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TW Series
Model's Covered
TW1-1/2-*-*
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TW5-1.5-*-*
TW6-2-*-*
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OPERATION MANUAL
COMPONENT IDENTIFICATION...............................................................................................................................................5
MAINTENANCE............................................................................................................................................................................14
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.
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.
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.
Component Identification
5 Micron Prefilter
The prefilter removes particulate matter larger than 5 microns in size. This protects both the pump and
the membranes.
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.
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.
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.
Electrical Controls
-- Warning! This switch does not remove power from all electrical
controls. Remove power from the system before working on the unit.
Pretreatment Lockout
This input allows the R.O. system to stop running while the Softener is regenerating or other
pretreatment devices are active.
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.
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).
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.
START-UP PROCEDURE
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
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
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
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.
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