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TW Series

Model's Covered
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OPERATION MANUAL

2226 S. Fairview, Santa Ana, CA 92704

(714) 850-0123 (800) 850-0123 in US http://www.FiltrationConcepts.com
 2
Table of Contents
Page
UNDERSTANDING REVERSE OSMOSIS ..................................................................................................................................3

COMPONENT IDENTIFICATION...............................................................................................................................................5

INSTALLATION (MUNICIPAL FEED) ......................................................................................................................................8

INSTALLATION (MUNICIPAL FEED) ......................................................................................................................................9

PRE-START CHECK LIST ..........................................................................................................................................................10

START-UP PROCEDURE ............................................................................................................................................................11

TROUBLE SHOOTING ................................................................................................................................................................12

MEMBRANE PRESSURE VESSELS..........................................................................................................................................13

MAINTENANCE............................................................................................................................................................................14

PARTS LIST ...................................................................................................................................................................................15

2226 S. Fairview, Santa Ana, CA 92704

(714) 850-0123 (800) 850-0123 in US http://www.FiltrationConcepts.com
 3
Understanding Reverse Osmosis

The process of reverse osmosis (RO) represents the finest level of liquid filtration available today. And
though the term sounds mysterious, reverse osmosis isn't really that complicated.

Ordinary water filters use a screen to separate particles from water streams. The particles get trapped on
the screen and the water passes through it. After a short time so much particulate material builds up on the
filter that no more water can pass through and you must replace the filter. So that the filter doesn't clog up
immediately, the holes that the water passes through must be fairly large. Of course, this allows just about
everything that is dissolved in the water to pass through as well.

An RO system employs a semi-permeable membrane. The membrane is a thin, multi-layered sheet with
pores so small that water molecules can pass through, but it acts as a barrier to dissolved solids like salts and
other chemicals.

For example, place a membrane between two

compartments in a container as shown in Figure
1. Then place a salt solution in one half of a
container and pure water in the other. While the
membrane will allow the water to pass through
it, the salt cannot.

Now a fundamental property of nature comes

into play. That is, dissimilar liquid systems will
try to reach equilibrium, they'll try to reach the
same concentration of materials on both sides
of the membrane. Of course, since the
membrane stops the movement of the salt, the
only way for equilibrium to happen is for pure
water to pass through the membrane to the
saltwater side in an attempt to dilute the salt solution. This attempt to reach equilibrium is called "Osmosis"
and is used by every living organism to control the passage of water through the cells of the body.

Obviously, in a water purification system the goal is to remove the salt from the water. Fortunately the
water can be forced to move in the reverse direction by applying pressure to the high concentration side.
Pure water is then forced through the membrane leaving the salt behind. Thus the term "Reverse Osmosis.
See Figure 1.

2226 S. Fairview, Santa Ana, CA 92704

(714) 850-0123 (800) 850-0123 in US http://www.FiltrationConcepts.com
 4
Understanding Reverse Osmosis (cont.)

So far, all we have is a normal filter with smaller holes. As the water moves to the other side of the
membrane the concentration of salt would continually increase. The system would then require increasingly
greater pressure to force water through the membrane, ultimately the membrane would become clogged by
precipitated salts and other impurities.

In actual practice, RO devices

employ cross-flow filtration as
shown in Figure 2.
With cross-flow filtration, the feed
stream continuously flows across
the membrane, anything that does
not go through the membrane gets
carried off with the cross-flow and
is sent to the reject port. In this
way the "Reverse Osmosis"
process can continue non-stop
without clogging the membrane.

Reverse osmosis can treat a wide

variety of health and aesthetic
contaminants that cause
unpleasant taste, color, and odor
problems like a salty or soda taste caused by chlorides or sulfates. RO can also be effective for treating
health contaminants like arsenic, herbicides/pesticides, lead, mercury, nitrate, and radium. When using
appropriate carbon prefiltering, additional treatment can also be provided for "volatile" contaminants such
as benzene, trihalomethanes, trichloroethylene, and radon.

2226 S. Fairview, Santa Ana, CA 92704

(714) 850-0123 (800) 850-0123 in US http://www.FiltrationConcepts.com
 5

Component Identification

2226 S. Fairview, Santa Ana, CA 92704

(714) 850-0123 (800) 850-0123 in US http://www.FiltrationConcepts.com
 6
Component Identification

Inlet Shut-Off Valve

This valve stops the flow of water to the R.O. system when closed.
Close this valve when changing the prefilter.

-- Warning! Do not close this valve while the system is running!

5 Micron Prefilter
The prefilter removes particulate matter larger than 5 microns in size. This protects both the pump and
the membranes.

-- Warning! Do not operate the system without a filter cartridge installed!

Inlet Solenoid Valve

When the system is not running, this valve closes to stop water from flowing due to feed water pressure.

High Pressure Pump

Produces the high pressures required to facilitate the Reverse Osmosis process.

-- Warning! Do not allow the High Pressure Pump to run dry,

and do not exceed the recommended operating pressure.

Membranes
This is where the Reverse Osmosis process actually takes place. For a more complete description of
Reverse Osmosis please see Page 3.

Recycle Valve
Adjusts the amount of water being re-circulated through the system.

Low Pressure Gauge

Indicates the amount of pressure being presented to the suction side of the High Pressure Pump. A
minimum of 20psi is required from the feed source for proper operation of this unit.

High Pressure Valve

This valve adjusts the amount of water being rejected from the system, which in turn controls the
amount of pressure within the system. The amount of water passing through this valve will be shown on
the Reject Flowmeter.

-- Warning! Never close the High Pressure Valve completely,

damage to the system will occur due to Over-Pressurization.

2226 S. Fairview, Santa Ana, CA 92704

(714) 850-0123 (800) 850-0123 in US http://www.FiltrationConcepts.com
 7

High Pressure Gauge

Indicates the pressure after the membranes. This pressure will be less than the pressure from the
discharge side of the High Pressure Pump.

Reject Flowmeter
Indicates the amount of waste water being rejected from the system.
Use the widest diameter of the float to read the flow rate in gallons per minute.

Reject Out Port

1/2" O.D. flexible tubing. Waste water to drain.

Product Flowmeter
Indicates the amount of good water being produced by the system.
Use the widest diameter of the float to read the flow rate in gallons per minute.

Product Out Port

1/2" O.D. flexible tubing. Good water to Storage Tank.

Electrical Controls

Main Power Switch

Turns the system On and Off.

-- Warning! This switch does not remove power from all electrical
controls. Remove power from the system before working on the unit.

Low Pressure Switch

Located in the Flow Panel, mounted on the top of the prefilter housing. This is a normally open switch
that closes when the feed pressure at the "High Pressure Pump" is sufficient to operate the R.O. system.
Problems causing reduced pressure include: Low Municipal pressure, Plumbing size too small, Inlet
Shut-Off valve not completely open, pre-filter dirty.

High Float Switch (optional)

Located in the Storage Tank, this switch stops the R.O. system when the tank is full.

Low Float Switch (optional)

Located in the Storage Tank, this switch starts the R.O. system when the water level in the tank is low.

Pretreatment Lockout
This input allows the R.O. system to stop running while the Softener is regenerating or other
pretreatment devices are active.

2226 S. Fairview, Santa Ana, CA 92704

(714) 850-0123 (800) 850-0123 in US http://www.FiltrationConcepts.com
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2226 S. Fairview, Santa Ana, CA 92704

(714) 850-0123 (800) 850-0123 in US http://www.FiltrationConcepts.com
 9
INSTALLATION (Municipal Feed)

Please refer to Drawing RO-INST which represents a typical installation. Requirements of your application
may differ from this recommendation.

Be sure to use piping large enough to support the flow requirement of your system. Insufficient flow will
cause a "Low Pressure Fault" on the R.O. system. (we recommend at least 3/4" pipes)
Long runs may require larger pipes.

All systems using Municipal Water Feed MUST have a Carbon filter installed before the reverse osmosis
system. This will insure that chlorine won't damage the membranes. It also gives the added benefit of
removing many other organic compounds such as herbicides, pesticides, and petroleum based contaminants.

Depending on the hardness of the water in your area, it may be beneficial to install a "Water Softener."
Calcium and Magnesium (hardness) tends to build up on R.O. membranes and will degrade its performance
over time. Removal of these minerals will greatly extend the life of your membranes.

An anti-scalent chemical injection pump can be used to control and remove any mineral deposits on the
membrane.

Connections
The Reverse Osmosis system has 3 plumbing connections:

1. Feed water inlet. 3/4" connection can be "hard plumbed" using rigid PVC pipes, or use the
supplied adapter for 3/4" flexible hose.

2. Reject water out. 1/2" O.D. tubing. Route this to drain.

3. Product water out 1/2" O.D. tubing. Route this to the storage tank. Do not place any valves in
this line, and avoid any restrictions such as smaller diameter fittings or kinks in the tubing.

Have a qualified electrician connect power to the unit. The R.O. should have it's own separate circuit
breaker properly sized for the unit. Power connections should be made to the white terminal blocks above
the timer.

Both the high and low floats in the storage tank are normally closed (when dry).

-- Warning! Full line voltage is used for float sensing. Safety

precautions must be taken to protect personnel and equipment.

2226 S. Fairview, Santa Ana, CA 92704

(714) 850-0123 (800) 850-0123 in US http://www.FiltrationConcepts.com
 10
REVERSE OSMOSIS SYSTEM

PRE-START CHECK LIST

Close the "Inlet Shut-off Valve."

Verify that a 5-micron filter cartridge is installed in the blue prefilter housing.

Open the Inlet "Shut-off Valve." Make sure you open this valve before turning on the R.O.

Insure that the feed water source is turned on and any pretreatment devices are in service mode.

Verify that "Reject" and "Product" tubes are connected to drain and Storage tank respectively.

Verify that Level Controls are properly connected. (if used)

Open "High Pressure Valve" all the way counter-clockwise.

Open "Recycle Valve" all the way counter-clockwise.

2226 S. Fairview, Santa Ana, CA 92704

(714) 850-0123 (800) 850-0123 in US http://www.FiltrationConcepts.com
 11
REVERSE OSMOSIS SYSTEM

START-UP PROCEDURE

1. Do not start system until pre-start checklist is completed.

2. Turn control switch to "On."

3. If the water level is below the "Low Float" in the storage tank, the system should immediately start.
If the water level is between the "High" and "Low" floats you can press the "Start" switch.

4. Immediately monitor the "High Pressure" gauge to insure that it does not exceed the maximum
operating pressure of 150 PSI.

5. Slowly adjust the "High Pressure Valve" until the "Product Flowmeter" reads the proper value as shown
in the graph below. (DO NOT allow the reject flow to go below the value shown in the graph)
If you don't get enough product flow, you can close the "Recycle Valve" some to increase the pressure,
which in turn causes the system to make more water. Both valves will affect the High Pressure as well
as the Reject and Product flowrates and you must find a balance between the three. Getting the flows as
close to graph as possible will insure a long lifetime for your membranes.

7.00
Flowmeter reading GPM

6.00
5.00
4.00
3.00
2.00
1.00
0.00
0 2000 4000 6000 8000 10000
System Size GPD Series1
Series2

2226 S. Fairview, Santa Ana, CA 92704

(714) 850-0123 (800) 850-0123 in US http://www.FiltrationConcepts.com
 12

TROUBLE SHOOTING
SYMPTOM POSSIBLE CAUSE SOLUTION
RO unit will not start No electrical power to controls Check Power
Storage Tank Full Drain some water out of tank
On-Off Switch Check or replace
Time Delay not operating Check or replace
Fuse Check or replace
Coil in magnetic motor starter Check or replace
Pump / Motor Check or replace
Level Control Relay Check or replace
Low Feed Pressure (min 20psi) Inlet Shut-Off valve closed Check
Pre-filter clogged Check or replace
Inlet water restriction Check
Low pressure switch defective Check or replace
Upstream pretreatment Check
Municipal water pressure Install booster Pump

No High Pressure High Pressure valve open Check (adjust)

Recycle valve open Check (adjust)
High Pressure gauge defective Check or replace
Pump / Motor Check or replace
Restriction in tubing Check or replace

No Reject water High Pressure valve closed Check / Open

Clogged drain line Check / Fix

No Product water or Low product

Pump pressure low Check / Adjust
water or High TDS
High press. valve open too much Check / Adjust
Membrane fouled Check, Clean or Replace
Water temperature low Check
Clogged drain line Check

2226 S. Fairview, Santa Ana, CA 92704

(714) 850-0123 (800) 850-0123 in US http://www.FiltrationConcepts.com
 13
Membrane Pressure Vessels

Description P/N
1. Single Port End Plug 16-1644
2. Dual Port End Plug 16-1645
3. PVC Housing 16-1646
4. Stainless Steel U-Pin 17-1647
5,6. O-Ring Kit 18-1648

2226 S. Fairview, Santa Ana, CA 92704

(714) 850-0123 (800) 850-0123 in US http://www.FiltrationConcepts.com
 14

MAINTENANCE

Your FCI Reverse osmosis system has been designed to be as trouble free as possible. However, in order to
keep your system operating in peak condition there are a few items that need to be maintained at regular
intervals. The following time frames are intended as a guideline for system maintenance. Depending on the
feed water quality and pre-treatment used at your location, these times may vary significantly.

1. 5-micron pre-filter cartridge: This filter should be replaced every 6 months or whenever flow is
reduced. Reduced flow can be detected by a reduced "Low Pressure" gauge reading or if the cartridge
becomes severely fouled the RO system will shut down due to a "LP Fault".

2. Membranes: The membranes are designed to last at least 2 years, however, with proper pre-treatment
and regular maintenance they should last longer. If the TDS of the product water increases or the
system makes significantly less water than it did at installation, the membranes may need to be replaced.
The system should be run a minimum of 30 minutes per week to minimize biological contamination
inside the membranes. If the system will not be operated for an extended period of time you should treat
the membranes with a preservative chemical. The membranes must be kept moist at all times. Never
allow the membranes to dry out.

3. High Pressure pump: The pump is rated "Continuous Duty" and does not require any periodic
maintenance. If the pump begins to leak you may need to replace the mechanical seals.

2226 S. Fairview, Santa Ana, CA 92704

(714) 850-0123 (800) 850-0123 in US http://www.FiltrationConcepts.com
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Parts List

P/N Description
20-0021 Filter cartridge, sediment, 5 micron, 15 sq. ft. 4-5/8" dia.
10-1623 Membrane, Low Energy, Tap Water, 4"x40"
See Page 13 for Membrane Pressure Vessels
43-1662 Seal Kit for 7GBS Pump
78-1641 Gauge, Back mount, -30-0-60 psi
78-1642 Gauge, Back mount, 0-300 psi
81-1640 Valve, Needle, Brass, 1/4" FPT
56-0283 Switch, Low pressure
68-0287 Shock mount - 70lb red

Electrical - 120 VAC

P/N Description
54-0277 Contactor, 3 Pole, 120vac, 2HP@1PH
55-1632 Light, Red, panel mount, 12.7 mm 120V, Spade Lug
55-1634 Light, Green, panel mount, 12.7 mm 120V, Spade Lug
55-1636 Light, Amber, panel mount, 12.7 mm 120V, Spade Lug
55-1638 Light, Clear, panel mount, 12.7 mm 120V, Spade Lug
56-1630 Switch, 2-Pos, Rotary, Maintained
56-1631 Switch, Pushbutton w/Black, Red and Green caps
57-0070 Relay, DPDT 8-Pin 120VAC
57-0072 Socket 8-Pin Din Mount
57-0075 Timer, Solid State, DPDT 0-60 sec, 120V
84-0580 Plug, F, Solenoid
84-1629 Valve, Solenoid, 1/2", 120VAC

Electrical - 240 VAC

P/N Description
54-0280 Contactor, 3 Pole, 240vac, LP pump 1.5HP@1ph, 3HP@3ph
55-1633 Light, Red, panel mount, 12.7 mm 240V, Spade Lug
55-1635 Light, Green, panel mount, 12.7 mm 240V, Spade Lug
55-1637 Light, Amber, panel mount, 12.7 mm 240V, Spade Lug
55-1639 Light, Clear, panel mount, 12.7 mm 240V, Spade Lug
56-1630 Switch, 2-Pos, Rotary, Maintained
56-1631 Switch, Pushbutton, w/Black, Red and Green caps
57-0071 Relay, DPDT 8-Pin
57-0072 Socket 8-Pin, Din Mount
57-0076 Timer, Solid State, DPDT, 0-60 sec, 240VAC
84-0580 Plug, F, Solenoid
84-0590 Valve, Solenoid,1/2", 240VAC

2226 S. Fairview, Santa Ana, CA 92704

(714) 850-0123 (800) 850-0123 in US http://www.FiltrationConcepts.com
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2226 S. Fairview, Santa Ana, CA 92704

(714) 850-0123 (800) 850-0123 in US http://www.FiltrationConcepts.com
 17
Wiring Diagram

2226 S. Fairview, Santa Ana, CA 92704

(714) 850-0123 (800) 850-0123 in US http://www.FiltrationConcepts.com
 18

2226 S. Fairview, Santa Ana, CA 92704

(714) 850-0123 (800) 850-0123 in US http://www.FiltrationConcepts.com