Author: DF
Part Number: SP003692
Revised By: DF
Part Description: TRAILER SYSTEM, SOLAR TURBINES Date Revised: 9/19/10
Test Procedure Description: Train & Trailer Test Procedure P/N TST- 0172 Rev C
TABLE OF CONTENTS:
I. Train Setup………………………………………………………….………………Pg. 2 – 3
II. Train Function & Leak Test……………………………….…….……………….Pg. 4 – 10
Backwash Flow Rate Verification…………………………………....Pg. 6
Initial Leak Inspection……………………………………………...….Pg. 6
AUX4 Verification….……………………………………………………Pg. 6
Flow Meter Calibration………………………………………………...Pg. 7
Verify Alarm……………………………………………………………..Pg. 8
Verify Compressor……………………………………………….…….Pg. 9
Final Leak Inspection…………………………………………….……Pg. 10
III. Train Shutdown…..…………………………………………………………….…Pg. 11 – 14
IV. Trailer Setup…………………………………………………………………….…Pg. 15 – 18
V. Electrical Setup on G2 Control Panel…………………………………………Pg. 19 – 22
VI. Trailer Testing……………………………………………………………….…….Pg. 23 – 40
Raw Water Tank Low Level Alarm…………………………………..Pg. 23, 31
Raw Water Tank & Product Water Tank Level Sensors………....Pg. 24 – 28
RO Low Level Alarm………………………………………………...…Pg. 25
Twin Train Operation…………………………………………………..Pg. 26 – 27
PH Meter Pump Operation…………………………………………….Pg. 27 – 28
Leak Inspection…………………………………………………………Pg. 25, 27, 39
Train Standby Operation……………...………………………………Pg. 27
Alternating Train Operation..…………………………………………Pg. 28
Flow Meter Inspection…………………………………………………Pg. 29
Product Water Pump Inspection………………….…………………Pg. 29
Filter Mapping & Alarm Signals…....………………………………..Pg. 30
RO Standby during Backwash Operation…………...…………….Pg. 30
Caustic Tank Low Level Alarm………………………………………Pg. 31
PH-10/20 Meter High & low Level Alarms………………………….Pg. 32 – 35
Feed Water Pump Low Pressure Alarms………………………….Pg. 35
RO Switched Mode Operation………………………………….……Pg. 36 – 37
Product Water Pump Pressure Transducer Inspection……...…Pg. 37 – 38
Product Water Pump Low Pressure Alarms………………………Pg. 38
Feed Water Pump Pressure Transducer Inspection………..…...Pg. 38 – 39
Feed Water Pump Inspection…………………………….………….Pg. 38 – 39
Emergency Pump Inspection……………………………………......Pg. 40
PRV Adjustment…………………………………………………...…..Pg. 40
Appendix I – PH Calibration………………………………………………………....Pg. 41 – 53
Iron
Clear
6. Start G2 feed pump (See TST- 0156, section “Start G2 Feed Pump”).
4. Navigate to ADV. SETUP\CYCLE TIMES & select “CUSTOM” option. Adjust the cycle
times as follows:
e. BACKWASH TIME to 3
f. BRINE DRAW-RINSE to 0
g. FAST RINSE-TIME to 2
h. FILL TIME to 0
6. Navigate to
ACCESSORIES\CHLORINATOR & do
the following:
a. CHLORINATOR to
“INSTALLED”
Home screen
shows date & time
b. CHLORINATOR to “ERROR
STATUS”
c. Go to Home screen to save
settings in memory.
10. Navigate to MANUAL MODE & select “REGEN NOW” option to start flow from Clear
Tube going to drain.
12. After air has purged from Clear Tube going to drain, record
the following:
a. Filter Number
b. Date Tested
c. Backwash flow rate from Feed Water Line flow meter
Verify backwash flow rate is within +/- 15% as shown
in table below for Filter being tested.
d. System pressure on Feed Water Line
e. Verify the Continuity test rig attached to wires
labeled “AUX4” has the light on. If step 9 & step 12.e
are true record “Pass” for AUX4.
13. Inspect for leaks on control, interconnecting system tubing, & interconnecting
plumbing fittings. If leaks occur, record where the leaks are in Comments and fix
leaks. Continue to inspect for leaks on control in all motor positions throughout
regeneration.
Record Firmware Version & Serial Number for GBE circuit board.
Note 1: No water should be flowing from any of the Clear Tubes on the three Filters. No
water should be flowing from both small tubes attached to Iron Clear.
Note 2: The adjustment for the pulses per gallon does not increment the second decimal,
so the exact value may not be able to be achieved.
19. Navigate to ACCESSORIES\EXT. FILTER & select the ”INSTALLED” option for the
EXT FILTER ALARM. Go to Home screen.
24. Place Bypass valve of Filter #2 into “Service” & place all other tanks into “Bypass” by
adjusting valves attached to the interconnecting fittings.
26. Repeat steps 1 – 23 for Filter #2. Verify compressor does not cycle during
regeneration (steps 10 – 12).
27. Place Bypass valve of Iron Cleer into “Service” & place all other tanks into “Bypass”
by adjusting valves attached to the interconnecting fittings.
28. Partially close Outlet Water Line ball valve to purge air from tank (flow rate should be
about 2 gpm).
31. If steps 26, 30 are true, record “Pass” for Compressor. Record the tank serial number
& the control serial number for the Iron Clear.
32. Place Bypass valve of Filter #3 into “Service” & place all other tanks into “Bypass” by
adjusting valves attached to the interconnecting fittings.
34. Verify there are no Leaks, record “Yes” for Pass Leak Test. If there are leaks, record
where leaks are in Comments, fix leaks, & repeat this step.
24VAC
Transformer
Attach to
black wire
from control
Attach to
red wire
from control
24VAC Light
2. Close Feed Water Line ball valve & close G2 feed manifold ball valve. Unplug &
remove power from all 3 filters & Iron Cleer. Remove two tubes going to Iron Cleer.
3. Remove Feed Water Line & Outlet Water Line from system.
7. Place Bypass valve of Filter #2 into “Service” & place all other tanks into “Bypass” by
adjusting valves attached to the interconnecting fittings.
9. Place Bypass valve of Iron Cleer into “Service” & place all other tanks into “Bypass”
by adjusting valves attached to the interconnecting fittings.
11. Remove water from Iron Cleer tank by repeating steps 5 & 6.
12. Place Bypass valve of Filter #1 into “Service” & place all other tanks into “Bypass” by
adjusting valves attached to the interconnecting fittings.
14. Remove plug in Drain outlet of Iron Cleer & remove all Clear Tubes from Drain outlets
of Filters.
18. Remove the two straps that secure the tank to the metal skid. Do this for all 4 tanks.
21. If there is too much water in tank, siphon water out of tank by:
a. Place a tube in center if manifold & push all the way to bottom of tank.
b. Connect a vacuum to open end of tube.
c. Start vacuum & place open end of tube into drain once water is observed.
23. Place tank back onto skid. Secure the tank to the metal skid with the two straps. Do
this for all three filter tanks.
Note: Get the straps snug, but do not over tighten the tank to the metal skid.
27. Repeat steps 21 – 23 to empty the water from the Iron Cleer tank & secure to metal
skid.
29. Place interconnect tubing back onto system by reversing steps 15 – 17.
Note: Be sure to put flow control sensor back to in-line flow meter.
Close
7. Navigate to SETUP\ACCESSORIES\PRESS
GAUGES\PG INSTALL & select the “NO”
option for PRESS GAUGES.
a. FM OR TDS
DISABLE
b. PRESS GAUGES
DISABLE
c. PS 1 = CLOSED
PTLO = CLOSED
FS HI = OPEN
FS LO = OPEN
STANDBY
SEP-10-10 3:40PM
Pretreat Lockout
14. Remove the PH sensors, remove the blue caps from the tip of the
probe, perform pH calibration. Install the PH sensors back into the
piping.
Note: See Appendix I for PH calibration.
a.
21. Lift the upper float up in the product water storage tank and
verify both Trains go into standby mode by:
a. Display on both G2’s will indicate “STANDBY” on the Home
screen.
b. Display on Main Control Screen shows “Auto” for both
d. Trains.
c. Pressure gauges on outlet of both Trains will go to 0 psig.
b. d. LSH is on right set of switch displays.
Note: Floats must be lifted for a minimum of 4 seconds in order
for the MCP to recognize the signal.
FT50 Indicated
Flow Rate
26. With Train 2 running, verify the Main Control
Screen indicates a flow rate for FT50 flow
meter that is within 10% of the actual flow
rate.
29. Adjust the ball valve on the external bypass loop to get the flow rate to match the flow
rate of FT50.
Note 1: This will allow the raw water storage tank to fill at about the same rate the product
water storage tank is filling.
Note 2: If the raw water tank gets to low, increase the flow rate through the external bypass
loop.
Note 3: If the product water storage tank gets too low, decrease the flow rate through the
external bypass loop.
g.
a.
56. Verify pressure gauge connected to recirculation loop near product water storage tank
is within 5% of the actual pressure. Close sample cock & remove calibrated pressure
gauge.
65. Close ball valve feeding the test port & remove
the gauge. Fully open the ball valve on the
outlet of Train 2.
66. Inspect for leaks on all plumbing connections
on Train 2 from the suction side of P20 feed
water transfer pump to the product water
storage tank.
Menu Directory:
►
Menu Directory:
System Setup
Channel 1 Type:
None ►
Enter Password:
____
Channel 1 Type:
None
Channel 1 Type:
pH
Channel 1 Type:
pH ►
Channel 2 Type:
None ►
Channel 1 ID:
1006070012 ►
Channel 2 ID:
1008070003 ►
Menu Directory:
System Setup
Menu Directory:
Output
Output 1 Source:
None ►
Output 1 Source:
pH1
Output 1 Source:
pH1 ►
Output 1 4mA:
0.00 pH ►
Output 1 20mA:
10.00 pH ►
Output 1 20mA:
14.00 pH ►
Output 2 Source:
None ►
Output 2 20mA:
14.00 pH ►
Menu Directory:
►
Menu Directory:
Calibration
Enter Password:
____
pH1 4.00 pH
T1 20.7 ˚C
Tab Slot
53. Install probe into mounting tee.