reverse osmosis system installation - excalibur water

REVERSE OSMOSIS SFCP SERIES

INSTALLATION AND USER GUIDE

BARRIE ● ONTARIO ● CANADA 705.733.8900 WWW.EXCALIBURWATER.COM

1 Reverse Osmosis System Installation

Table of Contents INTRODUCTION .................................................................................................................................................................. 3

MANUAL USER’S GUIDE ...................................................................................................................................................... 3

DISCLAIMER STATEMENT .................................................................................................................................................... 3

PROPRIETARY RIGHTS STATEMENT .................................................................................................................................... 3

INSTALLATION ......................................................................................................................................................................... 4

EQUIPMENT SUPPORT ........................................................................................................................................................ 4

GENERAL SAFETY GUIDELINES ............................................................................................................................................ 4

SAFETY PRECAUTIONS ......................................................................................................................................................... 5

SAFETY EQUIPMENT ............................................................................................................................................................ 5

REQUIRED TOOLS AND PARTS ............................................................................................................................................ 5

EQUIPMENT INSTALLATION GUIDELINES ............................................................................................................................ 6

EQUIPMENT INSTALLATION PROCEDURES ......................................................................................................................... 6

ELECTRICAL INSTALLATION ................................................................................................................................................. 7

START UP INSTRUCTIONS ........................................................................................................................................................ 8

PROCEDURE ........................................................................................................................................................................ 8

VALVE POSITIONS AND EQUIPMENT STAGE ....................................................................................................................... 8

VALVE POSITIONS EFFECT (↑=Increase; ↓=Decrease) .................................................................................................. 8

PIPING AND INSTRUMENTATION (No Clean in Place) ........................................................................................................ 9

MICRO850 SERIES PLC ........................................................................................................................................................... 15

PANELVIEW 800 TERMINAL – 4.3in TOUCHSCREEN ......................................................................................................... 16

SYSTEM OPERATION ............................................................................................................................................................. 17

GENERAL OPERATION ....................................................................................................................................................... 17

PANELVIEW 800 SCREEN NAVIGATION & COMMANDS ................................................................................................... 17

SCREEN 1 – HOME ......................................................................................................................................................... 17

SCREEN 2 – TROUBLESHOOTING .................................................................................................................................. 18

SCREEN 3 – TDS MONITOR ............................................................................................................................................ 19

SCREEN 4 - INFO ............................................................................................................................................................ 19

SCREEN 5 -SWITCH SELECTIONS .................................................................................................................................... 20

SCREEN 6 – FLOW METER SETPOINTS........................................................................................................................... 21

SCREEN 7 – SENSOR SETTINGS ...................................................................................................................................... 21

SCREEN 8 - SETPOINTS .................................................................................................................................................. 22

TANK FULL OPERATION ..................................................................................................................................................... 23

TANK FULL OVERRIDE ....................................................................................................................................................... 23

AUTO RESET ...................................................................................................................................................................... 23

ALARM RESET .................................................................................................................................................................... 23



SFCP UNIT MODELS/VIEWS OF CRITICAL COMPONENTS ..................................................................................................... 24

SERVICE INSTRUCTIONS ........................................................................................................................................................ 30

REGULAR MAINTENANCE .................................................................................................................................................. 30

MEMBRANE DIAGRAM...................................................................................................................................................... 30

MEMBRANE REPLACEMENT .............................................................................................................................................. 31

SEDIMENT FILTER CARTRIDGE REPLACEMENT ................................................................................................................. 31

SHUTDOWN PROCEDURE ................................................................................................................................................. 31

SHORT-TERM SHUTDOWN (MAINTENANCE OR SERVICE) ............................................................................................ 31

LONG-TERM SHUTDOWN (21 DAYS - 1 YEAR) .............................................................................................................. 31

TROUBLESHOOTING .............................................................................................................................................................. 32

MICRO850 CONTROLLER ................................................................................................................................................... 32

STATUS INDICATORS ..................................................................................................................................................... 32

ERROR CODES ................................................................................................................................................................ 33

SOLENOID VALVE TROUBLESHOOTING ............................................................................................................................. 34

HIGH PRESSURE / BOOSTER PUMP ................................................................................................................................... 35

PUMP TROUBLESHOOTING ........................................................................................................................................... 36

MULTI-STAGE VERTICAL PUMP ......................................................................................................................................... 40

PUMP TROUBLESHOOTING ........................................................................................................................................... 41

SEDIMENT FILTER HOUSING ............................................................................................................................................. 42

PERFORMANCE AND SERVICE LOG ....................................................................................................................................... 44

WARRANTY............................................................................................................................................................................ 45



INTRODUCTION

MANUAL USER’S GUIDE

This manual describes the procedures necessary to install, operate, and maintain your Excalibur Water Systems Reverse Osmosis system. Please read this manual carefully before installing and operating your equipment. The equipment warranty may be voided if installation or operation instructions are not followed correctly. This manual has been formatted for ease of use, combining the instruction for the entire RO unit into one manual. Literature supplied with some major components being used on this equipment is provided in the back of this manual. DISCLAIMER STATEMENT

The operation and maintenance manual are intended to be used with the information provided in the component manufacturer’s literature. These manuals should provide complete and accurate information to meet your operating and/or service requirements based on the information available at the time of publication. However, Excalibur Water Systems assumes no responsibility for the technical content of the component manufacturer’s literature. The information in these manuals may not cover all operating details or variations or provide for all conditions in connection with installation, operation and maintenance. Should questions arise which are not answered specifically in this manual, contact the Excalibur Water Systems Service Department. Excalibur Water Systems reserves the right to make engineering revisions that may not be reflected in these manuals. The material in these manuals is for informational purposes and is subject to change without notice. PROPRIETARY RIGHTS STATEMENT

This manual discloses information in which Excalibur Water Systems has proprietary rights. Neither receipt nor possession of this manual confers or transfers any right to the client, and by its retention hereof, the client acknowledges that it will not reproduce or cause to be reproduced, in whole or in part, any such information except by written permission from Excalibur Water Systems. The client shall have the right to use and disclose to its employees the information contained herein for the purpose of operating and maintaining the Excalibur Water Systems equipment, and for no other purpose. In the event the content of this manual is altered or section/items are omitted during a reproduction, in whole or in part, and instructions or definitions within the reproduction result in personal injury to those who follow the altered instructions, the burden of responsibility for personal injury falls solely on the party who affects the reproduction.



INSTALLATION

EQUIPMENT SUPPORT

Excalibur Water Systems continually strives to provide safe, efficient, trouble-free equipment using the optimum technology for your application. If problems should develop, our technical support line will be available to provide assistance. For service, sales, parts, or additional manual copies call your area representative or the number provided on the bottom of the manual pages. GENERAL SAFETY GUIDELINES

This equipment operates at high voltage and high pressure, has moving parts and hazardous chemicals that may cause serious injury or fatality if not operated and maintained according to the procedures outlined in this manual.

1. No one should use or service this equipment without proper training and supervision. It is the responsibility of the owner to ensure that this equipment is used properly and safely, strictly following the instructions contained herein.

2. Always remain alert during the operation of this equipment. Do not get near this equipment if you are

drowsy or impaired in any way.

3. Always wear safety equipment (safety glasses, gloves) for protection while working on the equipment.

4. Refer to Material Safety Data Sheets prior to handling hazardous chemicals.

5. Always operate the equipment at the parameters specified.

6. Never connect the system to piping that has not been approved by Excalibur Water Systems. If there are any doubts, please call your Excalibur Water Systems local branch.

7. Never remove any components from the unit while under pressure.

8. No one under the age of 18 years of age should operate or be allowed near this equipment.

9. Warning labels have been placed on the equipment to remind the operator of certain hazards. Never remove

these labels. If any warning label is illegible or missing, please contact Excalibur Water Systems for a free replacement.

10. Proper maintenance assures the equipment will run properly and can lower the risk of injury. Be sure to

follow the instructions on maintenance carefully.

11. Be sure to maintain all equipment, tools and sub-systems used with the equipment.

12. Continuously inspect the system for leaks and damage. Correcting problems as they occur will help prolong the life of the system.

13. Use Lock-Out and Tag-Out devices when servicing the unit.



14. This manual should be used as a guidance tool and should not replace common sense. If you are unsure

about a procedure, ask your supervisor. Excalibur Water Systems welcomes any questions you may have and can arrange to provide on-site training if necessary.

SAFETY PRECAUTIONS

The purpose of this manual is to provide the user with the necessary information to operate this equipment without undue risk. Failure to follow the instructions laid forth in this manual may put the operators at risk of injury and possible fatality. Please read this entire manual before beginning any procedure; it should always remain with the equipment to act as a ready reference guide for anyone who operates this system. SAFETY EQUIPMENT

Below is a list of equipment and materials that should be kept nearby the equipment.

1. Lock-out and Tag-out devices for servicing and shutdowns.

2. Eyewash/safety shower for any chemical accidents.

3. Safety glasses are always to be worn.

4. Earplugs should be worn when encountering high levels of noise.

5. Gloves that offer protection from the chemicals used herein.

6. Steel toe work boots for protection against heavy equipment and components.

REQUIRED TOOLS AND PARTS

The tools and parts specified in this section are the minimum required to install the RO unit at the site. The use of other tools and parts may be necessary, depending on the location chosen and other parameters.

Required Tools

Lock-Out/Tag-Out equipment Safety glasses, gloves, earplugs Moving equipment Hammer drill with masonry bit Pipe cutting, bending, gluing equipment

Required Material

Concrete anchor bolts (size determined by local seismic calculations). Plumbing and electrical materials as required



EQUIPMENT INSTALLATION GUIDELINES

1. All lifting and moving procedures must be performed by experienced construction workers using standard rigging methods.

2. Before beginning any equipment handling procedures, refer to the appropriate sections in the

Occupational Health and Safety Act: “General Industry Standards.” Also, refer to any other applicable literature and information for cranes, lift trucks, and other equipment used for lifting and moving.

3. Make sure all equipment used for lifting and moving is properly maintained and is in good repair.

4. Be sure that components being lifted are balanced and will not tip or slip out of the lifting device.

EQUIPMENT INSTALLATION PROCEDURES

1. Locate a level, flat, clean, hard surface, capable of supporting the weight of the RO unit. Refer to the Equipment Specification Drawing to determine the floor loading requirements and the service access space requirements for the unit.

NOTE: This area should have a local floor drain to carry away water which will fall to the floor during

operation, testing, and servicing of this equipment.

2. Lay out the area that the RO System will occupy.

3. Move the RO unit to the location laid down in the previous step.

4. Drill holes in the pad through the frame tie down holes.

5. Level the RO unit by installing shim stock under the frame near the frame tie down holes.

6. Install the anchor bolts and secure the frame to the anchor bolts using flat washers, lock washers, and nuts.

Do not use the RO unit to support external piping. All plumbing runs should be supported per manufacturers’ recommendations and local codes.

7. Install the feed water plumbing line. The plumbing runs should never be smaller than the actual RO inlet

pipe size and may need to be larger for pipe runs over 50 feet. NOTE: The plumbing materials should be of non-corroding materials (PVC, SST, Copper etc.) Use of

this material will reduce the tendency to foul the membranes from metal precipitation.

8. Install the reject line directly to an open drain.



NOTE: As a rule, no valves should be installed in this line. If necessary, install a relief valve set at no greater

than 5 PSIG. The valve should be directed to a visible drain, so relief is clear.

If the reject drain is below the level of the RO unit, install a vacuum breaker valve or open pipe leg on the reject line. This will prevent siphoning of all water out of the RO unit during shutdown.

The plumbing installation should now be complete. Check the plumbing to ensure all joints are properly connected and supported.

ELECTRICAL INSTALLATION

The following steps consist of electrical work to be performed by a qualified electrician only. 1. Employ a Lock Out Device and Lock Out Tag on the RO unit main power supply disconnect switch. 2. Run electrical conduit for the high voltage power supply between the Control Panel and the main power

supply.

3. Connect any required wiring between the System Controller and the product water storage tank level sensing device, if required.

4. Verify that all electrical connections are secure and wired per the electrical schematic. 5. Remove the Lock-Out / Tag-Out equipment from the main power supply for the RO unit, and energize

the circuit. Verify that the voltage supplied is correct and matches the Voltage Identification Tag located on the pump motor



START UP INSTRUCTIONS

PROCEDURE

The plumbing must be inspected properly before releasing the water pressure into the system. Direct the product water flow to drain for first hour of operation. Slowly open the supply valve halfway located upstream of the RO. Connect electrical power to the system. Press the start button and record the pump pressure gauge (Shut off the system immediately if pump pressure rises more than 150psi), the pump should start after a delay. The TDS conductivity will be displayed on controller which should decrease gradually. When concentrate flow and permeate flow stabilizes this means the air has been flushed out of the system. Tune up the concentrate valve and recirculation valve according to the flow rates given on the performance data sheet or WAVE projection. Check the pump pressure gauge and membrane pressure gauge. The pressure difference should always be less than 30 psi. After the normal run time of 1 hour, permeate (product) flow can diverted to storage tank. The RO pump should shut off and there should be no permeate flow. After 24 hours of operation the TDS, Permeate Flow, Concentrate Flow, Recirculation Flow, Pump Pressure and Membrane Pressure must be recorded and confirmed again. VALVE POSITIONS AND EQUIPMENT STAGE

VALVE POSITIONS EFFECT (↑=Increase; ↓=Decrease)

Valve Position Concentrate Valve (Flow Meter) Fully Open Recirculation Valve (Flow Meter) ¼ Open Drain Fully Open Water Supply Fully Open (Slowly) Storage Tank Ready for use Pre-Treatment Equipment Ready for use

Valve Action Product Flow

Concentrate Flow

Recirculation Flow

Pump Pressure

Membrane Pressure

Concentrate Closed ↑ ↓ ↑ ↑ ↑

Open ↓ ↑ ↓ ↓ ↓

Recirculation Closed ↓ ↑ ↓ ↑ ↑

Open ↑ ↓ ↑ ↓ ↓



PIPING AND INSTRUMENTATION

SFC4



SFC5



SFC6



SFC8



SFC14



SFC18



MICRO850 SERIES PLC

The Micro850 PLC controls the outputs of pressure pump, inlet solenoid valve and flush valve. It also controls the input signal from inlet pressure switch, tank full switch, pre-treat lockout switch and TDS conductivity cell. The controller functions, switches and TDS calibration can be controlled by navigating to the appropriate screen on the PanelView 800 HMI (Human Machine Interface).

Note: The Micro850 PLC is secured within the panel enclosure and should not be tampered with.



PANELVIEW 800 TERMINAL – 4.3in TOUCHSCREEN

ITEM DESCRIPTION

1 POWER STATUS LED

2 TOUCH DISPLAY & FUNCTION KEYS

3 24V DC POWER INPUT

4 USB DEVICE PORT

5 MICRO-SD CARD SLOT

6 MOUNTING SLOTS

7 10/100 MBIT ETHERNET PORT

8 RS-232 PORT

9 RS-422 & RS-485 PORT

10 USB HOST PORT

11 DIAGNOSTIC STATUS INDICATOR

12 REPLACEABLE REAL-TIME CLOCK BATTERY



SYSTEM OPERATION

GENERAL OPERATION

The SFCP Series Reverse Osmosis system uses a Micro850 PLC and PanelView800 T4T HMI in tandem to provide operational capability. The Micro850 PLC within the enclosure is not to be handled by the operator unless directed otherwise. When its power LED indicator is green it is in normal operational status and red when it is in screensaver/power-saving mode. The PanelView 800 T4T HMI allows the operator a degree of control over the SFCP system through its various screens.

PANELVIEW 800 SCREEN NAVIGATION & COMMANDS

SCREEN 1 – HOME

The default startup screen upon booting of the PLC and the PanelView 800 is the home screen. Here primary information is displayed. Note that not all the information displayed in Figure 1 will appear as is. Icons such as the ones for the Booster Pump, Inlet Valve, and Bypass Valve will change color when those components are verified as operational. The System Status panel will show either Active or Inactive dependent on the state of the RO system, tank level indicators will also vary, and the “FLUSH ACTIVE” alert is active only during the first 5 minutes of startup.

Command Action RO System Start Press & hold "System Start" until "System Status" becomes "Active" RO System Stop Press & hold "System Stop" until "System Status" becomes "Inactive" Next Screen Press F4 key or "Next" on the screen Previous Screen Press F1 key or "Prev" on the screen



SCREEN 2 – TROUBLESHOOTING

The “Troubleshooting” screen will allow the operator to bypass sections of the RO system during maintenance or diagnostics. The operator may also manually control outputs from the screen as well as reset fault alarms. The “FAULT” button will not appear unless there is a fault condition. Note: The “Login” and “Logout” options can only be accessed by contacting Excalibur Water Systems and receiving the proper information.

Command Action Low Pressure Switch Bypass Press and hold "LPS BYPASS" for desired length of time. High Pressure Switch Bypass Press and hold "HPS BYPASS" for desired length of time. pH Bypass Press and hold "PH BYPASS" for desired length of time. Permeate (Product) Bypass Press and hold "PRM TDS BYPASS" for desired length of time. Feed TDS Bypass Press and hold "FEED TDS BYPASS" for desired length of time. Booster Pump Control Press "BOOSTER PUMP" to toggle it on or off. Inlet Valve Control Press "INLET VALVE" to open or close the valve. Soft Water Fill Control Press "SOFT WATER FILL" to open or close the valve. Fault Reset Press "FAULT." The text will change to "FAULT RESET" to indicate success. Home Screen Press F3 key or "Home" on the screen. Next Screen Press F4 key or "Next" on the screen. Previous Screen Press F1 key or "Prev" on the screen.



SCREEN 3 – TDS MONITOR

The “TDS MONITOR” screen allows the operator to view the TDS of both the feed water and permeate in real time.

SCREEN 4 - INFO

The “INFO” screen allows for the viewing of other variables during operation of the RO system. No commands can be made on this screen aside from moving between other screens or returning to the home screen.

Command Action Home Screen Press F3 key or "Home" on the screen. Next Screen Press F4 key or "Next" on the screen. Previous Screen Press F1 key or "Prev" on the screen.



SCREEN 5 -SWITCH SELECTIONS

“SWITCH SELECTIONS” allows the operator to toggle switches within the program between Normally Open (N/O) or Normally Closed (N/C). Auto reset may also be enabled or disabled here (Auto Reset is enabled by default from the factory). The permeate valve may also be open or closed manually from here.

Command Action LOW NO Press "LOW NO" to toggle between N/O and N/C. HIGH NO Press "HIGH NO" to toggle between N/O and N/C. AUTO RESET Press "AUTO RESET" to disable or enable auto reset after a fault occurs. SOFT FILL Press "SOFT FILL" to either open or close the permeate valve manually. TANK LOW Press "TANK LOW" to toggle the switch between N/O and N/C in the program. TANK MID Press "TANK MID" to toggle the switch between N/O and N/C in the program. TANK HIGH Press "TANK HIGH" to toggle the switch between N/O and N/C in the program. Home Screen Press F3 key or "Home" on the screen. Next Screen Press F4 key or "Next" on the screen. Previous Screen Press F1 key or "Prev" on the screen.



SCREEN 6 – FLOW METER SETPOINTS

Flow meter setpoints can be changed on “FLOW METER SETPOINTS.” Note that settings on this screen may not be changed without approval from the manufacturer. Please contact directly for any requests.

SCREEN 7 – SENSOR SETTINGS

Command Action PERMEATE FLOW METER Press "MIN FLOW" and enter setpoint on numeric keypad. Repeat with "MAX FLOW." CONCENTRATE FLOW METER Press "MIN FLOW" and enter setpoint on numeric keypad. Repeat with "MAX FLOW." RECIRCULATION FLOW METER Press "MIN FLOW" and enter setpoint on numeric keypad. Repeat with "MAX FLOW." Home Screen Press F3 key or "Home" on the screen. Next Screen Press F4 key or "Next" on the screen. Previous Screen Press F1 key or "Prev" on the screen.



Read ranges on the TDS and pH level sensors can be adjusted from the “SENSOR SETTINGS” screen. Note that settings on this screen may not be changed without approval from the manufacturer. Please contact directly for any requests.

Command Action TDS LEVEL RANGE ADJUST

Press "MIN RANGE" and enter read range on numeric keypad. Repeat with "MAX RANGE."

pH LEVEL RANGE ADJUST Press "MIN RANGE" and enter read range on numeric keypad. Repeat with "MAX RANGE."

Home Screen Press F3 key or "Home" on the screen. Next Screen Press F4 key or "Next" on the screen. Previous Screen Press F1 key or "Prev" on the screen.

SCREEN 8 - SETPOINTS

Setpoints regarding limits on feed/permeate limits and delays can be adjusted on this screen. Note that settings on this screen may not be changed without approval from the manufacturer. Please contact directly for any requests.

Command Action FEED TDS UPPER LIMIT Press "FEED TDS" button to the right of text, enter limit setpoint on numeric keypad PERMEATE TDS UPPER LIMIT

Press "PERMEATE TDS" button to the right of text, enter limit setpoint on numeric keypad

SOLENOID VALVE DELAY Press "VALVE DELAY" button to the right of text, enter limit setpoint on numeric keypad

LOW PRESSURE DELAY Press "LOW PRESSURE" button to the right of text, enter limit setpoint on numeric keypad

HIGH PRESSURE DELAY Press "HIGH PRESSURE" button to the right of text, enter limit setpoint on numeric keypad

TANK LOW DELAY Press "TANK LOW" button to the right of text, enter limit setpoint on numeric keypad TANK FULL DELAY Press "TANK HIGH" button to the right of text, enter limit setpoint on numeric keypad Home Screen Press F3 key or "Home" on the screen. Previous Screen Press F1 key or "Prev" on the screen.



TANK FULL OPERATION

The RO system can be fitted with 1 or 2 level switches. Configurations with 1 level switch will have it connected to the “Tank Full” direct input 05 on the Micro850 controller. Once the input is triggered by a full tank condition, a delay timer of 5 seconds by default will begin timing. When 5 seconds have elapsed, the unit will shut down and the “Tank Full” banner will display on the home screen of the PanelView 800 HMI. The delay before unit shutdown can be changed on screen 8 by entering a new setpoint into “TANK FULL DELAY.”

If two level switches are connected, the “Tank Full” switch will still be located at input 5 while the “Tank Low” level switch will be connected to input 7. When the “Tank Low” level switch becomes active, the Tank Low banner will appear on the home screen and there will be a 5 second delay before the system starts filling with water. The system will continue to fill the tank with water until a “Tank High” input is detected by the program. This delay setpoint can be changed in screen 8.

TANK FULL OVERRIDE

A manual tank full override can be initiated when the RO unit is shut down due to a tank full condition. Navigating to Screen 5, “SWITCH SELECTIONS,” will allow the operator to bypass the full condition on the program as long as they maintain the “TANK HIGH NO” button pressed.

AUTO RESET

The unit is programmed to halt operation for faults regarding pH levels, Feed TDS levels, and Permeate TDS levels. Low-pressure and high-pressure conditions will also generate a fault in the program. The system will attempt to auto reset three times following any number of these faults in any combination after a preset delay. The first delay will be 5 seconds, followed by 30 seconds on the second attempt, and 60 seconds on the final attempt. If the unit faults again after being reset the third time, it will need to be manually reset by navigating to the “Troubleshooting” screen and pressing the “FAULT” button.

ALARM RESET

When a fault occurs that causes the alarm to sound an alarm banner will display at the top of the screen with three buttons to choose from; Acknowledge, Clear, and Close. Acknowledging the alarm will not clear it from the system but will silence the audible noise; clearing and closing the alarm banner will reset the alarm status.



SFCP UNIT MODELS/VIEWS OF CRITICAL COMPONENTS



SERVICE INSTRUCTIONS

REGULAR MAINTENANCE

PROCEDURE MAINTENANCE INDICATOR CHECK CHECK SYSTEM LEAKS Water anywhere on the frame Daily CHLORINE LEVEL ------ Daily PREFILTER CARTRIDGE Monthly or when pressure differential

reaches 10-15 PSIG Daily

TDS METER CALIBRATION ----- Six months MEMBRANCE CLEANING • Permeate flow drops 15%

• Feed pressure increases of 25PSIG over clean feed pressure

• RO rejection rate drops more than 3%

Daily

REPLACE RO MEMBRANE Performance is no longer restored post membrane cleaning

Post membrane cleaning

MEMBRANE DIAGRAM

MEMBRANE SEAL

LEADING END



MEMBRANE REPLACEMENT

Before initiating the membrane replacement, shut the supply water off. Press the red button located on sediment filter housing to release the pressure. Loosen the screws on the clamp and remove the clamp off the end cap on the feed side of the vessel. After removing the end cap pull the membrane straight out. If there is any dust present wipe it with a clean cloth. Lubricate the new membrane end seal with silicone or glycerin. Insert the end cap and fasten the clamp screws.

SEDIMENT FILTER CARTRIDGE REPLACEMENT

SHUTDOWN PROCEDURE

SHORT-TERM SHUTDOWN (MAINTENANCE OR SERVICE)

To initiate a short-term shutdown, press the POWER button on the panel to stop all operation. Disconnect the power by taking the power plug off and lockout the power plug. Shut the supply water off and press the red button located on cartridge filter to release the pressure. Now the RO system is prepared to be serviced.

If the system is to be down for a period longer than 21 days, it is recommended that a biocide be pumped into the membrane elements to prevent biological growth.

LONG-TERM SHUTDOWN (21 DAYS - 1 YEAR)

To initiate a long-term shutdown, press the POWER button to stop all operation. Divert the permeate (product) water to drain. Fully open the concentrate (reject) valve. Pump biocide into the inlet of pressure pump and add glycerin or propylene glycol as an anti-freeze. Switch off the pump and fully close the supply water valve. Lock out any sources of power. The RO system is now prepared for a long-term shutdown period.

Shut the supply water off. Remove the electrical power plug from source, then tag and lock the plug. Press the red button to release the pressure. Slip the filter wrench onto the blue housing from the bottom. Loosen the filter by turning it clockwise (watching rotation from top). Replace the filter and fasten the housing on the top holder.



TROUBLESHOOTING

MICRO850 CONTROLLER

CAUTION: Hazardous voltages are present when power is applied to the unit. Care should be taken when troubleshooting any of the input power or output circuits. When disconnecting or connecting any board or accessory, be sure power is turned off at the disconnect.

STATUS INDICATORS

Description State Indicates

1 Input Status Off Input is not energized On Input is energized (terminal status)

2 Power Status Off No input power, or power error condition Green Power on

3 Run Status Off Not executing the user program Green Executing the user program in run mode Flashing Green Memory backup/restore in progress

4 Fault Status Off No fault detected Red Non-recoverable fault that requires a power cycle Flashing Red Recoverable fault

5 Force Status Off No force conditions are active Amber Force conditions are active

6 Serial Communications Status

Off Force conditions are active

Green Traffic through RS-232/RS-485. The indicator only blinks when transmitting data. It does not blink when receiving data

7 Output Status Off Output is not energized On Output is energized (Logic Status)



8 Module Status

Steady Off No power Flashing Green Standby Steady Green Device Operational

Flashing Red Minor fault (minor and major recoverable faults)

Steady Red Major Fault (Non-recoverable) - Unit MUST be power cycled to recover

Flashing Green and Red

Self-test. The device is performing power-on self-test (POST). (POST). During POST, the network status indicator alternates flashing green and red. The duration of the self-test depends on the size of the project in the controller.

9 Network Status

Steady Off Not powered, no IP address. The device is powered off or is powered on but with no IP address.

Flashing Green No connections. An IP address is configured, but no Ethernet application is connected.

Steady Green Connected. At least one EtherNet/IP session is established. Flashing Red Connection timeout (not implemented).

Steady Red

Duplicate IP. The device has detected that its IP address is being used by another device in the network. This status is applicable only if the device's duplicate IP address detection (ACD) feature is enabled.

Flashing Green and Red

Self-test. The device is performing power-on self-test (POST). During POST, the network status indicator alternates flashing green and red. The duration of the self-test depends on the size of the project in the controller.

ERROR CODES

If, during operation a fault occurs and a corresponding error code from the PLC appears on the HMI attempt to recover the system by restarting. If the same error occurs and the same code appears, please contact Excalibur Water Systems for further assistance.



SOLENOID VALVE TROUBLESHOOTING

Problem Possible Cause Solution

1) Valve does not switch

Short circuit Check and replace the wiring

Core or core area dirty Clean the solenoid valve

Excess pressure in line Check and reduce the line pressure

2) Valve does not close

Internal space of the valve is dirty Clean the solenoid valve

Small control bore in the diaphragm blocked Clean the solenoid valve

Valve opened by manual control Check the manual override lever


35 SUPPLIER LITERATURE

HIGH PRESSURE / BOOSTER PUMP


36 SUPPLIER LITERATURE PUMP TROUBLESHOOTING



MULTI-STAGE VERTICAL PUMP


41 SUPPLIER LITERATURE PUMP TROUBLESHOOTING

Please note the exact model number on the indentification plate when inquiring about operational issues.



SEDIMENT FILTER HOUSING


44 MAINTENANCE LOG

PERFORMANCE AND SERVICE LOG

Date Flow Rate (GPM) Pressure (PSI) Product

TDS (PPM) Remarks Permeate Concentrate Recirculation Pump Membrane


45 WARRANTY

WARRANTY

5 Year Warranty Commercial Reverse Osmosis System

Thank you for your purchase of our COMMERCIAL REVERSE OSMOSIS SYSTEM. For proof of purchase, please retain your Invoice/Sales Order Copy. Warranty ~ Offered Excalibur Water Systems warranties its products to be free from defect in materials and workmanship to the original owner from the date on the proof of purchase as described below. Warranty ~ Working Procedures If during the suitable warranty period, a part is defective, then Excalibur Water Systems will repair or replace that part at no charge to the original owner, with the exception of charges for nominal shipping, service and/or installation. Warranty ~ Coverage Outlined Excalibur Water Systems guarantees, to the original owner, a period of 5 years, the CONTROLLER to be free of defects in materials and workmanship and to perform its proper functions. To the original owner, a period of 5 years, the CONTROLLER, MEMBRANE HOUSINGS, PUMP, FITTINGS, SOLENOIDS, AND FLOW METERS as well as all parts to be free of defects in materials and workmanship and to perform their normal functions. Warranty ~ Service In the event you require service, your local Excalibur Water Systems Dealer will provide all necessary service and installation for your Reverse Osmosis System. To obtain warranty service within 30 days of discovery of the defect, notification must be given to your local Excalibur Water Systems Dealer. General Provisions The above warranties are effective provided the COMMERCIAL REVERSE OSMOSIS is operated at water pressures not exceeding 125psi and at water temperatures not exceeding 120°F; also provided that the Reverse Osmosis is not subject to abuse, misuse, alteration, neglect, freezing, accident or negligence; and provided further that the Reverse Osmosis is not damaged as the result of any unusual force of nature such as, but not limited to flood, hurricane, tornado or earthquake. Excalibur Water Systems is excused if failure to perform its warranty obligations is the result of strikes, government regulation materials shortages or other circumstances beyond its control. THERE ARE NO WARRANTIES ON THE REVERSE OSMOSIS BEYOND THOSE SPECIFICALLY DESCRIBED ABOVE. ALL IMPLIED WARRANTIES, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE, ARE DISCLAIMED TO THE EXTENT THEY MIGHT EXTEND BEYOND THE ABOVE PERIODS. THE SOLE OBLIGATION OF EXCALIBUR WATER SYSTEMS UNDER THESE WARRANTIES IS TO REPLACE OR REPAIR THE COMPONENT OR PART PROVES TO BE DEFEFECTIVE WITHIN THE SPECIFIED TIME PERIOD AND EXCALIBUR WATER SYSTEMS IS NOT LIABLE FOR CONSEQUENTIAL OR INDIDENTAL DAMAGES. NO DEALER, AGENT, REPRESENTATIVE OR OTHER PERSON IS AUTHORIZED TO EXTEND OR EXPAND THE WARRANTIES EXPRESSED ABOVE. Certain provinces or states do not allow limitations on how long an implied warranty lasts or exclusions or limitations of incidental or consequential damage, therefore limitations and exclusions in this warranty may not apply to you. This warranty extends you specific legal rights as you may have other rights which vary from province to province or state to state. Excalibur Water Systems is a manufacturer of water treatment products. Barrie, ON Canada

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