLY…………………… 15
SECTION 5 SUITABILITY FOR INTENDED USE……………………… 17
SECTION 6 SAFETY……………………………………………………… 18
SECTION 7 TROUBLESHOOTING……………………………………… 19
SECTION 8 MEMBRANE HOUSING ASSEMBLY DRAWING……….
SECTION 9 (HIGH FLOW) PRESSURE DROP TEST GRAPH…………
Page 3
SECTION 1
OPERATION/MAINTENANCE GUIDE
Proper vessel handling and installation are important to safe use and long vessel
life. These guidelines should be followed carefully; however, they do not relieve the
purchaser from full responsibility for proper inspection, handling and installation.
Damage due to improper handling or installation is the sole responsibility of the
purchaser.
Improper assembly, misuse or corrosion damage can result in mechanical failure,

property damage and serious injury or death. Read and follow all instructions
carefully. Pay particular attention to the safety precautions given in this Operation
and Maintenance section. Should any information in this guide not agree with the
system supplier’s instructions, call Wave Cyber for clarification.
Corrections or recommendations for improvement of this manual should be

addressed to:
Wave Cyber (Shanghai) Co., Ltd.

No. 2, SongChun Road, SongZe Industries Zone, Shanghai New City, QingPu
District, 201703 Shanghai China
Tel: 86-21-69758588
Fax: 86-21-69758288
Page 4
SECTION 2
PIPING CONNECTIONS
The following are suggested guidelines to ensure that the vessel is allowed to expand
and is easily serviced.
1. Support the header and interconnecting piping in a manner that they are
self-supporting.
2. Connecting piping alignment to feed, Concentrate and Permeate ports should

not exceed 0.7 mm misalignment (Figure 1). If the misalignment exceeds 0.7
mm, please contact Wave Cyber for technical assistance.
3. Piping connections to the vessel’s feed/concentrate ports should be via

flexible Victaulic® couplings. To get maximum flexibility, install two
Victaulic® couplings on each Feed/Concentrate port of the vessel.
0.7
0.7
Figure 1
Page 5
SECTION 3
ELASTICITY AND MOUNTING REQUIREMENTS
Mounting design must allow for vessel expansion, both axially and radially. Although
the expansion under pressure is slight, undue restriction can result in damage to the
vessel and to other system components. Expansion is typically up to 0.8mm/m in
diameter and up to 0.4mm/m in length. A six-element vessel, for example, would
expand approximately 4.5mm in length. The following suggestions will help to ensure
the vessel is allowed to expand and will ease servicing.
1. Mount the vessel on the urethane support pads furnished. Do not mount directly to
any rigid structure.
2. Use the stainless steel straps furnished. Straps should be tightened sufficiently to
hold the vessel on the urethane support pads, but not so tightly as to restrict
expansion. A torque of 25-50 lbs-in. (11.3-22.7kgs) is sufficient.
3. U-bolts can not be used for vessel mounting under any circumstances.
4. Provide a flexible piping connection to permit decoupling the header from the
vessel. The recommended Permeate Port connection is a U-bend pipe with flexible
connections at each end, or a flexible hose. Recommended Feed and Concentrate
connections are via flexible Victaulic® couplings.
5. Do not hard plumb any piping connections to the vessel.
6. Support the header independently. Piping should be self supporting or supported
by the headers.
7. Include an expansion loop in the branch connection to allow for:
A. Elastic growth under pressure.
B. Thermal growth in vessel length.
8. The total weight of branch connection and fittings supported by the vessel should
not exceed 2 kg for the Permeate port ports and 4 kg for the Feed/Concentrate for
Wave Cyber series vessels.
The above suggestions are intended to help prevent damage in typical applications.
Unusual or special applications may involve other considerations, to be determined by
the system designer.
Page 6
SECTION 4
INSTALLATION GUIDE
A. Mounting Shell
This section is concerned with the mounting of Wave Cyber Series pressure vessels.
These guidelines must be integrated with any additional procedures required for your
specific installation.
Installation Guidelines:
1. Provide adequate room for servicing at both ends of vessel. Elements are
installed from the upstream end (feed), pushed through towards the
downstream end (concentrate) and, eventually, removed from the downstream
end.
2. Follow the procedures in Section 3-Elasticity and Mounting Requirements.
NOTE
It is important that each vessel be placed to minimize any strain on piping /tubing that
connects a vessel to a header. Normally each vessel should be centered in the frame
with the feed and concentrate ports positioned such that piping / tubing connections
can be made easily, without undue strain at each end of the vessel.
3. Mount vessels on urethane saddles (provided with the vessel) positioned in

line with predrilled frame holes for -1 through -3 vessels. Holes for the
mounting straps should be drilled at approximate center span 'S' (Figure 2).
For -4 and -8 vessels, holes for the mounting straps should be drilled at span
'S' from the middle of the vessel and a third saddle, without a strap, should be
placed at mid span (Figure 3). These dimensions are shown on the
corresponding engineering drawing.
Figure 2
Page 7
Figure 3
4. Connect the vessel to piping manifolds while adjusting the position of the
vessel and piping manifolds. Try to align the feed port and concentrate port.
The distance between the vessel and piping manifolds should be set as 3 mm
(Figure 4). Try to align in all directions. The Victaulic® coupling can be
tightened without applying any adhesive on it. Lock the vessel and piping
manifolds in place only after all the alignment procedures are finished.
3
Figure 4
Page 8
Warning
DO NOT MOUNT VESSEL RIGIDLY. RESTRICTED EXPANSION CAN
RESULT IN DAMAGE TO THE VESSEL. SEE ELASTICITY AND MOUNTING
REQUIREMENTS IN THE APPLICATION SECTION FOR FURTHER DETAILS.
DO NOT TIGHTEN THE NUTS OVERLY, OTHERWISE THE VESSEL MIGHT
GET DAMAGED.
5. Place mounting straps over vessel with plastic strip against vessel.
6. Provide adequate room for servicing at both ends of vessel. Elements are
installed and removed in the direction of feed flow.
7. Position screw through the frame mounting holes into strap nuts and run up to the
frame finger tight.
8. Connect vessel feed piping
9. Using a wrench, tighten mounting bolts one additional full turn. This should
result in 25-50 lbs-in. (11.3-22.7kgs) of torque.
NOTE
Straps are designed to secure the vessels during operation. They are not designed
to handle all loads that might occur during shipment. Appropriate vessel restraint
should be employed considering such factors as the mode of shipment, distance
to be traveled and the design of the system. The vessels and frame should be
blocked to prevent any differential movement which could be caused by the
forces experienced during shipment.
B. Element loading
1. Examine the inside diameter of the vessel for scratches or imperfections that may
affect sealing capability of head or element seals. Corrosion deposits or other
foreign matter, including any excess lubricant, should be removed.
2. Flush out the vessel with clean water to remove all dust and debris.
3. Examine membrane element surfaces for any imperfection which could scratch
the vessel bore. Pay particular attention to edges of anti-telescope device
(ATD/brine seal carrier). If any defects are found which can not be easily fixed,
please contact element supplier for solution.
4. Using an approximate 50% mixture of glycerine in water, lubricate the inside of
the vessel. This may best be accomplished using a suitably sized swab soaked in
the mixture. This procedure will ease membrane element loading and reduce
chance of scratching the vessel bore. (Note: Standard O-Rings are EPDM and it is
recommended that oil based lubricants NOT to be used with EPDM.)
Page 9
5. Load the first element into the upstream end of the vessel. Leave a few inches of
the element projecting from the vessel to facilitate interconnection to the next
element.
6. Apply a light film of a non-petroleum based lubricant, such as Parker Super
O-Lube, to the inter-connector O-ring. (The amount of O-lube should be just
enough to give a lustre to the O-ring. Excess O-lube must be removed to prevent
possibility of element contamination).
7. Assemble the inter-connector to the loaded element.
8. Line up the next element to be loaded and assemble it to the inter-connector
already assembled on first element.
NOTE
Take care to avoid pushing elements too far as it can be difficult to push the
stack in a reverse direction.
9. Push both elements into the vessel until a few inches are projecting from the
vessel. Repeat loading process until all elements are installed.
10. When the final element is installed, push the element stack forward until the
distance between the first (downstream) element and retaining ring groove is
about 170 mm. (Figure 5.)
Warning
Connect the central (permeate)
tube of the membrane element
stack, with an adapter on each
end, to the permeate port in the
head at both ends of vessel.
Pressurizing vessel without both
adapters installed could result in
explosive head failure.
Figure 5
Mounting element interface hardware

Put the adaptor/membrane PWT seal on the adaptor first. Then install the adaptor into
the membrane permeate tube.
Page 10
Minimize the Gap between element and vessel
PVC washers should be used to minimize the gap before pressurizing (Figure 6). This
is done to prevent the element from being damaged by movements inside the vessel.
Gap
Adaptor
PVC Washer
Figure 6
CAUTION
Excess gap inside the vessel may cause
damage to the element in operation.
C. Mounting Head Assembly

STEP 1 INSPECT SHELL INSIDE SURFACE
1. Inspect the vessel inside surface for any corrosion deposits or other foreign matter.
If any are found, clean the surface as follows:
A. Using a mild soap solution, clean each end of the vessel liner surface up to
300 mm from each end of vessel.
B. Rinse away all loosened deposits from the shell inside surface using clean
fresh water.
2. Inspect the vessel inside surface for scratches or other damage which could cause
leaks. Vessels that leak must be replaced.
3. Inspect Feed/Concentrate port seals and attachments for internal and external
damage or deterioration.
NOTE CAUTION
Contact Wave Cyber for guidance, if Never attempt to repair a
damage to the vessel's internal surface fiberglass shell.
or Feed/Concentrate port, seals or
attachments are discovered during
inspection.
Page 11
STEP 2 SET UP HEAD ASSEMBLY
1. Place the adaptor/permeate port seal into permeate port seal groove located on
inside of permeate port.
2. Place the PWT seal into seal groove on the permeate port.
3. Attach the thrust cone onto the down stream permeate port.
Warning
Install the thrust cone on the down stream. If the
thrust cone is not installed on the correct position,
serious damage may be caused.
STEP 3 HEAD SEAL AND HEAD LUBRICATION

1. Inspet the Shell
Before installing the head, check the inside surface of the shell for any
imperfections or foreign matter. Remove all foreign matter using a mild soap
solution and rinse with clean water. To remove imperfections, lightly sand the
surface of the vessel with 600-grit sandpaper and soapy water and then rinse with
water can.
2. Head Seal And Shell Lubrication

Ensure that the head seal is covered with a thin layer of glycerine and is free from
any dirt or dust contamination. Then lubricate the inside of the shell starting
directly inboard of the retaining ring groove and up the energizing ramp into the
vessel bore. Only a thin layer is required. Silicone lubricants can also be used;
however, care should be taken to use as little as possible. Check with your
membrane supplier before using these lubricants as they can foul membranes.
Page 12
Note
Lubricate the seal with a little NOTE
Non-Petroleum based lubricant, In some installations it may be advisable
such as glycerin or other suitable to tighten a system-required permeate port
silicon based lubricant. (Glycerin nipple or fitting into the Permeate port
is a commercially available before the head is assembled into the
lubricant that will not foul vessel.
membranes.)
STEP 4 INSTALL HEAD
a. Install Head
Holding the head square to the axis of the shell, slowly push the had into the shell
until the seal passes the retaining ring groove. As a resistance is felt, two hands
may be required. Push the head into shell until the head clears the retaining ring
groove. Head can be tapped lightly with a rubber mallet if necessary to seat the
head into position.
STEP 5 INSTALL INTERLOCK

a. Carefully wipe out any debris or moisture from the retaining ring groove. The
groove must be clear and dry before proceeding.
b. With the head assembly installed in shell, place the tip of the head retaining ring
in the stainless steel groove. (The non bent tab end)
c. Begin pushing the retaining ring into the groove as you rotate your hand around
the I.D. of the shell.
d. Continue until the entire retaining ring is installed in the groove.
Page 13
e. Verify that the retaining ring is fully seated in the groove before proceeding.
STEP 6 CONNECT PERMEATE PIPING

1. Connect manifold piping to the vessel Permeate port.
NOTE
Using teflon tape or anaerobic sealant on all NPT and BSPP threaded connections will
help ensure a leak-free assembly. Union fitting does not require teflon tap or
anaerobic sealing.
WARNING
Don’t overly tighten the thread, excessive force may cause the permeate port to crack.
STEP 7 PRE-PRESSURE CHECK

It is vitally important that the following checks be carried out before any attempt is
made to pressurize the vessel.
a. HEAD ASSEMBLY
Verify the following at each end of the vessel:
1. Head assembly is in good condition, with no evidence of damage or corrosion.
See the sections on Head Rebuilding and Maintenance
2. Retaining ring is properly in place.
b. Membrane Elements
Verify that...
1. Elements are installed in the vessel.
2. Element adapters are installed at each end of vessel.
Page 14
2. Thrust cone is installed at downstream end of vessel.
c. Piping Connections
1. Check all piping connections to ensure that they will provide a leak-free seal.
STEP 8 PRESSURIZATION
1. After following the above Warning
pre-pressurization checks, pressurize vessel
in accordance with element manufacturers DO NOT PRESSURIZE the
specifications VESSEL WITHOUT
2. Vessels should be filled slowly to assist ELEMENTS INSTALLED.
trapped air in escaping Do not pressurize the vessel until
3. Vessels should be pressurized slowly to verifying that the retaining ring is
properly installed.
avoid damage to membrane elements and
vessel components
4. Check for Leaks
After system start up, verify that all connections are leak free. Fix any leaks at this
time to prevent corrosion that may lead to component deterioration and possibly
unsafe operation.
Warning
Retaining ring must be correctly installed. Incorrect assembly or installation can result
in EXPLOSIVE HEAD failure.
D．Removing Head Assembly
Step 1 Relieve pressure

1. Shut off all sources of pressure and relieve pressure from the vessel, following the
system manufacturer’s recommendations.
Step 2 Disconnect PERMEATE port

1. Disconnect and remove permeate piping from the permeate port of the vessel.
Step 3 Examine end closure

1. Examine end closure of vessel for corrosion. If any is evident, proceed as follows:
A. Loosen any deposits.
B. Flush away loosened deposits with clean water.
Page 15
Step 4 Remove Retaining ring
Remove the retaining ring from the stainless steel groove inside the shell. Following
is the procedure: Use a tool with a peaked head (such as pliers) and insert the peaked
head into the hole on the head of the retaining ring. Raise the head of the retaining
ring and move it out of the stainless steel groove (Figure 7). Pull the head of the
retaining ring slightly out of the stainless steel groove with the left hand, meanwhile;
rotate the retaining ring clockwise with the right hand until the entire retaining ring is
pulled out of the stainless steel groove Take care to avoid hitting or levering against
the vessel, as this could result in delamination.
Hole
Figure 7
Step 5 Remove head

Add extension to permeate port or use head puller.
Note
It may be necessary to rock the head slightly and/or tap the head inboard to
break head seal bond. See trouble shooting section for more information.
Page 16
SECTION 5
SUITABILITY FOR INTENDED USE
Wave Cyber MPV pressure vessels are designed for continuous, long-term use as
housings for reverse osmosis membrane elements. Models are available for 150, 300 ,
450 , 600 and 1000 PSI. Any make of eight inch nominal diameter spiral wound
element is easily accommodated.
In an RO system there is considerable potential for explosive head failure, which
could result in serious injury or loss of life. All decisions as to suitability for use must
include full consideration of the various safety aspects involved. These include, but
are not limited to:
• Process fluid compatibility (e.g. chemical and temperature considerations).
• External environmental factors (e.g. corrosive atmosphere; remote or special
environments where plastics might be undesirable; etc.).
• Abnormal back pressure which might result in pressurizing permeate port above
125 PSI (alternate materials are available).
• Capability of the user to maintain vessel properly.
• Requirement for increased fire resistance in some circumstances (e.g. may
preclude use of PVC for permeate ports).
Use of a Wave Cyber pressure vessel for other than its intended application will void
the warranty.
Wave Cyber will assist the purchaser in determining the suitability of the standard
vessel for their specific operating conditions. For non-standard applications, alternate
materials are available on special order. The final determination, however, including
evaluation of the standard materials of construction for compatibility with the specific
environment, is the responsibility of the purchaser.
Page 17
SECTION 6
SAFETY
Safety in service of fiberglass pressure vessels depends on proper application,

installation, operation and maintenance. This section is intended to provide guidance
towards safe system design. The safety information given in the Installation and
Operation and Maintenance sections should also be studied and used appropriately in
conjunction with the precautions listed below.
DESIGN CONSIDERATIONS FOR SAFETY

Fluid Compatibility
The materials of construction selected must be compatible with the process fluid and
with proposed preserving and cleaning fluids. Standard materials are listed on the
engineering drawings. In cases where the standard materials are unacceptable, suitable
alternates may be available.
Pressure and Temperature Design Limits

Operation of a vessel outside its design limits will void the warranty and could result
in vessel fatigue with possible eventual explosive head failure. Although each Wave
Cyber MPV pressure vessel is tested to 1.5 times design pressure, long term operation
above design pressure must be prevented. Permeate port pressure must not exceed 125
psi (with standard materials). Vessels should not be continuously operated at
temperatures above 120°F without Wave Cyber’s specific permission.
Over-pressure Protection
It is essential that over-pressure protection be provided such that the pressure to which
any vessel is subjected cannot exceed 105% of design pressure.
Mounting
The pressure vessel should not be used as a support. Piping manifolds and other
fittings should be supported by properly designed system framework. Operating
personnel should be discouraged from applying undue force to any fittings connected
directly to a pressure vessel.
Accessibility
Pressure vessels should be positioned within the system such that elements can be
inserted at the upstream end and removed from the downstream end (i.e. elements are
installed and removed in the direction of feed flow).
Page 18
SECTION 7
TROUBLESHOOTING
Problem Possible Cause Solution
1. The head leaks a. Dust or dirt on the inside a. Remove the head and clean
when testing pressure surface of the vessel, the dust and dirt;
b. Inside surface of the b. Contact Wave Cyber for
vessel get damaged; assistance;
c. Head seal gets damaged; c. Replace the seal;
d. The water temperature d. Lower the water temperature
exceeds the max. operating to below the max. operating
temperature of the vessel. temperature with auxiliary
equipment.
2. The side port leaks a. Flexible Victaulic® a. Replace the flexible
when testing pressure coupling leaks Victaulic® coupling.
b. Side port seal gets b. Contact Wave Cyber for
damaged; assistance;
c. Side port endures impact c. Contact Wave Cyber for
force. assistance;
3. Sudden Drop in a. Element connecting pipe a. Replace element connecting
Permeate Quality seal gets damaged; pipe seal;
b. Permeate port seal gets b. Replace permeate port seal;
damaged; c. Replace adaptor seal.
c. Adaptor seal gets
damaged.
4. The adaptor cracks a. Installation sequence is a. Insert the adaptor into the
during installation not correct; element first, then install the
b. The installation is not head assembly;
performed following b. For correct procedures, see
procedure, Section 4. 3.4.2;
5. The retaining ring a. The retaining ring is a. Try soaking with a mold
can not be removed seriously deformed after release agent or rust remover in
after being used for being used for a long time. the connecting area of the
some time retaining ring and hit slightly
with handle of a screwdriver or
other tools so as to hit it off.
6. The head can not be a. The head seal gets a. Remove permeate port pure
removed after being deformed and corroded water pipe connecting head.
used for some time. seriously. Insert an iron rod (o.d.=20) into
the permeate port water outlet
pipe for about 150 mm and tap
the rod back and forth slightly
(take care not to hit the element)
until the head is removed.
b. You can also use a head
puller tool to remove the head.
Page 19
R0 Membrane Elements for Brackish Water
TM700
Type Diameter Membrane Area Salt Rejection Product Flow Rate

inch ft2 (m2) % gpd (m3/d)
TM710 4" 87 (8) 99.7 2,400 (9.1)

TM720-370 8" 370 (34) 99.7 9,500 (36)
TM720-400 8" 400 (37) 99.7 10,200 (39)
TM720-430 8" 430 (40) 99.7 11,000 (42)
1. Membrane Type Cross Linked Fully Aromatic Polyamide Composite

2. Test Conditions
Feed Water Pressure 225 psi (1.55 MPa)
Feed Water Temperature 77 ˚F (25 ˚C)
Feed Water Concentration 2,000 mg/l NaCl
Recovery Rate 15 %
Feed Water pH 7
3. Minimum Salt Rejection 99.0 %
4. Minimum Product Flow Rate 2,000 gpd (7.6 m3/d) (TM710)
7,500 gpd ( 28 m3/d) (TM720-370)
8,200 gpd ( 31 m3/d) (TM720-400)
8,800 gpd ( 33 m3/d) (TM720-430)
Dimensions
All dimensions shown in inches (millimeter).

Feed Water
Concentrated Brine
1.05 (26)
Flow direction
0.75 (19)
4 (101)
TM710
40 (1016)
Flow direction
TM720-370
1.125 (29)
7.9 (201)
TM720-400
TM720-430
40 (1016)
TM700 MAR/2005
Operating Limits
Maximum Operating Pressure 600 psi (4.1 MPa)

Maximum Feed Water Temperature 113 ˚F (45 ˚C)
Maximum Feed Water SDI15 5
Feed Water Chlorine Concentration Not Detectable
Feed Water pH Range, Continuous Operation 2-11
Feed Water pH Range, Chemical Cleaning 1-12
Maximum Pressure Drop per Element 20 psi (0.14 MPa)
Maximum Pressure Drop per Vessel 60 psi (0.4 MPa)
Operating Information
1. For the recommended design range, please consult the latest Toray technical bulletin, design guide-
lines, computer design program, and/or call an application specialist. If the operating limits giv-
en in this Product Information Bulletin are not strictly followed, the Limited Warranty will be null
and void.
2. All elements are wet tested, treated with a 1% by weight percent sodium bisulfite storage solution,
and then vacuum packed in oxygen barrier bags. To prevent biological growth during short
term storage, shipment, or system shutdown, it is recommended that Toray elements be immersed
in a protective solution containing 500 - 1,000 ppm of sodium bisulfite (food grade) dissolved in
permeate.
3. Permeate from the first hour of operation shall be discarded.
4. The customer is fully responsible for the effects of chemicals that are incompatible with the ele-
ments. Their use will void the element Limited Warranty.
Notice
1. Toray accepts no responsibility for results obtained by the application of this information or the
safety or suitability of Toray's products, either alone or in combination with other products. Users
are advised to make their own tests to determine the safety and suitability of each product combi-
nation for their own purposes.
2. All data may change without prior notice, due to technical modifications or production changes.
Asia and Oceania: Americas: Europe, Middle East and Africa:

Toray Industries, Inc. Toray Membrane America, Inc. Toray Membrane Europe AG
Membrane Products Department Sales Office
8-1, Mihama 1-chome 12520 High Bluff Drive, Suite 120 Grabenackerstrasse 8
Urayasu, Chiba 279-8555, Japan San Diego, CA 92130, U.S.A. CH-4142 Münchenstein 1, Switzerland
Te l : +81 47 350 6030 Te l : +1 858 523 0476 Te l : +41 61 415 87 10
Fax: +81 47 350 6066 Fax: +1 858 523 0861 Fax: +41 61 415 87 20
http://www.toray-membrane.com
TM700 MAR/2005
RSU-610
Feb. 04
1/1
Handling of New Elements
In order to maintain good element performance, observe the following:
1. Precautions which should be taken during storage

1) The elements are shipped sealed in oxygen impermeable plastic bags and
packaged in carton boxes. Open carton boxes directly before installation.
2) Elements can be stored within a temperature range of 5 °C to 35 °C. Avoid storage in direct
sunlight.
If outside temperature may drop to < 0 °C, cover cartons with insulating material and / or heat
storage room. Do not allow elements to freeze.
3) Don’t stack more than 5 layers of carton boxes. Make sure boxes are kept dry.
2. General notes for installation into pressure vessels.

1) Carefully open plastic bags at one end and do not tear open, for possible re-use.
2) Keep part of the packaging material for the event that elements must be removed and stored.
3) Enumerate pressure vessels and record installation location of each membrane element with
exact sequence of elements inside each pressure vessel. The recorded information must be
updated upon installation of new elements or change of element positions.
4) To avoid damage of elements, handle with care and do not drop. Touch elements with clean
hands or gloves only and avoid contamination where possible.
5) Take care to keep the exterior of element clean.
6) See detailed procedures in RSU-620.

RSU-620
Feb. 04
1/4
Fitting of RO elements into pressure vessels

1. Prior to installation - preparations
1) Before directing pre-treated feed water to elements, make sure piping system and pressure
vessels are free of dust, oil, met al residues etc. In case of severe pollution by foreign
contaminants, it may be effective to clean pressure vessels by soft rotary brush flushing with
pre-treated water. In no case the inside of the pressure vessels may be damaged or scratched.
This procedure also applies in case of element replacement or renewal
2) Examine feed water quality
Flush system with pre-treated raw water for approx. 30 minutes.
3) Remove end plates from both ends of pressure vessel, check the inside of the vessel and if
necessary clean mechanically, (see fig. 620.1 to 620.4).
4) Install permeate adapter with O-rings into the permeate port of concentrate end plate. Lubricate
both parts using only glycerin.
DO NOT install „thrust ring“ if SU types will be fitted into pressure vessel. Necessary
only for TM element types.
5) Attach brine side end plate onto the brine side of the vessel and inst all retaining ring set
according to instruction manual of the pressure vessels.
6) Prepare the necessary parts as shown in the following table:
required quantity
Parts
SU type TM type
Brine seals m m
O-Rings 2xm 4xm
Permeate adaptor open n n
Permeate adaptor closed – n
Interconnectors m–n m–n
Product tube cup n –
m: number of elements
n: number of pressure vessels
Note: The above parts except the vessel’s permeate adapter are shipped with each
element package. Permeate adaptors are shipped with pressure vessels. When
ordering pressure vessels, please specify type of RO element to be installed.
RSU-620
Feb. 04
2/4
7) Attach O-rings
Apply glycerin to the O-ring. Attach O-rings to the interconnectors and product tube caps.
2. Insertion of elements
Note: This is best done by a team of two persons.
1) Take an RO element out of the carton and the plastic bag.
Note: The shipping bags are made of a material with extra high oxygen rejection, which
improves lifetime of preservation solution. If bags are cleanly cut open at one end,
some can be kept and re-used in case any RO element s must be conserved or shipped.
The element is conserved in 0.5 % to 1 % sodium bisulfite solution! Protect eyes and
skin.
2) Apply glycerin to outer (SU type) resp. inner (TM type) surface of the element’ s product tube.
Install brine seal on the element as in fig. 620.1. Be sure to attach the brine seal correctly.
Note: Brine seal should be installed at feed end of each element.

3) Insert element from feed side end into the pressure vessel about 2/3 (see fig. 620.2), af ter
lubricating brine seals and vessel’s inner surface with glycerin. Insert element carefully and
smoothly, especially the first element.
4) Attach inter-connector to product tube at the feed end of the inserted element (see fig. 620.3)
5) Attach brine seal to the second element as described for first element. Connect the two
elements at the inter-connector, see fig. 620.3. The partly inserted element is best held in
place by a helper. Now push both elements smoothly and firmly into vessel, keeping them in
line to avoid damages to inter-connector or brine seal.
6) Repeat procedures described in step (4) to (5) (see Fig. 620.3). Insert elements one by one
into the pressure vessel.
7) After inserting last element, attach tube cap resp. end plug to front end of permeate tube for
SU-, SUL-, TR- and FR-types, or the correct permeate adaptor for TM types (see Fig.630.4
and 630.5).
8) Push the last element home until the first (downstream) element’ s permeate tube is firmly
connected
9) Check distance „A“ between product tube cap and plug installed in permeate adaptor of feed
side end plate. If all elements are correctly inserted, the distance „A“ must be < 5 mm, (see
Fig. 620.6). This procedure is only required if a tube cap or a plug is used.
10) Attach the feed side end plate of pressure vessel, and fit piping system to brine port of end
plate
3. Initial start-up checks
After finishing of piping and inst allation work, successively carry out initial st art-up checks
according to RSU-410
RSU-620
Feb. 04
3/4
Fig 620.1 to 620.4: Insertion of elements
open permeate „Thrust-Ring“

adapter (only for TM Elements)
Fig. 620.5: TM module 8 inch with thrust-ring on the concentrate side

RSU-620
Feb. 04
4/4
4. Distance A (SU-, SUL-, TR-, FR element types):

After installing all membranes (see Fig. 620.1 – 620.4), use shim rings provided by the pressure
vessel manufacturer to make sure that the dist ance „A“ (Fig. 620.6) is < 5mm (0.2 inch). If
distance „A“ is too large, element stack will move too much, causing damage of O rings (inter-
connectors and/or permeate adapter) and disconnection of permeate adapter . In both cases
brine/feed water will leak into permeate and spoil product quality . The risk of mechanical
disconnection of permeate adapters is especially high if the permeate header is connected to
feed side of pressure vessel. Therefore TORAY highly recommends to install permeate system
on the brine side of pressure vessels only.
On the feed side of element st ack, use the product tube cap (Fig. 620.4) supplied by TORAY
instead of the permeate adapter which may be supplied by the pressure vessel manufacturer.
This provides best protection against „short-circuit“ of permeate and brine. For end plate‘s
permeate port, use a correctly shimmed plug (available from pressure vessel manufacturer, to
indicate when ordering).
For SU elements, DO NOT install „thrust rings“ supplied by vessel manufacturer. Construction
of SU elements is such that axial forces (resulting from delta p) are absorbed by permeate tube.
The fiberglass wrapping of SU is not suitable for absorbing axial forces. Use of thrust rings may
result in damage to ATD, fiberglass wrapping or the element itself.
8''
4''
Shim-
plug
Fig. 620.6: Distance A between end cap and shim plug

RSU-621
Feb. 04
1/1
Removal of elements
If elements have to be removed from pressure vessels, e.g. for inspection, storage, shipment or
replacement, proceed as following:
1. Disconnect feed, brine and permeate ports of pressure vessel, and remove connected fittings
2. Remove end plates from both sides of the pressure vessel.
3. Push elements from the feed side until end of the downstream element appears at the brine
side.
4. Pull out the element from the brine side slowly . Remove the interconnector from the next
element.
5. Repeat this process, if necessary use e. g. a plastic pipe for pushing the elements through
6. If re-installation of element s is foreseen, they are to be p acked directly into clean plastic
bags, (see RSU-600). For re-fitting elements, proceed according to RSU-620.
4FOS and 5FOS
Multi-Cartridge Housings
We manufacture a complete line of four and five
round models to accommodate a wide range of flow
rates. Options include 304L or 316L stainless steel;
band clamp or swing bolt closure. Design pressure
150psi (10bar) @ 300ºF (149ºC). Standard inlet and
outlet connections are 2” MNPT with many other
options available. Standard finish is poly-coat over
stainless and other options can be special ordered.
Standard gasket is FDA grade Buna-N.
Features
• Designed for industrial and commercial filtration needs
• Heavy duty stainless steel construction for durability
• 304L standard and 316L stainless steel available.
• Band clamp and swing-bolt closures for quick cartridge change outs
• Pipe fittings readily accessible for easy installation
• Knife edge seal at both cartridge ends to eliminate by-pass
• Standard housings accept double-open-end cartridges
• Available with 222 or 226 cartridge adapters
• Complete selection of pipe fittings: flanged, sanitary, BSP, grooved and others
• See ordering guide for a complete selection of options to fit your application
Adjustable top plate accepts
variable length cartridges
Standard Design Specifications

Model Qty. (Length) Flow Rate Pipe Size Drains Vent Max Ctg Shipping Wgt. Box Size Shipping Wgt. Box Size
of Cartridges† GPM* Diameter Clamp Clamp Swing Bolt Swing Bolt
4FOS1 4 (10”) 28 2” MNPT 1/2”NPT 1/4”NPT 2 3/4” OD 25 lbs 12x12x23 62 lbs 18x18x27
†Housings will accept: 10” = (9 3/4” or 10”) 20” = (19 1/2” or 20”) 30” = (29 1/4” or 30”) 40” = (39” or 40”) lengths
*Based on 7gpm per 10” length with a 25 micron wound cartridge at 2PSID clean and a viscosity of 1 cps. Flow rates are for guide lines only.
Actual flow rates are based on fluid, viscosity, cartridge type, micron ratings and other factors.
Dimensions
HANDLE MOUNTING LEGS (3) 120º APART
WITH 9/16" DIA. HOLES ON A
VENT 11 1/8" B.C.
SWING BOLT ASSEMBLY
VENT
HEAD
120º"
CLAMP
GASKET
MOUNTING TABS (3) 120º APART
KNOB WITH 7/16" DIA. HOLES ON A
11 1/16" B.C.
PLATE BUSHING
BUSHING RETAINER
HOLD DOWN PLATE
1/2" DRAINS
DOE CARTRIDGE 10 1/4"
± 1/4"
A 12"
CENTER ROD
A ± 1/4"
222 CARTRIDGE
(OPTIONAL)
2" FLANGE
2" MALE PIPE NPT

MODEL CLAMP STYLE SWING BOLT STYLE
DIM A DIM A
4FOS1 20 7/8” 22 1/4”
7"
7" 4FOS2 30 7/8” 32 1/4”
1/2" DRAIN
3" PORTS
3" 4FOS3 40 7/8” 42 1/4”
4FOS4 50 7/8” 52 1/4”
MOUNTING 1 1/8" MOUNTING LEGS 1 1/8"
TABS 2 1/2" (Optional)
(Optional) 2 1/2" 5FOS1 20 7/8” 22 1/4”
5FOS2 30 7/8” 32 1/4”
5FOS3 40 7/8” 42 1/4”
5FOS4 50 7/8” 52 1/4”
ORDERING GUIDE
4 FOS 2 - SB - 316 - 222 - 2TC - EP - ML - E
No. of Product No. of Closure Material Cartridge Configuration Connection Type Finish Options Gasket
Columns Code Stacks Style
4 FOS 1 = 1 High Blank= Blank = 304L Blank = Double Open Ended Blank = 2” MNPT Blank = Standard Poly Coat Blank = None Blank = Buna
5 2 = 2 High V-Band 316 = 316L 222 = 222 Style Cartridge 1.5MNPT = 1 1/2” MNPT EP = Electro-Polished ML = Legs E = EPR
3 = 3 High Clamp Fin or Flat BSP = 2” BSP-NIPPLE GB = Glass Bead TABS = Tabs S = Silicone
4 = 4 High SB = 226 = 226 Style Cartridge 1F = 1” Flange P = Passivate OL = Heavy Duty V = Viton
Swing Fin or Flat 1.5F = 1 1/2” Flange Legs TS = Teflon
Bolt 2F = 2” Flange GP = Gauge Ports Encasulated
1TC = 1” Ferrules GPA = Gauge Ports Silicone
1.5TC = 1 1/2” Ferrules with gauges
2TC = 2” Ferrules UP = Universal Parts
2.5TC = 2 1/2” Ferrules
GF1.5 = 1 1/2” Grooved Fittings
GF2 = 2” Grooved Fittings
2FMPT = 2” Coupling
Mounting Tabs Sanitary Fittings Gauge Port Assembly Electro-polish

(May be installed at site) with Mounting Legs
tel: 860.854.6121
800.543.5843
fax: 860.854.6120
e-mail: info@shelco.com
www.shelco.com
SHELCO FILTERS
100 Bradley Street . Middletown, CT 06457 . USA
Bulletin: 4-5FOS-500.1 MicroVantage™, MicroSentry™, ShelcoFilters®, and the Shelco Filters logo are registered trademarks of the Tinny Corporation
© 2005 Shelco Filters Shelco Filters is a division of the Tinny Corporation.
7FOS
Universal Multi-Cartridge Housings
Our seven round models are designed for flow rates
to 200 GPM. “Universal” housings accept DOE, 222
fin or flat cartridges. Options include 304L or 316L
stainless steel; band clamp or swing bolt closure.
Design pressure 150psi (10bar) @ 300ºF (149ºC).
Standard inlet and outlet connections are 2” MNPT
with many other options available by special order.
Standard finish is poly-coat over stainless. All
seven round models are standard with mounting
legs. Standard gasket is FDA grade Buna-N.
Features
• Designed for industrial and commercial filtration needs
• Heavy duty stainless steel construction for durability
• 304L standard and 316L stainless steel available.
• Band clamp and swing-bolt closures for quick cartridge change outs
• Pipe fittings readily accessible for easy installation
• Mounting legs standard
• Knife edge seal at both cartridge ends to eliminate by-pass
Adjustable top plate takes
• Standard housings accept double-open-end cartridges and 222/Flat or Fin DOE or 222/Fin or Flat Cartridges
• Available with 226 cartridge adapters
• Complete selection of pipe fittings: flanged, sanitary, BSP, grooved and others
• See ordering guide for a complete selection of options to fit your application
Standard Design Specifications

Model Qty. (Length) Flow Rate Pipe Size Drains Vent Max Ctg Shipping Wgt. Box Size Shipping Wgt. Box Size
of Cartridges† GPM* Diameter Clamp Clamp Swing Bolt Swing Bolt
†Housings will accept: 10” = (9 3/4” or 10”) 20” = (19 1/2” or 20”) 30” = (29 1/4” or 30”) 40” = (39” or 40”) lengths
*Based on 7gpm per 10” length with a 25 micron wound cartridge at 2PSID clean and a viscosity of 1 cps. Flow rates are for guide lines only.
Actual flow rates are based on fluid, viscosity, cartridge type, micron ratings and other factors. It is recommended if your flow rate is greater
than 150gpm that you increase your pipe size to 3” to reduce the pressure drop across the housing.
Dimensions
VENT EYE NUT
BOLT
HEAD WASHER
MOUNTING LEGS (3) 120˚ APART
GASKET WITH 9/16" DIA. HOLES ON A 13 1/16" B.C.
KNOB
CLAMP PLATE
PIN
SPRING SEAL LUG
GASKET
120˚"
CENTER ROD
CARTRIDGE
12 1/2"
± 1/4"
A A
14"
± 1/4"
1/2" DRAINS 1/2" DRAINS

UNIVERSAL PEDISTALS UNIVERSAL
PEDISTALS
2" FLANGE
(OPTIONAL)
2" NIPPLE MODEL CLAMP STYLE SWING BOLT STYLE

8 1/16" 8 1/16"
DIM A DIM A
3 5/16" 3 5/16" 7FOS1 20 1/2” 21”
7FOS2 30 1/2” 31”
7FOS3 40 1/2” 41”
2 1/2" 2 1/2" LEGS
LEGS 7FOS4 50 1/2” 51”
ORDERING GUIDE
7 FOS 3 - SB - 316 - 226 - 2F - EP - OL - E
No. of Product No. of Closure Material Cartridge Configuration Connection Type Finish Options Gasket
Columns Code Stacks Style
7 FOS 1 = 1 High Blank= Blank = 304L Blank = Universal Pedistal Blank = 2” MNPT Blank = Standard Poly Coat Blank = ML Legs Blank = Buna
2 = 2 High V-Band 316 = 316L 226 = 226 Style Cartridge 1.5MNPT = 1 1/2” MNPT EP = Electro-Polished OL = Heavy Duty E = EPR
3 = 3 High Clamp Fin or Flat BSP = 2” BSP-NIPPLE GB = Glass Bead Legs S = Silicone
4 = 4 High SB = 1F = 1” Flange P = Passivate GP = Gauge Ports V = Viton
Swing 1.5F = 1 1/2” Flange GPA = Gauge Ports TS = Teflon
Bolt 2F = 2” Flange with gauges Encasulated
3F = 3” Flange Silicone
1TC = 1” Ferrules
2TC = 2” Ferrules
3TC = 3” Ferrules
GF1.5 = 1 1/2” Grooved Fittings
2FMPT = 2” Coupling
Flanged Fitttings Sanitary Fittings Gauge Port Assembly Electro-polish
tel: 860.854.6121
800.543.5843
fax: 860.854.6120
e-mail: info@shelco.com
www.shelco.com
SHELCO FILTERS
100 Bradley Street . Middletown, CT 06457 . USA
Bulletin: 7FOS-500.1 MicroVantage™, MicroSentry™, ShelcoFilters®, and the Shelco Filters logo are registered trademarks of the Tinny Corporation
© 2005 Shelco Filters Shelco Filters is a division of the Tinny Corporation.
SHELCO FILTERS
SERVICE INSTRUCTIONS MULTI TUBE BAND CLAMP DESIGN
SERVICE INSTRUCTIONS
FOR
FILTER SERIES
4FO, 5FO, 7FO, 12FO, 15FO, 17FO, 19FO, 22FO
This filter has been inspected and found to be free from manufacturing defects.
Before installing this housing be sure the proper cartridge and gasket seals have been
selected for the application.
Be sure to always follow the arrow in the directing of flow. Do not install the filter
backwards.
CARTRIDGE CHANGE
1. Close inlet side valve. Open bottom drain plug to begin draining filter.
2. Remove top vent plug and allow filter to drain completely.
3. When filter is drained loosen cover clamp nut and remove T-Bolt from retainer.
Remove cover clamp and head.
4. Loosen hold down knob and remove top plate. If filter is equipped with spring
seals be careful not to drop the spring seal assembly down into filter chamber.
5. Remove spring and seal assemblies.
6. Remove and discard the used cartridges and install new ones.
7. Examine the shell gasket for deterioration and positioning.
8. If gasket is warn replace it.
9. Replace spring seal assemblies (if provided) to the top of cartridges, replace top
seal plate making sure the individual seal plates are positioned in the top end of
each cartridge and tighten down knob.
10. Replace the head. Be sure the edge of the head is aligned with the bottom flange.
Position the cover clamp. Replace the T- Bolt and tighten the clamp nut. A gap of
about ½” should remain between clamp ends.
11. Replace drain plugs.
12. Open inlet valve slowly. Allow to vent to remain open until a steady stream of
liquid comes out the vent hole. Replace vent plug. Check for leaks. If a leak
appears close the inlet valve relieve the pressure by opening the drain and repeat
steps 1,3,10,11 and 12.
Your filter is now operational.
PLEASE NOTE SAFETY LABEL ON EACH HOUSING

ELECTRIC T E C H N I C A L D ATA S H E E T
RCEL-005L Series Actuators

Remote Control Inc.
RCEL-005L series electric
actuators are engineered
to provide efficient, high
performance automation
of quarter turn valves.
It’s lightweight and
compact design make it
one of the most versatile
electric actuators on the
market today.
FEATURES OPTIONS
• Standard enclosure IP68 Nema 4,4x,6
• Dome type position indicator for high visability PIU Potentiometer Unit
(1K OHM)
• Designed for small quarter-turn applications
CPT Current Position
• 2-watt space heater to minimize condensation due to Transmitter Output:
temperature and humidity changes DC 4-20 mA
• In case of power loss, a manual override provides for PCU Proportional Control Unit
positioning the valve Input: DC 4-20mA; 0-10V
• Worm gear drive, for longer life eliminates the possibility of LCU Local Control Unit
back drive and the need for a motor brake
• Cam actuated, end of travel limit switches are easily adjusted

to calibrate the actuator for precise valve position
• Two auxiliary limit switches are standard
• Thermal protection prevents overheating of the motor
Remote Control Inc. • P.O. Box 355 • North Kingstown, RI 02852

Phone 401-294-1400 • Fax 401-294-3388 • Website www.rciactuators.com
RCEL-005L Series T E C H N I C A L D ATA S H E E T
STANDARD SPECIFICATIONS
Enclosure IP68, Nema 4, 4X & 6
Indicator Dome type
Ambient Temperature -4°F to +158°F
Power Supply 110/230VAC 1 PH ± 10% 50/60Hz 24VDC (option 24VAC)
Limit switches (2) Open/Close plus (2) additional dry contacts Open/Close
Travel Angle 90° ± 5°
Manual Operation L-wrench (6mm hexagon)
Self locking Provided by means of worm gear
Space Heater 2 Watt (110/230VAC and 24VDC) Anti-Condensation
Conduit Entries Two 1/2” NPT
Lubrication Grease Moly (EP) type
Materials Steel, Aluminum Alloy, Bronze
Surface Treatment Anodizing
External Coating Dry Powder, Epoxy-Polyester
PERFORMANCE
Max Operating Time Square No of Current Draw Maximum (A)

TYPE Torque 90º Drive Handle 1-Phase
Inch Pounds 50hz/60 hz Drives 24 Vac 110 Vac 230 Vac 24 VDC Weight Lbs.
005L 434 12/14 14MM 6 1.8 0.35 0.23 1.8 7.7
DIMENSION
WIRING
120 and 220 VAC Standard Wiring 24 VDC Standard Wiring
24 VAC Standard Wiring

CLS Close Limit 250VAC 3A
Switch
OLS Open Limit 250VAC 3A
Switch
ACLS AUX Close 250VAC 3A
Limit Switch
AOLS AUX Open 250VAC 3A
Limit Switch
TP Thermal
Protector
RM Motor Regulation
SWITCH CLOSE OPEN

CLS
OLS
ACLS
AOLS
APPLICATION DATA
CUSTOMER DETAIL
Company _____________________________________ Job ____________________________________________
Street ________________________________________ ________________________________________________
City ___________________________________________ Item____________________________________________
Zip ____________________________________________ Tag ____________________________________________
Attention ______________________________________ ________________________________________________
VALVE INFORMATION
Mfg _____________________________Type ____________ Size _________ Fig No _________________________________
Valve rotation to close (as viewed from top) _______ Clockwise ________ Counter-clockwise ________
Max. required torque (with safety) ______________ Inch Pounds.
ACTUATOR REQUIREMENTS
Application ___________ Open/Close Service ________ Modulating Service _______ Other _____________________
Ambient Temperature ___________ F to ____________F
Supply Voltage _________ volt AC __________Hz ________ volt DC
Control Voltage ________ volt AC __________ Hz ________ volt DC
OPTIONAL ITEMS (AS REQUIRED)

Position Feedback Transmitter __________________________
Proportional Control Unit _______________________________
Transformer for 24VAC _________________________________
Local Control Unit______________________________________
Remote Control Inc. • P.O. Box 355 • North Kingstown, RI 02852

Phone 401-294-1400 • Fax 401-294-3388 • Website www.rciactuators.com
Direct Acting
3/2
1
4
NC U
General Service Solenoid Valves 3 2
SERIES
Brass or Stainless Steel Bodies
qwer 1/8" to 1/4" NPT NO 8320
Features
• All NPT connections are in the valve body to allow
%
in-line piping.
• No Minimum Operating Pressure Differential required.
• Sturdy design for long years of reliable service.
• Broadest range of applications. ^
• Mountable in any position.
)
Construction
Valve Parts in Contact with Fluids
Body Brass 303 Stainless Steel

Seals and Discs NBR or Cast UR, as Listed
Core Tube 305 Stainless Steel
Core and Plugnut 430F Stainless Steel
Core Springs 302 Stainless Steel
Shading Coil Copper Silver
Disc-Holder CA
Core Guide CA (10.1 and 17.1 Watt only)
Electrical
Watt Rating and Power
Consumption Spare Coil Part No.
Standard
Coil and AC General Purpose Explosionproof
Class of DC VA VA
Insulation Watts Watts Holding Inrush AC DC AC DC
F 10.6 6.1 16 30 238210 238310 238214 238314
F - 9.1 25 40 238210 - 238214 - 8320 1/4" NPT
F 11.6 10.1 25 50 238610 238710 238614 238714

F - 17.1 40 70 238610 - 238614 -
Standard Voltages: 24, 120, 240, 480 volts AC, 60 Hz (or 110, 220, volts AC,
50 Hz). 6, 12, 24, 120, 240 volts DC. Must be specified when ordering. Other
voltages are available when required. Nominal Ambient Temperature Ranges:
AC: 32˚F to 125˚F (0˚C to 52˚C)
AC: 32˚F to 104˚F (0˚C to 40˚C)
Refer to Engineering Section for details.
Solenoid Enclosures
Standard: Watertight, Types 1, 2, 3, 3S, 4, and 4X. Approvals:
Optional: Explosionproof and Watertight, Types 3, 3S, 4, 4X, 6, 6P, 7, and 9. CSA certified. UL listed General Purpose Valves.
(To order, add prefix “EF” to the catalog number.) Meets applicable CE directives.
See Optional Features Section for other available options.
Refer to Engineering Section for details.
3.19
SERIES
8320 4
Specifications (English units)
Operating Pressure Differential (psi) Max. Watt Rating/

Fluid Class of Coil
Max. AC Max. DC Temp. ˚F Brass Body Stainless Steel Body Insulation ➁
Pipe Orifice Cv Lt. Oil Lt. Oil

Size Size Flow Air-Inert @ 300 Air-Inert @ 300 Catalog Constr. Catalog Constr.
(ins.) (ins.) Factor Gas Water SSU Gas Water SSU AC DC Number Ref. No. Number Ref. No. AC DC
UNIVERSAL OPERATION (Pressure at any port)
1/8 3/64 .06 175 175 175 125 125 125 140 120 8320G130 ➀ 1 8320G140 ➀ 1 9.1/F 10.6/F
1/8 1/16 .09 100 100 100 65 65 65 180 120 8320G1 1 8320G41 1 9.1/F 10.6/F
1/8 3/32 .12 50 50 50 50 50 50 180 120 8320G83 1 8320G87 1 6.1/F 10.6/F
1/8 1/8 .21 30 30 30 20 20 20 180 120 8320G3 1 8320G43 1 9.1/F 10.6/F
1/4 1/16 .09 125 130 130 75 75 75 200 150 8320G172 2 -- -- 10.1/F 11.6/F
1/4 3/32 .12 100 100 100 60 60 60 200 150 8320G174 2 8320G200 3 17.1/F 11.6/F
1/4 1/8 .25 50 50 50 25 25 25 200 150 8320G176 2 8320G201 3 17.1/F 11.6/F
1/4 11/64 .35 20 20 20 12 12 12 200 150 8320G178 2 -- -- 10.1/F 11.6/F
NORMALLY CLOSED (Closed when de-energized)
1/8 3/64 .06 200 200 200 200 200 200 180 120 8320G132 1 8320G142 1 6.1/F 10.6/F
1/8 1/16 .09 150 125 125 125 125 125 180 120 8320G13 1 8320G45 1 6.1/F 10.6/F
1/8 3/32 .12 100 100 100 100 100 100 180 120 8320G15 1 8320G47 1 6.1/F 10.6/F
1/8 1/8 .21 40 40 40 40 40 40 180 120 8320G17 1 8320G49 1 6.1/F 10.6/F
1/4 1/16 .09 210 225 225 160 160 160 200 150 8320G182 2 -- -- 17.1/F 11.6/F
1/4 3/32 .12 150 150 150 115 115 115 200 150 8320G184 2 8320G202 3 10.1/F 11.6/F
1/4 1/8 .25 85 85 85 60 60 60 200 150 8320G186 2 8320G203 3 10.1/F 11.6/F
1/4 11/64 .35 45 45 45 25 25 25 200 150 8320G188 2 -- -- 10.1/F 11.6/F
NORMALLY OPEN (Open when de-energized)
1/8 3/64 .06 200 200 200 200 200 200 180 120 8320G136 1 8320G146 1 6.1/F 10.6/F
1/8 1/16 .09 150 125 125 125 125 125 180 120 8320G27 1 8320G51 1 6.1/F 10.6/F
1/8 3/32 .12 100 100 100 100 100 100 180 120 8320G29 1 8320G53 1 6.1/F 10.6/F
1/8 1/8 .21 40 40 40 40 40 40 180 120 8320G31 1 8320G55 1 6.1/F 10.6/F
1/4 1/16 .09 250 250 250 160 160 160 200 150 8320G192 2 -- -- 17.1/F 11.6/F
1/4 3/32 .12 150 140 140 100 100 100 200 150 8320G194 2 8320G204 3 10.1./F 11.6/F
1/4 1/8 .25 70 70 70 55 55 55 200 150 8320G196 2 8320G205 3 10.1/F 11.6/F
1/4 11/64 .35 40 40 40 30 30 30 200 150 8320G198 2 -- -- 10.1/F 11.6/F
Notes: ➀ Supplied with cast UR disc.
➁ On 50 hertz service, the watt rating for the 6.1/F solenoid is 8.1 watts; the watt rating for the 9.1/F solenoid is 11.1 watts.
3.20
SERIES
8320 4
Specifications (Metric units)
Operating Pressure Differential (bar) Max. Watt Rating/

Fluid Class of Coil
Max. AC Max. DC Temp. ˚C Brass Body Stainless Steel Body Insulation ➁
Pipe Orifice Kv Flow Lt. Oil

Size Size Factor Air-Inert @ 300 Air-Inert Lt. Oil @ Catalog Constr. Catalog Constr.
(ins.) (mm) (m3/h) Gas Water SSU Gas Water 300 SSU AC DC Number Ref. No. Number Ref. No. AC DC
UNIVERSAL OPERATION (Pressure at any port)
1/8 1.2 .05 12 12 12 9 9 9 59 48.4 8320G130 ➀ 1 8320G140 ➀ 1 9.1/F 10.6/F

1/8 1.6 .08 7 7 7 4 4 4 81 48.4 8320G1 1 8320G41 1 9.1/F 10.6/F
1/8 2.4 .10 3 3 3 3 3 3 81 48.4 8320G83 1 8320G87 1 6.1/F 10.6/F
1/8 3.2 .18 2 2 2 1 1 1 81 48.4 8320G3 1 8320G43 1 9.1/F 10.6/F
1/4 1.6 .08 9 9 9 5 5 5 92 64.9 8320G172 2 -- -- 10.1/F 11.6/F
1/4 2.4 .10 7 7 7 4 4 4 92 64.9 8320G174 2 8320G200 3 17.1/F 11.6/F
1/4 3.2 .21 3 3 3 2 2 2 92 64.9 8320G176 2 8320G201 3 17.1/F 11.6/F
1/4 4.4 .30 1 1 1 1 1 1 92 64.9 8320G178 2 -- -- 10.1/F 11.6/F
NORMALLY CLOSED (Closed when de-energized)
1/8 1.2 .05 14 14 14 14 14 14 81 48.4 8320G132 1 8320G142 1 6.1/F 10.6/F

1/8 1.6 .08 10 9 9 9 9 9 81 48.4 8320G13 1 8320G45 1 6.1/F 10.6/F
1/8 2.4 .10 7 7 7 7 7 7 81 48.4 8320G15 1 8320G47 1 6.1/F 10.6/F
1/8 3.2 .18 3 3 3 3 3 3 81 48.4 8320G17 1 8320G49 1 6.1/F 10.6/F
1/4 1.6 .08 14 16 16 11 11 11 92 64.9 8320G182 2 -- -- 17.1/F 11.6/F
1/4 2.4 .10 10 10 10 8 8 8 92 64.9 8320G184 2 8320G202 3 10.1/F 11.6/F
1/4 3.2 .21 6 6 6 4 4 4 92 64.9 8320G186 2 8320G203 3 10.1/F 11.6/F
1/4 4.4 .30 3 3 3 2 2 2 92 64.9 8320G188 2 -- -- 10.1/F 11.6/F
NORMALLY OPEN (Open when de-energized)
1/8 1.2 .05 14 14 14 14 14 14 81 48 8320G136 1 8320G146 1 6.1/F 10.6/F

1/8 1.6 .08 10 9 9 9 9 9 81 48 8320G27 1 8320G51 1 6.1/F 10.6/F
1/8 2.4 .01 7 7 7 7 7 7 81 48 8320G29 1 8320G53 1 6.1/F 10.6/F
1/8 3.2 .18 3 3 3 3 3 3 81 48 8320G31 1 8320G55 1 6.1/F 10.6/F
1/4 1.6 .08 17 17 17 11 11 11 92 65 8320G192 2 -- -- 17.1/F 11.6/F
1/4 2.4 .10 10 10 10 7 7 7 92 65 8320G194 2 8320G204 3 10.1./F 11.6/F
1/4 3.2 .21 5 5 5 4 4 4 92 65 8320G196 2 8320G205 3 10.1/F 11.6/F
1/4 4.4 .30 3 3 3 2 2 2 92 65 8320G198 2 -- -- 10.1/F 11.6/F
Notes: ➀ Supplied with cast UR disc.
➁ On 50 hertz service, the watt rating for the 6.1/F solenoid is 8.1 watts; the watt rating for the 9.1/F solenoid is 11.1 watts.
3.21
SERIES
8320 4
Dimensions: inches (mm)
Constr. Ref. 1
Constr. Ref. 2
FLOW DIAGRAMS
Universal
De-Energized Energized
3 3
1
2 2 1
Normally Closed
Constr. Ref. 3
3 2 3 1
2 1
Cyl. Cyl.
Press. Press.
Exh. Exh.
Normally Open
3 *
2 1 3 1
2
Cyl.
Exh. Cyl.
Exh.
* MOUNTING BRACKET
Press. IS STANDARD ON THIS
Press.
CONSTRUCTION
3.22
IM10-05
Spectra 10 Series
Pressure Switch
UNITED ELECTRIC
CONTROLS
Installation and Maintenance

Instructions
Please read all instructional literature carefully and thoroughly before starting. Refer to the final page for the listing of Recommended
Practices, Liabilities and Warranties.
GENERAL WIRING
BEFORE INSTALLING, CHECK THE SENSOR DISCONNECT ALL SUPPLY CIRCUITS BEFORE WIRING
MODEL SELECTED FOR COMPATIBILITY TO UNIT. ELECTRICAL RATINGS STATED IN LITERATURE
THE PROCESS MEDIA IN CONTACT WITH AND NAMEPLATES MUST NOT BE EXCEEDED. OVER-
THE SENSOR AND WETTED PARTS. LOAD ON A SWITCH CAN CAUSE FAILURE ON THE
FIRST CYCLE.
The Spectra-10 pressure switch utilizes a diaphragm
or piston sensor to detect a pressure change. The WIRE IN ACCORDANCE WITH LOCAL AND NATIONAL
response, at a predetermined set point, actuates ELECTRICAL CODES.
a SPDT snap-acting switch, converting a pressure
signal into an electrical signal. Control set point may Termination Type A, 0.11" push-on terminals
be varied by turning the internal slotted adjustment Unit is supplied with male and female terminals.
screw bushing according to procedures outlined in Insert 18-22 AWG stripped leadwire into female
this document. terminal and crimp using appropriate hand tool.
Part I - Installation Refer to molded-in N.O., N.C., and COM designa-

tions for proper wiring.
Tools Needed
11⁄16" Open end wrench
Termination Type B, 0.25" push-on terminals
Screwdriver for customer- N.O., N.C., and COM terminals require 1/4” female
supplied mounting screws push-on terminals. Insulated female terminals
(option M449 only) are recommended for safety. Use non-conductive
protective grease for corrosion resistance in outdoor
MOUNTING use.
Termination Type C & D, 18" leads 18 AWG

ALWAYS LOCATE UNITS WHERE SHOCK, VIBRATION AND Color coding:
AMBIENT TEMPERATURE FLUCTUATIONS ARE MINIMAL. TERMINALS COLOR
DO NOT MOUNT IN AMBIENT TEMPERATURE AREAS
EXCEEDING 160° F (WITH BUNA N CONSTRUCTION) OR N.O. Blue
180°F (WITH VITON CONSTRUCTION). IF SEVERE PRESSURE N.C. Black
SURGES ARE EXPECTED, CONSIDER THE USE OF A PRESSURE Com Violet
SNUBBER.
TO ATTACH TYPE C TO CONDUIT CONNECTION, HOLD
ELECTRICAL CONNECTION STEADY WITH WRENCH ON
MOUNT USING PRESSURE CONNECTION: ALWAYS USE A HEX, THEN THREAD ON CONDUIT.
WRENCH ON PRESSURE CONNECTION WRENCH FLATS.
UNIT MAY BE MOUNTED IN ANY POSITION. HOWEVER, Termination Type E, 1/2 NPT with 5’ cord
IF INSTALLATION LOCATION RESULTS IN FREQUENT Cut cord to desired length. Strip back insulation.
EXPOSURE TO LIQUID, IT IS RECOMMENDED THAT THE UNIT Color coding:
BE MOUNTED VERTICALLY WITH THE PRESSURE CONNEC-
TERMINALS COLOR
TION DOWN. IF UNIT IS TO BE SET AFTER MOUNTING, RAISE
ADJUSTMENT COVER, THEN THREAD IN PRESSURE CONNEC- N.O. Red
TION UNTIL SNUG. VERIFY THAT ADJUSTMENT OPENING IS N.C. Black
ACCESSIBLE. Com White
1/2" NPT Electrical Connection (termination type C) TO ATTACH TYPE E TO CONDUIT CONNECTION, HOLD
Mount through 7/8" clearance hole in panel. Hold in ELECTRICAL CONNECTION STEADY WITH WRENCH
place with serrated 1/2" conduit nut. Always support the ON HEX, THEN THREAD IN CONDUIT.
unit by holding a wrench on the 11⁄16" hex nearest the
conduit connection. Termination Type F, DIN Connector with 4 Male Terminals
Connector conforms to DIN 43650. Use a mating DIN
connector (female type). Coding:
Optional Surface Mounting Bracket (option M449) TERMINALS
The surface mounting bracket is a “C” style clamp with Terminal #1 Common
a single clearance hole to accommodate a 1/4" screw. Terminal #2 Normally Closed
Insert the unit into the bracket, pressure connection Terminal #3 Normally Open
end first. Open the adjustment cover and mount the Terminal #4 Not used
unit so that adjustment opening will be accessible when
the switch is mounted. Close the adjustment cover Termination Type G, 5’ cord
ensuring that the bracket does not interfere with the Cut cord to desired length. Strip back insulation.
cover. Failure to do so may result in improper sealing of Color coding:
adjustment cover. Mount assembly in desired location.
TERMINALS COLOR
N.O. Red
N.C. Black
Com White
Part II - Adjustments
Tools Needed
Screwdriver
1. Connect control to pressure source. For setting on rise, apply desired pressure and turn
2. With power disconnected, slide cover toward adjustment left until switch clicks (circuit across N.O. and
electrical terminations while twisting it to overcome COM terminals closes). For setting on fall, apply pres-
friction. sure equal to normal system operating pressure. Reduce
source pressure to setpoint value. Turn adjustment right
3. Connect power to terminals or leads.
until switch clicks (circuit across N.C. and COM closes).
4. Insert screwdriver into adjustment slot and turn left
(clockwise) to increase setting or right (counterclock- 5. After completing adjustments, slide cover closed over
wise) to decrease setting. adjustment compartment. Recheck set point.
Dimensions RECOMMENDED PRACTICES AND WARNINGS

Dimension A Dimension B United Electric Controls Company recommends careful consideration
Diaphragm Piston Model 10-12: 1/8 NPT of the following factors when specifying and installing UE pressure
Model 13-16: 1/4 NPT and temperature units. Before installing a unit, the Installation and
Model 10-12 Model 13-16 Maintenance instructions provided with unit must be read and understood.
10-A 3” 3.31” • To avoid damaging unit, proof pressure and maximum temperature lim-
76.2 mm 84.1 mm its stated in literature and on nameplates must never be exceeded, even
10-B 3.5” 3.81” by surges in the system. Operation of the unit up to maximum pressure
88.9 mm 96.8 mm or temperature is acceptable on a limited basis (e.g., start-up, testing)
but continuous operation must be restricted to the designated adjust-
10-C 4.06” 4.38” able range. Excessive cycling at maximum pressure or temperature limits
103.2 mm 111.1 mm
could reduce sensor life.
10-D 3.19” 3.5” • A back-up unit is necessary for applications where damage to a pri-
81.0 mm 88.9 mm mary unit could endanger life, limb or property. A high or low limit
10-E 3.9” 4.25” switch is necessary for applications where a dangerous runaway con-
100 mm 108 mm “A” dition could result.
• The adjustable range must be selected so that incorrect, inadvertent
10-F 4.13” 4.44”
104.8 mm 112.7 mm “B” or malicious setting at any range point cannot result in an unsafe
system condition.
10-G 3.88” 4.19” • Install unit where shock, vibration and ambient temperature fluctua-
98.4 mm 106.4 mm
Type 10-A tions will not damage unit or affect operation. Orient unit so that mois-
ture does not enter the enclosure via the electrical connection. When
appropriate, this entry point should be sealed to prevent moisture
entry.
• Unit must not be altered or modified after shipment. Consult UE if
modification is necessary.
• Monitor operation to observe warning signs of possible damage to
unit, such as drift in set point or faulty display. Check unit immedi-
ately.
• Preventative maintenance and periodic testing is necessary for critical
applications where damage could endanger property or personnel.
• For all applications, a factory set unit should be tested before use.
• Electrical ratings stated in literature and on nameplate must not be
exceeded. Overload on a switch can cause damage, even on the first
cycle. Wire unit according to local and national electrical codes, using
“A” “A” wire size recommended in installation sheet.
• Do not mount unit in ambient temp. exceeding published limits.
“B” LIMITED WARRANTY

Seller warrants that the product hereby purchased is, upon delivery, free
Type 10-B Type 10-C from defects in material and workmanship and that any such product
which is found to be defective in such workmanship or material will be
repaired or replaced by Seller (Ex-works, Factory, Watertown, Massachusetts.
INCOTERMS); provided, however, that this warranty applies only to equip-
ment found to be so defective within a period of 24 months from the
date of manufacture by the Seller. Seller shall not be obligated under this
warranty for alleged defects which examination discloses are due to tam-
pering, misuse, neglect, improper storage, and in any case where products
are disassembled by anyone other than authorized Seller’s representatives.
EXCEPT FOR THE LIMITED WARRANTY OF REPAIR AND REPLACEMENT
STATED ABOVE, SELLER DISCLAIMS ALL WARRANTIES WHATSOEVER WITH
RESPECT TO THE PRODUCT, INCLUDING ALL IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.
LIMITATION OF SELLER’S LIABILITY
“A”
“A” Seller’s liability to Buyer for any loss or claim, including liability incurred
in connection with (i) breach of any warranty whatsoever, expressed or
“B” implied, (ii) a breach of contract, (iii) a negligent act or acts (or negligent
failure to act) committed by Seller, or (iv) an act for which strict liability will
“B”
Type 10-D Type 10-E be inputted to seller, is limited to the “limited warranty” of repair and/or
replacement as so stated in our warranty of product. In no event shall the
Seller be liable for any special, indirect, consequential or other damages
of a like general nature, including, without limitation, loss of profits or
production, or loss or expenses of any nature incurred by the buyer or any
third party.
UE specifications subject to change without notice.
UNITED ELECTRIC
“A” “A”
CONTROLS
“B” 180 Dexter Avenue, P.O. Box 9143
Watertown, MA 02471-9143 USA
“B” Telephone: 617 926-1000 Fax: 617 926-2568
Type 10-F Type 10-G http://www.ueonline.com
IM10-05 EMCO15M303
ENGLISH
‡ SIGNET 515/2536 Rotor-X Flow Sensors
Instructions for all versions of: 515/8510-XX and 2536/8512-XX
3-0515.090 D (2/03) English
SAFETY INSTRUCTIONS
1. Depressurize and vent system prior to installation or removal.
2. Confirm chemical compatibility before use.
3. Do not exceed maximum temperature/pressure specifications.
4. Wear safety goggles or faceshield during installation/service.
5. Do not alter product construction.
1. Specifications
2536 Sensor
General Data Signal:
Flow Rate Range: 515: 0.3 to 6 m/s (1 to 20 ft/s) Frequency: 49 Hz per m/s nominal (15 Hz per ft/s nominal)
2536: 0.1 to 6 m/s (0.3 to 20 ft/s) Supply voltage: 3.5 to 24 VDC regulated
Pipe Size Range: DN15 to DN1000 (0.5 to 36 in.) Supply current: <1.5 mA @ 3.3 to 6 VDC
Linearity: ±1% of full range <20 mA @ 6 to 24 VDC
Repeatability: ±0.5% full range Output Type: Open collector transistor, sinking
Cable Length: 7.6 m (25 ft) standard Output current: 10 mA max.
515: 60 m (200 ft) maximum
2536: 305m (1000 ft) maximum Fluid Conditions
Cable Type: 2-conductor twisted pair w/shield (22 AWG) Rotor-X Sensor Pressure/Temperature Ratings:
Minimum Reynolds Number Required: 4500
Cap Material: Glass Filled Polypropylene Polypropylene Body:
515: Red • 12.5 bar (180 psi) max. @ 20 °C (68 °F)
2536: Blue • 515: 1.7 bar (25 psi) max. @ 90 °C (194 °F)
Wetted Materials: • 2536: 1.7 bar (25 psi) max. @ 85 °C (185 °F)
• Sensor Body: Glass filled Polypropylene (black) or PVDF
(natural) PVDF Body:
• O-Rings: FPM-Viton® (Std) or EPDM or FFKM-Kalrez® • 14 bar (200 psi) max @ 20 °C (68 °F)
• Pin: Titanium or Hastelloy-C or PVDF; other • 515: 1.7 bar (25 psi) max @ 100 °C (212 °F)
material options available • 2536: 1.7 bar (25 psi) max @ 85 °C (185 °F)
• Rotor: Black PVDF or natural PVDF; optional Tefzel® bar psi
with or w/o Fluoraloy B® sleeve 14 200
Shipping Weight: -X0 0.454 kg (1 lb)
-X1 0.476 kg (1.04 lbs) 11 160
51
51
-X2 0.680 kg (1.50 lbs)
5/
5/
85
85
-X3 0.794 kg (1.75 lbs)
10
8 120 10
-X
-X
-X4 0.850 kg (1.87 lbs)
X
X
-P
-P
-X5 1.0 kg (2.20 lbs) 6 80
oly
VD
3519 1.3 kg (2.86 lbs)
pr
F
pyo
515 Sensor 3 40
le ne
Signal:
Frequency: 19.7 Hz per m/s nominal (6 Hz per ft/s)
Amplitude: 3.3 V p/p per m/s nominal (1 V p/p per ft/s) °F 0 40 80 120 160 200 240
Source Impedance: 8 kΩ °C -18 4 27 49 71 93 115
Dimensions
8510-XX/8512-XX bar psi
515/2536 Sensor Integral Sensor 14 200
shown with Transmitter
Standard
7.6 m/25 ft. and Integral Adapter Kit
11 160
25
25
cable (sold separately)

36
36
included
/85
/85
8 120
12
12
-X
-X
X
X
-P
-P
1-1/4" NPSM 6 80
oly
VD
threaded cap 102 mm/ -X0 or

pr
-X (0 thru 5) 4.0 in.

op
-X1
26.7 mm/ 3 40
yle
1.05 in.
ne
°F 0 40 80 120 160 200 240
Pipe Range: °C -18 4 27 49 71 93 115

1/2 to 4 in. -X0 = 104 mm/4.1 in.
5 to 8 in. -X1 = 137 mm/5.4 in. Standards & Approvals
10" and up -X2 = 213 mm/8.4 in. • Manufactured under ISO 9001 and ISO 14001
1/2 to 4 in. -X3 = 297 mm/11.7 in.
Wet-tap -X0 = 152 mm/6.0 in. • CE
5 to 8 in. -X4 = 333 mm/13.1 in. Lengths
-X1 = 185 mm/7.3 in.
10" and up -X5 = 409 mm/16.1 in. • 515 Only: FM Class I, II, III/Div. I/Groups A-G
‡ SIGNET 515/2536 Rotor-X Flow Sensors page 1 of 4
Inlet Outlet
2. Location of Fitting Flange Reducer 90° Elbow
Recommended sensor upstream/downstream 10x I.D. 5x I.D. 15x I.D. 5x I.D. 20x I.D. 5x I.D.
mounting requirements
2 x 90° Elbow
3 dimensions
2 x 90° Elbow Pump/Valve
25x I.D. 5x I.D. 40x I.D. 5x I.D. 50x I.D. 5x I.D.
0°
3. Sensor Mounting Position -45° +45°
• Horizontal pipe runs: Mount sensor in the upright (0°) position for best performance. Mount
at a maximum of 45° when air bubbles are present (pipe must be full). Do not mount on the Process
bottom of the pipe when sediments are present. Pipe
• Vertical pipe runs: Mount sensor in any orientation. Upward flow is preferred to ensure full
pipe.
4. Standard Sensor Installation 3. Engage one thread of the sensor cap then turn the sensor
until the alignment tab is seated in the fitting notch. Hand
1. Lubricate the sensor O-rings with a silicone lubricant (e.g. tighten the sensor cap. DO NOT use any tools on the
GE silicone compound #G632 or equivalent). Do not use sensor cap or the cap threads and/or fitting flange threads
any petroleum based lubricant that will attack the O-rings. will be damaged, see Figure B.
black sensor
conduit bale
black conduit sensor bale cap
cap
tab
PROCESS PIPE
(TOP VIEW) direction of flow notch Figure B
Figure A
2. Using an alternating/twisting motion, lower the sensor into sensor

the fitting, making sure the installation arrows on the black cap
cap are pointing in the direction of flow, see Figure A.
5. Sensor Wiring 515 Sensor Connections to ‡ SIGNET Instruments
Technical Notes Black

Frequency (-)
• Use 2-conductor shielded cable for cable extensions.
• Cable shield must be maintained through cable splice. Red
Frequency (+)
• Refer to your instrument manual for specific wiring details.
Shield
Ground
2536 Sensor Connections to Other Brand Instruments
Other Brands
black
+ 3.3 to 24
-
2536 Sensor Connections to ‡ SIGNET Instruments
10 kΩ VDC
shield Black
Gnd. Other 5 VDC
red instrument Red
Input Frequency in
DC sensor power supplied from +GF+ SIGNET instrument. Shield
10KΩ Pull-up resistor may be required for non +GF+ SIGNET brand instrument. Ground
6. Rotor Replacement Procedure
1. To remove the rotor, insert a small screwdriver between the rotor and the ear of the sensor.
2. Twist the screwdriver blade to flex the ear outward enough to remove one end of the rotor and pin.
DO NOT flex the ear any more than necessary! If it breaks, the sensor cannot be repaired.
3. Install the new rotor by inserting one tip of the pin into the hole, then flex the opposite ear back
enough to slip rotor into place.
page 2 of 4 ‡ SIGNET 515/2536 Rotor-X Flow Sensors
7. K-Factors
A K-Factor is the number of pulses a sensor will generate for each engineering unit of fluid which passes the sensor. K-factors for
water are listed below in U.S. gallons and liters. For example, in a 1-inch PVC pipe, the 515 paddlewheel generates 174.67 pulses per
gallon of water passing the rotor. K-factors are listed for pipes up to 12 inches. For pipes over 12 inches, consult your +GF+ SIGNET
distributor.
PIPE PIPE PIPE
SIZE FITTING
515/8510-XX 2536/8512-XX SIZE FITTING
515/8510-XX 2536/8512-XX SIZE FITTING
515/8510-XX 2536/8512-XX
(IN.) TYPE U.S. GAL LITERS U.S. GAL LITERS (IN.) TYPE U.S. GAL LITERS U.S. GAL LITERS (IN.) TYPE U.S. GAL LITERS U.S. GAL LITERS
SCH 80 PVC TEES FOR SCH 80 PVC PIPE CARBON STEEL TEES ON SCH 40 PIPE STAINLESS STEEL WELDOLETS ON SCH 40 PIPE
1/2 PV8T005 480.19 126.87 991.71 262.01 1/2 CS4T005 370.20 97.808 756.00 199.74 2-1/2 CR4W025 18.800 4.9670 37.600 9.9339
3/4 PV8T007 257.72 68.090 545.14 144.03 3/4 CS4T007 212.06 56.027 438.69 115.90 3 CR4W030 12.170 3.2153 24.340 6.4306
1 PV8T010 174.67 46.148 352.44 93.114 1 CS4T010 141.14 37.289 286.78 75.768 4 CR4W040 6.9600 1.8388 13.920 3.6777
1-1/4 PV8T012 83.390 22.032 177.18 46.812 1-1/4 CS4T012 60.655 16.025 121.22 32.026 5 CR4W050 5.2600 1.3897 10.860 2.8692
1-1/2 PV8T015 58.580 15.477 117.85 31.137 1-1/2 CS4T015 45.350 11.982 91.139 24.079 6 CR4W060 3.6900 0.9749 7.5200 1.9868
2 PV8T020 32.480 8.5812 66.739 17.633 2 CS4T020 26.767 7.0717 54.468 14.391 8 CR4W080 2.1300 0.5627 4.3400 1.1466
2-1/2 PV8T025 21.833 5.7683 42.994 11.359 10 CR4W100 1.3500 0.3567 2.7600 0.7292
3 PV8T030 13.541 3.5775 26.652 7.0414 STAINLESS STEEL TEES ON SCH 40 PIPE 12 CR4W120 0.9600 0.2536 1.9400 0.5125
4 PV8T040 7.6258 2.0147 15.006 3.9645 1/2 CR4T005 358.96 94.838 734.20 193.98
3/4 CR4T007 202.61 53.530 412.10 108.88 CARBON STEEL WELDOLETS ON SCH 40 PIPE
SCH 80 CPVC TEES FOR SCH 80 CPVC PIPE 1 CR4T010 127.14 33.590 252.70 66.764 2-1/2 CS4W025 18.800 4.9670 37.600 9.9339
1/2 CPV8T005 480.19 126.87 991.71 262.01 1-1/4 CR4T012 61.910 16.357 128.12 33.849 3 CS4W030 12.170 3.2153 24.340 6.4306
3/4 CPV8T007 257.72 68.090 545.14 144.03 1-1/2 CR4T015 40.410 10.676 77.320 20.428 4 CS4W040 6.9600 1.8388 13.920 3.6777
1 CPV8T010 174.67 46.148 352.44 93.114 2 CR4T020 22.300 5.8917 45.780 12.095 5 CS4W050 5.2600 1.3897 10.860 2.8692
1-1/4 CPV8T012 83.390 22.032 177.18 46.812 6 CS4W060 3.6900 0.9749 7.5200 1.9868
1-1/2 CPV8T015 58.580 15.477 117.85 31.137 GALVANIZED IRON TEES ON SCH 40 PIPE 8 CS4W080 2.1300 0.5627 4.3400 1.1466
1 IR4T010 104.54 27.619 213.01 56.277 10 CS4W100 1.3500 0.3567 2.7600 0.7292
SCH 80 PVC SADDLES FOR SCH 80 PVC PIPE 1-1/4 IR4T012 62.979 16.639 127.75 33.751 12 CS4W120 0.9600 0.2536 1.9400 0.5125
2 PV8S020 32.480 8.5812 66.739 17.633 1 1/2 IR4T015 46.688 12.335 94.401 24.941
2-1/2 PV8S025 21.833 5.7683 42.994 11.359 2 IR4T020 29.459 7.7832 59.420 15.699 COPPER/BRONZE BRAZOLETS ON SCH 40 PIPE
3 PV8S030 13.541 3.5775 26.652 7.0414 2-1/2 BR4B025 18.800 4.9670 37.600 9.934
4 PV8S040 7.6258 2.0147 15.006 3.9645 BRONZE TEES ON SCH 40 PIPE 3 BR4B030 12.170 3.2153 24.340 6.431
6 PV8S060 4.1623 1.0997 8.3246 2.1994 1 BR4T010 104.54 27.619 213.01 56.277 4 BR4B040 6.9600 1.8388 13.920 3.678
8 PV8S080 2.3705 0.6263 5.0164 1.3253 1-1/4 BR4T012 62.979 16.639 127.75 33.751 5 BR4B050 5.2600 1.3897 10.860 2.869
10 PV8S100 1.5300 0.4042 3.0600 0.808 1-1/2 BR4T015 46.688 12.335 94.401 24.941 6 BR4B060 3.6900 0.9749 7.5200 1.987
12 PV8S120 1.0600 0.2801 2.1600 0.571 2 BR4T020 29.459 7.7832 59.420 15.699 8 BR4B080 2.1300 0.5627 4.3400 1.147
10 BR4B100 1.3500 0.3567 2.7600 0.729
SCH 80 PVC SADDLE ON SCH 40 PVC PIPE COPPER TEE FITTINGS ON COPPER PIPE SCH K 12 BR4B120 0.9600 0.2536 1.9400 0.513
2 PV8S020 27.350 7.2259 54.700 14.452 1/2 CUKT005 443.21 117.10 917.84 242.50
2-1/2 PV8S025 18.874 4.9866 37.159 9.8175 3/4 CUKT007 212.16 56.052 428.27 113.15 SCH 80 IRON SADDLES ON SCH 80 PIPE
3 PV8S030 12.638 3.3389 23.697 6.2608 1 CUKT010 127.18 33.600 256.43 67.749 2 IR8S020 32.360 8.5495 64.720 17.099
4 PV8S040 6.7282 1.7776 13.456 3.5552 1-1/4 CUKT012 88.218 23.307 176.44 46.615 2-1/2 IR8S025 22.220 5.8705 42.480 11.223
6 PV8S060 3.7297 0.9854 7.4594 1.9708 1-1/2 CUKT015 56.962 15.049 115.69 30.565 3 IR8S030 13.420 3.5456 26.420 6.980
8 PV8S080 2.1527 0.5688 4.5292 1.1966 2 CUKT020 29.370 7.7595 63.385 16.746 4 IR8S040 7.6600 2.0238 14.700 3.884
10 PV8S100 1.3500 0.3567 2.8000 0.740 5 IR8S050 5.8600 1.5482 12.180 3.218
12 PV8S120 0.9600 0.2536 1.9800 0.523 COPPER TEE FITTINGS ON COPPER PIPE SCH L 6 IR8S060 4.0900 1.0806 8.4400 2.230
1/2 CUKT005 414.41 109.49 858.22 226.74 8 IR8S080 2.3300 0.6156 4.9000 1.295
PP CLAMP-ON SADDLE ON SCH 80 PP PIPE 3/4 CUKT007 191.09 50.485 385.74 101.91 10 IR8S100 1.5300 0.4042 3.0600 0.808
10 PPS100 1.5300 0.4042 3.0600 0.808 1 CUKT010 119.84 31.662 241.64 63.841 12 IR8S120 1.0600 0.2801 2.1600 0.571
12 PPS120 1.0600 0.2801 2.1600 0.571 1-1/4 CUKT012 85.451 22.576 170.90 45.152
1-1/2 CUKT015 55.160 14.573 112.03 29.598 SCH 80 IRON SADDLE ON SCH 40 PIPE
PP CLAMP-ON SADDLE ON SCH 40 PP PIPE 2 CUKT020 28.605 7.5575 61.74 16.310 2 IR8S020 26.820 7.0859 53.640 14.172
10 PPS100 1.3500 0.3567 2.8000 0.740 2-1/2 IR8S025 18.800 4.9670 37.600 9.934
12 PPS120 0.9600 0.2536 1.9800 0.523 3 IR8S030 11.990 3.1678 23.220 6.135
4 IR8S040 6.8500 1.8098 13.260 3.503
5 IR8S050 5.3300 1.4082 11.040 2.917
6 IR8S060 3.7600 0.9934 7.2400 1.913
8 IR8S080 2.1300 0.5627 4.4000 1.162
10 IR8S100 1.3500 0.3567 2.8000 0.740
12 IR8S120 0.9600 0.2536 1.9800 0.523
K-Factors DIN Pipes

8. H-Dimensions
PIPE FITTING
515/8510-XX 2536/8512-XX
"H"
SIZE TYPE U.S. GAL LITERS U.S. GAL LITERS CODE The plastic sensor insert in the Weldolet
POLYPROPYLENE FITTINGS (DIN/ISO AND BS AND ANSI) fitting MUST be removed during the
DN 15 PPMT005 481.55 127.23 952.87 251.75 198.150.522
DN 20 PPMT007 277.09 73.207 563.10 148.77 198.150.523 welding process. When reinstalled, it is
DN 25 PPMT010 141.18 37.300 291.60 77.042 198.150.524 important that the insert be threaded to
DN 32 PPMT012 83.540 22.071 169.22 44.709 198.150.525
DN 40 PPMT015 51.265 13.544 103.90 27.450 198.150.526 the proper height ("H" dimension).
DN 50 PPMT020 29.596 7.8193 60.789 16.060 198.150.527
DN 65 PPMT025 20.658 5.4579 41.498 10.964 198.150.560
DN 80 PPMT030 13.330 3.5218 26.786 7.0769 198.150.561
DN 100 PPMT040 8.7077 2.3006 17.415 4.6011 198.150.562
DN 125 PPMT050 5.0667 1.3386 10.168 2.6864 198.150.563
DN 150 PPMT060 3.6892 0.9747 7.3119 1.9318 198.150.564
DN 200 PPMT080 2.0398 0.5389 3.9946 1.0554 198.150.565
PVDF FITTINGS (DIN/ISO AND BS AND ANSI)

DN 15 SFMT005 420.87 111.19 827.26 218.56 198.150.529
DN 20 SFMT007 228.15 60.277 489.87 129.42 198.150.530
DN 25 SFMT010 136.70 36.116 283.55 74.915 198.150.531
DN 32 SFMT012 79.294 20.950 158.59 41.899 198.150.532 Weldolet "H" dimension Weldolet "H" dimension
DN 40 SFMT015 43.490 11.490 86.980 22.980 198.150.533 part number inches mm part number inches mm
DN 50 SFMT020 25.908 6.8450 50.385 13.312 198.150.534
DN 65 SFMT025 18.067 4.7732 36.133 9.5465 198.150.571 CS4W020 2.38 60.45 CS4W240 4.16 105.66
DN 80 SFMT030 12.357 3.2648 24.715 6.5297 198.150.572
DN 100 SFMT040 8.0599 2.1294 16.120 4.2589 198.150.573
CS4W025 2.33 59.18 CS4W360 4.10 104.14
DN 125 SFMT050 4.4312 1.1707 8.8624 2.3415 198.150.574 CS4W030 2.32 58.92
DN 150 SFMT060 3.2271 0.8526 6.4543 1.7052 198.150.575
DN 200 SFMT080 2.0360 0.5379 4.0720 1.0758 198.150.576 CS4W040 2.30 58.42 CR4W020 2.38 60.45
CS4W050 3.09 78.48 CR4W025 2.33 59.18
PVC FITTINGS (DIN/ISO) - EUROPE ONLY
DN 15 PVMT005 486.18 128.45 972.37 256.90 198.150.480 CS4W060 2.96 75.18 CR4W030 2.32 58.92
DN 20 PVMT007 242.85 64.160 485.69 128.32 198.150.481 CS4W080 2.73 69.34 CR4W040 2.30 58.42
DN 25 PVMT010 148.64 39.270 297.274 78.540 198.150.482
DN 32 PVMT012 85.125 22.490 170.249 44.980 198.150.483 CS4W100 5.48 139.19 CR4W050 3.09 78.48
DN 40 PVMT015 51.855 13.700 103.709 27.400 198.150.484
DN 50 PVMT020 29.750 7.8600 59.500 15.720 198.150.485
CS4W120 5.25 133.35 CR4W060 2.96 75.18
DN 65 PVMT025 17.487 4.6200 34.9734 9.2400 198.150.538 CS4W140 5.10 129.54 CS4W080 2.73 69.34
DN 80 PVMT030 12.491 3.3000 24.9810 6.6000 198.150.539
DN 100 PVMT040 8.1377 2.1500 16.2754 4.3000 198.150.540 CS4W160 4.85 123.19 CR4W100 5.48 139.19
DN 150 PVMT060 4.0878 1.0800 8.1756 2.1600 198.150.543 CS4W180 4.60 116.84 CR4W120 5.25 133.35
DN 200 PVMT080 2.0439 0.5400 4.0878 1.0800 198.150.545
CS4W200 4.38 111.25
‡ SIGNET 515/2536 Rotor-X Flow Sensors page 3 of 4

9. ‡ SIGNET Fittings
Type Description Type Description
Plastic tees • 0.5 to 4 inch versions Iron, Carbon Steel, • 0.5 to 2 in. versions
• PVC or CPVC 316 SS Threaded • Mounts on threaded pipe ends
tees
PVC • Available in 10 and 12 inch sizes only Carbon steel & • 2 to 4 inch, cut 1-7/16 inch hole in pipe
Glue-on • Cut 2-1/2 inch hole in pipe stainless steel • Over 4 inch, cut 2-1/4 inch hole in pipe
Saddles • Weld in place using solvent cement Weld-on
Weldolets
PVC • 2 to 4 inch, cut 1-7/16 inch hole in pipe
Saddles • 6 to 8 inch, cut 2-1/4 inch hole in pipe Fiberglass • 1.5 in. to 8 in. PVDF insert
tees & • > 8 in. PVC insert
saddles: • Special order 12 in. to 36 in.
FPT FPS
PP • Available in 10 and 12 inch sizes only
Clamp-on • Cut 2-1/4 inch hole in pipe Metric • For pipes DN 65 to 200 mm
Saddles Wafer Fitting • PP or PVDF
Iron • 2 to 4 inch, cut 1-7/16 inch hole in pipe Metric • For pipes from DN 15 to 50 mm
Strap-on • Over 4 inch, cut 2-1/4 inch hole in pipe Union • PP or PVDF
saddles • Special order 12 in. to 36 in. Fitting
515/8510-XX 2536/8512-XX
Ordering Information Ordering Information Product Description
Part No. Code Part No. Code
P51530-P0 ...... 198 801 620 3-2536-P0 ....... 198 840 143 Sensor, Polypropylene, Titanium Rotor Pin, PVDF Rotor (black), 1/2 to 4 Inch Pipe
P51530-P1 ...... 198 801 621 3-2536-P1 ....... 198 840 144 Sensor, Polypropylene, Titanium Rotor Pin, PVDF Rotor (black) 5 to 8 Inch Pipe
P51530-P2 ...... 198 801 622 3-2536-P2 ....... 198 840 145 Sensor, Polypropylene, Titanium Rotor Pin, PVDF Rotor (black) 10 to 36 Inch Pipe
P51530-P3 ...... 198 840 310 3-2536-P3 ....... 159 000 758 Sensor, Wet-Tap, Polypropylene, Titanium Rotor Pin, PVDF Rotor (black), 1/2 to 4 Inch Pipe
P51530-P4 ...... 198 840 311 3-2536-P4 ....... 159 000 759 Sensor, Wet-Tap, Polypropylene, Titanium Rotor Pin, PVDF Rotor (black) 5 to 8 Inch Pipe
P51530-P5 ...... 198 840 312 3-2536-P5 ....... 159 000 760 Sensor, Wet-Tap, Polypropylene, Titanium Rotor Pin, PVDF Rotor (black) 10 to 36 Inch Pipe
P51530-V0 ...... 198 801 623 3-2536-V0 ....... 198 840 146 Sensor, PVDF (natural), Hastelloy Rotor Pin, PVDF Rotor (natural), 1/2 to 4 Inch Pipe
P51530-V1 ...... 198 801 624 3-2536-V1 ....... 198 840 147 Sensor, PVDF (natural), Hastelloy Rotor Pin, PVDF Rotor (natural), 5 to 8 Inch Pipe
P51530-V2 ...... 198 801 625 N/A N/A Sensor, PVDF (natural), Hastelloy Rotor Pin, PVDF Rotor (natural), 10 to 36 Inch Pipe
P51530-T0 ...... 198 801 663 3-2536-T0 ....... 198 840 149 Sensor, PVDF (natural), PVDF (nat.) Rotor Pin, PVDF Rotor (nat.), 1/2 to 4 Inch Pipe
P51530-T1 ...... 198 801 664 N/A N/A Sensor, PVDF (natural), PVDF (nat.) Rotor Pin, PVDF Rotor (nat.), 5 to to 8 Inch Pipe
3-8510-P0 ....... 198 864 504 3-8512-P0 ....... 198 864 513 Sensor, Integral, PP, Titanium Rotor Pin, PVDF Rotor (black), 1/2 to 4 Inch Pipe
3-8510-P1 ....... 198 864 505 3-8512-P1 ....... 198 864 514 Sensor, Integral, PP, Titanium Rotor Pin, PVDF Rotor (black) 5 to 8 Inch Pipe
3-8510-T0 ....... 159 000 622 3-8512-T0 ....... 198 864 518 Sensor, Integral, PVDF (nat.), Hastelloy Rotor Pin, PVDF Rotor (nat.), 1/2 to 4 In. Pipe
3-8510-V0 ....... 198 864 506 3-8512-V0 ....... 198 864 516 Sensor, Integral, PVDF (nat.), PVDF (nat.) Rotor Pin, PVDF Rotor (nat.), 1/2 to 4 In. Pipe
3519/515-P3 ... 159 000 819 3519/2536-P3 . 159 000 822 Sensor & Wet-Tap Assy., PP, Titanium Rotor Pin, PVDF Rotor (black), 1/2 to 4 In. Pipe
3519/515-P4 ... 159 000 820 3519/2536-P4 . 159 000 823 Sensor & Wet-Tap Assy., PP, Titanium Rotor Pin, PVDF Rotor (black), 5 to 8 In. Pipe
3519/515-P5 ... 159 000 821 3519/2536-P5 . 159 000 824 Sensor & Wet-Tap Assy., PP, Titanium Rotor Pin, PVDF Rotor (black), 10 to 36 In. Pipe
Accessories
M1538-2 .......... 198 801 181 3-2536.320-1 ... 198 820 052 Rotor, PVDF Black
P51547-3 ........ 159 000 474 3-2536.320-2 ... 159 000 272 Rotor, PVDF Natural
M1538-4 .......... 198 820 018 3-2536.320-3 ... 159 000 273 Rotor, Tefzel®
P51550-3 ........ 198 820 043 3-2536.321 ...... 198 820 054 Rotor and Pin, PVDF Natural
3-0515.322-1 ... 198 820 059 3-2536.322-1 ... 198 820 056 Sleeved Rotor, PVDF Black
3-0515.322-2 ... 198 820 060 3-2536.322-2 ... 198 820 057 Sleeved Rotor, PVDF Natural
3-0515.322-3 ... 198 820 017 3-2536.322-3 ... 198 820 058 Sleeved Rotor, Tefzel®
M1546-1 .......... 198 801 182 M1546-1 .......... 198 801 182 Rotor Pin, Titanium
M1546-2 .......... 198 801 183 M1546-2 .......... 198 801 183 Rotor Pin, Hastelloy-C
M1546-3 .......... 198 820 014 M1546-3 .......... 198 820 014 Rotor Pin, Tantalum
M1546-4 .......... 198 820 015 M1546-4 .......... 198 820 015 Rotor Pin, Stainless Steel
P51545 ............ 198 820 016 P51545 ............ 198 820 016 Rotor Pin, Ceramic
1220-0021 ....... 198 801 186 1220-0021 ....... 198 801 186 O-Ring, FPM-Viton®
1224-0021 ....... 198 820 006 1224-0021 ....... 198 820 006 O-Ring, EPDM
1228-0021 ....... 198 820 007 1228-0021 ....... 198 820 007 O-Ring, FFKM-Kalrez®
P31536 ............ 198 840 201 P31536 ............ 198 840 201 Sensor Plug, Polypro
P31536-1 ........ 198 840 202 P31536-1 ........ 198 840 202 Sensor Plug, PVDF Metric
P31536-2 ........ 159 000 649 P31536-2 ........ 159 000 649 Sensor Plug, PVDF
P31542 ............ 198 801 630 P31542 ............ 198 801 630 Sensor Cap, Red (for use w/515)
---- ---- P31542-3 159 000 464 Sensor Cap, Blue (for use w/2536)
P31934 159 000 466 P31934 159 000 466 Conduit Cap
P51589 ............ 159 000 476 P51589 ............ 159 000 476 Conduit Adapter Kit
5523-0222 ....... 159 000 392 5523-0222 ....... 159 000 392 Cable (per foot), 2 cond. w/shield, 22 AWG
‡ SIGNET
Signet Scientific Company, 3401 Aerojet Avenue, El Monte, CA 91731-2882 U.S.A. • Tel. (626) 571-2770 • Fax (626) 573-2057
For Worldwide Sales and Service, visit our website: www.gfsignet.com • Or call (in the U.S.): (800) 854-4090
GEORGE FISCHER ‡ Piping Systems

3-0515.090 (D-2/03) English © Signet Scientific Company 2003 Printed in U.S.A. on recycled paper
page 4 of 4 ‡ SIGNET 515/2536 Rotor-X Flow Sensors
Signet 2850 Conductivity/Resistivity Sensor Electronics ENGLISH
3-2850.090-1
3-2850.090-1 Rev. B 05/06 English
SAFETY INSTRUCTIONS
1. Depressurize and vent system prior to installation or removal.
2. Confirm chemical compatibility before use.
3. Do not exceed maximum temperature/pressure specifications.
4. Wear safety goggles or faceshield during installation/service.
5. Do not alter product construction.
6. When using chemicals or solvents, care should be taken and appropriate
eye, face, hand, body, and/or respiratory protection should be used.
Contents
1. Description 7. Wiring Dual Digital Output (S3L) version
2. Specifications 8. Cell Constant Selection
3. In-Line Installation 9. Range Selection for 4 to 20mA Output
4. Submersible Installation 10. Calibration
5. Wiring 4-20 mA Output version 11. Maintenance
6. Wiring Digital Output (S3L) version 12. Ordering Information
1. Description
Signet 2850 Conductivity/Resistivity Sensor Electronics provides a two-wire 4 to 20 mA output, or a digital interface in S3L™ format.
The 4 to 20 mA output models provide eight ranges for each electrode cell constant, plus the ability to invert each range.
The Easy-Cal feature allows the devices to automatically recognize standard conductivity test solution values for simple field calibration.
2. Specifications
Available data via Digital (S3L) Output:
General
• Raw conductivity
Compatible Electrodes: All Signet models with PT-1000 RTD
• Calibrated conductivity
• Calibrated temperature-compensated conductivity
Materials and Shipping Weight:
• Temperature
• Integral mount: PBT: 0.75 kg (1.75 lb.)
Error Indication: Open input and out of range diagnostics for
• Remote mount: PBT, CPVC: 0.75 kg (1.75 lb.)
temperature or internal electronic error.
Temperature Compensation: PT-1000 RTD
Current Output:
Easy-Cal:
• Field-selectable ranges
Automatic recognition of the following conductivity values:
• Factory set Span:
• 146.93 µS, 1408.8 µS, 12856 µS (@25°C)
0.01 cell (2819, 2839): 4 to 20 mA = 0 to 100 µS
(Test solutions Per ASTM D1125-95)
0.10 cell (2820, 2840): 4 to 20 mA = 0 to 1000 µS
• 10 µS, 100 µS, 200 µS, 500 µS, 1000 µS, 5000 µS,
1.0 cell (2821, 2841): 4 to 20 mA = 0 to 10,000 µS
10,000 µS, 50,000 µS, 100,000 µS (@25°C)
10.0 cell (2822, 2842): 4 to 20 mA = 0 to 200,000 µS
20.0 cell (2823): 4 to 20 mA = 0 to 400,000 µS
Electrical
Power: 12 to 24 VDC for 4 to 20 mA output
• Max. Loop Resistance: 50 Ω @ 12 VDC
5 VDC +/-5% regulated, 3.0 mA max. for Digital (S3L)
325 Ω @ 18 VDC
output (Reverse polarity and short circuit protected)
600 Ω @ 24 VDC
• Accuracy: ±2% of output span
Digital (S3L) Output: Serial ASCII, TTL level 9600 bps
• Resolution: 7 µA
• Accuracy: Conductivity: ±2% of reading
• Update Rate: <600 ms
Temperature: ±0.5°C
• Error Indication: 22 mA
• Resolution: Conductivity: 0.1% of reading
Temperature: <0.2°C
Standards and Approvals
• Update Rate: Single channel models: <600 ms
• NEMA 4X/IP65
Dual channel models: <1.2 s
• CE
• Immunity: EN61326-1
• Emissions: EN55011 Class B
• Manufactured under ISO 9001 and ISO 14001
Dimensions
2850-51, -52 Integral mount 2850-61, -62, -63 Universal mount
95 mm
3.74 in. 95 mm
3.74 in.
85 mm 82 mm
3.34 in. 3.24 in.
Conductivity Sensor Dimensions
73.7 mm
2.90 in. 59.3 mm
2.33 in. 35.8 mm 41.9 mm
1.41 in. 21.5 mm 1.65 in. 26.8 mm
0.85 in. 1.13 in.
3-2839 3-2840 3-2841 3-2842

0.01 cell 0.1 cell 1.0 cell 10.0 cell
Operating Range Chart
Cooling Tower Deionization Regen. Chemicals

Bottled Waste Waters Alkali Cleaners, Acids/Bases
UPW @ 25°C USP Water
(20.0 Cell) 2823
2842
(10.0 Cell)
2822
(1.0 Cell) 2841

2821
(0.10 Cell) 2840

2820
(0.01 Cell)
2839
2819
0.010 µS 0.055 µS 1 µS 10 µS 50 µS 100 µS 200 µS 400,000 µS

1,000 µS 10,000 µS 100,000 µS
100 MΩ 18.2 MΩ 1 MΩ 100 KΩ 10 KΩ
50,000 µS 200,000 µS
0.5 µS 20 µS
2 2850 Conductivity/Resistivity Sensor Electronics

3. In-Line Installations
Most of the Conductivity/Resistivity electrodes used with the 2850
can be installed into standard 3/4 in. (NPT or ISO 7-R3/4) fittings.
The 2850-5X models are designed for integral systems, where

the electronics are attached directly to the sensor. For these
models, select any electrode with a short (6 inch) cable.
The preferred installation for in-line applications directs flow

straight into the electrode. This configuration reduces the
probability of entrapped air bubbles, and provides the best
continuous sampling of the fluid content.
If the electrode is mounted vertically in a tee, do not recess the

electrode orifices inside the tee. Mounting upside down may help
prevent air entrapment.
An oversized tee or flow cell may be helpful for inline installations.

At least 4 threads (ANSI B1.20.1) must be engaged to meet the
pressure rating as published in the specifications.
Use the 2850-6X models for in-line installations where the

electronics must be separated from the electrode. Conductivity
electrodes with sanitary flange fittings must be installed using this
option.
4. Tank Installations
While the 2850-5X and -6X electronics cannot be submerged, either model will
accomodate tank installation.
Select any electrode with a 5 m (15 ft.) cable. The cable may be cut to length, but it
CANNOT BE EXTENDED.
The universal adapter included with 2850-6X models can be attached to the top of a
tank or mounted to a surface near the tank.
Adapt the 2850-5X models to tank installations by attaching a clamp to the conduit.
2850 Conductivity/Resistivity Sensor Electronics 3

8. Cell Constant Selection
Cell Constant Selection
• Switch banks SW3 and SW4 are used to select the CELL 0.01/cm-1
CONSTANT of the electrode. The Dual Input model is ON CTS
illustrated. Single input models use only SW3. 1 2 3 Closed
• Make all switch settings before connecting power. Switch ON CTS Open
1 2 3 4
changes made with the power ON will take 15-20 seconds 1 2 3 4
before becoming effective.
SW1
0.1/cm-1
• Use SW3 #1-3 to select the cell constant for the first sensor. ON CTS ON CTS ON CTS
Closed
• Use SW3 #4 to disable the PT1000 Temp Compensation 1 2 3 4 1 2 3 4
D3
SW3 SW4
function in the 2850 (as required for USP applications.) 4
Open
Ch 1 Ch 2 1 2 3
This disables the function for BOTH CHANNELS.
• Use SW4 #1-3 to select the cell constant for the second 1.0/cm-1
CTS
sensor. ON
Closed
• Set SW4 #4 to OPEN to disable the second channel.
Open
Example: 1.0 cell constant, temp comp ON 1 2 3 4
SW3 Cell Constant and Temp Compensation
ON CTS
#1 #2 #3 #4 For Cell Constant Closed 10.0/cm-1
ON CTS
C O O O 0.01/cm-1
Open Closed
O C O O 0.1/cm-1 1 2 3 4
Open
C C O O 1.0/cm-1 1 2 3 4
O O C O 10.0/cm-1 Example: 1.0 cell constant, temp comp OFF
C O C O 20.0/cm-1 ON CTS
Closed
20.0/cm-1
ON CTS
#4: Open = Temp Comp ON
Closed
Closed = Temp Comp OFF 1 2 3 4
Open
Open
1 2 3 4
SW4: #1, #2 and #3 operate the same as SW3.

#4 turns turns channel 2 OFF when set to OPEN.
(Open = Off, Closed = On)
9. Range Selection for 4 to 20mA Output

ON CTS
C=Closed
• The Range selection switch bank (SW2) provides eight
range selections for each cell constant. Each range can be O=Open 1 2 3 4
1
2
3
SW2
inverted, making a total of 16 range options. ON CTS
• Select a range from the table below and set SW2 as 1 2 3 4
indicated. SW2
SW1
Example (refer to shaded selections of chart): ON CTS
SW3
• The electrode installed is the 3-2840-1, with a 0.10 cell 1 2 3 4
D3
constant.
• The required output is 4-20 mA = 0-100 µS.
• Set SW2 switch bank to C-C-O-O.
• To invert range (4-20 mA = 100-0 µS), Close switch #4.
SW2 Switch setting 0.01 Cell 0.10 Cell 1.0 Cell 10.0 Cell 20.0 Cell
#1 #2 #3 #4 Resistivity Ranges in BOLD
C C C O 10 to 20 MΩ 0 to 2 µS 0 to 20 µS 0 to 200 µS 0 to 400 µS
C C C C 20 to 10 MΩ 2 to 0 µS 20 to µS 200 to 0 µS 400 to 0 µS
O C C O 2 to 10 MΩ 0 to 5 µS 0 to 50 µS 0 to 500 µS 0 to 1000 µS
O C C C 10 to 2 MΩ 5 to 0 µS 50 to 0 µS 500 to 0 µS 1000 to 0 µS
C O C O 0 to 2 MΩ 0 to 10 µS 0 to 100 µS 0 to 1 000 µS 0 to 2000 µS
C O C C 2 to 0 MΩ 10 to 0 µS 100 to 0 µS 1 000 to 0 µS 2000 to 0 µS
O O C O 0 to 1 µS 0 to 50 µS 0 to 500 µS 0 to 5 000 µS 0 to 10000 µS
O O C C 1 to 0 µS 50 to 0 µS 500 to 0 µS 5 000 to 0 µS 10000 to 0 µS
C C O O 0 to 5 µS 0 to 100 µS 0 to 1 000 µS 0 to 10 000 µS 0 to 20 000 µS
C C O C 5 to 0 µS 100 to 0 µS 1 000 to 0 µS 10 000 to 0 µS 20 000 to 0 µS
O C O O 0 to 10 µS 0 to 200 µS 0 to 2 000 µS 0 to 50 000 µS 0 to 100 000 µS
O C O C 10 to 0 µS 200 to 0 µS 2 000 to 0 µS 50 000 to 0 µS 100 000 to 0 µS
C O O O 0 to 50 µS 0 to 500 µS 0 to 5 000 µS 0 to 100 000 µS 0 to 200 000 µS
C O O C 50 to 0 µS 500 to 0 µS 5 000 to 0 µS 100 000 to 0 µS 200 000 to 0 µS
O O O O 0 to 100 µS 0 to 1 000 µS 0 to 10 000 µS 0 to 200 000 µS 0 to 400 000 µS
O O O C 100 to 0 µS 1 000 to 0 µS 10 000 to 0 µS 200 000 to 0 µS 400 000 to 0 µS
C = CLOSED O = OPEN Switch #4 inverts the output: OPEN = 4-20 mA, CLOSED = 20-4 mA

10. Calibration
• All 2850 Conductivity/Resistivity Sensor Electronics are factory-calibrated for maximum out-of-the-box accuracy.
• The Easy-Cal feature allows calibration to be performed at the sensor.
a. SW2: 4-20 mA output range selection switch bank

b. Power and 4 to 20 mA or Digital (S3L) output terminal block
c. SW3 and SW4: Electrode Cell Constant selection switch banks
d. D3: LED indicator
e. SW1: Easy-Cal Push-button
f. Conductivity Electrode connections
CTS
a
4
3
2
ON
1
3
CTS
4
b 2 CH 2
3
2
ON
1
1
f
CTS
4
3
CH 1
c
2
ON
1
SW1 e
d D3
10.1 Easy-Cal
Easy-Cal is a single-point calibration system. During this procedure, if the measured value is within ±10% of any of the test values
listed below, the 2850 will automatically recognize the test value and calibrates the output to that value.
Note:
The first step (Reset) is recommended each time an electrode is replaced, but is NOT necessary upon initial installation or periodic
calibration.
1. Reset the 2850 Sensor to factory calibration: Set all switches on SW3 (and SW4 for dual input) to OPEN. Apply power, wait at
least 3 seconds, then press and hold SW1 until the LED (D3) comes on steady then goes off again (approx. 10 seconds). When
the LED goes off, release SW1; reset is complete. Reset SW3 and SW4 to the proper settings.
2. Place the electrode/sensor assembly into the conductivity test solution appropriate to your operating range. Shake the electrode to
dislodge any air bubbles visible on the surface of the electrode.
• 146.93 µS, 1408.8 µS, 12856 µS (per ASTM D1125-95)
• 10 µS, 100 µS, 200 µS, 500 µS, 1000 µS, 5000 µS, 10,000 µS, 50,000 µS, 100,000 µS
• Allow at least 2 minutes for the electrode response to stabilize.
3. Press and hold SW1 for approximately 8 to 10 seconds. During this time, the LED will come on steady then go back off. (If the
LED blinks several times rapidly, the calibration was not successful. See the troubleshooting section.)
Calibration is complete. Return the system to service.
Calibrating the Dual-channel model 3-2850-63

• The 2850-63 can only be calibrated if both channels are used, or if channel 2 is disabled.
• To disable channel 2: Set SW4, #4 to OPEN.
• Place each sensor into a test solution that represents the operating range of that sensor. When SW1 is pressed, the 2850 will
calibrate both channels simultaneously.
• Dual channel applications usually include one sensor with a smaller cell constant and one sensor with a larger cell constant. Place
the larger cell constant on channel 1. This allows periodic recalibration of the larger cell by simply turning channel 2 OFF.
6 2850 Conductivity/Resistivity Sensor Electronics

11. Maintenance
• The 2850 requires no periodic maintenance.
• Coatings on the electrode may cause slow response or drift.
Clean metallic surfaces with a mild detergent and a non-abrasive brush or cotton swab.
11.1 Troubleshooting
LED and Output Condition Possible Causes Suggested Solutions
Current Out: • SW3 and SW4 set to all OPEN (factory • Normal for new system
LED off, current output is 22 mA setting) • Install electrode
• No electrode installed • Set SW3 and SW4 correctly
S3L out: "Check Sensor" • SW3 (and SW4) not set correctly • Retry (recycle power)
• System not ready
• Measured value of the test solution is • Use fresh test solutions and restart the
During EasyCal, the LED blinks outside the ±10% tolerance. calibration.
rapidly for 4 seconds. • The electronics or the electrode is • Replace the electronics or the electrode.
defective.
• Insufficient time allowed for electrode • Recalibrate and wait at least 2 minutes after
After completing calibration stabilization during Cal procedure. placing electrode in solution before pressing
procedure, the output values are • Test solutions are contaminated. SW1.
inaccurate. • EZ-Cal performed with temp comp • Use fresh test solutions and restart the
OFF, then temp comp turned ON for calibration.
measurement. (or vice versa)
The output of the 2850 indicates • The cell constant selection on the 2850 • Match the 2850 switch settings to agree with
a value that is off by a factor (SW3 or SW4) does not match the the sensor being used.
of 10 (ie: 10x, 100x the correct actual input.
value)
Electronic Certification/Calibration
Signet offers conductivity simulators in five different values. These tools enable the user to validate the performance of the electronics
independently of the electrode. This requirement is defined by ASTM D 1125-95 (Standard Test Methods for Electrical Conductivity and
Resistivity of Water) which is commonly used for USP 24 applications.
3-2850.101-1 (159 001 392) 1.0 µS ±0.1% 3-2850.101-2 (159 001 393) 2.5 µS ±0.1%
Cond. - Resist.
Simulator 3-2850.101-3 (159 001 394) 10.0 µS ±0.1% 3-2850.101-4 (159 001 395) 18.2 MΩ ±0.1%
1.0 µS
@ 25°C 3-2850.101-5 (159 001 396) 10.0 MΩ ±0.1%
For use with Signet
2850 Conductivity
NIST Traceable
Before using the Simulator:
Before using the simulators, disconnect all electrodes and reset the 2850 Electronics to factory calibration:
1. Set all switches on SW3 (and SW4 for dual input) to OPEN. Turn the power on, wait at least 3 seconds
2. Press and hold SW1 until the LED (D3) comes on steady then goes off again (approx. 10 seconds).
3. When the LED goes off, release SW1. Reset is complete.
To validate channel 1:
1. Turn the power off.
2. Set SW3 to accept a 0.01 cell constant. Leave SW4 in the all-OPEN position.
3. Install the simulator into the 2850 at the channel 1 conductivity electrode terminals.
4. Connect the 2850 output terminals to the appropriate display instrument. Turn the power on.
• The display should indicate a conductivity value within ±2% of the simulator value.
• If the output is x10 or x100 of the correct value, recheck step 2. The 2850 is not set to accept a 0.01 cell constant.
• If the correct value is displayed, the electronics are calibrated to ASTM D 1125 specifications. Remove the simulator and reset
SW3 to the correct cell constant before reinstalling the electrode.
• If the correct value is not displayed, contact the factory.
To validate channel 2:
1. Turn the power off.
2. Set SW4 to accept a 0.01 cell constant.
3. Install the simulator into the 2850 at the channel 2 conductivity electrode terminals.
4. Set SW3 switches to the all-OPEN position.
5. Turn the power on and repeat step 4.
Remember to reset all switches to their correct position before resuming normal operation.

12. Ordering Information
Mfr. Part No. Code Description
3-2850-51 159 001 398 2850 Sensor Electronics w/ Digital Output and ¾ inch adapter
3-2850-52 159 001 399 2850 Sensor Electronics w/ 4-20 mA Output and ¾ inch adapter
3-2850-61 159 001 400 2850 Sensor Electronics w/ Digital Output and Universal adapter
3-2850-62 159 001 401 2850 Sensor Electronics w/ 4-20 mA Output and Universal adapter
3-2850-63 159 001 402 2850 Sensor Electronics w/ Dual Inputs, Digital Outputs and Universal adapter
3-2850-51-39 159 001 339 Integral 2850 system, Digital (S3L) output, 0.01 cell, NPT threads
3-2850-51-39D 159 001 343 Integral 2850 system, Digital (S3L) output, 0.01 cell, ISO threads
3-2850-52-39 159 001 347 Integral 2850 system, 4-20 mA output, 0.01 cell, NPT threads
3-2850-52-39D 159 001 351 Integral 2850 system, 4-20 mA output, 0.01 cell, ISO threads
Parts and Accessories

3-9000.392-1 159 000 839 Liquid-tight connector kit, 1 set, 1/2 in. NPT
3-9000.392-2 159 000 841 Liquid-tight connector kit, 1 set, PG 13.5
3-9000.392-3 159 001 430 Liquid-tight connector kit, dual-cable gland
3-2850.101-1 159 001 392 Plug-in NIST traceable recertification tool, 1.0 µS
3-2850.101-4 159 001 395 Plug-in NIST traceable recertification tool, 18.2 MΩ
3-2850.101-5 159 001 396 Plug-in NIST traceable recertification tool, 10.0 MΩ
95 mm
95 mm (3.74 in.)
(3.74 in.) Cond. - Resist.
Simulator
1.0 µS
@ 25°C
82 mm 85 mm For use with Signet

(3.24 in.) 2850 Conductivity
(3.34 in.)
NIST Traceable
3-2850-61
3-2850-62 3-2850-51
3-2850-51-XX
3-2850-63 3-2850-52
3-2850-52-XX
Electronics w/Universal adapter Electronics w/¾ in. adapter 3-2850.101-1 NIST
Integral System
traceable recertification
tool, 1.0 µS
George Fischer Signet, Inc., 3401 Aerojet Avenue, El Monte, CA 91731-2882 U.S.A. • Tel. (626) 571-2770 • Fax (626) 573-2057
3-2850.090-1 Rev. B 05/06 English © George Fischer Signet, Inc. 2006 Printed in U.S.A. on Recycled Paper
Signet 2750 DryLoc™ pH/ORP Sensor Electronics English
*3-2750.090*
3-2750.090 Rev. G 11/05 English
1. Description
2. Specifications
WARNING! SAFETY INSTRUCTIONS 3. In-line Installation
1. Depressurize and vent system prior to installation or removal. 4. 2750 In-line Assembly
2. Confirm chemical compatibility before use. 5. Submersible Installation
3. Do not exceed maximum temperature/pressure specifications. 6. Digital (S3L) wiring
4. Wear safety goggles or faceshield during installation/service. 7. 4-20 mA Loop wiring
5. Do not alter product construction. 8. Calibration
6. When using chemicals or solvents care should be taken and appropriate eye, 9. Troubleshooting
face, hand, body, and/or respiratory protection should be used. 10. Ordering Information
1. Description
Signet 2750 pH/ORP Sensor Electronics provide two-wire 4 to 20mA loop output for pH and ORP measurements, without the expense
of local display and other luxuries available in full-featured transmitters. Preamplification is built-in, reducing system costs while ensuring
absolute signal integrity up to 304.8m/1,000 feet.
These sophisticated field-mount devices also provide the digital (S3L™: Signet Sensor Serial Link) output, the latest development in
leading-edge technology from Signet. The 2750 Sensor Electronics self-configure for pH or ORP operation via automatic recognition of
electrode type, and the DryLoc™ electrode connector quickly forms a robust assembly for submersible and in-line installations.
NEMA 4X Junction Boxes are integral parts of the in-line version and are available as accessories for the submersible version. The
optional Easy-Cal feature allows simple push-button calibration and includes an LED for visual feedback.
2. Specifications
General Electrical
• Compatible Electrodes: Signet DryLoc Electrodes • Input Impedance: >1011Ω
• Input response time: 500 ms
• Operational Range: 0.00 to 14.00 pH, ±2000 mV ORP • Temperature drift: ±0.002 pH per ºC
0°C to 85°C (32ºF to 185ºF) ±0.1 mV ORP per ºC
• Input resolution: 0.02 pH, 1 mV ORP, 0.3ºC
• Response Time (includes electrode response):
pH: <6 s for 95% of change Current output:
ORP: application dependent • Description: pH: Fixed 4 to 20 mA, isolated, 0 to
pH Temp τ: 140 s (2754) 14 pH (custom scaling available)
196 s (2756) ORP: Fixed 4 to 20 mA, isolated, -1000 to
438 s (2756-WT) 2000 mV (custom scaling available,
-2000 to 2000 mV)
Materials: • Power: Regulated 12-24 VDC ± 10%, 20 mA
2750-1, -2 (in-line): PBT (thermal plastic polyester) max.
2750-3, -4 (submersible): CPVC • Max Loop Resistance: 50Ω max. @ 12V
325Ω max. @ 18V
Cable for -3, -4 submersible versions: 600Ω max. @ 24V
5 m (15 ft.) 3-conductor shielded, 22 AWG. • Accuracy: ±32µA @ 25ºC
• May be extended up to 183 m (600 ft) with current output. • Temperature drift: ±1µA per ºC
• May be extended up to 305 m (1000 ft) with S3L output. • Output resolution: ± 5 µA
• Error indication: 3.6 mA
Weight:
2750-1, -2 (in-line): 0.75 kg (1.75 lb.) Digital (S3L) output:
2750-3, -4 (submersible): 0.64 kg (1.4 lb.) • Description: Serial ASCII, TTL level 9600 bps
• Power: 5VDC ± 10% regulated, 3 mA max
Environmental • Accuracy: pH: ± 0.03 pH @ 25°C
• Ambient Temp.: -10°C to 85°C ORP: ± 2 mV @ 25°C
• Storage Temp.: -20°C to 85°C • Resolution: pH: 0.02 pH
• Relative Humidity: 95% max, non-condensing ORP: 1 mV
• Immunity: EN50082-2 Temp. 0.2°C
• Emissions: EN50081-1 • Error indication: Temp output "+999.9"
• Enclosure Rating:
2750-1, -2 (in-line): NEMA 4X/IP65 (with electrode Standards and Approvals
connected) • CE
2750-3, -4 (submersible): NEMA 6P/IP68 (with electrode • Manufactured under ISO 9001 & ISO 14001
and watertight extension pipe
connected)
3. In-line Dimensions
• The 2750-1 in-line sensor (without Easy-Cal) is designed for applications where electrode calibration is facilitated by remote
equipment.
• The 2750-2 In-Line sensor includes Easy-Cal.
• A Signet installation fitting (1/2 in. to 4 in.) or a Signet pipe adapter is required to secure the electrode in the pipe.
• The Signet Measurement and Instrumentation catalog offers a complete selection of fittings.
• The 2750-3 and 2750-4 submersible sensor electronics are recommended for in-line applications using the 2764 series differential
electrodes and the 2774 series Threaded DryLoc electrodes.
• 2764 and 2774 series electrodes thread directly into standard 1 in. or 3/4 in. NPT fittings.
115 mm
(4.5 in.)
89.4 mm
178 mm (3.52 in.)
(7 in.)
248 mm
(9.75 in.)
3.7 in./
94 mm
45 mm
(1.75 in.)
5.5 in./
140 mm
Mounting position
2754 and 2764 series electrodes must be mounted upright.

• Vertical (0°) position optimum
• Do not install within 30º of horizontal (Contact factory for horizontal or inverted installation requirements.)
• Recommended maximum flow rate 10 ft/s.
• Wet-tap electrodes and 2774 series electrodes have pressurized electrolyte chambers, enabling them to be mounted at any angle.
OK OK
OK OK Vertical ± 60°
YES YES OK OK
OK OK
30° OK OK OK
30° OK
NO NO
NO
2 Signet 2750 DryLoc pH/ORP Sensor Electronics

4. 2750 In-line pH Sensor Assembly
Note: This procedure applies to systems using standard 2754-2757 electrodes.
If the 3719 pH/ORP Wet-Tap is used, refer to the 3719 manual for instructions.
1. Insert electrode into Signet installation fitting. Seat the

electrode tabs into the alignment notches in the fitting.
2. Thread the in-line retaining cap onto fitting to secure the Retaining cap
electrode into place. Hand-tighten the cap. DO NOT use any
tools to avoid damaging the threads.
Note:
Keep the electrical interconnection between electrode and sensor
electronics dry and clean at all times.
Locking Ring Unlocked

3. Unlock the ring on base of 2750 (The ring is unlocked when the
lines on the ring and body of the 2750 are not aligned.)
The molded alignment
marks are enhanced
for clarity.
The molded alignment

4. Place 2750 onto top of electrode and turn until the assembly marks are enhanced
drops into position. for clarity.
5. Turn locking ring 1/4 turn to secure the 2750 assembly. (The
ring is locked when the line on the ring and the line on the body
of the 2750 are aligned.)
Locked
In-Line Sensor and Electrode Removal

• To remove electronics assembly only:
Turn locking ring 1/4 turn; lift assembly straight up.
• To remove electrode from the pipe: CAUTION!
Remove electronics assembly, then unthread retaining cap; • Do not remove the electrode from a pressurized pipe.
pull electrode straight up. • Wear appropriate protective clothing when working
• To remove the complete 2750 system: with chemicals in pressurized pipe.
Hold locking ring in place. Unthread retaining cap and pull
electrode straight up.
Signet 2750 DryLoc pH/ORP Sensor Electronics 3

5. 2750-3, -4 Submersible Sensor Assembly and Installation
1. Insert electrode into base 2. Thread retaining cap over 3. Attach 3/4 in. watertight pipe to the top of the 2750.
of the 2750-3 or 2750- electrode and hand-tighten onto Secure the threaded connection to prevent any leakage.
4 and turn until keyed 2750.
contacts are seated. • For additional defense against possible accumulation of
condensation at the back seal area of the sensor, fill the
lower 3-4 inches (75-100 mm) of conduit or extension
pipe with a flexible sealant such as silicone.
2750-3: 3/4 in. NPT threads

2750-4: ISO 7-1/R3/4 threads
Fill with
75-100 mm
(3 to 4 in.)
A light coat of non-petroleum of sealant
based lubricant on the O-ring
will ease installation. 208 mm/
8.2 in.
Note:
Keep the electrical interconnection between electrode and sensor
55 mm/
electronics dry and clean at all times.
2.16 in.
Use standard installation OR The 8052-1 NPT Mount Junction box (or OR The 8050-1 Universal Mount
hardware to connect the 8052-2 with Easy-Cal) connects to 3/4 in. junction box (or 8050-2 with Easy-
submersible 2750-3 or -4 pipe or conduit and provides convenient Cal) mounts flat onto a wall or can
directly to external equipment. wiring termination. be strapped to a post or pipe.
106 mm/
94 mm/ 4.2 in.
3.7 in.
94 mm/
3.7 in.
107 mm/
4.2 in.
1/2 in. NPT threads
Fill with
3 to 4 in.
of sealant
Fill with
3 to 4 in.
of sealant
Cable supplied: 5 m (15 ft.) 3-conductor + shld, 22 AWG.

May be extended up to 183 m (600 ft) with current output.
May be extended up to 305 m (1000 ft) with S3L output.

6. Digital (S3L) wiring
• When the 2750 is powered with 5 VDC, the digital (S3L) serial data output is automatically selected.
• S3L data is used exclusively by Signet instruments.
• Remove approximately 10 mm (0.4 in.) of insulation and tin each conductor before inserting into connectors.
S3L with no junction box S3L with Junction box
SW2
Black
+5 VDC Run Cal
Red S3L data SW1

4
D1
3
2
White Signal Ground 1
Shield
+ 4 +5 VDC
3 S3L data
- 2 Signal Ground
S 1
Optional
Earth ground
• When the 2750 includes a terminal block, connect the 2750

terminals as shown to any S3L I/O port.
• 8900 users: If the 2750 includes the Easy-Cal accessory,
• Connect the 2750 cable directly to S3L I/O terminals. set the CALIBRATE menu to "perform Calibration at either
• 8900 users: If this direct wiring is used, set the CALIBRATE SENSOR or INSTRUMENT"
menu to "perform calibration at INSTRUMENT" • If SENSOR, use standard pH buffer values (pH 4, 7, or 10) to
perform periodic calibration.
• If INSTRUMENT, any pH value can be used.
7. 4-20 mA Loop wiring

• When the 2750 is powered with 12 to 24 VDC, the 4-20 mA loop output is automatically selected.
• Remove approximately 10 mm (0.4 in.) of insulation and tin each conductor before inserting into connectors.
Current Loop with no junction box Current loop with Junction box
Black
+ Power Supply
Red (no connection) DC 12 - 24 V SW2
- Run Cal
White
SW1
4
D1 + 4 + Power Supply
Shield 3
DC 12 - 24 V
2 3 -
1
- 2
Optional
Earth Ground S 1
4 20 4 20
Optional
Earth Ground
4-20 mA loop 4-20 mA loop
monitor monitor
• Connect the 2750 cable directly to a Loop device as shown. • When the 2750 includes a terminal block, connect the 2750
• This configuration does not provide any calibration capability terminals to the Loop device as shown.
within the 2750 system. Periodic calibration must be • If the 2750 includes the Easy-Cal accessory, use standard pH
performed at the external equipment. buffer values (pH 4, 7, or 10) to perform periodic calibration.

8. Calibration
All 2750 pH/ORP Sensor Electronics are factory-calibrated for maximum out-of-the-box accuracy. Periodic calibration is required to
compensate for electrode aging.
The optional Easy-Cal feature allows calibration to be performed local to the sensor.
SW1 Easy-Cal button

SW2 RUN/CALIBRATE switch for S3L system
D1 Easy-Cal Indicator (green LED)
SW2
Run
Cal
SW1
SW2
D1
Run Cal + 4 BLK
3 RED
+ 4
D1 - 2 WHT
SW1
S 1 SHLD
3
- 2
S 1
Easy-Cal Procedure:
The first step (Reset) is recommended each time an electrode is replaced, but is NOT necessary upon initial installation or periodic
calibration. In fact, for periodic calibration it is best for the electrode/sensor assembly to remain intact to minimize the possibility of
moisture or other contamination entering the electrical interconnection area. The electrode/sensor connection must remain dry and clean
at all times.
1. Reset the 2750 pH/ORP Sensor to factory calibration: With no electrode connected to the Sensor, press and hold SW1 until the LED
(D1) comes on steady then goes off again (approx. 10 seconds). When the LED goes off, release SW1; reset is complete.
2. Connect an electrode to the 2750 pH/ORP Sensor.
3. If S3L output is being used, place SW2 in the “Cal” position. If 4-20 mA output is being used, SW2 position is of no
consequence.
4. Place the electrode/sensor assembly into a calibration solution as follows: (If the electrode is “healthy”, then the 2750 will
automatically recognize the solution. The order in which the solutions are used during the calibration procedure is of no
consequence.)
• For pH calibration, use any two of these international standards: pH 4.0, 7.0 or 10.0 buffer solutions.
(Signet part number 3-0700.390 contains one capsule of each value)
• To produce standards for ORP calibration, mix the chemical Quinhydrone into pH 7.0 and 4.0 buffers to saturation (1/8g per 50ml).
• Regardless of the size of the container used for calibration, one inch of solution is adequate to completely submerge the tip of the
electrode.
• Allow at least 30 seconds for the electrode response to stabilize before calibration.
5. Press and hold SW1 for approximately 8 to 10 seconds. During this time, the LED (D1) will come on steady then go back off.
Release SW1 (If the LED blinks several times rapidly, the calibration was not successful. See the troubleshooting section.)
6. Remove the electrode/sensor assembly from the first calibration solution, rinse the electrode with clean water, and place it in a second
solution.
• Allow at least 30 seconds for the electrode response to stabilize before calibration.
7. Press and hold SW1 for approximately 8 to 10 seconds. During this time, the LED will come on steady then go back off. Release
SW1. (If the LED blinks several times rapidly, the calibration was not successful. See the troubleshooting section.)
8. For S3L systems ONLY: Return SW2 to the RUN position.
Calibration is complete. Return the system to service.

9. Troubleshooting
LED and Output Possible Causes

Condition Suggested Solutions
Current Out: • No electrode installed • Install electrode

LED off, current output is 3.6 mA • Check interconnection between electrode
• Bad/dirty contacts between electrode and 2750, clean contacts
S3L: Temp out is +999.9 and 2750
During Easy-Cal, the LED blinks • The buffer solution is outside of the • pH system: Use fresh 4 pH, 7 pH, or 10 pH
rapidly for 4 seconds and the accepted tolerance for the 2750 buffer and restart the calibration.
current output is frozen at a • The electrode is depleted (> 1.1 pH or • ORP system: Use fresh 4pH and 7 pH buffer
random fixed value. 65 mV offset) solution saturated with quinhydrone.
• Replace the electrode.
After completing calibration • Insufficient time allowed for electrode • Recalibrate, verify that test solutions are
procedure, the output values are stabilization during calibration. at room temperature and wait at least 30
inaccurate. seconds after placing electrode in solution
before pressing S1 EasyCal button.

10. Ordering Information
3-2750-1 159 000 744 In-line Sensor Electronics w/Junction Box
3-2750-2 159 000 745 In-line Sensor Electronics w/Junction Box and Easy-Cal
3-2750-3 159 000 746 Submersible Sensor Electronics with 15 ft. cable, 3/4 in. NPT threads
3-2750-4 159 000 842 Submersible Sensor Electronics with 15 ft. cable, ISO 7-1/R3/4 threads
Parts and Accessories

DryLoc pH Electrodes
3-2754 159 000 747 Electrode, pH, DryLoc, flat, PT1000
3-2754-1 159 001 380 Electrode, pH, DryLoc, flat, 3KΩ
3-2754-HF 159 000 748 Electrode, pH, DryLoc, flat, PT1000, HF-resist (<2%)
3-2754-HF-1 159 001 381 Electrode, pH, DryLoc, flat, 3KΩ, HF-resist (<2%)
3-2756 159 000 750 Electrode, pH, DryLoc, bulb, PT1000
3-2756-DI 159 000 751 Electrode, pH, DryLoc, bulb, PT1000, DI (<100 µS)
3-2756-DI-1 159 001 382 Electrode, pH, DryLoc, bulb, 3KΩ, DI (<100 µS)
3-2756-WT 159 000 834 Electrode, pH, DryLoc, bulb, PT1000, wet-tap
3-2756-WT-1 159 001 383 Electrode, pH, DryLoc, bulb, 3KΩ, wet-tap
3-2756-WTP 159 001 390 Electrode, pH, DryLoc, bulb, PT1000, wet-tap
3-2756-WTP-1 159 001 384 Electrode, pH, DryLoc, plastic bulb, 3KΩ, wet-tap
3-2764-1 159 000 943 Electrode, pH, DryLoc, flat, 3KΩ, differential, 1 in. NPT process connection
3-2764-2 159 000 944 Electrode, pH, DryLoc, flat, PT1000, differential, 1 in. NPT process connection
3-2764-3 159 000 945 Electrode, pH, DryLoc, flat, 300Ω, differential, 1 in. NPT process connection
3-2766-1 159 000 949 Electrode, pH, DryLoc, bulb, 3KΩ, differential, 1 in. NPT process connection
3-2766-2 159 000 950 Electrode, pH, DryLoc, bulb, PT1000, differential, 1 in. NPT process connection
3-2766-3 159 000 951 Electrode, pH, DryLoc, bulb, 300Ω, differential, 1 in. NPT process connection
3-2774 159 000 955 Electrode, pH, DryLoc, flat, 3KΩ, ¾ in. NPT process connection
3-2774-1 159 000 956 Electrode, pH, DryLoc, flat, PT1000, ¾ in. NPT process connection
3-2776 159 000 959 Electrode, pH, DryLoc, bulb, 3KΩ, ¾ in. NPT process connection
3-2776-1 159 000 960 Electrode, pH, DryLoc, flat, PT1000, ¾ in. NPT process connection
DryLoc ORP (Redox) Electrodes

3-2755 159 000 749 Electrode, ORP, DryLoc, flat, 10KΩ ID
3-2757 159 000 752 Electrode, ORP, DryLoc, bulb, 10KΩ ID
3-2757-WT 159 000 835 Electrode, ORP, DryLoc, bulb, 10KΩ ID, wet-tap
3-2765-1 159 000 946 Electrode, ORP, DryLoc, flat, 10KΩ ID, differential, 1 in. NPT process connection
3-2765-2 159 000 947 Electrode, ORP, DryLoc, flat, PT1000, differential, 1 in. NPT process connection
3-2765-3 159 000 948 Electrode, ORP, DryLoc, flat, 300Ω, differential, 1 in. NPT process connection
3-2767-1 159 000 952 Electrode, ORP, DryLoc, bulb, 10KΩ ID, differential, 1 in. NPT process connection
3-2767-2 159 000 953 Electrode, ORP, DryLoc, bulb, PT1000, differential, 1 in. NPT process connection
3-2767-3 159 000 954 Electrode, ORP, DryLoc, bulb, 300Ω, differential, 1 in. NPT process connection
3-2775 159 000 957 Electrode, ORP, DryLoc, flat, 10KΩ ID, ¾ in. NPT process connection
3-2775-1 159 000 958 Electrode, ORP, DryLoc, flat, no tc, ¾ in. NPT process connection
3-2777 159 000 961 Electrode, ORP, DryLoc, bulb, 10 KΩ ID, ¾ in. NPT process connection
3-2777-1 159 000 962 Electrode, ORP, DryLoc, bulb, no tc, ¾ in. NPT process connection
Miscellaneous Accessories
3-8050-1 159 000 753 Universal Mount Junction Box
3-8050-2 159 000 754 Universal Mount Jct. Box w/Easy-Cal
3
3-8052-1 159 000 755 /4 in. NPT Mount Junction Box
3
3-8052-2 159 000 756 /4 in. NPT Mount Jct. Box w/Easy-Cal
3-2759 159 000 762 pH/ORP Simulator/System tester
3-2759.391 159 000 764 Adapter cable to connect 2759 and 2750
3-0700.390 198 864 403 pH Buffer Kit
P31515-0P200 159 000 630 Universal Pipe Adapter PVC
P31515-0C200 159 000 631 Universal Pipe Adapter CPVC
P31515-0V200 159 000 459 Universal Pipe Adapter PVDF
5523-0322 159 000 761 Cable, 3-conductor + shield (blk/red/wht/shld) 22AWG (per ft)
George Fischer Signet Inc. 3401 Aerojet Avenue, El Monte, CA 91731-2882 U.S.A. • Tel. (626) 571-2770 • Fax (626) 573-2057
3-2750.090 Rev. G 11/05 English © George Fischer Signet Inc. 2001 Printed in U.S.A. on Recycled Paper
Signet 2724 Series DryLoc pH and ORP Electrodes
*3-2724.090*
3-2724.090 Rev. D 02/10 English
1. Use appropriate eye, face, hand, body and/or respiratory protection when using
chemicals or solvents
2. Prior to installation or removal: CAUTION
a. Depressurize and vent system
b. Drain below sensor level
3. Confirm chemical compatibility before use
4. Do not exceed the maximum temperature/pressure specifications.
5. Do not alter product construction
If installing into a threaded connection:
6. Inspect threads to ensure integrity. Do not install a sensor that has damaged threads Do not use tools!
7. Apply PTFE tape to the process connection threads in accordance with industry practices. Hand-tighten only.
8. Hand tighten the sensor into the process connection. DO NOT USE TOOLS
1.0 Description
The Signet 2724 Series of pH and ORP electrodes is designed to minimize maintenance time and maximize value.
• The unique DryLoc® connector provides quick assembly and a secure connection featuring gold-plated contacts and an O-ring seal.
• The patented design features a lengthened reference chamber pathway to extend the operational life of the electrode.
• Wetted materials are selected to withstand a wide array of industrial applications.
• Multiple mounting features address the need for installation flexibility. These electrodes can be threaded into ¾ in. NPT or ISO 7/1 R¾
inch pipe fittings, submerged in a tank, or mounted into familiar Signet installation fittings.
• To build a stand-alone, self-contained pH control system, combine the electrode with a 2760 pH Preamplifier and add a 5700 pH/ORP
Monitor or a 8750 pH/ORP Transmitter to move your control capability to the next level.
• Combine the electrode with the 2750 pH Sensor Electronics to provide a 4 to 20 mA pH loop to a Programmable Logic Controller
(PLC), a SCADA system, or a datalogger.
• Finally, connect up to six pH signals to one 8900 Multi-Parameter Controller with six 2750 pH/ORP Sensor Electronics using digital
(S3L) serial data output for a truly amazing set of features, options and measurements.
1.1 Specifications
General Performance
• Compatibility: 2750 Electronics, 2760 Preamplifier • Efficiency: >97% @ 25 °C (77 °F)
• Shipping Weight: 0.25 kg (0.55 lb) Efficiency indicates the "wellness" of a new electrode.
• pH Temp Sensor: Efficiency is measured by comparing the actual slope (mV/pH)
PT1000 versions are compatible with Signet 2750 pH/ORP at 25 °C to the theoretical output of 59.16 mV/pH. An efficiency
Sensor electronics for connection to a PLC or to the Signet of 97% to 100% is equivalent to a slope of 57.39 to 59.16 mV/pH.
8900 Multi-Parameter Controller.
3 KΩ Balco versions are compatible with the Signet 2760 pH/ • Measuring range:
ORP preamplifier for connection to the Signet 5700 pH/ORP pH: 0 to 14 pH
Monitor and the Signet 8750 pH/ORP Transmitter. ORP: ±2000 mV
3-2726-LC: Low Conductivity fluids (20 μS/cm to 100 μS/cm).
• Process connection: ¾ in. NPT or ISO 7/1 R¾ threads ≤ 20 μS/cm, flow must be less than 150 ml/min. in a properly
or Signet flow fittings grounded system.
3-2726-HF: For applications where Hydrofluoric acid will attack
Wetted Materials standard pH glass in levels of pH 6 and below, or in situations
• pH: PPS, glass, UHMW PE, FPM where process upsets may temporarily drop to these pH levels.
• ORP: PPS, glass, UHMW PE, FPM,
Platinum Standards and Approvals:
• Manufactured under ISO 9001 and ISO 14001
China RoHS (Go to www.gfsignet.com for details)
Recommended storage temperature:

• The best storage temperature for the 272X pH and ORP
electrodes is 0 °C to 50 °C (32 °F to 122 °F)
• The electrode glass will be shattered if shipped or stored at
temperatures below 0 °C (32 °F).
DO NOT • The performance life of the electrode will be shortened if stored
FREEZE
at temperatures above 50 °C (122 °F)
1.2 Dimensions 1.3 Operating Temperature and Pressure Specifications
(psi) (bar)
150 10.3
125 8.6
109 mm 100 6.9

(4.3 in.)
Threads:
¾ in. NPT 75 5.2
or
ISO 7/1 R-¾
50 3.4
44.45 mm
53.34 mm 25 1.7
(1.75 in.)
(2.1 in.)
25.4 mm
(1.0 in.) 0
°C -40 -20 0 20 40 60 80 100 120
9.3 mm °F -40 -4 32 68 104 140 176 212 248
(0.37 in.)
Max. Temperature/Pressure Rating
Operating Temperature Range*:
-10 °C to 85 °C (14 °F to 185 °F)
Operating Pressure Range:
-10 °C to 65 °C (14 °F to 149 °F),
0 to 6.9 bar (0 to 100 psi)
65 °C to 85 °C (149 °F to 185 °F),
linearity derated 6.9 to 4.0 bar (100 psi to 58 psi)
2.0 In-Line Installations *Best performance for 3-2726-HF-XX sensors is above 10 °C (50 °F)
2.1 In-Line Installation Tips:

The 3-2726-LC pH electrodes can be used in low conductivity water of less than 100 uS.
When used in the range of 20 to 100 uS, the flow range must not exceed 1 m/s (3 ft/s) velocity.
When used in liquids of less than 20 uS, the flow range must not exceed 150 ml/min; the sensor should also be Yes
Yes
Yes
mounted in a well grounded cell.
• Use the ¾ in. threads on the electrode body to install the electrode into reducing tee fittings. The fitting must
place the electrode in the flow but must not bottom out in the pipe. 0°
Horizontal
• The electrode can be mounted at any angle. Avoid air pockets and sediment.
• Select a Signet installation fitting for convenience.
• Inspect threads to ensure integrity. Do not install an electrode with damaged threads. Yes Yes
• Use piping installation hardware with smooth, well-finished threads to facilitate the installation. Yes
• Apply PTFE tape to the process connection threads, in accordance with industry standards.
• If necessary, the pipe should be plumbed with a depression (trap) so liquid is maintained around the electrode tip.
• Hand-tighten the electrode into the process connection.
Do not use any tools to install the electrode.
The use of wrenches, pliers or similar may over-stress the sensor body, and lead to breakage and subsequent spillage of the process
liquid. A broken sensor may be ejected forcefully from the fitting and cause severe injury.
• The safety instructions have an adhesive label that should be placed near the sensor.
3-2760-X1
In-Line
3-2760-X Flexible conduit Preamplifier
Submersible
Preamplifier Flexible conduit
Electrode
Electrode
PTFE tape
Fitting (customer supplied) Signet Installation Fitting

DN15 to DN100 (½ in. to 4 in.)
2 Signet 272X Series pH and ORP Electrodes
2.2 Signet Installation Fittings
Type Description Type Description
Plastic tees Carbon steel
• Available in ½ in. to 4 in. sizes weldolets • Available in 2 in. to 4 in. sizes
• PVC, CPVC w/solvent cement socket • Requires 1-7/16 in. hole in pipe
• PVDF ans PP w/union end fittings • Install by certified welder only
PVC saddles Carbon steel

• Available in 2 in. to 4 in. sizes threaded tees • Available in ½ in. to 2 in. sizes
• Requires 1-7/16 in. hole in pipe • Female NPT ends
Iron Universal
strap-on pipe adapters • Use for installation in pipes >4 in. (1¼ in. NPT
saddles • Available in 2 in. to 4 in. sizes • PVC, CPVC, or PVDF versions
• Requires 1-7/16 in. hole in pipe • Specify socket or 1¼ inch NPT male threads
• Do not use tools or lubricant to install Do not use as a handle!

3-2700.615 (B-04/08)
yellow retaining cap
WARNING • Do not overtighten
SAFETY INSTRUCTIONS
1. Use appropriate eye, face, hand, body
and/or respiratory protection when using
chemicals or solvents
2. Prior to installation or removal:
a. Depressurize and vent system
b. Drain below sensor level
3. Confirm chemical compatibility before use
4. Do not exceed the maximum
temperature/pressure specifications
5. Do not alter product construction
If installing into a threaded connection:
6. Inspect threads to ensure integrity. Do not PTFE tape
install a sensor that has damaged threads
7. Apply PTFE tape to the process connection
threads in accordance with industry
practices 3 2700.615 (B 04/08) 3 2700.615 (B 04/08) 3 2700.615 (B 04/08)
8. Hand tighten the sensor into the process WARNING WARNING WARNING
connection. DO NOT USE TOOLS SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS
1. Use appropriate eye, face, hand, body 1. Use appropriate eye, face, hand, body 1. Use appropriate eye, face, hand, body
and/or respiratory protection when using and/or respiratory protection when using and/or respiratory protection when using
Failure to follow
chemicals or solvents chemicals or solvents chemicals or solvents
2. Prior to installation or removal: 2. Prior to installation or removal: 2. Prior to installation or removal:
a. Depressurize and vent system a. Depressurize and vent system a. Depressurize and vent system
b. Drain below sensor level b. Drain below sensor level b. Drain below sensor level
3. Confirm chemical compatibility before use 3. Confirm chemical compatibility before use 3. Confirm chemical compatibility before use
these instructions may

4. Do not exceed the maximum 4. Do not exceed the maximum 4. Do not exceed the maximum
temperature/pressure specifications temperature/pressure specifications temperature/pressure specifications
5. Do not alter product construction 5. Do not alter product construction 5. Do not alter product construction
If installing into a threaded connection: If installing into a threaded connection: If installing into a threaded connection:
result in personal injury

6. Inspect threads to ensure integrity. Do not 6. Inspect threads to ensure integrity. Do not 6. Inspect threads to ensure integrity. Do not
install a sensor that has damaged threads install a sensor that has damaged threads install a sensor that has damaged threads
7. Apply PTFE tape to the process connection 7. Apply PTFE tape to the process connection 7. Apply PTFE tape to the process connection
threads in accordance with industry threads in accordance with industry threads in accordance with industry
practices practices practices
8. Hand tighten the sensor into the process 8. Hand tighten the sensor into the process 8. Hand tighten the sensor into the process
connection. DO NOT USE TOOLS connection. DO NOT USE TOOLS connection. DO NOT USE TOOLS
Failure to follow Failure to follow Failure to follow

these instructions may these instructions may these instructions may
result in personal injury result in personal injury result in personal injury
2.3 Removing the electrode from In-line installations
The use of this product assumes that operators are trained and are familiar with this type of device.
They should be knowledgeable of the potential risks associated with pressurized piping systems.
Operators MUST follow all necessary safety procedures.
In-line removal Instructions:

1. Depressurize and vent the piping system.
2. Drain the system to below sensor level.
3. Wear safety goggles or face shield during removal.
Use all appropriate eye, face, hand, body and/or respiratory protection when working with chemicals or solvents.
4. Place a Lockout tag on the pipe when the sensor is removed for maintenance to prevent accidental opening and exposure to
potentially hazardous chemicals.
Signet 272X Series pH and ORP Electrodes 3

3.0 Submersibile Installations
3.1 Submersible Installation Tips:
• Choose a location that keeps the electrode glass completely submerged at all times.
• Mount electrodes in a location with ample clearance for removal.
• Mount the electrode near tank outlets, away from reagent addition areas.
• Use the ¾ in. threads at the top of the preamplifier to run the cable inside pipe or conduit.
• Backfill a few inches of the conduit with sealant to prevent moisture intrusion from inside the conduit.
• Place the electrode tip in pH 4 buffer during system maintenance or storage to avoid dehydration.
3.2 Submersible Installation, 2724-2726 with 2750/2760 Preamplifier
The Signet 2724 and 2726 pH electrodes are designed to install in tanks by attaching conduit to the ¾ in. threads at the top of the
accompanying preamplifier or sensor electronics:
1. The O-ring at the top of the electrode fits very tightly into the preamplifier. Use a small amount of lubricant (non-petroleum based) to
assist the assembly.
2. To prevent moisture from migrating into the preamplifier, backfill the conduit with 3-4 inches of sealant.
3. Mount electrodes in a location with ample clearance to remove them for periodic cleaning and recalibration.
4. Choose a location that keeps the electrode glass completely submersed at all times.
5. The user must supply the following hardware to complete a submersible installation:
• ¾ in. NPT threaded pipe or conduit
• Wiring junction box
• Pipe clamps (quick-release type recommended)
• Tank flange for closed tanks
Fill with
3 to 4 in.
of sealant
Open Closed
tanks tanks
1 2 3 4

4. pH System Calibration
There are two functions in a pH electrode that require the system to be calibrated:
4.1 Temperature
• The temperature output of the electrode (from a 3K Balco or PT1000 RTD) must be calibrated only once, when a new electrode is
installed. It does not need to be repeated.
• Because the temperature measurement has a significant influence on the electrochemical measurement, the temperature output in
new pH electrodes should always be calibrated before the pH/mV calibration.
pH error due to temperature changes in fluid

°C pH 2 pH 3 pH 4 pH 5 pH 6 pH 7 pH 8 pH 9 pH 10 pH 11 pH 12
15 0.15 0.12 0.09 **0.06 0.03 0 0.03 0.06 0.09 0.12 0.15
25 0 0 0 *0 0 0 0 0 0 0 0
35 0.15 0.12 0.09 0.06 0.03 0 0.03 0.06 0.09 0.12 0.15
45 0.3 0.24 0.18 0.12 0.06 0 0.06 0.12 0.18 0.24 0.3
55 0.45 0.36 0.27 0.18 0.09 0 0.09 0.18 0.27 0.36 0.45
Table 1:
As the pH value moves away from neutral (7 pH) or the temperature moves away from 25 ºC, the
electrochemical output is affected.
* Example: At pH 5 the mV output of the electrode is not affected if the temperature is at 25 °C.
** The electrode output will be shifted by 0.06 pH units if the temperature is reduced to 15 °C.
4.2 Electrochemical pH vs. mV Ratio

• The mV output from the electrode is created by the interaction
of the electrode and the fluid. The electrode contains a gel Theoretical mV Values @ 25 °C
that depletes over time, so the instrument must be readjusted
periodically to maintain system accuracy. The need for pH mV
recalibration varies with each application, but the life of the 2 +295.8 mV
electrode is usually consistent. 3 +236.64 mV
• Keep a maintenance log to establish a depletion trend in new
4 +177.48 mV
systems.
• The mV calibration is a two-point procedure. Signet offers pH 5 +118.32 mV
buffer solutions prepared specifically for this purpose. 6 +59.16 mV
• pH buffer solutions can be used for calibrating more than one 7 0 mV
sensor within a day provided that the solutions are protected
from debris and are not diluted by rinse water from the 8 -59.16 mV
calibration procedure. 9 -118.32 mV
• Use clean water to rinse buffer solutions from the electrode. 10 -177.48 mV
• Dispose of all buffer solutions at the end of the day.
11 -236.64 mV
• If the pH sensor will not calibrate within acceptable limits, clean
the electrode and recalibrate. If the calibration results remain 12 -295.8 mV
outside of acceptable limits, the sensor is depleted and must Table 2:
be discarded. Electrode slope is the ratio of mV to pH units. At 25 °C the
• Follow the guidelines of local waste disposal regulations when theoretical slope is 59.16 mV per pH.
discarding buffer solutions and spent electrodes.

5. ORP System Calibration
ORP electrodes do not incorporate a temperature sensor, so the only system calibration required is the electrochemical adjustment.
5.1 Electrochemical ORP vs. mV Ratio

• ORP measurements are relative values, and single-point adjustments are sufficient for most applications.
• Calibration should be done using ORP test solutions such as Light's Solution, Zobell's solution, or in pH buffers that have been
saturated with quinhydrone (Table 3). Quinhydrone is the oxidizer that is measured by the ORP electrode.
• Light's Solution and Zobell's solution are not compatible with the AutoCal function in Signet pH instrumentation
• A new ORP electrode measures the listed values ±15 mV.
• The ORP electrode is functional until the offset exceeds 50 mV.
• An electrode whose offset measures greater than 50 mV should be cleaned and replaced if necessary.
• ORP solutions made with quinhydrone are very unstable and may not read properly after being exposed to air for a prolonged time.
These solutions must be discarded after a few hours.
• Dispose of all calibration solutions in accordance with local, state and federal guidelines.
• Use clean water to rinse buffer solutions from the sensors.
Zobell's solution Light's solution 4 pH buffer 7 pH buffer

w/quinhydrone* w/quinhydrone*
ORP at 20 °C 268 mV 92 mV
ORP at 25 °C 228 mV 469 mV 263 mV 86 mV
ORP at 30 °C 258 mV 79 mV
Table 3: *Saturate 50 mL of pH 4 or pH 7 buffer with ⅛ g quinhydrone

ORP test solutions
6.0 Electrode Date Code

The electrode date code indicates the manufacturing date of the electrode. Electrodes should be put into service as soon as possible
and should not remain in the box for more than two years. Over time, the storage solution (found in the "boot" covering the electrode tip)
will evaporate or leak, allowing the delicate sensing tip and reference junction dry.
To rehydrate a dry electrode, soak it in pH 4 buffer for 24 to 48 hours. Electrodes more than 2 years old may still be functional, but will
take longer to rehydrate. Restoration may not be effective for severely dehydrated electrodes.
First Letter = Month

K4 Second Numeral = Year
N = January
K4 3 = 2008
M = February 4 = 2009
L = March 5 = 2010
K = April 6 = 2011
J = May 7 = 2012
H = June 8 = 2013
G = July 9 = 2014
F = August 0 = 2015
E = September 1 = 2016
D = October 2 = 2017
C = November 3 = 2018
B = December 4 = 2019
Example: K4 = manufactured in April 2009

7. Maintenance and Cleaning
7.1 Electrode care and application
pH/ORP electrodes are similar to batteries; they age with time and usage. The following information will help maximize electrode life.
General Tips:
• To ensure uninterrupted operation of critical pH systems, replacement electrodes should be available.
• Store boxed electrodes flat or upright (electrode tip down) to maximize hydration of the glass surface.
• Keep the glass surface wet at all times.
• Soak the sensor tip in pH 4.0 buffer during system maintenance intervals.
• If the sensor dehydrates, soak the sensor tip in pH 4 buffer for 24 to 48 hours, then visually inspect the electrode for surface cracks,
swelling, or discoloration.
• It may not be possible to restore severely dehydrated electrodes to normal operation.
• High temperatures, strong acids or caustics will increase electrochemical reactions and speed electrode aging.
• Coatings (e.g. grease) on the glass or junction surfaces cause extended response time and inaccurate measurement.
• Never store the electrode tip in deionized (DI) water. Use pH 4 buffer solution to keep the glass wet when out of the process.
• Never store the electrode at temperatures below 0 °C (32 °F) or allow it to dehydrate.
• Never scrape or sand the glass electrode surface.
• Treat glass electrode surfaces with care to prevent accidental breakage.
7.2 Cleaning
Problem Suggested Solution
Hard Coatings Use a dilute acid solution (HCl solution of 5% or less). If the electrode has been used in applications
with a pH value higher than 7 pH, soak the electrode for 2 to 5 minutes.
Use a dilute alkaline solution (NaOH solution at 5% or less) if the electrode has been used in
applications with pH values less than 7 pH, soak the electrode for 2 to 5 minutes.
Alternating immersion in acidic and alkaline solutions may be necessary for thorough cleaning.
Soft Coatings Spray or vigorously stir the electrode with a mild detergent, such as dishwashing liquid. Chlorine
bleach can also be used.
Oily or Organic Coatings Spray or vigorously stir the electrode with a mild detergent or an appropriate solvent that will not
attack the materials of construction. (isopropyl alcohol or similar)
ORP Platinum Coating Gently wipe the electrode surfaces with a paper towel.
After Cleaning Always rinse the electrode with water after cleaning.
Soak the electrode in a pH 4 buffer (with KCl if available) for at least 10 minutes after cleaning.

8.0 Ordering Information

3-2724-00 159 001 545 Electrode, pH, flat, PT1000, ¾ in. NPT
3-2724-01 159 001 546 Electrode, pH, flat, PT1000, ISO 7/1 R¾
3-2724-10 159 001 547 Electrode, pH, flat, 3K Balco, ¾ in. NPT
3-2724-11 159 001 548 Electrode, pH, flat, 3K Balco, ISO 7/1 R¾
3-2726-00 159 001 553 Electrode, pH, bulb, PT1000, ¾ in. NPT
3-2726-01 159 001 554 Electrode, pH, bulb, PT1000, ISO 7/1 R¾
3-2726-10 159 001 555 Electrode, pH, bulb, 3K Balco, ¾ in. NPT
3-2726-11 159 001 556 Electrode, pH, bulb, 3K Balco, ISO 7/1 R¾
3-2726-HF-00 159 001 549 Electrode, pH, HF resistant, bulb, PT1000, ¾ in. NPT
3-2726-HF-01 159 001 550 Electrode, pH, HF resistant, bulb, PT1000, ISO 7/1 R¾
3-2726-HF-10 159 001 551 Electrode, pH, HF resistant, bulb, 3K Balco, ¾ in. NPT
3-2726-HF-11 159 001 552 Electrode, pH, HF resistant, bulb, 3K Balco, ISO 7/1 R¾
3-2726-LC-00 159 001 557 Electrode, pH, bulb, Low Cond, PT1000, ¾ in. NPT
3-2726-LC-01 159 001 558 Electrode, pH, bulb, Low Cond, PT1000, ISO 7/1 R¾
3-2726-LC-10 159 001 559 Electrode, pH, bulb, Low Cond, 3K Balco, ¾ in. NPT
3-2726-LC-11 159 001 560 Electrode, pH, bulb, Low Cond, 3K Balco, ISO 7/1 R¾
3-2725-60 159 001 561 Electrode, ORP, flat, 10 KΩ ID, ¾ in. NPT
3-2725-61 159 001 562 Electrode, ORP, flat, 10 KΩ ID, ISO 7/1 R¾
Accessories and Replacement Parts

3-2750-1 159 000 744 In-line Sensor Electronics w/Junction Box
3-2750-2 159 000 745 In-line Sensor Electronics w/Junction Box and EasyCal
3-2750-3 159 000 746 Submersible Sensor Electronics with 15 ft cable, ¾ in. NPT threads
3-2750-4 159 000 842 Submersible Sensor Electronics with 15 ft cable, ISO 7/1 R¾ threads
3-2760-1 159 000 939 Submersible Preamplifier with ¾ in. NPT threads and 4.6 m (15 ft) cable
3-2760-2 159 000 940 Submersible Preamplifier with ¾ in. ISO threads and 4.6 m (15 ft) cable
3-2760-3 159 000 941 Submersible Connector with 4.6 m (15 ft) cable and ¾ in. NPT threads
3-2760-4 159 000 942 Submersible Connector with 4.6 m (15 ft) cable and ISO 7/1 R¾ in. threads
3-2760-11 159 001 367 In-line Preamplifier with ¾ in. NPT threads and 4.6 m (15 ft) cable
3-2760-21 159 001 368 In-line Preamplifier with ¾ in. ISO threads and 4.6 m (15 ft) cable
3-2760-31 159 001 369 In-line Connector with 4.6 m (15 ft) cable and ¾ in. NPT threads
3-2760-41 159 001 370 In-line Connector with 4.6 m (15 ft) cable and ISO 7/1 R¾ threads
3-2759 159 000 762 pH/ORP System Tester (adapter cable sold separately)
3-2759.391 159 000 764 2759 DryLoc Adapter Cable (for use with 2750 and 2760)
3-0700.390 198 864 403 pH Buffer Kit (1 each 4, 7, 10 pH buffer in powder form, makes 50 mL)
3822-7004 159 001 581 pH 4 buffer solution, pint (16 oz) (473 ml)
3822-7115 159 001 606 20 gram bottle Quinhydrone for ORP calibration
3-2700.395 159 001 605 Calibration kit: included 3 Polypropylene cups, box used as cup stand, 1 pint
pH 4.01, 1 pint pH 7.00
Georg Fischer Signet LLC, 3401 Aerojet Avenue, El Monte, CA 91731-2882 U.S.A. • Tel. (626) 571-2770 • Fax (626) 573-2057
For the most up-to-date information, please refer to our website at www.gfsignet.com
3-2724.090 Rev. D 02/10 English © Georg Fischer Signet LLC 2010

SECTION 7
System General Arrangement Drawings
Electrical Enclosure Drawings
Wiring Diagrams

8 7 6 5 4 3 2 1
CONNECTION SCHEDULE
ITEM DESCRIPTION LOCATION MAX. FLOW CONNECTION MATERIAL
CONSTRUCTION NOTES:
A RAW WATER INLET @50PSI MIN PRETREATMENT SKID 122 GPM 3" 150# FLG SCH 80 PVC
B SOFT WATER OUTLET PRETREATMENT SKID 87 GPM 3" 150# FLG SCH 80 PVC
1. ALL PRESSURE VESSELS CONSTRUCTED OF POLYGLASS OR 1-1/2" 150# FLG
C REGEN WASTE TO DRAIN PRETREATMENT SKID 35 GPM SCH 80 PVC
COMPOSITE MATERIAL WITH A POLYETHYLENE INTERIOR
LINER. ALL VESSELS HAVE THE NSF RATING AND A 150 PSIG
WORKING PRESSURE. ALL PRESSURE VESSELS TO BE
CERTIFIED PER THE LASTEST ASME CODE FOR FIBERGLASS
D PRESSURE VESSELS. NOTE THE SYSTEM PRESSURE RATING IS D
100 PSIG
2. STRUCTURAL STEEL SKID TO BE COATED WITH SAFETY

BLUE EPOXY.
3. ALL PRESSURE VESSEL INTERNAL DISTRIBUTORS TO BE

SCH 80 WITH ABS SLOTTED NOZZLES.
4. ALL AUTOMATIC REGENERATION VALVES TO BE A

PENTAIR MODEL 3900 VALVE WITH THE NXT ALTERNATING
CONTROL FEATURE.
5. ALL MANUAL ISOLATING VALVES TO BE PVC QUARTER 89" 50 1/2"

TURN BALL VALVES WITH EPDM SEALS AND SOLVENT WELD 4 5/8"
OR SCREWED CONNECTIONS.
6. ALL EXTERNAL PIPING TO BE SCH 80 PVC. ALL EXTERNAL

13 1/2"
FITTINGS AND FLANGES TO BE SCH 80 PVC WITH SOCKET
WELD CONNECTIONS. SOME ITEMS MAYBE THREADED WHEN
REQUIRED.
1-1/2" DRAIN
7. ALL WATER SOFTENERS TO HAVE INLET AND OUTLET
PRESSURE GAUGES AND SAMPLE VALVE. 51"
8. ALL EXTERIOR HIGH VOLTAGE (115V OR HIGHER) WIRING

TO BE CONTAINED IN EMT STEEL CONDUIT WITH LIQUID
TIGHT FITTINGS. CONDUIT RUNS 6’ OR SHORTER MAY BE
CONTAINED IN LIQUID TIGHT FLEXIBLE CONDUIT SUITABLE
3/4" TYP.
C FOR OUTDOOR USE. ALL EXTERIOR LOW VOLTAGE CONDUIT C
(24V OR LOWER) WILL BE 3 WIRE CABLE NEATLY BUNDLED
WITH THE MANIFOLD PIPING.
n 9/16"
3/4" TYP.
9. THE WATER SOFTENER SKID TO HAVE AN OUTLET FLOW AUTOMATIC BACKWASH
SENSOR SIGNET MODEL 2536 WITH A SCH 80 PVC FLOW CONTROLLER
INSTALLATION FITTING.
10. FLOW RATES PER TANK:

SERVICE: 185 GPM AT 15 PSIG DROP
BACKWASH: 35 GPM
BRINE DRAW: 12 GPM
SLOW RINSE: 8 GPM
FAST RINSE: 35 GPM
11. SOFTENING MEDIA AND SUPPORT GRAVEL / TANK

SOFTENING MEDIA: 20 CU. FT. STRONG ACID CATION WATER INLET WATER OUTLET
LOWER SUPPORT: 400 LBS 1/8” X 1/16” GRAVEL PRESSURE GAUGE PRESSURE GAUGE
AND SAMPLE COCK AND SAMPLE COCK
12. SHIPPING WEIGHTS: (TYP.) (TYP.) ALLOW 36" FOR
EQUIPMENT ONLY: 1,896 LBS RESIN LOADING
MEDIA ONLY: 2,920 LBS
TOTAL: 4,816 LBS
13. OPERATING WEIGHT (INCLUDING RECOMMENDED SALT

STORAGE): 10,822 LBS INLET ISOLATION
VALVE
14. THE COMPLETE WATER SOFTENING SKID WILL HAVE A
FULL HYDRO-TEST BEFORE SHIPPING TO INSURE THE SKID TO OUTLET ISOLATION
B BE LEAK FREE BEFORE SHIPPING. IF MINOR LEAKS OCCUR VALVE B
AFTER START-UP MARLO WOULD NOT CONSIDER THOSE
LEAKS TO BE COVERED UNDER THE NORMAL EQUIPMENT
WARRANTY.
A
OVER FLOW
TO DRAIN
BY-PASS VALVE
(NORMALLY CLOSED)
(115 5/8")
REF.
B
C
72"
37 1/4"
36" X 72" 36" X 72" 39" X 60"

RESIN TANK RESIN TANK BRINE TANK BACK VIEW
A A
FRONT VIEW
REVISIONS MGT-600-3 TW-ALT SKID - PVC ASME
NO. DATE BY REMARKS GENERAL ARRANGEMENT
FRAC. DEC.
INCORPORATED ` `
FILE ID.
DRN.
Anthony SCALE SHEET 1 OF 1
Combustion & Control Solutions -Project PC21597 APP'D. DRAWING NO. REV.
DATE
1/26/2016
EP16-016-03-01
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
CONNECTION SCHEDULE
D RAW WATER INLET @30 PSI MIN R.O. SKID 87 GPM 2-1/2" 150# FLANGE PVC SCH 80
E PERMEATE OUTLET R.O. SKID 65 GPM 2" 150# FLANGE PVC SCH 80
F CONCENTRATE OUTLET R.O. SKID 22 GPM 1-1/12" 150# FLANGE PVC SCH 80
D D
27 1/2" 194"
164"
121" 300 PSI FRP
ALLOW 48" FREE SPACE ALLOW 48" FREE SPACE
51" MEMBRANE VESSELS
FOR MEMBRANE REMOVAL FOR MEMBRANE REMOVAL
CC-3B
C CC-5B MEMBRANE CC-4A C

CIP CONN MEMBRANE
CIP CONN
40" CHEMICAL
LOW LEVEL
SWITCH
CC-4B
MCP MCC CC-1A

P-2
MASTER CONTROL PANEL MOTOR STARTER PANEL MEMBRANE
MEMBRANE CIP PUMP MEMBRANE CIP TANK
WITH ALLEN BRADLEY PLC 5 HP 304SS CIP CONN
39" DIA x 48" HIGH
AND PANELVIEW HMI 460V/60HZ/3PH 250 GAL CAPACITY
(TANK INCLUDES QUICK
CONNECT HOSES)
FE-1
CONCENTRATE
FLOW SENSOR
EACH MEMBRANE VESSEL INCLUDES
4 TORAY TM720-370 460V/60HZ/3PH HCV-5
MEMBRANES FACTORY INSTALLED AND CIP THROTTLE VALVE
120V/60HZ/1PH FV-1
SHIPPED IN PRESERVATIVE SOLUTION D AUTO INLET E
F
VALVE
B CHEM PUMP B
RECEPTACLE CC-3A
MEMBRANE
CIP CONN
FV-2
AUTO FLUSH VALVE FE-2
PERMEATE
MEMBRANE CONCENTRATE PRESSURE FLOW SENSOR
HCV-4
HCV-2 MIX VALVE
CONCENTRATE THROTTLE VALVE
6 GPD CC-2A
CHEM PUMP
CC-2B
70"
OPERATING PARAMETERS
1-1/2" CIP TANK - OPERATING PRESSURE: 200-250 PSI
DILUTION - NOMINAL RECOVERY: 75-80%
CIP
WATER INLET - NOMINAL SALT REJECTION: 98-99%
ROTAMETER
- OPERATING TEMPERATURE: 45-85° F
- DESIGN TEMPERATURE: 55° F
- MINIMUM INLET PRESSURE: 30 PSIG
- CONTROL CIRCUIT: 120 VAC, 1-PHASE, 60HZ
- PUMP POWER: 460V/60HZ/3PH
MATERIALS OF CONSTRUCTION
- SKID FRAME: EPOXY-COATED CARBON STEEL
ANTISCALANT P-1 SHELCO 5FOS4 CC-1B CC-6
HCV-1 MEMBRANE - MEMBRANE HOUSING: FRP (300 PSIG RATED)
FEEDER GRUNDFOS CRI 15-12 5 MICRON PREFILTER MEMBRANE CIP CONN
MEMBRANE FEED CIP FILTERS - LOW PRESSURE PIPING: SCH 80 PVC
RO HIGH PRESSURE PUMP 304SS (QTY 5) 2.5x40" PERMEATE VACUUM BREAKER - HIGH PRESSURE PIPING: SCH 10 304SS
THROTTLE VALVE
A MEMBRANE FEED 304SS 25HP 460V/60HZ/3PH CARTRIDGES (PIPE TO FLOOR DRAIN) A
CC-5A - LIQUID FILLED STAINLESS STEEL PRESSURE GAUGES
PRESSURE CE-1
MEMBRANE
PERMEATE REVISIONS RO SYSTEM ASSEMBLY MRO-94K-8H
CIP CONN
ORP CELL CONDUCTIVITY CELL NO. DATE BY REMARKS GENERAL ARRANGEMENT
TEMPERATURE GAUGE INCORPORATED FRAC. DEC.
FILE ID.
` `
DRN.
SBS INJECTION FITTING AJJG SCALE SHEET 1 OF 1
DATE
1/27/2016
EP16-016-03-03
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
CONNECTION SCHEDULE
G PERMEATE INLET RO PERMEATE HOLDING TANK 65 GPM 2" 150# FLANGE PVC SCH 80
H PERMEATE OUTLET RO PERMEATE HOLDING TANK 75 GPM 3" 150# FLANGE PVC SCH 80
J EMERGENCY OVERFLOW RO PERMEATE HOLDING TANK 75 GPM 3" 150# FLANGE PVC SCH 80
D D
n 90"
C C
6" 6"
12"
J
B B
RO CONTROL
FLOAT SWITCH
103" 2500 GAL

RO PERMEATE
HOLDING TANK
POLYETHYLENE
LOW LEVEL
PUMP CUTOFF
FLOAT SWITCH
H
18"
8 1/4"
A A
REVISIONS RO PERMEATE HOLDING TANK

FRAC. DEC.
INCORPORATED ` `
FILE ID.
DRN.
AGray SCALE SHEET 1 OF 1
KENTON, OH. DATE

1/27/2016
EP16-016-03-05
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
CONNECTION SCHEDULE
ITEM DESCRIPTION LOCATION MAX FLOW SIZE MATERIAL
K PUMP SUCTION TRANSFER PUMP SKID 75 GPM 3" 150# FLG SCH 80 PVC
L PUMP DISCHARGE TRANSFER PUMP SKID 75 GPM 3" 150# FLG SCH 80 PVC 34"
D D
ISOLATION VALVES
49"
C C
CUSTOMER SUPPLIED PUMP

START/STOP SIGNAL
460V/60HZ/3PH
120V/60HZ/1PH
PUMP CONTROL PANEL
SCH 80 PVC
PIPING
B B
63"
CHECK VALVES
42 3/4"
FLOODED
K SUCTION
REQUIRED
8 1/4"
EBARA 3U-32-160 PUMPS

EPOXY COATED 5HP 304SS PUMP
A STRUCTURAL A
460V/60HZ/3PH
STEEL SKID 75 GPM @ 50 PSI
REVISIONS DUAL TRANSFER PUMP SKID 304SS 5HP-460V
FRAC. DEC.
INCORPORATED ` `
FILE ID.
DRN.
AJJG SCALE SHEET 1 OF 1
DATE
1/27/2016
EP16-016-03-06
8 7 6 5 4 3 2 1
1
3
R.O. MCP
3
OPERATOR INTERFACE
A-B
QUALITY
Allen-Bradley PanelView C600
3
4,12
4
4
3 R.O. SYSTEM 3 3 FAULT-STEADY

ALARM SILENCE
CLEAN SHUTDOWN AUTO ALARM-FLASH
8
8
8,9,17 9,16,17 15
R 1
1
SS-3 PB-1 LT-3 6
4
ELECTRICAL SPECIFICATIONS
Max Line Voltage: 120VAC Phase: 1 Hz: 60
2 11 NOTE 1
6
Largest Motor FLA: NA Total FLA: 0.5
7
SCCR: NA Ref Dwg: B1331133
CAUTION: TO REDUCE THE RISK OF FIRE, REPLACE

FUSE ONLY WITH SAME TYPE AMPS OR
EQUIVALENT. UL LISTED ONLY.
FUSE REPLACEMENT CHART
FU-1 FNM-5 5A
11 NOTE 1
NOTE: THIS PANEL DOES NOT HAVE A MAIN

DISCONNECT OR BRANCH CIRCUIT PROTECTION. IT 11 NOTE 1
NOTE 1 IS UP TO THE INSTALLER TO INSTALL ENCLOSURE
TO UL REQUIREMENTS.
WARNING - CONDUIT HUBS AND/OR ANY DEVICE

THAT PENETRATES THIS ENCLOSURE MUST
MAINTAIN THE UL RATING OF THIS ENCLOSURE.
11 NOTE 1
6
UL ENVIRONMENTAL RATING: 1
NOTES:
2
SV-1 1. LOCATE LABEL ON INSIDE OF ENCLOSURE DOOR.

3
6,7,22,23
PSL 5,6,7
1
8 7/29/14 TCB ADDED REPRESS PUMP OPTION

7 9/6/12 MRP UPDATED ELEC. SPEC. LABEL
R.O. MAIN CONTROL PANEL (MCP)

ENCLOSURE ASSEMBLY
1 12-22-08 RMM ADDED ITEMS 118 & 119.
2 1-5-09 RMM SEQN 106 WAS 72 QTY.
B1331131
3 10/1/09 KLT ADDED ITEM 11 RMM NTS 1 1
4 10/16/09 KLT UPDATED B.O.M.
5 11/09/10 KLT UPDATED LABELS
6 5/16/11 KCA ITEM 120 WAS A2307012, UPDATED LABELS 8-11-08 B1331131 8
104,105 1 5
TERMINAL B USE 90°C MINIMUM A 106 107

TB-2 TORQUE TO 6-10 IN-LBS COPPER WIRE ONLY
111
101
110
100
112
113
102
103
104
105
106
107
108
109
301
401
300
400
302
303
304
305
306
402
403
404
51
51
51
51
51
51
51
51
51
50
50
50
50
50
50
50
50
50
50
50
3
R1 R2 NOTE 1
103
104,105
TERMINAL B
TORQUE TO 6-10 IN-LBS
120 7
114
TB-1
120
L
6
N
2
ALLEN-BRADLEY MicroLogix
2 1200
MicroLogix MicroLogix
1200 1200
2
G DC INPUT ANALOG
INPUT
G 0 0 POWER
1 1
G 2
3
2
3
INPUT
0
4 4 1
1 5 5 2
6 6 3
7 7
1 7
1
7
1
101 115 1
1
1
1
8 6
9 4
10
104,105 11
104,105 104,105
12
30
31 102 (TYP) 113
FU-1
32
120 + + - - 120
200 21 COM 11 21 COM 11 21 COM 11 21 COM 11 21 COM 11
6 22.5-29.5V Output DC
6
201 24 NO 14 24 NO 14 24 NO 14 24 NO 14 24 NO 14 24V 1.75A
202 22 NC 12 22 NC 12 22 NC 12 22 NC 12 22 NC 12
DC
OK
USE 90°C MINIMUM A
203 COPPER WIRE ONLY
FU- 1
204 CR-1 CR-2 CR-3 CR-4 CR-6

OMRON
MY4N
110/120VAV(S)
5
STEP POWER
205 CR-5
106 TERMINAL B
206
TORQUE TO 6-10 IN-LBS
207
Input AC
208 100-240V
A2 A1 A2 A1 A2 A1 A2 A1 A2 A1
209 L(+) N(-)
210 116,117 = LOW VOLTAGE DUCT

211
108,109
SP
SP 107
104,105 NOTES:
103 1. INSULATE ALL EXPOSED RESISTOR LEADS.
7 7/29/14 TCB ADDED REPRESS PUMP
104,105 R.O. MAIN CONTROL PANEL (MCP)

SUB-PANEL
1 12-22-08 RMM ADDED ITEMS 118 & 119.
2 1-5-09 RMM DELETED (2) SPARES.
B1331132
3 10-1-09 KLT ADDED ITEM 11 RMM NTS 1 1
4 10/16/09 KLT UPDATED B.O.M.
5 12/15/10 KLT CHANGE SUB-PANEL & UPDATED LABELS
6 5/16/11 KCA ITEM 120 WAS A2307012 8-11-08 B1331132 7
FROM LINE 1020
LINE # 1 2
#14 AWG GRN 1021
115V/60Hz/1pH
15A MAX
LINE # L N G DOOR 1022

1000 #14 AWG BLK GND
CR-3 [2023] SV- 1
11
1023 INLET FEED VALVE (FV-1)
1001 5A FU-1 11 14
#14 AWG RED G
#18 AWG WHT 1024
1002
1 2
1025
1003
CR-6 [2031]
210 211 REPRESS PUMP CONTACT
1026 6 (OPTIONAL)
1004 11 14
1027
1005
1028
1006
FV-2
CR-5 [2027]
30
1029 4 OPEN
1007 9 5
1 FLUSH VALVE (FV-2)
CR-5 [2027]
31
#18 AWG RED #18 AWG WHT 1030 3 CLOSE
1008 L N 24V DC POWER SUPPLY 10 2 G
2 G
+ 24VDC - 1031
#18 AWG BLUE
1009
#18 AWG BLU/WHT

1032
1010
50
CR-3 [2023]
32 SBS PUMP RECEPTACLE
1033
OPTIONAL, #1033
1011 21 24
51
1034
1012 G
CR-5 [2027]
1035
1013 11 7
TB2
PANELVIEW
50 C600
+ 1036
1014
51
- 2711C-T6C 1761-CBL-PMØ2
COMM CABLE ANTISCALANT MIXER RECEPTACLE
1037
G OPTIONAL, #1037
1015
CR-4 [2030]
12 TO MCC
NOTE 1 1038 CIP AUTO ENABLE
1016 TERMINAL 12 G
11 14
1039
COMM 0
1017
CR-2 [2025] DRY ALARM CONTACTS
VAC VAC 9 10
L1 NEUT 1040 CUSTOMER USE OPTIONAL
MICROLOGIX 1200
1018 21 24 (CLOSE ON ALARM)
G POWER SUPPLY
1041
1019 16 AWG
G CR-2 [2025] (20)
1042 ALARM HORN
1020 11 14
G
1 NOTES: 2 1043
TO LINE 1021 KEY 1. FACTORY SUPPLIED CABLE.
CR-1 [2026]
WIRE DESIGNATIONS (DO NOT RUN WITH AC POWER CABLES) 8 TO MCC
2. ALL EQUIPMENT IS SHOWN DE-ENERGIZED. 1044 P-1 HIGH PRESSURE PUMP CONTROL
TERMINAL 8
= FIELD WIRING 3. WIRE COLOR CODE AS FOLLOWS: 11 14
A. BLACK 115VAC HOT
= CENTER JUMPER ANTISCALANT PUMP RECEPTACLE
B. RED 115VAC FUSED 1045
= TERMINAL DESIGNATION C. WHITE COMMON OPTIONAL, #1045
NUMBER OR WIRE D. GREEN GROUND
ON DEVICE E. YELLOW EXTERNAL POWER
(XX) = WIRE NUMBERS F. BLUE +DC WIRING 1046
G. BLUE/WHITE STRIPE -DC WIRING G
[ ] = COIL / CONTACT LINE & REF. 4. ALL WIRE #18 AWG UNLESS OTHERWISE NOTED.
= TERMINAL IN PANEL 5. WIRE NUMBERS TO BE THE SAME AS TERMINAL NUMBERS
UNLESS OTHERWISE NOTED. GROUND AND NEUTRAL
= HARNESS OR SPLICE 1 2
WIRES N0T TAGGED,COLOR CODED ONLY.
= CABINET GROUND 6. RUN LOW AND HIGH VOLTAGE LINES SEPARATE.
= SUB-PANEL GROUND 7. LOW VOLTAGE TAGS ARE TAGGED TB2. ALL OTHERS ARE TB1.
LINE WIRING DIAGRAM
1 1-20-09 RMM ADDED REFERENCES AND CORRECTED DASHED LINES.
2 9/30/09 KLT REVISED LINES 1001 & 1002
B1331133-01
3 10/08/09 kjg added wire # 1 to flush valve RMM NTS 1 1
4 6/1/11 KJG DC- TO BLU/WHT FROM PURPLE
5 8/12/11 MRP DASHED LINES FV-2
6 7/29/14 TCB ADDED REPRESS PUMP OPTION 8-11-08 B1331133-01 6
24VDC
FROM LINE 1010 MICROLOGIX 1200 FROM LINE 1011 MICROLOGIX 1200
BASE UNIT BASE UNIT
TERMINAL 50 TERMINAL 51
1762-BWA FROM LINE 1002 1762-BWA
LINE # RELAY OUTPUTS
DC INPUTS 1 2
2021
LINE #
50 51
2000 4
R-1 5.1 KΩ
200
BELD. 8451 2022 OUT 0 SPARE
BLK FE-1 RED 100 RED
2001 IN 0 PERMEATE FLOW CR-3 [1023]
SHLD 201 RO INLET
SHLD 2023 OUT 1
FEED VALVE FV-1 RELAY
A1 A2
2002 4 LT-3
R-2 5.1 KΩ 202 RO FAULT STEADY
BELD. 8451 2024 OUT 2 R
/ ALARM FLASH
BLK FE-2 RED 101 RED
2003 IN 1 CONCENTRATE FLOW CR-2 [1040,1042]
SHLD 203
SS-1 2025 OUT 3 ALARM RELAY
SHLD
50 H A 102 102 A1 A2
2004 IN 2 P-1 AUTO CR-1 [1044]
204 P-1 PRESSURE PUMP
2026 OUT 4
103 CONTROL RELAY
103 A1 A2
2005 IN 3 P-1 HAND CR-5 [1029,1030,1035]
205
SS-3 2027 OUT 5 RO FLUSH
CLEAN AUTO 104 RO SYSTEM AUTO 13 14
2006 IN 4
206
2028 OUT 6 SPARE
105 RO SYSTEM CLEAN
2007 IN 5 CR-6 [1026]
207 REPRESS PUMP CONTROL
5 2029 OUT 7
(OPTIONAL)
LSL PERMEATE TANK A1 A2
106
5 2008 IN 6 LOW LOW LEVEL CR-4 [1038]
NOTE B 208
2030 OUT 8 CIP P-3 PUMP ENABLE
A1 A2
2009
P-1 209
2031 OUT 9 SPARE
AUX1
50 107 107
2010 IN 7 P-1 RUN AUXILIARY
43 44 MCC
2032
2011
VAC 4
2033
2012
108
IN 8
RO LOCKOUT (OPTIONAL) KEY
(CLOSE ON LOCKOUT) VAC 3 WIRE DESIGNATIONS
PSL 2034
109 RO INLET PRESSURE = FIELD WIRING
2013 IN 9
(OPEN ON LOW) = CENTER JUMPER
C NO VAC 2
2035
= TERMINAL DESIGNATION
LS-1 NOTE A 110 NUMBER OR WIRE
2014 IN 10 PERMEATE TANK HIGH LEVEL
VAC 1 ON DEVICE
2036 (XX) = WIRE NUMBERS
111 PERMEATE TANK LOW LEVEL
2015 IN 11 [ ] = COIL / CONTACT LINE & REF.
PB-1 (1) VAC 0
2037 = TERMINAL IN PANEL
112 ALARM SILENCE = HARNESS OR SPLICE

2015 IN 12
= CABINET GROUND
1 2
= SUB-PANEL GROUND
PSH R.O. MEMBRANE
113
3 2017 IN 13 HIGH PRESSURE
(OPTIONAL)
NOTES:
DC
#18 AWG ORG JUMPER COM 0 5 3 A. DIFFERENTIAL STYLE LEVEL SWITCH IS SHOWN.
2018
(REMOVE IF PRESSURE IF LEVEL SIGNAL IS ANALOG REFERENCE LINES
SWITCH IS INSTALLED) 4015 AND 4016.
DC
COM 1 (51) B. ONLY USED WITH REPRESS PUMP OPTION WITH
2019 1
LEVEL SWITCH OFF/ON CONTACT - NOT ONE LEG LEVEL
#18 AWG BLU/WHT
2020
LINE WIRING DIAGRAM
1 12-22-08 RMM VARIOUS CHANGES.
50 51 2 1-20-09 RMM ADDED COIL REFERENCE.
B1331133-02
TO LINE 3000 TO LINE 3000 3 9/30/09 KLT ADDED HIGH PRESSURE OPTION, ANALOG LEVEL RMM NTS 1 1
4 7/26/11 KJG ADDED BELDON CABLE TO INPUTS 0,1
5 7/29/14 TCB ADDED CR-6 REPRESS PUMP
8-11-08 B1331133-02 5
FROM LINE 1010 FROM LINE 1011
TERMINAL 50 TERMINAL 51
50 51
EXPANSION 1
1762-IQ8
24VDC INPUT
LINE # 300 ANTISCALANT TANK LEVEL

#18 AWG BLUE
3000 IN 0 (OPEN ON LOW)
C NO #18 AWG ORG OPTIONAL, #3000
301 #18 AWG BLUE SBS TANK LOW LEVEL
1 NOTE:
REMOVE JUMPER IF LEVEL SWITCH IS USED.
#18 AWG ORG C NO OPTIONAL, #3001
302 ACID TANK LOW LEVEL
#18 AWG BLUE
#18 AWG ORG OPTIONAL, #3002
303 #18 AWG BLUE
2
3003 IN 3 REPRESS PUMP A RUNNING
304 #18 AWG BLUE

2
3004 IN 4 REPRESS PUMP B RUNNING
305 #18 AWG BLUE

2
3005 IN 5 SPARE
306 #18 AWG BLUE

2
3006 IN 6 SPARE
INPUT NOT WIRED TO

3007 IN 7 SPARE TERMINAL STRIP
3008
KEY
3009
WIRE DESIGNATIONS
= FIELD WIRING
3010 = CENTER JUMPER
NUMBER OR WIRE
3011 ON DEVICE
(XX) = WIRE NUMBERS
[ ] = COIL / CONTACT LINE & REF.
3012
= TERMINAL IN PANEL
= HARNESS OR SPLICE
3013 #18 AWG BLU/WHT = CABINET GROUND
COMMONS
CONNECTED = SUB-PANEL GROUND
DC COM
INTERNALLY 1
3014

50 51 LINE WIRING DIAGRAM
1 9/30/09 KLT DELETED LS TAG NO's
2 7/29/14 TCB ADDED REPRESS PUMP RUNNING, TERMS 305,306
B1331133-03
RMM NTS 1 1
8-7-08 B1331133-03 2
LINE #
4000
50
BELDEN 8451
EXPANSION SLOT 2
4001 ANALOG INPUT
BLK 1762-IF4
1 +
2850 BELDEN 8451
4002 CT-1
RED 400 RED
3 - + IN 0
PERMEATE CONDUCTIVITY
4003 0-100 S= 4-20mA
SHLD 51 BLK
- IN 0
4004 SHLD
4005
50
BELDEN 8451
4006
BLK
4 +
2750 BELDEN 8451
4007 ORPT-1
RED 401 RED
2 - + IN 1
INLET ORP
4008 -1000→+2000mV=4-20mA
SHLD 51 BLK OPTIONAL, #4007
- IN 1
4009 SHLD
50
BELDEN 8451
4010 BLK
4 +
2750 BELDEN 8451
PHT-1
4011 RED 402 RED
2 - + IN 2
INLET pH
0-14=4-20mA
4012 SHLD 51 BLK OPTIONAL, #4011
- IN 2
SHLD
4013 50
SHIELDED CABLE
BLK
4014 +
BELDEN 8451
RED 403 RED

4015 - + IN 3 PERMEATE LEVEL
1 ANALOG SIGNAL
SHLD 404 BLK
(OPTIONAL #4014) 1 NOTES:
NOTE 1
4016 - IN 3
JUMPER 51 SHLD 1. PERMEATE ANALOG SIGNAL LEVEL SHOWN WITH THIS PANEL
#18 AWG PURPLE
4017 COM POWERING THE LOOP. IF TRANSMITTER IS TO BE POWERED
KEY
EXTERNALLY, REMOVE JUMPER BETWEEN TERMINALS 404 &
WIRE DESIGNATIONS
51, AND WIRE POWERED LOOP BETWEEN TERMINALS 403 &
4018 COM = FIELD WIRING 404.
= CENTER JUMPER
NUMBER OR WIRE
FOR DIFFENTIAL STYLE LEVEL SWITCH R.O. START / STOP
ON DEVICE SEE LINES 2014 AND 2015.
(XX) = WIRE NUMBERS
[ ] = COIL / CONTACT LINE & REF.
= TERMINAL IN PANEL
= HARNESS OR SPLICE
= CABINET GROUND
= SUB-PANEL GROUND

LINE WIRING DIAGRAM
1 9/30/09 KLT ADDED ANALOG LEVEL
2 7/29/14 TCB ADDED REPRESS PUMP OPTION
B1331133-04
RMM NTS 1 1
8-7-08 B1331133-04 2
6 1
1 6
2
! DANGER
Electric shock hazard.
32 Equipment may be
powered by multiple 2
3 sources.
MCC-1 Lock out all sources
before servicing.
SLSOL.COM 800-226-0642 No. C8002-29DHYD
ON
7
O
F
F
3 R.O. PUMP P-1

HAND OFF AUTO 6
6
G 6
SS-1 6,9,10,11
LT-10
3 CIP PUMP P-2

HAND OFF AUTO
24"H X 20"W X 8"D
4 6
SS-4 6,11,29
MARLO ELECTRICAL SPECIFICATIONS

Max Line Voltage: 460VAC Phase: 3 Hz: 60
6 33 NOTE 1
Largest Motor FLA: 34 Total FLA: 41.6
SCCR: 5KA@460V Ref Dwg:
CAUTION: TO REDUCE THE RISK OF FIRE, REPLACE

FUSE ONLY WITH SAME TYPE AMPS OR
EQUIVALENT. UL LISTED ONLY.
FUSE REPLACEMENT CHART
6 33 NOTE 1
FU-1,2,3 LPJ-50SP 50A
FU-4,5,6 LPJ-12SP 12A
WARNING - CONDUIT HUBS AND/OR ANY DEVICE

THAT PENETRATES THIS ENCLOSURE MUST
MAINTAIN THE UL RATING OF THIS ENCLOSURE.
6 33 NOTE 1
UL ENVIRONMENTAL RATING: 1
NOTE 1
6
6 NOTES:
1. LOCATE LABEL ON INSIDE OF ENCLOSURE DOOR.
R.O. & CIP PUMPS STARTER

MCC1 ENCLOSURE ASSEMBLY
1 2-3-09 RMM VENDOR NO. B1340006 WAS B1340007.
2 2-3-09 RMM ITEM 12 WAS A2203043. ADDED ITEM 7.
B1331112
3 2-9-09 RMM SEQN.#'S 24 & 25 ELIMINATED. RMM NTS 1 1
4 3-4-09 RMM ADDED SIZE TO ENCLOSURE.
FOR USE WITH
5 10-1-09 KLT ADDED ITEMS 4 & 5
6 5-17-11 KCA MRO-94K & MRO-115K 8-4-08 B1331112 6
SECTION 8
Pretreatment

INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
MGT 600M–3
TWIN ALTERNATING
WATER SOFTENER
COMMERCIAL WATER CONDITIONERS
Marlo Incorporated
COMPLETE FOR FUTURE REFERENCE: 2227 South Street
MODEL NO: P.O. Box 044170
Racine, WI 53404-7003
SERIAL NO:
Ph. (262) 681-1300
DATE INSTALLED: Fax (262) 681-1318
DEALER:
Info@Marlo-Inc.com
www.Marlo-Inc.com
8-246 A2170319
FRP TOP MOUNT WATER CONDITIONERS
PRIOR TO Inspection Requirement AFTER

Media Loading Prior to Loading Media Media Loading
1. Inspect condition of upper distributor piping. Verify
fittings are tight and positioned as shown.
2. Inspect condition of strainers, laterals and hub through
top or side access ports. Verify fittings are secured
to hub.
3. DO NOT load media if damaged components are
observed. Contact factory.
4. Installer is responsible for media loss into treated water
resulting from failure to report and repair damaged
SIDE components inside media tank prior to media loading.
VIEW
5. INSTALLER WARNING:
Refer to installation instructions for media loading
procedure. Improper loading of media will damage
components inside media tank.
Softener/
Media Tank
Filter Media
TOP
VIEW
Media Tank Lateral
Hub
Distributor Tube
Hub
Lateral Gravel
Media
5-272
Phone: (262) 681-1300 • Web: www.Marlo-Inc.com • E-mail: info@marlo-inc.com

MGT 240M–1200M NXT 3” TWIN ALTERNATING
TABLE OF CONTENTS
SYSTEM INFORMATION
Product Warranty............................................................................................................................................................1
General Arrangement Drawings.....................................................................................................................................2
Dimension Chart . ..........................................................................................................................................................3
Specification Chart ........................................................................................................................................................4
INSTALLATION
General Information........................................................................................................................................................5
Loading Softener ...........................................................................................................................................................6
Mounting Control Valve .................................................................................................................................................7
Installation Instructions ..................................................................................................................................................7
OPERATION
Start-Up Procedure .......................................................................................................................................................8
User Mode Programming Flow Chart ............................................................................................................................9
Batch Size Calculation ................................................................................................................................................10
Timer Operation . ......................................................................................................................................................... 11
Network / Communication Cables & Connections........................................................................................................15
Master Programming Mode Flow Chart ......................................................................................................................16
Master Programming Guide ........................................................................................................................................20
Diagnostic Mode Flow Chart .......................................................................................................................................26
Diagnostic Programming Guide ..................................................................................................................................27
Flow Diagrams ............................................................................................................................................................29
Wiring Diagram . ..........................................................................................................................................................31
MAINTENANCE
Powerhead Assembly ..................................................................................................................................................32
Control Valve Assembly................................................................................................................................................34
Brine Injector Assemblies ............................................................................................................................................36
Meters and Flow Sensors . ..........................................................................................................................................38
Brine Tank Assemblies ................................................................................................................................................40
Service Assemblies .....................................................................................................................................................44
Troubleshooting............................................................................................................................................................45

TERMS/CONDITIONS/WARRANTY
Ordering: Freight Claims:
Orders may be phoned, faxed, or emailed to Marlo Incorporated Purchase Any damage, discrepancies and/or freight claims must be made immedi-
orders must include Marlo Incorporated part numbers and pricing. ately and directly, in writing within ten (10) days to Marlo Incorporated. Marlo
Purchase orders must also state if partial shipments are allowed. If you do Incorporated will help as much as possible in settling claims. However, Marlo
not have the correct part numbers, pricing, or case quantities, please con- Incorporated will not be held responsible for breakage or shortage after prod-
tact our customer service department. ucts are accepted by common carrier. All shipments must be inspected for
damages and counted for shortages at the time of delivery.
Order Confirmations: Order Changes:
All purchase orders will be confirmed by phone, fax, or email. Any discrep- Additions to an order may be made at no charge prior to the processing of
ancies in part numbers, pricing, descriptions, or case quantities will be an order. Processing of an order typically begins within one hour of receipt
listed in the order confirmation. It is the customer’s responsibility to review of a purchase order and is typically accomplished within one working day.
the order confirmations and advise if any changes are to be made. If we
do not hear from the customer regarding the confirmation within 24 hours, Orders cancelled after the order has been processed and sent to shipping
we will assume everything is correct and will invoice and ship accordingly. or engineering, will be subject to a minimum 10% cancellation fee, assum-
ing manufacturing has not commenced, and no detailed engineering or
special parts have been ordered. Additional fees may be charged depend-
Quotes & Prices: ing on the level of completion of detailed engineering, manufacturing,
Quotations are valid for a period of up to 45 days or for the term stated
and/or if any special parts have been ordered.
on the quote, whichever term is shortest. We make every effort to notify
customers with price change information. However, prices are subject to Returns & Restocking:
change or correction without notice. Shipping weights, dimensions and A Return Goods Authorization (RGA) number must be obtained from Marlo
anticipated ship dates are all approximate and subject to change. Incorporated before any product returns can be accepted and/or replace-
ments shipped. All returns for warranty consideration are to be shipped
Minimum Orders: prepaid and must be returned within ten (10) business days from the
Minimum order accepted is $25.00, not including freight or taxes. RGA issuance. Returns determined to be in warranty will be replaced or
repaired and will be returned to Buyer prepaid. Products returned, other
Taxes: than valid warranty claims, may be subject to a restocking charge of up to
Taxes are not included. Quoted prices are exclusive of all taxes. 25%. Orders shipped incorrectly by Marlo Incorporated are not subject to
Purchaser shall be responsible for payment of all applicable state/local restocking charges and correct items will be shipped to Buyer prepaid.
taxes. Orders shipped within Wisconsin are subject to applicable state tax Excusable Delays:
rates unless a completed resellers card or exempt certificate is on file. Marlo Incorporated shall not be in default for failure to deliver or delay
in delivery arising out of causes beyond its control and without its negli-
Freight: gence, including but not limited to Acts of God or the public enemy; acts
All shipments are F.O.B. Marlo Incorporated Racine, Wisconsin, unless of the Government in either its sovereign or contractual capacity; fires;
otherwise specified. floods; epidemics; quarantine restrictions; strikes; shortages of materials
or supplies; labor disputes; freight embargoes; delays in transit; consign-
Shipment: ments lost or damaged by freight agent(s); and unusually severe weather.
The shipment method should be specified by the customer on the pur- Warranty:
chase order; otherwise, Marlo Incorporated will choose the best method of Marlo Incorporated warrants its products to be free from defects in design,
shipment. material, or workmanship for a period of 18 months from shipment date
or 12 months from installation, whichever occurs first, when said products
Packaging: are installed and operated in accordance with the written instructions pro-
Pricing includes packaging that is satisfactory for air, truck, or container- vided. The fiberglass reinforced polyester (FRP) resin/media tanks used
ized shipment at no additional cost, unless otherwise stated. Ocean export in certain products alone have an extended warranty period of five (5)
crating will require an additional charge. years from the shipment date. If within that period any products shall be
proven to Marlo, Inc.’s satisfaction to be defective, those products will be
Terms - Domestic Customers: replaced, or the price refunded at Marlo Inc.’s option. Marlo Inc.’s obliga-
Terms of payment on open accounts are net 30 days from the date of tions or nonperformance, defective, or any damage caused by its products
invoice, unless otherwise stated and mutually agreed upon by both par- or their use, and buyer’s exclusive remedy therefore, shall be limited to
ties. This agreement is subject to credit approval. Terms will only be product replacement or refund and shall be conditioned upon Marlo Inc.’s
issued to companies which reside in the United States of America. Orders receiving written notice together with a demand for such replacement or
will not be shipped if any account is past due and/or until payment by refund:
check has cleared. The foregoing warranty is exclusive and in lieu of all other expressed
Orders in excess of $60,000 will require partial payments prior to ship- implied warranty (except of title) including but not limited to implied war-
ment. A specific progress payment schedule will be stated in the quotation. ranty of merchantability and fitness for particular purpose.
Partial payments may also be required for orders involving special engi- Marlo Inc. will not be subject to and disclaims the following:
neering or custom ordered items regardless of order amount.
1. Any other obligations or liabilities arising out of breach of contract or out
Interest will be charged on past due accounts. Interest charges will be of warranty.
calculated on the unpaid balance at 1.5% per month. All questions regard-
2. Any obligations whatsoever arising from tort claims (including negli-
ing invoices and terms must be addressed with our accounting department
gence and strict liability) or arising under other theories of law with respect
before invoices become due.
to products sold or services rendered by Marlo Inc. or any undertakings,
Unless specifically included as a separate item, prices quoted do not acts, or omissions relating thereto.
include any city, county, state or federal taxes, or transportation of
3. All consequential, incidental, and contingent damages including labor
merchandise.
charges, back charges or handling charges are excluded from Marlo Inc.’s
warranty provisions.
Terms - International Customers:
All payments due are in U.S. dollars and must be made in advance by Policy:
check (must clear before shipment), money orders, wire transfer, or credit These terms and conditions may be superseded by specific provisions
card. Credit cards that are accepted are Visa, MasterCard, and American provided by Marlo Incorporated. However, should any of these terms and
Express. Irrevocable Letters of Credit are accepted with a minimum order conditions be contrary to or inconsistent with any terms and conditions
of $25,000.00 U.S. dollars, per order. Unless specifically included as a contained in any purchase order form or other document between Marlo
separate item, prices quoted do not include any city, county, state or fed- Incorporated and the buyer, which is prepared by the buyer and whenever
eral taxes, or transportation of merchandise. A deposit may be required for executed, the provisions hereof shall be controlling and shall supersede
special or custom ordered items. the conflicting terms and conditions which are contained in such other
document. No changes shall be made to our terms and conditions unless
prior written authorization by Marlo Incorporated
5-264
Phone: (262) 681-1300 • Web: www.Marlo-Inc.com • E-mail: info@marlo-inc.com 1
8 7 6 5 4 3 2 1
CONNECTION SCHEDULE
CONSTRUCTION NOTES:
A RAW WATER INLET @50PSI MIN PRETREATMENT SKID 122 GPM 3" 150# FLG SCH 80 PVC
B SOFT WATER OUTLET PRETREATMENT SKID 87 GPM 3" 150# FLG SCH 80 PVC
1. ALL PRESSURE VESSELS CONSTRUCTED OF POLYGLASS OR 1-1/2" 150# FLG
C REGEN WASTE TO DRAIN PRETREATMENT SKID 35 GPM SCH 80 PVC
COMPOSITE MATERIAL WITH A POLYETHYLENE INTERIOR
LINER. ALL VESSELS HAVE THE NSF RATING AND A 150 PSIG
WORKING PRESSURE. ALL PRESSURE VESSELS TO BE
CERTIFIED PER THE LASTEST ASME CODE FOR FIBERGLASS
D PRESSURE VESSELS. NOTE THE SYSTEM PRESSURE RATING IS D
100 PSIG
2. STRUCTURAL STEEL SKID TO BE COATED WITH SAFETY

BLUE EPOXY.
3. ALL PRESSURE VESSEL INTERNAL DISTRIBUTORS TO BE

SCH 80 WITH ABS SLOTTED NOZZLES.
4. ALL AUTOMATIC REGENERATION VALVES TO BE A

PENTAIR MODEL 3900 VALVE WITH THE NXT ALTERNATING
CONTROL FEATURE.
5. ALL MANUAL ISOLATING VALVES TO BE PVC QUARTER 89" 50 1/2"

TURN BALL VALVES WITH EPDM SEALS AND SOLVENT WELD 4 5/8"
OR SCREWED CONNECTIONS.
6. ALL EXTERNAL PIPING TO BE SCH 80 PVC. ALL EXTERNAL

13 1/2"
FITTINGS AND FLANGES TO BE SCH 80 PVC WITH SOCKET
WELD CONNECTIONS. SOME ITEMS MAYBE THREADED WHEN
REQUIRED.
1-1/2" DRAIN
7. ALL WATER SOFTENERS TO HAVE INLET AND OUTLET
PRESSURE GAUGES AND SAMPLE VALVE. 51"
8. ALL EXTERIOR HIGH VOLTAGE (115V OR HIGHER) WIRING

TO BE CONTAINED IN EMT STEEL CONDUIT WITH LIQUID
TIGHT FITTINGS. CONDUIT RUNS 6’ OR SHORTER MAY BE
CONTAINED IN LIQUID TIGHT FLEXIBLE CONDUIT SUITABLE
3/4" TYP.
C FOR OUTDOOR USE. ALL EXTERIOR LOW VOLTAGE CONDUIT C
(24V OR LOWER) WILL BE 3 WIRE CABLE NEATLY BUNDLED
WITH THE MANIFOLD PIPING.
n 9/16"
3/4" TYP.
9. THE WATER SOFTENER SKID TO HAVE AN OUTLET FLOW AUTOMATIC BACKWASH
SENSOR SIGNET MODEL 2536 WITH A SCH 80 PVC FLOW CONTROLLER
INSTALLATION FITTING.
10. FLOW RATES PER TANK:

SERVICE: 185 GPM AT 15 PSIG DROP
BACKWASH: 35 GPM
BRINE DRAW: 12 GPM
SLOW RINSE: 8 GPM
FAST RINSE: 35 GPM
11. SOFTENING MEDIA AND SUPPORT GRAVEL / TANK

SOFTENING MEDIA: 20 CU. FT. STRONG ACID CATION WATER INLET WATER OUTLET
LOWER SUPPORT: 400 LBS 1/8” X 1/16” GRAVEL PRESSURE GAUGE PRESSURE GAUGE
AND SAMPLE COCK AND SAMPLE COCK
12. SHIPPING WEIGHTS: (TYP.) (TYP.) ALLOW 36" FOR
EQUIPMENT ONLY: 1,896 LBS RESIN LOADING
MEDIA ONLY: 2,920 LBS
TOTAL: 4,816 LBS
13. OPERATING WEIGHT (INCLUDING RECOMMENDED SALT

STORAGE): 10,822 LBS INLET ISOLATION
VALVE
14. THE COMPLETE WATER SOFTENING SKID WILL HAVE A
FULL HYDRO-TEST BEFORE SHIPPING TO INSURE THE SKID TO OUTLET ISOLATION
B BE LEAK FREE BEFORE SHIPPING. IF MINOR LEAKS OCCUR VALVE B
AFTER START-UP MARLO WOULD NOT CONSIDER THOSE
LEAKS TO BE COVERED UNDER THE NORMAL EQUIPMENT
WARRANTY.
A
OVER FLOW
TO DRAIN
BY-PASS VALVE
(NORMALLY CLOSED)
(115 5/8")
REF.
B
C
72"
37 1/4"
36" X 72" 36" X 72" 39" X 60"

RESIN TANK RESIN TANK BRINE TANK BACK VIEW
A A
FRONT VIEW
REVISIONS MGT-600-3 TW-ALT SKID - PVC ASME
FRAC. DEC.
INCORPORATED ` `
FILE ID.
DRN.
Anthony SCALE SHEET 1 OF 1
DATE
1/26/2016
EP16-016-03-01
8 7 6 5 4 3 2 1


5-232

2
SYSTEM INFORMATION
SYSTEM INFORMATION
DIMENSION CHART
TANK SIZE
INLET SIZE LENGTH WIDTH HEIGHT*
MODEL SOFTENER BRINE
(Inches) (Inches) (Inches) (Inches)
(Inches) (Inches)
240 3 24x72 24x50 90 24 91
300 3 24x72 24x50 90 24 91
450 3 30x72 30x50 90 30 91
600 3 36x72 39x48 108 39 91
750 3 42x72 39x60 129 42 110
900 3 42x72 42x60 144 42 110
1050 3 48x72 42x60 144 48 110
1200 3 48x72 42x60 156 48 110
*Leave a minimum 24 inch clearance to the height of the unit for loading media.
Dimensions are for general arrangement use only.

SYSTEM INFORMATION
SPECIFICATION CHART
MODEL 240 300 450 600 750 900 1200

SYSTEM SIZE
VALVE SIZE (IN) 3 3 3 3 3 3 3
MAX CAPACITY (KILOGRAINS) 240 300 450 600 750 900 1,200
MIN CAPACITY (KILOGRAINS) 160 200 300 400 500 600 800
CONTINUOUS FLOWRATE (GPM) 120 114 160 185 200 165 205
FLOWRATE (GPM)
PEAK FLOWRATE (GPM) 170 150 213 250 268 225 275
BACKWASH & FAST FLUSH (GPM) 15 15 25 30 30 35 35
BRINE DRAW & RINSE (GPM) 3.2 3.2 3.5 4.5 6.5 6.5 10
BRINE TANK REFILL (GPM) 2 2 5 5 10 10 10
BACKWASH & FAST FLUSH (MIN) 10 10 10 10 10 10 10

SETTINGS
BRINE DRAW & RINSE (MIN) 60 60 80 80 80 90 90

TIMER
FAST FLUSH (MIN) 10 10 10 10 10 10 10
BRINE TANK REFILL (MIN) 20 26 16 20 12 16 20
SIZE (IN) 24x72 24x72 30x72 36x72 42x72 42x72 48x72

SOFTENER
GRAVEL (LBS) 120 120 225 400 400 650 1000

TANK
RESIN (FT3) 8 10 15 20 25 30 40
FREEBOARD (IN) 30 21 22 23 23 15 15
TANK SIZE 24x50 24x50 30x50 39x60 39x60 42x60 42x60

EQUIPMENT
MAX SALT STORAGE (LBS) 550 450 590 1250 1700 2000 1700
INJECTOR CODE 4 4 5 6 7 7 8
BRINE SYSTEMS
INJECTOR COLOR GRN GRN RED WHT BLU BLU YEL
SALT DOSAGE- MAX (LBS) 120 150 225 300 375 450 600
MAX
REFILL TIME - MAX (MIN) 20 26 16 20 13 16 20
SALT DOSAGE- MIN (LBS) 48 60 90 120 150 180 240

MIN
REFILL TIME - MIN (MIN) 8 10 6 8 5 6 8
REGENERATION WASTE VOLUME (GAL) 520 544 860 1020 1210 1315 2100
NOTES:
1. FLOW RATES
Continuous: pressure loss does not exceed 15 psig.
Peak: pressure loss does not exceed 25 psig
Backwash & Flush: maximum flow to drain
Brine & Rinse: Injector flow to drain
Brine Tank Refill: flow to refill Brine Tank
2. SOFTENER TANK
Freeboard: distance in inches from surface of resin to top sealing flange of tank
3. SALT DOSAGE
Maximum 15 lbs./cu.ft. - regeneration efficiency: 2,000 grains/pound of salt (factory setting)
Maximum 6 lbs./cu.ft. - regeneration efficiency: 3,000 grains/pound of salt
4. REGENERATION WASTE VOLUME - Total gallons water discharged per regeneration

INSTALLATION
INSTALLATION INSTRUCTIONS WATER SOFTENERS
GENERAL INFORMATION
1. Operating pressure range is 25-100 psi. If pressures over 100 psi are encountered, a regulator must be installed.
2. Power requirements are shown on inside cover of the control valve.
3. Standard units are designed to soften unheated water not to exceed 100F. Special valve assemblies are available
to handle heated water supplies exceeding 100 F. Consult factory if applicable.
4. Each softener tank is shipped with distributor manifold and control valve preassembled. Take care when uncrating
and erecting so that no items are damaged.
5. The distributor assembly has been shipped inside the fiberglass mineral tank. Check to make sure that there is no
damage to the riser pipe, baskets, laterals or hub (if applicable).
LOCATE SOFTENER
1. Select a location that is accessible and near a floor drain that has adequate carrying capacity to handle the
softener backwash flow (see specification table).
2. Erect the softener tank(s) on a concrete or other firm foundation and level.
3. Position the brine tank according to the illustration and supplementary brine tank information. Keep the brine tank
as close as possible to the softener tank(s).
Note: The distance between the softener and brine tanks will affect the brine injector performance, as the distance
increases the injector performance decreases. This may cause an inadequate regeneration.
4. A grounded electric receptacle is required for the control valves.

INSTALLATION
LOAD SOFTENER TANK
1. Fill tank(s) approximately 1/3 full of water using a hose, bucket, etc. Plug the PVC distributor manifold pipe using a
plastic cap, cork, rag, etc. NO gravel or resin should go into this distributor manifold pipe.
2. Verify the distributor manifold is center in the tank with the distributor resting on the bottom of the tank. Verify the
riser pipe is still plugged.
NOTE: Reference the specification table in the front of this manual for the correct quantities of gravel and resin. Note
that these quantities are for each tank. Make sure you have the required amounts on site before you begin.
3. With care not to damage any lateral, pour in the gravel provided for each tank through the top opening in the tank
and level out evenly. This will cover the distributor assembly.
NOTE: Wetting the gravel in the bags before loading will eliminate the normal amount of dust.
4. When gravel is loaded and leveling is completed, proceed as follows:
5. With the distributor riser pipe still plugged, add the proper amount of resin supplied for each tank through the top
opening in the tank.
Caution: The softener resin is very slippery. Take care when stepping on any spilled resin. Remove spilled resin from
standing surface immediately.
6. When loading is complete, remove plastic cap, cork, or rag that was used to plug the distributor riser pipe. Be
careful not to let any foreign debris fall into the pipe. The result could be damage to system.
7. Repeat instruction steps 1-6 for each softener tank (if applicable).

INSTALLATION
MOUNT CONTROL VALVE ASSEMBLY
1. Verify that the distributor riser pipe is not plugged.
2. Lubricate the distributor o’ring on the bottom of the control valve with silicone.
3. Insert disperser in threaded base of control valve. The threaded base has a groove machined into the inside of the
threaded part of the base to allow for the installation of this disperser.
4. Screw control valve into top opening of tank making sure the distributor riser pipe slides easily through the
distributor o’ring. Care must be taken not to “nick” this o’ring as hard water leakage could result.
5. Tighten down the control valve to ensure positive o’ring seal at top of tank.
6. Repeat instruction steps 1-5 for each softener tank (if applicable).
INSTALLATION OF CONNECTION PIPING

NOTE:
• Use thread sealing tape on all threaded piping connections.
• Install the piping conforming to federal, provincial, and local codes.
• Union or flanges are recommended at the control valve’s inlet, outlet, and drain connections
• To enhance the monitoring of the system’s performance sample valves and pressure gauges can be installed at
the inlet and outlet piping to each control valve.
Caution: All piping must be properly supported. The tank and valve assemblies are not meant to support the
connecting piping.
1. Install piping as shown on installation diagram. It is recommended that unions be installed on inlet and outlet
connections to facilitate service of unit. Be sure piping is free of thread chips and other foreign matter. The
connecting piping should be the same size or larger then the service inlet and outlet of the control valve. On
multiple units that are both in service at the same time the common service inlet and outlet headers should be
up-sized to accommodate the total flow
2. Verify that the flow arrow stamped on the brass flow controller is pointing away from the control valve. See
installation diagram or valve manual for the location. Install a drain line from backwash control assembly to an
appropriate drain using a minimum of elbows. Install a union near the backwash control to facilitate cleaning. Do
not install a valve on the drain line.
NOTE:
• If distance of drain line is over a 10 ft. vertical or 25 ft. horizontal run, increase drain line one pipe size over that
provided on the control valve.
• Do not make a direct connection to the drain. Provide an air gap of at least four times the diameter of the pipe to
conform to sanitation codes and to permit observation of the flow.
• It is not recommended that an overhead or a long horizontal drain run be used. The increase of backpressure will
cause problems when drawing brine.
3. Connect the brine line tubing to the softener(s) and to the brine tank. Verify that the brine line tubing is not kinked
or restricted.
4. Run flexible tubing from the brine tank over flow fitting to an appropriate, non-elevated, open drain.

OPERATION
START-UP PROCEDURES
Again, make sure all plumbing is complete and tight, including drain line and brine line. Make sure all electrical
components, including the communication cables (multi tank systems only) are properly installed and connected.
1. Using a bucket or hose, fill brine tank with water to 2” above salt platform. Do not add salt at this time.
2. Make sure inlet and outlet isolation valves are closed, and then turn on power to the system.
Note: Start up only one (1) tank at a time.
3. Open the manual bypass valve. The manual inlet and outlet valves are to remain closed.
4. Connect electrical power to the control valve by plugging in the valve. Once the valve is powered it will drive to the
service position. The LED light should be blue.
5. Program the NXT controller. The water hardness, day override, time of regeneration, and time of day will need to
be set on site to the desired settings. (Refer to the User Mode Programming section of the manual.) The softener
settings are pre-programmed at the factory. Instructions for changing these settings are in the Master
Programming Guide section.
6. Manually initiate a regeneration by pressing and holding the Extra Cycle button on the NXT controller.
7. The LED light on the NXT timer should change from Blue indicating the unit is In Service color to Green indicating
the unit is in Regeneration.
8. Slowly open the manual inlet supply valve of the unit that is in backwash. Do not open the valve fully. Water will
enter from the bottom of the mineral tank as air is expelled from the top to the drain. Full flow of water could cause
loss of mineral. Continue to fill slowly until all air is expelled and only water flows to the drain.
9. When only water flows to the drain, open the inlet valve fully and backwash the unit until the water looks clean
when caught in a container.
10. Press the Extra Cycle push button to advance the valve to the Brine/Rinse position.
11. While the unit is in the brine/rinse position, check the level in the brine tank. The level should be dropping at
a slow rate (approximately 2” per minute). Allow the level to drop until the air check valve closes.
12. Press the Extra Cycle push button to advance the valve to the Fast Flush position. Allow the water to flow to the
drain until clear.
13. Press the Extra Cycle push button to advance the valve to the Brine Tank Refill position. Allow the brine tank to fill
with water for the duration of the step. The water level should be 1”-2” inches above the salt platform.
14. Press the Extra Cycle push button to advance the valve to the Service/Standby position.
15. If applicable repeat steps 3 - 13 for the other unit(s).
16. Fill the brine tank with the proper amount and type of salt recommended for use with the system.
17. Close the manual bypass valve and open all outlet valves fully. The system is now in service.
Program Notes:
• The valve programmed as Valve Address #1 will be the Lead unit.
• The Meter must be connected to the Lead unit.- Unit 1
• Water hardness is programmed on the Lead Unit only in a System 6 (Sequential) or System 7 (Twin-Alternating)
configuration.

OPERATION
USER MODE PROGRAMMING FLOW CHART

NOTE: User Mode is only displayed when a metered option is chosen under System Type.
Depending on current option settings, some displays cannot be viewed or set.
Entering User Mode:

Hold the Up and Down buttons for 5 seconds.
NOTE: User Mode cannot be entered on the Lag unit for System 6.

1. Enter User Mode
Press and hold the Up and Down buttons for 5 seconds.

2. Set Feed Water Hardness
Press the Shift, Up, and Down buttons to move the cursor and change the value of the numbers.
Press the Extra Cycle button to proceed to the next step.
NOTE: Only displayed when a metered option is chosen under System Type.
3. Set Regeneration Day Override

To turn on and set the days, press the Down button.
Press the Extra Cycle button to proceed to the next step.
4. Regeneration Time
Press the Extra Cycle button
5. End of User Programming Mode

OPERATION
BATCH SIZE CALCULATION

Batch size is the term used for the amount of water being softened by the water softener between regenerations. The
NXT controller calculates this value automatically based on the values in the program. This is a simple calculation
provided two pieces of information are known:
Capacity of the water softener in grains (gr.)

(i.e. MGT-300 has 300,000 grains capacity per tank).
Hardness of the raw water being treated by the water softener.
BATCH SIZE EQUATION:
Hardnessof Water (grains per gallon)

Batch Size = Grain Capacity of Softener
SAMPLE CALCULATION
Assume:
Unit is a model MGT-300 softener
The hardness of the water was measured to be 20 grains per gallon
Using our equation take 300,000 ÷ 20 = 15,000 gallons.

10% Safety factor - reserve capacity = 1,500 gallons.
15,000 gallons – 1,500 gallons = 13,500 gallons (batch size)
For immediate regeneration type meter control the meter setting would be at 15,000 gallons. Commonly this value is
adjusted to 90 percent of the actual value (in this example 13,500 gallons) to assure not over-running the softener.
NOTE:
For meter delayed options, the batch size is determined as in our example, except an additional amount of gallons
must be accounted for and deducted from the total to allow soft water to be available until the softener regenerates
at the selected delay time of day or night. This compensation is necessary since the meter will indicate regeneration
required time prior to the set delay time. This can be accomplished on the NXT timer by increasing the safety factor in
the Master Programming mode.

OPERATION
TIMER OPERATION
SETTING THE TIME OF DAY
NOTE:
Set Time of Day on the Lead Unit (#1) and the rest of the units in the system will populare with the Time of Day within
10 seconds.
1. Press and hold the Up or Down button for 2 seconds.
2. Press the Shift button to select the digit you want to modify.
3. Press the Up or Down buttons to adjust the value.
4. Press the Extra Cycle button to return to the normal display screen, or after a 5 second timeout.
NOTE:
The “D” button (Diagnostic) can be pressed to exit without saving.
MANUALLY INITIATING A REGENERATION

1. When timer is in service, press the Extra Cycle button for 5 seconds on the main screen.
2. The timer advances to Regeneration Cycle Step #1, and begins programmed time count down.
3. Press the Extra Cycle button once to advance valve to Regeneration Cycle Step #2 (if active).
7. Press the Extra Cycle button once more to advance the valve back to in service.
NOTE:
A manually initiated or queued regeneration can be cleared by pressing the Extra Cycle button for less than 5
seconds. A system queued regeneration can only be cleared by stepping through a manual regeneration. If
regeneration occurs for any reason prior to the delayed regeneration time, the manual regeneration request shall be
cleared. Pressing the Extra Cycle button while in regeneration will cause the upper drive to advance to the next step
immediately.
TIMER OPERATION DURING REGENERATION

In the Regeneration Cycle Step display, the timer shows the current regeneration cycle number the valve is on, or
has reached, and the time remaining in that step. Once all regeneration steps are complete the timer returns to in
Service and resumes normal operation.
Example: 12 Minutes Remaining in Cycle 1 (Back Wash)
Press the Extra Cycle button during a Regeneration Cycle to immediately advance
the valve to the next cycle step position and resume normal step timing.
FLOW METER EQUIPPED TIMER

• During normal operation, the Time of Day screen alternates with the error screen (if errors are present).
• As treated water is used, the Volume Remaining display counts down from the calculated system capacity
to zero. When this occurs a Regeneration Cycle begins if no other units are in regeneration.

OPERATION
TIMER OPERATION
TIMER OPERATION DURING PROGRAMMING

The timer enters the Program Mode in standby or service mode as long as it is not in regeneration. While in the
Program Mode the timer continues to operate normally monitoring water usage. Timer programming is stored in
memory permanently.
TIMER OPERATION DURING A POWER FAILURE

All program settings are stored in permanent memory. Current valve position, cycle step time elapsed, and time of
day are stored during a power failure, and will be restored upon power re-application. Time is kept during a power
failure, and time of day is adjusted upon power up (as long as power is restored within 12 hours).
NOTE:
The time of day on the main display screen will flash for 5 minutes when there has been a power outage.
The flashing of the time of day can be stopped by pressing any button on the display.
REMOTE LOCKOUT
The timer does not allow the unit/system to go into Regeneration until the Regeneration Lockout Input signal to
the unit is cleared. This requires a contact closure to activate the unit. The recommended gauge wire is 20 with a
maximum length of 500 feet. See P4 remote inputs in the wiring diagrams in the service manual.
REGENERATION DAY OVERRIDE FEATURE

If the Day Override option is turned on and the valve reaches the set Regeneration Day Override value, the
Regeneration Cycle starts if no other unit is in Regeneration. If other units are in regeneration, it is added to a
regeneration queue. This occurs regardless of the remaining volume available.

OPERATION
TIMER DISPLAY FEATURES
Valve State
(SBY, SRV, INI, CHG, LCK)
Valve
Address
System Flow Time
Number Indicator of Day Display Screen
Time of Day alternates with Error Screen
Example: Valve #, Volume Remaining,
Errors
Volume Remaining
Diagnostic Button
View Flow Rate, Peak Flow Rate, Totalizer, Hours
Between Last Two Regenerations, Hours Since Last
Regeneration, Adjustable Volume Remaining, Valve
Position, Send & Receive Errors, Software Version
Extra Cycle Button
Cycle Valve in Regeneration/Cycle Programming Steps
Shift Button
Adjusts Values to the Left
Up Button
Adjusts Values Up
Down Button
Status LED Adjusts Values Down
VALVE STATE:
CHG (Change of State)
CHG will be displayed when the lower drive changes from one state to another in dual piston valves.
INI (Initializing)
INI will display on the screen for 30 to 45 seconds when initializing after a power failure reset or programming.
RGQ (Regeneration Queued)
RGQ indicates that the reserve has been entered in a delayed system and regeneration has been queued.
When in the main screen, press the Extra Cycle button to toggle service (SRV) with RGQ.
Service (SRV)
SRV will display when the unit is in service.
LCK (Lock)
Lock will be displayed when the terminal/remote input block P4 on the circuit board is switched to “lock”.
See the “Network/Communication Cables & Connections” section of this manual.
LED STATUS LIGHTS:

Blue LED:
Illuminates while the unit is in service and no errors exist. The unit will always be in service unless a
regeneration trigger has occurred (green LED light will be displayed).
A blinking blue light indicates the timer is in service, and queued for regeneration.
Green LED:
Illuminates when the unit is in Regeneration mode, unless an error condition exists.
A blinking green light indicates the timer is in standby, and not in regeneration.
Red LED:
Illuminates when there is an error.
FLOW INDICATOR:
A rotating line (appearing as a rotating star shape) will display on the screen when flow is going through the
the meter.

OPERATION
TIMER DISPLAY - SCREEN EXAMPLES
EXAMPLE:
In Service:
System 4 Time Clock
EXAMPLE:
In Service:
1. System 4 Flow Meter Initiated
or
2. System 4 Flow Meter Delayed
EXAMPLE:
In Service:
1. System 5 Flow Meter Initiated (Lead Unit)
EXAMPLE:
In Service:
1. System 5 Flow Meter Initiated (Lag Unit #3)
EXAMPLE:
In Service:
1. System 6 Flow Meter Initiated (Lead Unit)

OPERATION
NETWORK/COMMUNICATION CABLES & CONNECTIONS

Use either a CAT3 or CAT5 Network/Communication cable.
1. Connect the network/communication cable first before programming.
2. The maximum cable lenth between timers is 100 feet.
3. Connect each unit together from one communication port to the next communication port. It does not matter which
one goes to the next one.
Ground
Regen
Lock
1 2
3200NXT Circuit Board
The number of network/communication cables needed for setup is one less than the total number of valves.
Two-Unit System: One network/communication cable

Three-Unit System: Two network/communication cables
Network Timer System Configuration Wiring Diagrams
Four-Unit Systems: Three network/communication cables
NETWORK TIMER SYSTEM CONFIGURATION WIRING
System 7 Twin Alternating

CAT 5 CABLE
UNIT 1 UNIT 2

OPERATION
MASTER PROGRAMMING MODE FLOW CHART

NOTE: Depending on current option settings, some displays cannot be viewed or set.
Entering Master Programming Mode:

1. Press and hold the Shift and Up buttons for 5 seconds.
Press the Extra Cycle button once per display until all displays are viewed and Normal Display is resumed.Option
setting displays may be changed as required by pressing either the Up or Down button. Use the Shift button to
move one space to the left.
2. Depending on current valve programming, certain displays may not be viewed or set.
NOTE: If the “D” button is pressed while in master programming, no changes will be saved.
Example:
System Type 4, Single Unit
Options: System 4 (Single unit - Timeclock, Immediate Metered, Delayed Metered)

System 5 (2-4 units - Interlock - Meter on each system)
System 6 (2-4 units - Sequential - Single meter on common outlet)
System 7 (2 units - Twin Alternating)
System 9 (2-4 units - Alternating - 1 unit always in standby)
NOTE: This screen will not display for

System Type 4. Example:
Valve Address #2 (Second Control Valve) (Default)
Options: Valve Address #1 (First Control Valve)

Valve Address #2 (Second Control Valve) (Default)
Valve Address #3 (Third Control Valve)
Valve Address #4 (Fourth Control Valve)
NOTE: This screen will not display for Example:

System Type 4. 2 Valves in the System (Default)
Options: 2 Valves in the System (Default)

3 Valves in the System
4 Valves in the System
Range: 2 to 4 Valves in the System
Example:
Time Clock Delayed (Default)
Options: Time Clock Delayed (System 4 Only) (Default)

Meter Immediate (All System Types)
Meter Delayed Fixed Reserve (Systems 4 & 6 Only)
Remote Signal Start Immediate (All System Types)
Example:
2750 (Default)
Options: 2750 (Default)

2850
2900
3150
3900
Stager - Butterfly
Stager - Notch Cam
CAUTION: Before entering Master Programming, please contact your local professional water dealer.

OPERATION

NOTE: Depending on current option settings, some displays cannot be viewed or set.
Example:
Downflow (Default)
Options: Downflow (Default)

UF Brine Draw
UF Fill First
Example:
06:00:00 (Default)
(Hours:Minutes:Seconds)
Options: 00:06:00 (Default)
Range: 1 second to 99 minutes (1 hour, 39 minutes)
Example:
U.S. Gallons (Default)
Options: U.S. - Gallons (Default)

European Units - Cubic Meters (Metric)
NOTE: In U.S. - Gallons mode, the display will be in 12-hour time.
NOTE: In European Units - Cubic Meters (Metric) mode, the display will
be in 24-hour time.
Example:
Grains (Default)
Options: Grains (in U.S. Format) (Default)

Degrees (in Metric Format)
Range: 9,000 to 9,900,000 Grain Capacity in U.S. Format

90.0 to 190,000 Degree Capacity in Metric Format
NOTE: The word “GRAINS” will change to “DEGREES” in the metric

Display Format. Use the Shift button to move to the left.
Example:
00% (Default)
Range: 0 to 50%
NOTE: Use the Shift button to move to the left.
NOTE: This screen will only display on

the lead unit for System Types 6 & 7. Example:
For all other System Types, it will display 15 GPG (U.S. Format) (Default)
for all units.
Range: 1 to 199 Grains/Gallon (U.S. Format)
2 to 199 Degrees (Metric Format)
NOTE: Use the Shift button to move to the left.

OPERATION
Example:
Off (Default)
Example:
1 Day
Options: Off (Default) or On
Range: 1 to 99 Days
Example:
2:00 A.M. (Default)
Options: A.M. (U.S. Format)

HR (Metric Format)
NOTE: Regeneration time will not appear unless

Regeneration Day Override is on.
NOTE: If Stager is chosen for Valve Example:

Type, the Regeneration Cycle Step Cycle 1 in Back Wash Mode
description will not display.
Options: Regeneration Cycle Step #1
Regeneration Cycle Step #2
NOTE: Please refer to the “Regenerant Flow Default Cycle Steps & Times”
in the Master Programming Mode section of the manual.
Example:
Auxiliary Relay is Disabled
Options: Enabled
Disabled (Default)
NOTE: Only displayed if Auxiliary

Relay is enabled in previous screen. Example:
Auxiliary Relay will only display if Auxiliary Relay Output in Start 1 at
Chemical Pump is OFF for System 0 hours, 0 minutes, & 0 seconds
Types 6 & 7.
Range: 00:00:00 to 18:00:00
Example:
Auxiliary Relay Output in End 1 at
0 hours, 0 minutes, & 0 seconds
Range: 00:00:00 to 18:00:00
NOTE: This screen will only display on

the lead unit for System Types 6 & 7.
For all other System Types, it will display Example:
for all units. Chemical Pump is Disabled
Options: Enabled
Disabled (Default)

OPERATION
NOTE: Only displayed on units that

physically have a meter (Lead
always has a meter). Only shown if Example:
Auxiliary Relay is disabled on Chemical Pump Auxiliary Relay
System Types 6 & 7. Volume at 0 Gallons
Range: 000 to 999 gallons in U.S. Format
0.000 to 9.999 m3 in Metric Format
Example:
Chemical Pump Auxiliary Relay at 0 Hours,
0 Minutes, & 0 Seconds
Range: 00:00:00 to 02:00:00
NOTES: Default flow meter type is Example:

based on the valve type. This screen 1.0 Paddle Flow Meter
will only display on the lead unit for
System Types 6 & 7. All other system
Options: 1.0 Paddle
types it will display for all units.
1.0 Turbine
1.5 Paddle
1.5 Turbine
2.0 Paddle
3.0 Paddle
Generic
Example:
Maximum Flow Rate of 0 gpm
Range: 20 - 2,000 gpm (U.S. Format)

2.0 - 200.0 m3 (Metric Format)
Example:
Add 1 Gallon for Each Pulse in U.S. Format
Options: Gallons (U.S. Format)

Meter3 (Metric Format)
Range: 1 - 99 Gallons (U.S. Format)
0.1 - 09.9 M3 (Metric Format)
Pulses: 1 - 99
Example:
Master Programming Mode is Exiting
K-FACTOR TABLE - SIGNET 2536

(Pulses per Gallon) AUTO TURBINE METER CLACK METER
PIPE GENERIC FLOW METER SETTINGS
METER SIZE K-FACTOR METER SIZE K-FACTOR
SIZE TEE TEE SADDLE
(inches) GALVANIZED PVC IRON 1 65 1-1/2 37
1 213 352 2 15 2 20
1-1/4 128 177 3 8
1-1/2 94 118
2 59 67 54
2-1/2 43 38
3 27 23

OPERATION
MASTER PROGRAMMING GUIDE
When the Master Programming Mode is entered, parameters can be set to make the timer(s) function as needed.
NOTE:
Depending on current option settings, some displays cannot be viewed or set.
Entering Master Programming Mode:

1. Press and hold the Shift and Up buttons for 5 seconds.
OR
2. Set the time of day display to 12:01 PM or 12:01HR (See the “Setting the Time of Day” section on the “Timer
Operation” page). Then go to the main display screen, press the Up and Down buttons at the same time for
5 seconds.
Exiting Master Programming Mode:

1. Press the Extra Cycle button once per display until all are viewed. Master Programming Mode is exited and the
normal display screen appears.
2. To exit the Master Programming Mode without saving, press the Diagnostic button.
NOTE:
If no keypad activity is made for 5 minutes while in the Master Programming Mode, or if there is a power failure, no
changes will be made, and the unit will go back to the main display screen.
Resets:
Soft Reset: Press and hold the Up and Down buttons for 25 seconds until 12:00PM (or 12:00HR) appears. This resets
all parameters except for the flow meter totalizer volume. Master Reset: Hold the Extra Cycle button while powering
up the unit. This resets all of the parameters in the unit. Check and verify the choices selected in Master
Programming Mode.
1. Choice of Language
This option selects the language for programming and display.
1. Use Up or Down to select language.
2. Press the Extra Cycle button.
2. System Type
This program type selects the system type (4, 5, 6, 7, or 9).
1. Use Up or Down buttons to adjust this value.
3. Valve Address
This program step selects the valve address (1, 2, 3, or 4) within the network needed for each timer for
communication. The #1 is the “master” or “lead” which contains programmed parameters, that will be used by all
of the timer(s) in the network to control Regeneration, in Service, or Standby of all the valve(s) in the system.
OPERATION
4. System Type
This program step is used to set up the number of valves (1, 2, 3, or 4) in the system.
5. Regeneration Type
This program step is used to set up the trigger type.
6. Valve Type
This program step selects the valve type (2750, 2850, 2900s, 3150, 3900, Stager-Butterfly, or Stager-Notch Cam)
7. Regenerant Flow
This program step selects the regenerant flow type (Downflow, Upflow, or Upflow Fill First)
8. Remote Signal Start

This program step selects the remote signal start. Hours, minutes, and seconds can be changed. When Remote
Signal Start is active, the main screen will display. The options are either Off or set to the desired time.
Example: Remote Signal Start set to 6 minutes. The display counts down
to 0. If Remote Signal Start is detected for 6 minutes, it will remotely signal start.

OPERATION
9. Display Format
This program step is used to set the desired volume display format. This option must be the same on all system units.
U.S. will display volumes in gallons and is in 12 hour timekeeping. Metric will display volumes in liters and is in 24
hour timekeeping.
10. Unit Capacity

This program selects the individual timer’s total capacity of hardness that can be removed. The unit capacity is
measured in grains if in U.S. mode and degrees in Metric mode.
U.S. Range: 9,000 to 9,900,000 Grains (Default = 300,000 Grains)
Metric Range: 90.0 to 199,000.0 Degrees (Default = 300.0 Degrees)
1. Use the Shift button to select the digit you want to modify.
11. Capacity Safety Factor

This program step is used to adjust the capacity of the system. This is a percentage by which the unit’s capacity
is reduced.
Range: 0 – 50% (Default = 0%)
12. Feed Water (Hardness)

This program step is used to set the feed water hardness. The system will automatically calculate volume remaining
based on the Unit Capacity, Capacity Safety Factor and Feed Water Hardness entered.
U.S. Range: 1 – 199 gpg (Grains per Gallon)(Default = 15)
Metric Range: 2 – 199 Degrees (Default = 30)

OPERATION
13. Regeneration Day Override

This program step sets the maximum amount of time (in days) the unit can be In Service without a Regeneration.
U.S. Range: 1 – 199 gpg (Grains per Gallon)(Default = 15)
Metric Range: 2 – 199 Degrees (Default = 30)
14. Regeneration Time

This program step sets time of day for a delayed regeneration to occur, or regeneration day override.
Default U.S.: 02:00 AM
Default Metric: 02:00 HR
15. Regeneration Cycle Steps

This program step programs the Regeneration Cycle step times 1 through 5. Please refer to the chart below for
regenerant flow default cycle steps and times.
Regenerant Flow Cycle 1 Time Cycle 2 Time Cycle 3 Time Cycle 4 Time Cycle 5 Time
10 Brine & Rapid 10
Down Flow Back Wash 1 Hour Brine Tank Fill 12 Minutes Pause N/A
Minutes Slow Rinse Rinse Minutes
16. Auxiliary Relay Output

The next two displays are part of a series of settings used to program the optional relay output. The first setting turns
the output on/off during Regeneration only. The second turns the output on during Service only, every time a set
volume of water used has accumulated.
17. Timed Auxiliary Relay Output Window (Start & End Time Setting, If Auxiliary Relay is Enabled)
This option setting consists of two displays. The first display sets the turn-on time of the output, referenced to the
start of the first Regeneration Cycle. The second display sets the output turn-off time, referenced again to the start of
first Regeneration Cycle.
Start Time: Anytime During Regeneration (Except Last Minute of the Regeneration Time)
End Time: At start time, and anytime during the regeneration cycle.

OPERATION

18. Chemical Pump Auxiliary Relay Output Window
This option setting consists of two displays. The first display sets the volume of water flow at which the output turns
on. The second display sets the time of the output.
U.S. Range: 0 – 999 Gallons (1 – 999 Seconds)
Metric Range: 0.00 – 9.99 m3 (1 – 999 Seconds)
Activate Output After Volume Set is Reached.
Use the Shift button to move one space to the left for each number entered.
Use Up or Down buttons to adjust this value.
Press the Extra Cycle button.
19. Fleck Flow Meter Size (Default to Valve Type)

This program step sets the size of the Fleck flow meter.
• 1.0” Paddle (2750 Default)
• 1.5” Paddle (2850/2900 Default)
• 1.0” Turbine
• 1.5” Turbine
• Generic Flow Meter (Non Fleck Brand)
K-FACTOR TABLE - SIGNET 2536 AUTO TURBINE METER
(Pulses per Gallon)
METER SIZE K-FACTOR
SIZE TEE TEE SADDLE 1 65
(inches) GALVANIZED PVC IRON 2 15
1 213 352
1-1/4 128 177 CLACK METER
1-1/2 94 118
METER SIZE K-FACTOR
2 59 67 54
2-1/2 43 38 1-1/2 37
3 27 23 2 20
Note: Make sure to select the proper K-factor for 3 8

the fitting and pipe size of your system.
20. Maximum Flow Rate

This program step sets maximum flow rate of the generic flow meter.
2. Press the Up or Down buttons to adjust this value.

OPERATION
21. Pulses per Gallon/Liter

This program step sets the pulses per gallon/liter for generic flow meters.
2. Press the Up or Down buttons to adjust this value.
22. End of Master Programming Mode
OPERATION
DIAGNOSTIC MODE FLOW CHART
Entering Diagnostic Mode:

1. Push and release the “D” button.
2. Press the Extra Cycle button once per display until all displays are viewed and Normal Display is resumed.
3. Push and release the “D” button at anytime during diagnostic mode and the timer will exit the mode.
4. Depending on current valve programming, certain displays may not be able to be viewed or set.
NOTE: If a System 6, Unit#1 of “Tank

Remaining” will display “System
Remaining).

OPERATION
DIAGNOSTIC PROGRAMMING GUIDE

When the Diagnostics Mode is entered, all available displays are viewed as needed. Depending on current option
settings, some displays cannot be viewed.
Overview Diagnostic Mode
The current diagnostic will be displayed until Extra Cycle key is pressed. There is no time limit on each display. The
timer will display individual valve information, not system information. In the event of regeneration occurring while
displaying diagnostics, the regeneration step and time remaining will be displayed. When regeneration has been
completed, the display will return to the normal Time of Day display.
Overview Diagnostic Mode
Push and Release the “D” button to enter. Pressing the Extra Cycle button will move to the next diagnostic to be
displayed. Push the Extra Cycle button once per display until all are viewed. Pressing the Diagnostic button, while
in the Diagnostic Mode, will cause the unit to leave the Diagnostic Mode and return to the normal time of day
display.
Current Flow Rate
Flow Rate for this particular Timer will be calculated and displayed. Flow rates will be calculated every second. The
display updates once per second. Flow rates are dependent upon the meter used.
• 1” Paddle Meter Maximum Flow Rate: 75 gpm (.28 m3/m)
• 1.5” Paddle Meter Maximum Flow Rate: 90 gpm (.34 m3/m)
• 2” Paddle Meter Maximum Flow Rate: 175 gpm (.66 m3/m)
• 3” Paddle Meter Maximum Flow Rate: 350 gpm (1.32 m3/m)
• 1” and 1.5” Turbine Meter: 75 gpm
Peak Flow Rate

The Peak Flow Rate since the last regeneration will be captured.
• Range: 0 to Maximum Number
Totalizer
The total volume of treated water that passes through a meter will be counted.
NOTE: The user cannot edit below the current volume remaining.
1. Reset to zero by holding the Up and Down arrow keys for 5 seconds during the Totalizer display.
Hours Between Last Two Regenerations

The hours between the last two regenerations will be saved and displayed.
1. Depress the Extra Cycle button.

OPERATION
DIAGNOSTIC PROGRAMMING GUIDE

Hours Since Last Regeneration
The hours since the last regeneration will be saved and displayed.
Volume Remaining (This Tank Only)

Volume remaining in the current tank will be adjustable when displayed in this mode. Regeneration will occur if set
to zero.
NOTE: Volume Remaining will not display for System Type 6.
The maximum ranges are the same as the maximum volume calculated on the main screen.
2. Use Up or Down buttons is used to adjust this value.
3. Depress the Extra Cycle button
Volume Remaining (System)

Volume remaining in the system cannot be edited when displayed in this mode, except for the Lead unit. It can only be
viewed on the Lag unit.
1. Depress the Extra Cycle button
Valve Address
This diagnostic display is for 2 control valves or more in a system (a single valve will not display).
Software Version
The electronic timer’s software program version number will be displayed.
1. Depress the Extra Cycle button to exit.
NOTE: Diagnostic Mode programming will stop if the system goes into regeneration.

OPERATION
SERVICE
1 SERVICE POSITION
OUTLET
INLET
DRAIN
REGENERATION
VALVE
SERVICE
INLET VALVE
Hard water enters at valve inlet and flows down thru mineral to the bottom distributor. Conditioned water
flows up thru the distributor tube, around the piston and out the outlet.
2 BACKWASH POSITION 3 BRINE POSITION

NO HARD WATER BY-PASS
SERVICE OUTLET
DRAIN
DRAIN
INLET
INLET
Hard water enters at valve inlet  flows thru service adapter

piston for by-pass, and up thru coupling to regeneration valve
inlet. Flow continues thru the regeneration valve piston  down
the distributor tube  thru the bottom distributor and up thru the
mineral  around the piston and out the drain. If optional no
hard water by-pass piston is used, water flow to service outlet is Hard water enters at valve inlet  flows thru injector nozzle and throat
prevented by an extension on the service outlet until the end of to draw brine from the brine tank. Brine flows down thru the mineral 
the rapid rinse cycle or brine tank refill cycle, depending on into the bottom distributor  up the distributor tube  around the
options chosen. piston and out the drain.

OPERATION
4 SLOW RINSE POSITION
DRAIN
INLET
Hard water enters at valve inlet  flows thru injector nozzle and throat  down thru the mineral  into the
bottom distributor  up the distributor tube  around the piston and out the drain..
5 RAPID RINSE POSITION 6 BRINE TANK REFILL POSITION

SERVICE
OUTLET
INLET
DRAIN DRAIN
INLET INLET
Hard water enters at valve inlet  flows thru the regeneration Hard water enters at valve inlet  flows thru nozzle and thru throat to
valve directly down thru the mineral  into the bottom distributor brine valve to refill the brine tank. Inlet flow also continues down thru
 up the distributor tube  around the piston and out the drain. mineral to the bottom distributor. Conditioned water flows up thru the
distributor tube, around the piston and out the outlet. Note: An option
is available to keep service valve in by-pass position until the end of
brine tank refill cycle.

MAINTENANCE
3900 INPUT & OUTPUT WIRING
FLOW METER (FM) WIRING

GROUND ( - ) POWER ( + ) SIGNAL
FLECK BLACK RED GREEN
SIGNET SHIELD BLACK RED
CLACK BLACK RED WHITE
AUTOTROL CLEAR RED BLACK

MAINTENANCE
3900 POWERHEAD ASSEMBLY
49 32 37 48
50 24 28 5 52 1
38 30
28
32 33
29 52
28
20 18
23 31 22 21
14
34
16
15 25 17
11 4 19 39
2
3
7 12 6
5 36 13
27 26 11 10 8
24
41
31 23
31 22
21 20 17 18
44
23
14 43
51
16
16
35
9
27 15 25
11 45
26
11 42 4
46 7 8 12 6 47 40
39

MAINTENANCE
3900 POWERHEAD PARTS LIST

Item No. Quantity Part No. Description
. 1...................... 1........................19304-04.....................backplate, 3150/3900
. 2...................... 1........................15120...........................bracket, motor mtg, 3150/3900
. 3...................... 1........................40391...........................motor, drive, 24V, 50/0 hz, sp
. 4...................... 8........................11224...........................screw, hex hd, 5/1 - 18 x 5/8, ss
. 5...................... 4........................16346...........................nut, hex, jam, 5/1 - 18, 18-8-ss
. 6...................... 2........................17797...........................bracket, switch, mounting, 3150/3900
. 7...................... 5........................10302...........................insulator, limit switch
. 8...................... 4........................10218...........................switch, micro
. 9...................... 2........................16053...........................bracket, brine side
. 10.................... 2........................12624...........................screw, phil pan, 40 x 1 1/2
. 11.................... 4........................16052...........................bushin, 3150/3900
. 12.................... 4........................17567...........................screw, hex, wsh hd, 8 x 1/2
. 13.................... 1........................16494...........................cam assy, 3150/3900
. 14.................... 8........................10231...........................screw, slot hex, 1/4 - 20 x 1/2 18-8 ss
. 15.................... 2........................16046...........................gear, drive
. 16.................... 3........................11774...........................ring, retaining
. 17.................... 2........................16047...........................link, drive
. 18.................... 2........................11709...........................pin, drive link
. 19.................... 1........................16048...........................bearing, drive link
. 20.................... 2........................11898...........................clip, 3150/3900
. 21.................... 2........................16045...........................pinion, drive
. 22.................... 2........................11381...........................pin, roll, 2900/3900
. 23.................... 7........................10872...........................screw, hex wsh, 8-32 x 17/4
. 24.................... 8........................11235...........................nut, hex, 1/4 - 20
. 25.................... 2........................16050...........................ring, retaining
. 26.................... 2........................16059...........................washer, ss, .88, 3150/3900
. 27.................... 2........................16051...........................ring, retaining, bowed
. 28.................... 8........................19800...........................plug, .140, white
. 29.................... 1........................15806...........................plug, hole, heyco, #293
. 30.................... 1........................19591...........................plug, .8750 hole, recessed, black
. 31.................... 3........................11080...........................screw, flt hd mach, 8-32 x 3/8
. 32.................... 2........................17967...........................fitting assy, liquid tight, blk
. 33.................... 1........................40941...........................wire harness, upper drive
. 34.................... 1........................40943...........................wire harness, lower drive w/molded strain relief
. 35.................... 1........................41034...........................transformer, US, 120V, 24V, 108VA
. ..................................................41049...........................transformer, euro, 230V/24V 108VA
. ..................................................41050...........................transformer, aust, 230V/24V, 108VA
. 36.................... 1........................19121...........................meter cable assy, 3200NT
. ..................................................19121-08.....................meter cable assy, NT, 35” w/connector
. ..................................................19121-09.....................meter cable assy, NT, 99.5” w/connector
. ..................................................19121-10.....................meter cable assy, NT, 303.5” w/connector
. 37.................... 1........................14202-01.....................screw, hex wsh, 8-32 x 5/1
. 38.................... 1........................17421...........................plug, 1.20 hole
. 39.................... 2........................0240-02.....................cover assy, 3150/3900, env, black
. 40.................... 1........................40392...........................motor, drive, 115V, 50/0Hz, sp
. 41.................... 1........................19305...........................backplate, 3900, lower, env
. 42.................... 1........................16086...........................bracket, motor mounting
. 43.................... 1........................19315...........................indicator, service/standby, 3900
. 44.................... 1........................18726...........................spacer, indicator
. 45.................... 1........................16048...........................bearing, drive link
. 46.................... 2........................11805...........................screw, rd hd, 4-40 x 5/8, type 1
. 47.................... 1........................16495...........................cam assy, 3900, lower
. 48.................... 1........................41102...........................label, 3200NT, ground
. 49.................... 1........................19801...........................plug, .190 dia, white
. 50.................... 1........................19691...........................plug, .750 dia, recessed, black
. 51.................... 1........................41047...........................kit, communication cable
. 52.................... 1........................424-11......................timer assy, NXT, right hand

MAINTENANCE
3900 CONTROL VALVE BODY
12
11
10
5
6
7 28
8
9 13
2
3
2 14
2 4
15
3
2
4
2 3
19 32
6
20 29
21
22
29
17 27
18 16
26
17
24
16 24
23 30
35 31
25
33
34
24
36B

MAINTENANCE
3900 CONTROL VALVE PARTS LIST

1. . . . . . . . . . . 1 . . . . . . . . . . . 15114 . . . . . . . . . . . . . . . Valve Body
2. . . . . . . . . . . 8 . . . . . . . . . . . 11720 . . . . . . . . . . . . . . . Seal
8 ........... 11720-02 . . . . . . . . . . . . . Seal, Silicone
3. . . . . . . . . . . 5 . . . . . . . . . . . 10369 . . . . . . . . . . . . . . . Spacer - Port
4. . . . . . . . . . . 2 . . . . . . . . . . . 10368 . . . . . . . . . . . . . . . Spacer
10368-01 . . . . . . . . . . . . . Spacer, Hot Water
5. . . . . . . . . . . 1 ........... 16130 . . . . . . . . . . . . . . . Piston
6. . . . . . . . . . . 2 ........... 14818 . . . . . . . . . . . . . . . Clip - Piston Rod
7. . . . . . . . . . . 1 ........... 15125 . . . . . . . . . . . . . . . Piston Rod
8. . . . . . . . . . . 1 ........... 14922 . . . . . . . . . . . . . . . O-Ring -035
9. . . . . . . . . . . 1 ........... 16398-01 . . . . . . . . . . . . . End Plug Assembly
10 . . . . . . . . . . 2 ........... 40118 . . . . . . . . . . . . . . . Screw - Hex Hd.
11 . . . . . . . . . . 1 ........... 16078 . . . . . . . . . . . . . . . O-Ring - 149
12 . . . . . . . . . . 1 ........... 16074 . . . . . . . . . . . . . . . Coupling
13 . . . . . . . . . . 1 ........... 16077 . . . . . . . . . . . . . . . O-Ring - 140
14 . . . . . . . . . . 1 ........... 15112 . . . . . . . . . . . . . . . Seal
15 . . . . . . . . . . 1 ........... 16067-02 . . . . . . . . . . . . . 3″ Adapter Body
16 . . . . . . . . . . 4 ........... 16068 . . . . . . . . . . . . . . . Seal
4 ........... 16068-02 . . . . . . . . . . . . . Seal, Silicone
17 . . . . . . . . . . 2 ........... 16069 . . . . . . . . . . . . . . . Spacer - Narrow
2 ........... 16069-01 . . . . . . . . . . . . . Spacer - Narrow, Hot Water
18 . . . . . . . . . . 1 ........... 16070 . . . . . . . . . . . . . . . Spacer - Wide
1 ........... 16070-01 . . . . . . . . . . . . . Spacer - Wide, Hot Water
19 . . . . . . . . . . 1 ........... 16071 . . . . . . . . . . . . . . . Piston
1 ........... 16082 . . . . . . . . . . . . . . . Piston - No Hard Water By-Pass
20 . . . . . . . . . . 1 ........... 16072 . . . . . . . . . . . . . . . Piston Rod
21 . . . . . . . . . . 1 ........... 16076 . . . . . . . . . . . . . . . O-Ring - 042
22 . . . . . . . . . . 1 ........... 16399-01 . . . . . . . . . . . . . End Plug Assy - White
1 ........... 16399-11 . . . . . . . . . . . . . End Plug Assy - Black, NHWB-P
1 ........... 19901 . . . . . . . . . . . . . . . End Plug Assy - Brass, Hot Water
23 . . . . . . . . . . 1 ........... 16800 . . . . . . . . . . . . . . . O-Ring - 238
24 . . . . . . . . . . 2 ........... 16345 . . . . . . . . . . . . . . . O-Ring - 362
25 . . . . . . . . . . 1 ........... 16255 . . . . . . . . . . . . . . . Tank Adapter - 6″ -8
1 ........... 16256 . . . . . . . . . . . . . . . Welded Flange
26 .......... 2 ........... 16257 . . . . . . . . . . . . . . . Flange Segment
27 .......... 12 . . . . . . . . . . 11238 . . . . . . . . . . . . . . . Screw - Hex Hd.
28 .......... 1 ........... 16088 . . . . . . . . . . . . . . . Pipe Plug - 2″ NPT
35 .......... 1 ........... 16258 . . . . . . . . . . . . . . . Flow Disperser
Options
29 .......... 2 ........... 16482 . . . . . . . . . . . . . . . Flange Segment
30 .......... 1 ........... 16483 . . . . . . . . . . . . . . . Flange Ring
31 .......... 1 ........... 16484 . . . . . . . . . . . . . . . O-Ring -442
32 .......... 12 . . . . . . . . . . 16517 . . . . . . . . . . . . . . . Screw, Park Tank
12 . . . . . . . . . . 19592 . . . . . . . . . . . . . . . Screw, Structural Tank
33 . . . . . . . . . . 12 . . . . . . . . . . 18619 . . . . . . . . . . . . . . . Washer
34 . . . . . . . . . . 12 . . . . . . . . . . 16346 . . . . . . . . . . . . . . . Nut
35 . . . . . . . . . . 1 ........... 19608-20 . . . . . . . . . . . . . Disperser (Upper)
36B . . . . . . . . . 1 ........... 18584 . . . . . . . . . . . . . . . Adapter, Side Mount

MAINTENANCE
1800 BRINE SYSTEM
16
15 16
6
5
4
2
1
6
8 1
3
10 6 15
9
7
3
4
6
11
14
12
13
17
17

MAINTENANCE
1800 BRINE SYSTEM ASSEMBLY

1 . . . . . . . . . . . .1 . . . . . . . . . . . . 16340 . . . . . . . . . . . . . . . . Injector Body
2 . . . . . . . . . . . .1 . . . . . . . . . . . . 15128-✽ . . . . . . . . . . . . . . Injector Nozzle
3 . . . . . . . . . . . .1 . . . . . . . . . . . . 15127-✽ . . . . . . . . . . . . . . Injector Throat
4 . . . . . . . . . . . .3 . . . . . . . . . . . . 15246 . . . . . . . . . . . . . . . . O-Ring - 116
5 . . . . . . . . . . . .1 . . . . . . . . . . . . 16341-01. . . . . . . . . . . . . . Injector Cover
6 . . . . . . . . . . . .8 . . . . . . . . . . . . 12473 . . . . . . . . . . . . . . . . Screw - Hex Hd.
8. . . . . . . . . . . . 19677 . . . . . . . . . . . . . . . . Screw - Hex Hd. (Metric)
7 . . . . . . . . . . . .1 . . . . . . . . . . . . 16341-02. . . . . . . . . . . . . . Cover
8 . . . . . . . . . . . .1 . . . . . . . . . . . . 18879 . . . . . . . . . . . . . . . . O-Ring - 021
9 . . . . . . . . . . . .1 . . . . . . . . . . . . 16497-01. . . . . . . . . . . . . . Brine Stem Assembly
10 . . . . . . . . . . .1 . . . . . . . . . . . . 18713 . . . . . . . . . . . . . . . . Brine Valve Body
11 . . . . . . . . . . .1 . . . . . . . . . . . . 11772 . . . . . . . . . . . . . . . . Spring
12 . . . . . . . . . . .1 . . . . . . . . . . . . 11774 . . . . . . . . . . . . . . . . Retaining Ring
13 . . . . . . . . . . .1 . . . . . . . . . . . . 16498-01. . . . . . . . . . . . . . Stem Guide Assembly
14 . . . . . . . . . . .1 . . . . . . . . . . . . 16387 . . . . . . . . . . . . . . . . Pipe Plug - 1/2 NPT
15 . . . . . . . . . . .2 . . . . . . . . . . . . 18702 . . . . . . . . . . . . . . . . Tube Fitting - Straight
16 . . . . . . . . . . .1 . . . . . . . . . . . . 18703 . . . . . . . . . . . . . . . . Brine Tube
Option Without Brine Valve

1 . . . . . . . . . . . . 16605 . . . . . . . . . . . . . . . . Retainer Plate
1 . . . . . . . . . . . . 16620 . . . . . . . . . . . . . . . . Fitting - Brine Tank
1 . . . . . . . . . . . . 18879 . . . . . . . . . . . . . . . . O-Ring, 021
Delete: Items 9 thru 16
Injector Throat
15127-04 . . . . . . . . . . . . . . . . . . . #4 . . . . . . . . . . . . . . . . . . . Green
15127-05 . . . . . . . . . . . . . . . . . . . #5 . . . . . . . . . . . . . . . . . . . Red
15127-06 . . . . . . . . . . . . . . . . . . . #6 . . . . . . . . . . . . . . . . . . . White
15127-07 . . . . . . . . . . . . . . . . . . . #7 . . . . . . . . . . . . . . . . . . . Blue
15127-08 . . . . . . . . . . . . . . . . . . . #8 . . . . . . . . . . . . . . . . . . . Yellow
15127-09 . . . . . . . . . . . . . . . . . . . #9 . . . . . . . . . . . . . . . . . . . Violet
15127-10 . . . . . . . . . . . . . . . . . . . #10 . . . . . . . . . . . . . . . . . . Black
Injector Nozzle
Size Color
15128-04 . . . . . . . . . . . . . . . . . . . #4 . . . . . . . . . . . . . . . . . . . Green
15128-05 . . . . . . . . . . . . . . . . . . . #5 . . . . . . . . . . . . . . . . . . . Red
15128-06 . . . . . . . . . . . . . . . . . . . #6 . . . . . . . . . . . . . . . . . . . White
15128-07 . . . . . . . . . . . . . . . . . . . #7 . . . . . . . . . . . . . . . . . . . Blue
15128-08 . . . . . . . . . . . . . . . . . . . #8 . . . . . . . . . . . . . . . . . . . Yellow
15128-09 . . . . . . . . . . . . . . . . . . . #9 . . . . . . . . . . . . . . . . . . . Violet
15128-10 . . . . . . . . . . . . . . . . . . . #10 . . . . . . . . . . . . . . . . . . Black

MAINTENANCE
3” BRASS PADDLE METER
8 4
5
7
5
11
9 2
10
1
5
8
9
10

1. . . . . . . . . . . 1 . . . . . . . . . . . 16254 . . . . . . . . . . . . . . . Meter Body
2. . . . . . . . . . . 1 . . . . . . . . . . . 16279 . . . . . . . . . . . . . . . Impeller Shaft
3. . . . . . . . . . . 1 . . . . . . . . . . . 16575 . . . . . . . . . . . . . . . Impeller Assembly
4. . . . . . . . . . . 1 . . . . . . . . . . . 16400 . . . . . . . . . . . . . . . Meter Cover Assembly - Std.
1 ........... 16401 . . . . . . . . . . . . . . . Meter Cover Assembly - Ext. Range
5. . . . . . . . . . . 3 . . . . . . . . . . . 15707 . . . . . . . . . . . . . . . O-Ring - 236
6. . . . . . . . . . . 6 . . . . . . . . . . . 12112 . . . . . . . . . . . . . . . Screw - Hex Hd.
6 ........... 15886 . . . . . . . . . . . . . . . Screw - Hex Hd. (Metric)
7. . . . . . . . . . . 1 . . . . . . . . . . . 16280 . . . . . . . . . . . . . . . Flow Straightener
8. . . . . . . . . . . 2 . . . . . . . . . . . 16328 . . . . . . . . . . . . . . . Connecting Flange
9. . . . . . . . . . . 8 . . . . . . . . . . . 40118 . . . . . . . . . . . . . . . Screw - Hex Hd.
8 ........... 17122 . . . . . . . . . . . . . . . Screw - Hex Hd. (Metric)
10 . . . . . . . . . . 8 . . . . . . . . . . . 16386 . . . . . . . . . . . . . . . Nut - 1/2-13
11 . . . . . . . . . . 1 . . . . . . . . . . . 16574 . . . . . . . . . . . . . . . Stainless Steel Washer

MAINTENANCE
2536 STANDARD MOUNT SENSOR
Galvanized Iron Threaded Tee

with NPT Threads
PVDF Insert
1
4
Iron Strap-on Saddle with

PVDF Insert
2
K-FACTOR TABLE - SIGNET 2536
(Pulses per Gallon)
SIZE TEE TEE SADDLE
(inches) GALVANIZED PVC IRON
1 213 352
1-1/4 128 177
1-1/2 94 118
2 59 67 54
2-1/2 43 38
3 27 23
ITEM NUMBER PART NUMBER DESCRIPTION

1 A2296001 Flow Sensor
2 A2456004 Rotor/Paddle
A2294012 Tee Install 1 Galv
A2294002 Tee Install 1-1/4 Galv
3
A2294003 Tee Install 1-1/2 Galv
A2294004 Tee Install 2 Galv
A2295001 Saddle 2-1/2 Iron
4
A2295002 Saddle 3 Iron

MAINTENANCE
BRINE SYSTEM - MGT 240M-300M
1 5
4
10
3
2
8
7
9
Item Description Part

Number Number
1 Brine Tank 24”x50” w/ Holes - MGT 240M-300M B1002016
2 24” Diameter 5BW Plastic Grid Plate A2284007
Brine Valve (474) for MGT 240 B1180018
3 Brine Valve (474) for MGT 270 B1180019
Brine Valve (474) for MGT 300 B1180020
4 1/2” Overflow Elbow w/ Nut A2250003
5 5” x 46” Drilled Brine Well B1015008
6 5” Red Cap plug A2072001
7 1-1/2” SDR or SCH40 DWV Pipe A2275007
8 1/2” Poly Insert A2476001
9 1/2” x 3/8” Black Poly Tubing A2165002
Complete Brine Tank Assembly for MGT 240M (20” Shelf Height) B1295019
10 Complete Brine Tank Assembly for MGT 270M (23” Shelf Height) B1295020
Complete Brine Tank Assembly for MGT 300M (26” Shelf Height) B1295021

MAINTENANCE
BRINE SYSTEM - MGT 450M
2
5
10
6
3
8
7

Number Number
1 Brine Tank 30” x 50” w/ Holes - MGT 450M B1002041
2 5” x 48” Drilled Brine Well B1015005
3 Brine Valve Assembly 16-1/4” x 24” B1042007
4 5” Red Cap plug A2072001
5 1/2” Overflow Elbow w/ Nut A2250003
6 30” Plastic Top/Bottom Grid Plate A2284010
7 1-1/2” SDR or SCH40 DWV Pipe A2275007
8 1/2” Poly Insert A2476001
9 1/2” x 3/8” Black Poly Tubing A2165002
10 Complete Brine Tank Assembly for MGT 450M B1141009

MAINTENANCE
BRINE SYSTEM - MGT 600M
1
6 8
11
4&5
3 2
9
10

Number Number
1 Tank Brine 39 X 60 Black Mld Cvr A2042040
2 Brine Valve Assy 10-1/4 X 30 B1042006
3 Grid Support Set 39 Dia 22” B1043009
4 Salt Shelf 38-1/8 Dia. B1041003
5 Salt Screen 39 Dia. B1040003
6 Brine Well 5 X 48 Slotted A2071009
7 Cap Brine Well Red 5 Inch A2072001
8 Brine Tank Overflow Assembly B1233003
9 Insert 1/2 Poly (P8TS6) A2476001
10 Tubing 1/2x3/8 Black Poly (H1041) A2165002
11 MGT 600M Brine Tank Assembly B1141005

MAINTENANCE
BRINE SYSTEM - MGT 750M - 1200
7
6
8
2
3,4
5 HT

Number Number
Brine Tank w/Holes & Cover - 39x60 - MGT 750 B1002019
1
Brine Tank w/Holes & Cover - 42 X 60 - MGT 900-MGT 1200 B1002020
Brine Valve Assembly 494 - MGT 750-MGT 1050 B1042015

2
BRINE VALVE ASSY 494 - MGT 1200 B1042016
SALT SCREEN 39" DIA. - MGT 750 B1040003

3
SALT SCREEN 42" DIA. - MGT 900-MGT 1200 B1040004
SALT SHELF 39" DIA. - MGT 750 B1041003

4
SALT SHELF 42" DIA. - MGT 900-MGT 1200 B1041003
GRID SUPPORT SET - 39" HT - MGT 750 B1043009

5 GRID SUPPORT SET - 24” HT - MGT 900-MGT 1050 B1043030
GRID SUPPORT SET - 29” HT - MGT 1200 B1043011

6 BRINE WELL 5x46 DRILLED B1015008
7 CAPPLUG RED 5 INCH A2072001
8 ELBOW OVERFLOW 1/2 W/NUT 2PC SET A2250003
MGT 750M Brine Tank Assembly B1141010
9

MAINTENANCE
SERVICE ASSEMBLIES
ADAPTERS - SIDE MOUNT
18584 Sidemount Adaper Assembly
AUXILARY MICRO SWITCH

A2203010 3200 Series Timer
A2203108 Lower Drive (2nd Switch)
BRINE VALVES
A2005027 Model 1800 brine valve assy
COVERS
A2103018 Environmental Cover
60240-02 Environmental
DRAIN LINE FLOW CONTROLS

A2138014 1” Drain Line Fitting (15 gpm)
A2138023 1-1/2” Drain Line Fitting (25 gpm)
A2138024 1-1/2” Drain Line Fitting (30 gpm)
A2138029 2” Drain Line Fitting (35 gpm)
CAM
A2082052 Upper
16495 Lower
PISTON ASSEMBLIES
A2309008 Upper Piston
A2309045 Lower piston, Hard Water By-Pass
A2309011 Lower Piston, No By-Pass
SEAL & SPACER KITS

A2297002 Upper kit
A2435048 Lower kit
SERVICE EQUIPMENT
A2475003 Seal & Spacer stuffer tool upper
A2474003 Spacer puller tool upper
A2423002 Silicone, 2 oz. Tube
A2164006 Meter Checker Std. Range
A2164005 Meter Checker Ext. Range
SERVICE VALVE OPERATOR ASSEMBLY ( SVO )

A2207015 SVO (Old Style)
60150-01 SVO (New Style)

MAINTENANCE
TROUBLESHOOTING
DETECTED ERRORS
NOTE: It can take up to 30 seconds for an error to be detected and displayed. All errors on each timer in the
system must be displayed before the errors can be corrected.
If a communication error is detected, an Error Screen will alternate with the main (time of day) screen every
few seconds.
• All units In Service remain in the In Service position.
• All units in Standby go to In Service.
• Any unit in Regeneration when the error occurs completes Regeneration and goes to In Service.
• No units are allowed to start a Regeneration Cycle while the error condition exists, unless they are manually
forced into Regeneration.
• When an error is corrected and the error no longer displays (it may take several seconds for all of the units
in a system to stop displaying the error message), the system returns to normal operation.
NOTE: During the error condition the control continues to monitor the flow meter and update the volume re-
maining. Once the error condition is corrected all units return to the operating status they were in prior to the
error. Regeneration queue is rebuilt according to the normal system operation. Or, if more than one unit has
been queued for regeneration, then the queue is rebuilt according to which one communicates first.
CAUSE CORRECTION
A. One or more units have a missing or bad communication cable. A. Connect the communication cables and/or replace.
B. One or more units has a communication cable plugged into the wrong receptacle. B. Connect the communication cable as shown in the wiring diagrams.
C. One or more units is not powered. C. Power all units.
PROGRAMMING ERRORS
During the error condition the control continues to monitor the flow meter and update the remaining capacity. Once the
error condition is corrected all units return to the operating status they were in prior to the error and regeneration is
queued according to the normal system operation. If reprogramming the unit in the Master Programming Mode clearS
the error, the volume remaining may be reset to the full unit capacity (i.e. as though it were just regenerated).
1. All units in standby go In Service.
2. Any unit in regeneration when the error occurs completes regeneration and goes to In Service.
3. No units are allowed to start a regeneration cycle while the error condition exists.
When the problem is corrected and the error no longer displays (it may take several seconds for all of the units in a
system to stop displaying the error message), the system returns to normal operation.
Programming Errors Detected:
• Duplicate unit addresses or numbers
• Size of system (ex: if sized for a 4 units, and only have 2 units)
• Display format mismatches
Solution:
• Program the units correctly in the Master Programming Mode.
NOTE:
If these errors are detected, numbers 1 through 3 become true, and the main screen (time of day) will alter-
nate with an error screen.

MAINTENANCE
TROUBLESHOOTING
CAUSE CORRECTION
A. Any or all of two or more units programmed with the same unit number (Matching A. Connect the communication cables and/or replace.
Address Error)
B. Flashing/blinking display. B. Power outage has occurred.
C. Format Mismatch (Units have both U.S. and Metric Formats) C. Verify all units have same Format selected (all U.S. or all Metric)
D. No messages displayed/small black squares appear in display D. Turn the contrast button on the back of unit until text appears (see “Problems
Viewing Display/Changing Contrast of Display” below)
E. Size Error (Units not correctly numbered/more than one unit has the same E. Check each unit and verify each as the correct number, and that only one unit
number assigned) has that number
F. Com Error (Communication Error) F. Check the wiring of the system and verify it is correct and that all are connected
EXAMPLE ERROR SCREENS

Detected Error
1. Go through Master Programming to program the unit.
No Message #1
1. Make sure all communication cables are connected.
2. If “No Message #1” ensure it is the lead unit.
3. Ensure #1 is configured for the correct system type.
No Message #3
1. Make sure all communication cables are connected.
2. If “No Message #3” ensure it is unit #3.
3. Ensure #3 is configured for the correct system type.
Program Mismatch
1. Ensure the units on the network are not configured the same as #1/the
Lead unit.
Exceed Unit Size

1. There are more units on the system than the Lead is programmed for.
Matching Address
1. The unit is programmed the same # as another unit.
NOTE: The rest of the system will still function without this unit.

MAINTENANCE
TROUBLESHOOTING 3900 VALVE
PROBLEM CAUSE CORRECTION
1. Softener Fails To Regenerate. A. Electrical Service To Unit Has A. Assure Permanent Electrical Ser-
Been Interrupted. vice (Check Fuse, Plug, Pull Chain
or Switch).
B. Timer Is Defective. B. Replace Timer.
C. Power Failure. C. Reset Time of Day.
2. Hard Water. A. By-Pass Valve is Open. A. Close By-Pass Valve.

B. No Salt in Brine Tank B. Add Salt To Brine Tank and Main-
tain Salt Level Above Water Level.
C. Injector Screen Plugged. C. Clean Injector Screen.
D. Insufficient Water Flowing Into D. Check Brine Tank Fill Time And
Brine Tank Clean Brine Line Flow Control If
Plugged.
E. Hot Water Tank Hardness. E. Repeated Flushings Of The Hot
Water Tank is Required.
F. Leak At Distributor Tube. F. Make Sure Distributor Tube Is Not
Cracked. Check O-Ring And Tube
Pilot.
G. Internal Valve Leak G. Replace Seals and Spacers And/
Or Piston.
H. Service Adapter Did Not Return To H. Check Drive Motor And Switch.
Service.
3. Unit Used Too Much Salt A. Improper Salt Setting. A. Check Salt Usage and Salt Set-
B. Excessive Water in Brine Tank ting.
B. See Problem No. 7.
4. Loss Of Water Pressure. A. Iron Buildup In Line To Water Con- A. Clean Line To Water Conditioner.
ditioner.
B. Iron Buildup in Water Conditioner. B. Clean Control and Add Mineral
Cleaner to Mineral Bed.
Increased Frequency of
Regeneration.
C. Inlet of Control Plugged Due to C. Remove Piston and Clean Control.
Foreign Material Broken Loose
From Pipes By Recent Work Done
On Plumbing System.
5. Loss of Mineral Through Drain A. Air In Water System. A. Assure That Well System Has
Line. Proper Air Eliminator Control.
Check For Dry Well Condition.
B. Improperly Sized Drain Line Flow B. Check For Proper Drain Rate.
Control.
6. Iron In Conditioned Water. A. Fouled Mineral Bed. A. Check Backwash, Brine Draw And
Brine Tank Fill. Increase Fre-
quency of Regeneration. Increase
Backwash Time.

MAINTENANCE
TROUBLESHOOTING 3900 VALVE (CONTINUED)
PROBLEM CAUSE CORRECTION
7. Excessive Water In Brine Tank. A. Plugged Drain Line Flow Control. A. Clean Flow Control.
B. Plugged Injector System. B. Clean Injector and Screen.
C. Timer Not Cycling. C. Replace Timer.
D. Foreign Material In Brine Valve. D. Replace Brine Valve Seat And
Clean Valve.
E. Foreign Material In Brine Line Flow E. Clean Brine Line Flow Control.
Control.
8. Softener Fails To Draw Brine. A. Drain Line Flow Control Is A. Clean Drain Line Flow Control.
Plugged. B. Clean Injector.
B. Injector Is Plugged. C. Clean Screen.
C. Injector Screen Plugged. D. Increase Line Pressure To 20 P.S.I.
D. Line Pressure Is Too Low. E. Change Seals, Spacers and Piston
E. Internal Control Leak Assembly.
F. Service Adapter Did Not Cycle. F. Check Drive Motor And Switches.
9. Control Cycles Continuously. A. Misadjusted, Broken or Shorted A. Determine If Switch or Timer Is

Switch. Faulty and Replace It or Replace
Complete Power Head.
10. Drain Flows Continuously. A. Valve Is Not Programming Cor- A. Check Timer Program and Posi-
rectly. tioning of Control. Replace Power
Head Assembly If Not Positioning
Properly.
B. Foreign Material In Control. B. Remove Power Head Assembly
And Inspect Bore. Remove Foreign
Material and Check Control In Var-
ious Regeneration Positions.
C. Internal Control Leak C. Replace Seals and Piston
Assembly.
General Service Hints For Meter Control

Problem: Softener Delivers Hard Water.
Cause could be that . . . Reserve Capacity Has Been Exceeded.
Correction: Check salt dosage requirements and reset program wheel to provide additional reserve.
Cause could be that . . . Program Wheel Is Not Rotating With Meter Output
Correction: Pull cable out of meter cover and rotate manually. Program wheel must move without binding and clutch
must give positive “clicks” when program wheel strikes regeneration stop. If it does not, replace timer.
Cause could be that . . . Meter Is Not Measuring Flow.
Correction: Check meter with meter checker.

2227 South Street • P.O. Box 044170 • Racine, WI 53404-7003
Ph. (262) 681-1300 • Fax (262) 681-1318 • Info@Marlo-Inc.com • www.Marlo-Inc.com
8-246 A2170319

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REVERSE OSMOSIS SYSTEM

INSTALLATION, OPERATION, AND

JOB NAME: PROJECT PC21597

MODEL: MRO-94K-8H REVERSE OSMOSIS UNIT

P.O. NUMBER: 037858

JOB NUMBER: EP-160016

Operation Parameters & Projected Performance

Basics of Chemical Pretreatment

Basics of Reverse Osmosis

Membrane Housing Size: 8” Diameter x 4 Long

Membrane Type: Brackish Toray TM720-370

Prefilter Cartridges (5 micron) 2.5" x 40"Long (5 required)

Power Supply Required 460 volts/ 60 hertz/ 3 phase (pump power)

Permeate Flow Sensor K factor 2" 66.739

RO SYSTEM FEEDWATER CHARACTERISTICS AND QUALITY REQUIREMENTS

RO SYSTEM OPERATIONAL PARAMETERS

Designed inlet feedwater flowrate: 87 GPM

Membrane feed pressure: 100-300 PSIG (Monitored only)

Membrane cleaning frequency: At 10% system performance loss,

RO SYSTEM PROJECTED PERFORMANCE:

REVERSE OSMOSIS UNIT CHEMICAL FEED RECOMMENDED DOSAGES:

(Dosages may need adjustment under actual operating conditions.)

Pretreatment (if needed)

Recommended Starting Dosage – 2-3 ppm

Post treatment (if needed)

Caustic – Fed after the RO to achieve the target pH level of 7

Recommended Starting Dosage - 1 ppm

Chlorine– Fed after the RO to achieve the target chlorine residual

Recommended Starting Dosage - 0.5 ppm

PRETREATMENT CONSIDERATIONS FOR REVERSE OSMOSIS

1. Reduce RO recovery to where salt concentrations are below solubility limits.

1. Softening which removes the calcium ion.

Metal Oxide Fouling:

1. Multimedia filtration – with or without upstream addition of polyelectrolyes

CATEGORY EXAMPLES SOURCES PRETREATMENT

Scaling Salts Calcium Carbonate Feedwater pH Adjustment (Improve Solubility)

Metal Oxides Iron Feedwater, Oxidation followed by filtration

Coloids (SDI) Clay Surface Waters Coagulation / Flocculation

Biological Bacteria Non-Chlorinated Feed, Chlorinate (Disinfect)

4. Boron rejection is higher at higher pH levels (particularly above a pH of 9).

Na2S2O5 (sodium metabisulfite) + H2O —> 2 NaHSO3 (sodium bisulfite)

NaHSO3 + HOCl —> NaHSO4 (sodium bisulfate) + HCl (hydrochloric acid)

NaHSO3 + Cl2 + H2O —> NaHSO4 + 2 HCl

Less common mineral scalants are:

Foulants treated by dispersants:

Maintaining proper dosing levels of an antiscalant/dispersant is important. Under-dosing can ca u se

Antiscalants/dispersants are supplied as either a concentrated liquid or in a powder form. Dilution

 Is it compatible with the RO membrane type in question?

 Are there any special discharge concerns?

 Is it suitable for potable water applications (if required)?

Basics of RO and NF: Principle of Reverse Osmosis and

The phenomenon of osmosis is illustrated in Figure 1.4. A semi-permeable membrane is

Figure 1.4 Overview of osmosis

Osmosis Reverse Osmosis

Passage - the opposite of “rejection”, passage is the percentage of dissolved constituents

Permeate - the purified product water produced by a membrane system.

Figure 1.6 Performance vs. Figure 1.7 Performance vs. temperature

Recovery Feed Concentration