Installation, operation and

maintenance manual

Reverse Osmosis Plant AQE-60D

Model: AQE60D

Documentation ref.: 02-09-0186

Gefico
Pol. O Acevedo, Parcela A
15185 Cerceda
A Coruña – Spain
Tel +34 981 250 111
Fax +34 981 258 439
www.gefico.com

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 GUARANTEE
Products of GEFICO ENTERPRISE, are designed and produced according to highest
international standards. Each component was tested before assembly, each plant was
tested on quality and function before leaving works, in order to guarantee trouble less
and efficient service to owners on site of application for many years.

GEFICO ENTERPRISE trust that operator/shipyard installs the concerned plant

according to its best technical standard of workmanship in an appropriate site,
connecting it with qualified piping material and correct power supply. Damages occurred
to GEFICO ENTERPRISE Products due to mishandling, wrong installation or
negligence of operator or his delegate are excluded from any warranty.

GEFICO ENTERPRISE guarantees for the period of 1 year on date plant leaving works
to replace any part of the supplied plant free of charge to the owner subject the
concerned applicant supplies the faulty part free of charge to the GEFICO
ENTERPRISE works to be examinees, proving the part has not been damaged by force
or other misuse.

GEFICO ENTERPRISE reserves the right to apply technical alternations to their

products according to developments of technical researches. Nevertheless GEFICO
ENTERPRISE guarantees to owners to hold stock of spare parts according to
international standards.

The efficiency of the GEFICO ENTERPRISE Product will be guaranteed if the designed
and described technical parameters are met.

GEFICO ENTERPRISE Performance Guaranty

GEFICO ENTERPRISE guaranties that equipment manufactured by our company will

meet the applicable specifications when installed, operated and maintained in
accordance with our instructions.

Limited Warranty

GEFICO ENTERPRISE warrants the equipment of its manufacturer to be free from

defects in workmanship and materials for a period of 12 months after first start up, or 18
months after shipment, whichever occurs sooner. This warranty applies only to the
original BUYER and for new and unused equipment and cannot be altered or changed
by GEFICO ENTERPRISE employees or its representatives. Warranty related repairs
attempted and/or executed by our authorized representative shall only apply and
extended when supported in writing by GEFICO ENTERPRISE.
Where equipment sold hereunder is used with attachment and/or modifications which
have been not recommended or approved by GEFICO ENTERPRISE in writing, such

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use shall not be considered normal and this Warranty shall not apply.

GEFICO´s liability is limited to the replacement or repair of defective parts returned,

freight prepaid by BUYER to a location to be specified by GEFICO ENTERPRISE.
Repaired parts shall be returned to BUYER F.O.B. shipping point. When circumstances
permit, GEFICO ENTERPRISE will invoke for the benefit of BUYER, the guarantee or
warranty of GEFICO´s vendor for equipment or materials furnished, but not
manufactured by GEFICO ENTERPRISE.

This warranty does not extend to, and GEFICO ENTERPRISE assumes no liability for,
consequential and secondary damages, or losses of any kind sustained directly or
indirectly as a result of any defect in any equipment, material, or installation. GEFICO
ENTERPRISE shall in no event be liable in an amount exceeding the purchase price on
the equipment and transportation charges thereon.

GEFICO ENTERPRISE MAKES NO WARRANTIES REGARDING EQUIPMENT

MANUFACTURED BY IT OR NO OTHERS (INCLUDING WITHOUT
LIMITATION, WARRANTIES AS TO MERCHANTABILITY AND FITNESS FOR
A PROPOSE), EITHER EXPRESSED OR IMPLIED, EXCEPT AS PROVIDED
HEREIN. THE FOREGOING SHALL CONSTITUTE THE EXCLUSIVE
REMEDIES OF BUYER FOR ANY BREACH BY GEFICO ENTERPRISE OR IT
WARRANTIES HEREIN.

All information contained herein is based on data believed to be accurate, however,

errors and/or design changes are possible. It is the BUYER´s responsibility to determine
suitability for his own use of the products described.

The information presented in this proposal supersedes all previous information

published or presented about this units.

CUSTOMER:

ORDER Nº:

SHIP:

EQUIPMENT:

SERIAL NUMBER:

DELIVERY DATE:

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02-09-0186 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

INDEX

1. INTRODUCTION ...................................................................................................................................... 5

2. SYMBOLS ................................................................................................................................................ 5

3. SECURITY ............................................................................................................................................... 6

4. INSTALLATION ........................................................................................................................................ 6

4.1. General ............................................................................................................................. 6

4.2. Reception .......................................................................................................................... 7

4.3. Lifting and transport........................................................................................................... 7

4.4. Materials of construction, corrosion control ....................................................................... 8

RO plants with concentrate stream higher than 7.000 ppm ........................................... 9

4.5. Torque for connection flanges ........................................................................................... 9

4.6. Electrical connections...................................................................................................... 10

5. OPERATION ..........................................................................................................................................10

5.1. General ........................................................................................................................... 10

5.2. Pre-start up check list ...................................................................................................... 11

5.3. Commissioning................................................................................................................ 13

5.4. Shutdown ........................................................................................................................ 16

5.5. Start-up procedure .......................................................................................................... 17

5.6. Normal running checks.................................................................................................... 19

5.7. Shut down of less than 24 hours ..................................................................................... 20

5.8. Shut down of up to 72 hours ............................................................................................ 20

5.9. Shut down for longer than 72 hours ................................................................................. 20

5.10. Membrane preservation sequence................................................................................ 21

5.11. Sand filter back flushing procedure ............................................................................... 21

6. MAINTENANCE .....................................................................................................................................22

6.1. General ........................................................................................................................... 22

6.2. Routine maintenance ...................................................................................................... 23

6.3. Membrane cleaning procedure ........................................................................................ 25

6.4. Membrane Handling and preservation ............................................................................. 28

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02-09-0186 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

6.5. Reverse osmosis modules .............................................................................................. 31

6.6. Instrumentation / control .................................................................................................. 31

High pressure and low pressure cut-out switches ....................................................... 31

Low pressure relief valve ............................................................................................ 32

High pressure relief valve ........................................................................................... 32

Presure regulating valve ............................................................................................. 33

Conductivity measuring cell ........................................................................................ 33

Electronic conductivity controller ................................................................................. 34

Solenoid valves........................................................................................................... 35

6.7. Cartridge filter.................................................................................................................. 37

7. PARTS LIST RECOMMENDED .............................................................................................................37

8. ANNEX ...................................................................................................................................................38

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1. INTRODUCTION

This manual describes the installation, operation and maintenance of the Reverse Osmosis
(RO) unit model AQE60D. Two RO plants have been supplied that share the following units:
sand filter, mineralizer filter, dosing units and chemical/flushing cleaning unit. Bear in mind that
the RO plants are not meant to work in parallel but one in standby. The dosing units and
chemical/flushing cleaning unit constitute the Chemical Module and are controlled by a separate
control panel. A wiring diagram is provided in the Annex that shows the interconnexion among
the control panel of the RO plants and the control panel of the Chemical Module.

In this manual the operation and maintenance is described for each RO unit. Check P&ID in the
Annex for the valves tag. The cleaning of one of the RO unit can be done while the other is in
normal operation. Make sure that valves are in the correct position for working with each of the
units.

Check individual manuals for the units in the scope of supply for the instructions in the
installation, operation and maintenance of these units.

This manual contains instructions for the installation, operation and

maintenance of the unit supplied. This equipment should not be used in
applications other than those recommended without first consulting the
manufacturer. Improper use may damage the equipment.

Remember that only one RO unit AQE60D can be working at a time. Cleaning
of one unit can be performed while the other one is in normal operation.

It is recommended that this manual is readily accessible to the staff responsible of installation,
operation and maintenance of the unit and that the instructions and warnings that are collected
in it are followed.

2. SYMBOLS

Situation that can cause personal injury or damage to the pump.

Indication of electrical hazard.

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3. SECURITY

Before peforming any work on the equipment, operators must know and fully
understand the contents of this manual.

Both mechanical and electrical installation must be performed by qualified and experienced
personnel. Such staff should consider the following points:

 Always act on the pump with appropriate clothing (avoid clothing with very long sleeves,
ties, necklaces, etc.) and protective equipment (goggles, gloves, shoes, etc.) appropriate
to the operations to be performed.
 Never remove the protections of the components rotating with the pump.
 Reposition any security devices that have been moved or canceled for performing
maintenance tasks before starting the pump.
 Do not modify the equipment. Consult factory if a modification is deemed necessary.

 Mechanical installation should be completed before making electrical

connection. Remember that the mixture of water and electricity can be fatal.

Appropiate cautions must be taken in storage of parts, lubricants, preservatives and

chemical for cleaning.

Do not operate this equipment above its rated speed or with different parameters than
those contained in the instructions in this manual. This equipment has been designed
to work satisfactorily in the conditions specified in the purchase order and for which it was sold.
Operation above these conditions could lead efforts for which it was not calculated.

4. INSTALLATION

4.1. GENERAL

Reference should be made to the drawings supplied in Annex.

For installation and maintenance work adequate means of lifting and transport, as well
as suitable tool, must be available. The following points must be taken into account:

 It must be provided a clearance of obstacles around the unit for ease of inspection and
maintenance (see dimensional drawing of the unit in Annex).
 In the room where the equipment is going to be installed, there must be adequate
ventilation for engine cooling.

Check sea water supply required in Technical Specification.

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 02-09-0186 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Feed pump must be always installed below seawater level and very close to the cross-over or
sea chest if it is a not self-prime pump. Special care must be taken to avoid pressure losses on
this suction pipe and interferences from other pumps.

The pipe work should contain no tight bends or other restrictions.

All fittings and joints should be secure and free from leaks.

The brine discharge lines should be piped so that the back-pressure is not greater than 5 bar.

A suitable isolator should be provided in the electrical supply to the system; that is, additional to
the isolator on the control panel door.

All electrical connections should be made to the relevant approved standard.

When plant containing a new reverse osmosis membrane is first started, product water should
be diverted to discharge for at least 60 (sixty) minutes before it is collected for storage.

When the plant is being re-commissioned or started up after chemicals have been used for
storage or cleaning, product water should be diverted to discharge for at least 30 (thirty)
minutes before it is collected for storage.

Water used in contact with the membranes must not have any chlorine content.

When dynamic permeate back pressure is employed during plant operation, the limiting
component is the permeate port which is made of PVC. Check Annex for the membranes data
for maximum dynamic permeate backpressure.

4.2. RECEPTION

Remove all individual components from package and inspect for any visible damage.

In case of damage or discrepancies contact seller or freight company.

4.3. LIFTING AND TRANSPORT

Because the equipment weights more than 25 kg, the use of lifting methods as slings
or lifting eyes is required by European Directive 90/269/CEE of May 29.

Suitable lifting devices such as cranes will be used.

The use of lifting loads equipment will follow the provisions of European Directive 95/63/CE on
minimum safety and health requirements for the use by workers.

Never use only one sling.

The vertical position of the equipment during transport and the prevention from slipping on the
suspension must be ensured. A slip can cause personal injury and damage.

It is necessary to ensure that the load is balanced before hoisting.

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ANCHORING

In the dimensional drawings, the necessary data for anchoring can be found: number, diameter,
length and position of bolts.

It is essential to properly anchor the unit in a metal or concrete base, as well as

choose a flat support to avoid vibrations and twisting.

The bolts will have the right dimensions and the mounting holes will have length enough to
ensure a complete anchor security.

4.4. MATERIALS OF CONSTRUCTION, CORROSION CONTROL

From a corrosion point of view a very harsh environment prevails in an RO water desalination
plant.

Hence the materials of construction must possess a certain degree of corrosion resistance. This
count for both the exterior parts exposed to spillage and a humid and saline atmosphere as well
as for the interior of the system exposed to the wide variety of waters treated.

Although not to be underestimated, the control of the exterior corrosion can usually be
overcome by using a surface coating (painting, galvanizing, etc.) on materials supposed to
corrode (mild steel, cast iron, etc.) and by establishing a maintenance program involving
periodical flush down and cleaning, repair of leaks, etc.

Selecting materials of construction for the interior wetted system is a far more complicated task.

Apart from being compatible with the pressures, vibrations, temperatures, etc. existing in an RO
system, the materials are also able to withstand the potential corrosion attacks caused by the
high chloride content of the feed water, seawater attack, the concentrate stream, the aggressive
product water and the chemicals used for applications such as membrane cleaning.

Application of non-metallic materials such as plastics, fiber glass, etc. are used for preventing
corrosion and chemical attacks as well in the low-pressure parts ( < 16 bar) of the RO system
as in the RO elements and pressure vessels.

However, it is necessary to use metals for the high-pressure (16 - 70 bar) parts such as pumps,
piping and valves. Carbon and low alloy steels do not have sufficient corrosion resistance, and
their corrosion products can foul the membranes.

Al-bronze can be an alternative for pumps, etc.

The most relevant material to be used for the high-pressure parts is stainless steel.

Stainless steel has as basic advantages that they are very resistant to general corrosion and
erosion corrosion. Stainless steel is rarely attacked by galvanic corrosion, but it will influence

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the attack on the other metal in a two-metal couple (e.g. copper, brass, steel, etc.). Stress
corrosion cracking of stainless steels in media containing chloride rarely occurs below 70°C
(158°F) so it does not need to be considered in RO desalination plant.

Unfortunately, some stainless steels are prone to pitting and crevice corrosion in the waters
occurring in an RO plant.

Pitting means localized attacks that result in holes in the metal. Pitting occurs where the passive
film formed by chromium oxides breaks and chlorides can attack the bare metal.

Crevice corrosion is pitting associated with small volumes of stagnant water caused by holes,
gasket surfaces, deposits and crevices under bolts, etc.

In order to avoid pitting and crevice corrosion in the RO water desalination plant the following
recommendations must be followed:

RO PLANTS WITH CONCENTRATE STREAM HIGHER THAN 7.000 PPM

Stainless steel type 904 L is recommended for pipes and bends for welding and for similar parts
without crevices.

Where crevices occur, such as at flange connections, in valves, in pumps, etc. stainless steel
type 254 SMO or alike with > 6% Mo is recommended.

Sensor element of instruments may be coated or lined.

Besides the above recommendations general precautions must be taken during design,
construction and installation, such as:

Minimum of crevices and dead ends.

Design the piping so that the flow velocity is above 1.5 m/s (5 ft/s). It promotes the forming and
maintenance of the passive film.

Use backing gas when welding in order to avoid the weld oxide film forming base for crevice
corrosion.

Pickle and passivate the pipe system as this gives the optimum safety against chloride attack.

Flush the plant with low TDS water before a shut-down period.

4.5. TORQUE FOR CONNECTIO N FLANGES

External connection flanges are made in PVC. No greater force is required to tighten bolts. A
torque wrench should be used to tighten the bolts on a flanged joint with flat gaskets in order to
prevent damage to the flanges and the adaptors. The table below contains approximate torque
values required for different pipe diameters.

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O.D. pipe
mm
16 20 25 32 40 50 63 75 90 110 125 140 160 200 225 280 315

Nominal
10 15 20 25 32 40 50 65 80 100 110 125 150 175 200 250 300
bore mm
Torque Nm 6 7 9 10 20 25 30 35 40 45 50 50 60 75 75 75 75

Flat gasket are used as a rule with flanged joints. Flat gaskets in EPDM (d20-d225), FPM (d20-
d110) and IIR (d90-d225) are used.

4.6. ELECTRICAL CONNECTIONS

All electrical installation work will be performed in the absence of tension, by qualified
personnel and following the instructions of current regulations and the engine
manufacturer.

5. OPERATION

5.1. GENERAL

Successful long term performance of the RO system depends on proper operation and
maintenance of the system. This includes the initial plant start-up, operational start-up and shut-
downs. Preventing fouling or scaling of the membranes is not only a matter of system design,
but also a matter of proper operation. Record keeping and data normalisation is required in
order to know the actual plant performance and to enable corrective measures when necessary.
Complete and accurate records are also required in case of a system performance warranty
claim.

To ensure that the plant continues operating in the most efficient manner, the following points
should be observed.

1. The plant is to be operated, maintained and cleaned in accordance with the instructions
provided in this manual.
2. The operating parameters must be within the guidelines quoted in the Technical
Specification of the unit.
3. Care should be taken to ensure that the feed water being used contains no impurities,
foreign, organic or inorganic matter which is liable to be harmful to the filters or
membrane elements.
4. The filters should be maintained in a clean and serviceable condition at all times.
5. The membranes must not come into contact with water containing chlorine.
6. When shutting the plant down, except for membrane cleaning, the membranes must be
preserved as described in this manual.
7.

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5.2. PRE-START UP CHECK LIST

 Corrosion resistant materials of construction are used for all equipment including piping
and wetted parts of pumps.
 All piping and equipment are compatible with designed pressure.
 All piping and equipment are compatible with designed pH range (cleaning).
 All piping and equipment are protected against galvanic corrosion.
 Sand filter is back washed and rinsed until clean water is seeing through sight glass.
 Mineralizer filter is prepared for operation.
 New / clean cartridge filters are installed
 Feed line, including RO feed manifold, is purged and flushed.
 Chemical addition points are properly located.
 Check valves and safety valves are properly installed.
 Provisions exist for proper mixing of chemicals.
 Provisions exist for preventing the RO system from operating when the dosage pumps
are shut down.
 Check level dosing tanks.
 If chlorine is used, make sure provisions exist to ensure complete chlorine removal prior
to the membranes. Check that carbon filter is installed in the hydrophore tank line.
 Planned instrumentation is installed.
 Instrumentation is calibrated.
 Pressure relief protections are installed and correctly set.
 Provisions exist for preventing the product pressure from exceeding the feed / brine
pressure more than 0.3 bar (5 PSI) at any time (valve 15 must be fitted).
 Interlocks and alarms are properly set.
 Pressure vessels are properly piped both for operation and cleaning mode.
 Pressure vessels are secured to the rack or frame.
 Precautions for assembly and loading of pressure vessels are taken.
 Membranes are protected from extreme temperatures (freezing, direct sunlight, heater
exhaust, etc.).
 Pumps are ready for operation (proper rotation, purge, etc).
 Fittings are tight.
 Permeate line is open.
 Permeate flow is directed to drain.
 Reject flow control valve is in full open position.
 Check high pressure pump direction of rotation as it is described next. It is critical
to avoid severe damage on the pump and on the installation.

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VERY IMPORTANT

Prior to starting-up the system must be flushed without the high pressure pump being
connected.

Before starting-up, loosen the top bleeding plug “C”. When water appears from the bleeding
plug, retighten the plug. With its inlet line connected to the water supply, the pump is now
started with open outlet port.

At the initial start of the system, the pump should be flushed for about 5 minutes, thus removing
possible impurities from pipes, hoses, etc. from the high-pressure side of the pump.

Warning:

Make sure that the direction of rotation of the electric motor corresponds to the direction of
rotation of the pump (see label on pump). Otherwise the pump will be damaged if a check valve
is placed between the pump and the tank.

The high pressure pump has only one direction of rotation.

Before starting the unit, check the rotation of the electric motor of high pressure pump.

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5.3. COMMISSIONING

Ensure that the plant is in a safe condition to operate.

Visually check that the plant is securely mounted, that pipework and electrical connections have
been made, that the control panel door is closed, and that all tools used during installation have
been removed from the area.

Check that all valves from the seawater circuit are open.

Check the booster seawater pump rotation.

Check booster seawater pump is primed.

Check sand filter is filled and rinsed.

Check mineralizer is filled and prepared for operation.

Check tanks of dosing units

Check the direction of rotation of high pressure pump.

1. Check the setting of the following valves (See Annex, P&ID):

Description Reference valve Position

Sand filter V1, V2, V3 Rinse position
Sea water feed inlet valve 1 Closed
Brine by-pass valve 5 Open
Pressure regulating valve 4 Open fully
Chemical cleaning inlet valve 3 Closed
Chemical cleaning outlet valve 7 Closed
Brine discharge valve overboard 6 Open
Dosing units tank drain Closed (if required)
Dosing units tank outlet Open (if required)
Dosing units tank inlet Closed (if required)
Instrument valves Open
Any external valves in sea water feed Open fully
Any external valves in brine discharge Open fully
Any external valves in heating water system Open fully (if required)

2. Check the level in the chemical cleaning tank. Top up if necessary with chlorine free
water.

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3. Fill the tanks of the dosing units with the required quantity of chlorine free water and the
chemical (if it is required).
4. Switch on main switch in RO unit control panel and in Chemical Module control panel.
5. Pump lamps must be red.
6. Salinity indicator must show 0, and low salinity green light is lighting.
7. Start seawater booster pump. Pump green lamp is lighting.
8. Check sand filter filtration discharging seawater to the bilge (rinse position). Look sight
glass until seawater is total clear. When seawater is clean, put sand filter in filter position
(valves V1, V2 and V3).
9. Slowly open seawater supply to the module opening slowly valve (1). Do not overpass
the 5 m3/h of feed flow checking the feed flow meter F1.
10. Seawater is circulating through all units. This initial circulation must be done slowly using
low pressure water at a low flow rate (50% of operation feed flow). Flush at a gauge
pressure of 2-4 bar.
11. After the system has been flushed for a minimum of 30 minutes, regulate the seawater
feed flow meter (F1) as indicated in the Technical Specification through booster pump
discharge valve.
12. Pressure through sand filter must be between 2 and 6 bar. Check that there is not
leakage.
13. Pressure through cartridge filters must be between 2 and 6 bar. Check that there is not
leakage.
14. Check seawater temperature. If the unit is supplied with seawater heater, regulate the
thermostatic valve (see chapter if installed).
15. Adjust the salinometer central knob inside the electrical control panel to “zero”(0). Then
the high salinity alarm will be activated and the bilge solenoid valve will be opened
(energized).
16. Before starting-up the HP pump, loosen the bleeding plug “C”. When water appears from
the bleeding plug, retighten the plug.
17. Press the start button to start the HP pump (if booster pump is stopped the high
pressure pump is blocked as safety; if this occurs push reset button). As the pump starts
the high pressure pump running lamp will be illuminated. Check that the pump runs
smoothly and allow the water to flush the RO membranes for five minutes.
18. Check the seawater feed flow is in accordance with the Technical Specification.
19. Close by-pass valve (5) slowly.
20. Regulate the dosing pumps. Check the manuals of the dosing units supplied with your
RO system.

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21. Close the pressure regulating valve (4) to increase the indicated system pressure into
the membranes, (< 0,7 bar per second) until the salinometer indicates that good product
is being produced and the production rate (F2) is reached.
22. Continue sending all permeate to the bilge.

CAUTION
Carefully monitor the sea water supply pressure between the HP pump and the
membranes as the pressure control valve is adjusted to ensure that the maximum
operating pressure (70 bar (g) is not exceeded). Irreversible damage to the
membranes can be caused by using too high pressure.

23. Initially, the product water will be diverted, via the Normally Open solenoid valve (9), to
the waste discharge line. Anyhow, sample valve 15 must be fully open during the first
hour.

CAUTION
The product flow during the first hour of operation of a new or replacement
membrane must be discharged to bilge. If the system has been filled with a
storage preservative, or after a cleaning procedure, the product water must be
diverted to discharge for the first 30 (thirty) minutes of operation.

24. After the required flush time of membranes (60 minutes or 30 minutes), the salinometer
central knob must be adjusted to number 8 (alarm set value to 450ppm). While the
product water conductivity is above the pre-set level of salinity alarm, the salinometer /
High Salinity warning red lamp will be illuminated and product water will continue to be
diverted to discharge via the Normally Open solenoid valve (9).

NOTE
After a short period of time the product water quality will start to improve. When the
product water conductivity drops below the pre-set level the high salinity red lamp will be
extinguished and the low salinity green lamp will be illuminated. Product will now be
diverted to the potable water outlet via the Normally Closed solenoid valve (8), which
opens while the bilge solenoid valve (9) closes.

25. Potable water should now be flowing through the outlet to storage.
26. Check the product flow using the flow indicator (F2).
27. If necessary, adjust the pressure regulating valve (4) to achieve the desired product flow.
Do not exceed maximum operation pressure.

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28. When conditions are seen to be stable, check the plant for correct operation and log the
commissioning date and operating conditions as described in Annex.

NOTE
The readings obtained after the reverse osmosis elements have been in operation for
between 25 and 48 hours must be recorded. These readings are considered as
reference conditions for the plant to decide when the elements should be cleaned.
29. Switch ON the control panel of the Chemical Module and make sure the switches for the
dosing pumps are in ON position.

5.4. SHUTDOW N

First of all, fill the chemical cleaning tank with permeated water free of chlorine in order to do the
flushing with fresh water.

It is good practice to fill up pre-treatment and post-treatment tanks.

Open permeate sample valve (15) to fill those tanks.

Stop pre-treatment and post-tretament systems (if installed).

When the RO membrane system is shut down the pressure regulating valve (4) must be slowly
opened (<0,7 bar per second), before the high pressure pump is switched off. When regulation
valve is fully open, open by-pass valve (5) and stop the high pressure pump.

Stop seawater booster pump.

Close sand filter valves V1, V2 and V3 and mineralizer valves.

Then, the system must be flushed with either permeate water or high quality feed water (free of
chlorine), to remove the high salt concentration from the modules. Start the chemical cleaning
pump from the Chemical Module control panel and feed the system with the chlorine free water
previously dropped inside the chemical tank. Flushing is done at low pressure (about 3 bar/ 40
PSI). A high feed flow is beneficial for a cleaning effect; however a pressure drop of 1,4 bar (20
PSI) per element must not be exceeded.

The water used for flushing shall contain no chemicals; especially the scale inhibitors must be
absent. Therefore all dosing units are stopped before flushing.

After flushing, the system feed valve and outlet valves must be closed completely, otherwise the
vessels might be emptied.

The membrane elements must not dry out. Dry elements will irreversibly lose flux.

When the system has to be shut down for extended periods of time, longer than 48 hours, take
care that:

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 The system is adequately protected against microbiological growth, or regular flushing is

carried out every 24 hours.
 When applicable, the system is protected against extreme temperatures.

The RO unit can be stopped for 24 hours without preservation and precautions for
microbiological fouling; only flushing with fresh water must be done.

If feed water for flushing every 24 hours is not available, preservation with chemicals is
necessary for stops longer than 48 hours. Please refer to Section of maintenance.

5.5. START-UP PROCEDURE

The following start-up procedure assumes that the system has been shut down for a short
period, for example when in in-shore waters where the feed water may be unsuitable, and is
simply being returned to service producing potable water. It is assumed that all valves have
been left as they were set during the previous period of operation.

1. Check that all valves from the seawater circuit are opened.
2. Check the setting of the following valves and check that filters were rinsed:

Description Reference valve Position

Sand filter V1, V2, V3 Filter position
Sea water feed inlet valve 1 Open
Brine by-pass valve 5 Open
Pressure regulating valve 4 Open fully
Chemical cleaning inlet valve 3 Closed
Chemical cleaning outlet valve 7 Closed
Brine discharge valve overboard 6 Open
Permeate sample valve 15 Open
Instrument valves Open
Check dosing tank levels and valves Open
Any external valves in sea water feed Open fully
Any external valves in brine discharge Open fully
Any external valves in heating water system Open fully (if required)

3. Main Switch ON (I0) in RO and Chemical Module control panel.

4. Adjustment of operation parameters

The normal way of operating GEFICO RO plants is to keep the feed flow constant and the only
production regulation is through the high pressure. Any change in the membrane flux, e.g. by

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 02-09-0186 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

temperature or fouling, is compensated by adjusting the feed pressure to the membranes.

However, the maximum specified feed pressure must not be exceeded.

If the feed water analysis changes such that the scaling potential increases, the system
recovery has to be decreased (reducing production), or other measures have to be
taken to cope with the new situation.

The most common situation is that the permeate capacity of the plant has to be
adjusted to the needs. Normally, the capacity is designed to meet the peak needs.
Operating with overcapacity is generally not recommended. Thus, adjustment means
lowering the design permeate output. The easiest way is to shut the plant down when
no permeate is needed. A high start / stop frequency, however, can lower the
performance and the lifetime of the membranes.

Reducing the feed pressure is the way to reduce the permeate flow in our reverse
osmosis units. Normally, the system recovery is kept more or less constant when the
permeate flow is reduced. It has to be ensured, that single element recoveries do not
exceed their limits. During low flow operation, the system salt rejection is lower than
during design flow operation. Also, you must be certain that minimum concentrate flows
are maintained during low flow operation.

Decreasing feed seawater temperature can be compensated by increasing the feed

pressure up to the maximum. Once the maximum pressure is reached, a further
decreasing temperature causes the permeate flow to decrease.

Increasing temperature is compensated by lowering the feed pressure. This is only

possible; however, as far as the tolerated permeate TDS is not exceeded.

A system analysis has to be run to make sure that maximum element permeate flows
are not exceeded.

An increase in the feed water salinity can be compensated by increasing the feed
pressure up to the maximum. lf further pressure increase is not possible, than a lowered
permeate flow and system recovery has to be accepted. A lower feed water salinity
allows to decrease the feed pressure and to increase the system recovery and/or to
increase the permeate flow.

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 02-09-0186 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

5.6. NORMAL RUNNING CHECKS

Periodically check the plant for correct operation and log the operating conditions:

1. Date and time.

2. Feed water supply temperature.
3. Feed water supply flow rate.
4. Sand filter inlet/outlet pressures.

NOTE
If the pressure drop across sand filter increases by 1 bar the filter should be back-
washed to remove impurities (high pressure pump must be stopped).

5. First Cartridge filter inlet/outlet pressure.

NOTE
If the pressure drop across a filter increases by 2 bar, the cartridge elements should be
changed.

6. Second Cartridge filter inlet/outlet pressure.

NOTE
If the pressure drop across a filter increases by 2 bar, the cartridge elements should be
changed.

7. Pressure at the outlet from the HP pump.

NOTE
This pressure should be adjusted at the pressure regulating valve (4) to give nominal
product flow as indicated in the Technical Specification. If the pressure required to
achieve this is greater than expected (check Technical Specification) the reason should
be investigated, the membranes may require cleaning or sea water temperature is too
low.

8. Product water conductivity (salinometer reading).

9. Potable water outlet flow quantity.
10. Potable water outlet pressure.
11. Level in dosing units tanks. If necessary, top up the dosing unit and record the quantities
added.

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 02-09-0186 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

12. If necessary, for example when a cleaning operation is to be carried out, top up the
chemical cleaning tank level with chlorine free water before stopping.

5.7. SHUT DOW N OF LESS THAN 24 HOURS

The normal plant shut-down procedure must ensure that the RO elements are flushed at low
pressure with clean, chlorine free, fresh / product water via valve 3.

5.8. SHUT DOW N OF UP TO 7 2 HOURS

The plant should be flushed through at low pressure with a solution of 1% sodium bisulphite (by
weight). Prepare the solution by dissolving 1kg of sodium metabisulphite (food grade) per 100
litres of clean, chlorine free, product water. Or it can be used PERMACLEAN 55, making a
solution of 0,01%. Consult the chemical manufacturer for detailed information about safety,
handling and disposal.
These solutions should be recirculated through the system for approximately 5 (five) minutes
and then the brine control valve closed to entrap the preserving solution within the membranes.

5.9. SHUT DOW N FOR LONGER THAN 72 HOURS

The plant should be flushed through at low pressure with a solution of 1% sodium bisulphite and
20% glycerine in freeze conditions (by weight). Prepare the solution by dissolving 5 kg of
glycerine and 1 kg of sodium metabisulphite (food grade) per 100 litres of clean, chlorine free,
product water. Instead of sodium bisulphite PERMACLEAN 55 can be used, making a solution
of 0,05%. Consult the chemical manufacturer for detailed information about safety, handling and
disposal.

The solution should be recirculated through the system for approximately 5 (five) minutes and
then the brine control valve closed to entrap the preserving solution within the membranes.

Disinfecting with chlorinating agents is not recommended. The membrane is permeable to

chloramine and to chlorine dioxide. Either of these will pass through the membrane resulting in
a small residual disinfectant in the product water. The membrane has only limited resistance to
free chlorine.

Continuous exposure to hydrogen peroxide at concentrations up to 0.2% will eventually damage

the membrane.

Copper sulphate can be used to control algae growth. Iodine, quaternary germicides, and
phenolic compounds should not be used as tests show that all of these agents cause flux loss.

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 02-09-0186 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Formaldehyde should not be used as a biocide unless the elements have been in operation for
at least 6 (six) hours. Exposure to formaldehyde before the elements have been in use for this
period of time will result in a loss of flux.

5.10. MEMBRANE PRESERVATION SEQUENCE

1. The plant should be flushed with clean, chlorine free water before a chemical cleaning
operation.
2. Thoroughly mix the required quantity of chemicals into the Chemical Tank. Top up with
product water (from sample valve 15) before stopping, or by obtaining fresh, chlorine
free, water from storage tank.
3. Close the brine discharge valve (6) and open the cleaning valve (7)
4. Start the cleaning pump and recirculate the chemicals through wound polypropylene
filters, the HP pump and RO modules back to the chemical tank.
5. Let the chemical solution circulate for at least 5 (five) minutes. Stop the cleaning pump.
Close the cleaning tank valves and module valves 3 and 7 to entrap the preserving fluid
within the membranes.

Note
Before the system is returned to service after using a preservative, the product water
must be diverted to discharge (sample valve 15 must be open) for the first 30 (thirty)
minutes of operation.

5.11. SAND FILTER BACK FLU SHING PROCEDURE

Back flushing the filter is carried out when the pressure differential across the filter in normal
operation has increased by approximately 1 bar. It is recommended to do it at least every week.
Back flushing removes the entrained matter from the surface and reduces the colmatation of
sand introducing the seawater in the opposite direction of the filtration mode.

1. Stop the plant.

2. Open filter valves V1, V2 and V3. The seawater must enter from the bottom to the top.
3. Backflusing must be done during 5 minutes with a flow rate of 20 m 3/h starting booster
pump.
4. Rinse the filter during at least 5 minutes or until clean water can be seen through the
glass. Rinse must be done with a flow rate of 20 m3/h.
5. Reset the valves to their service positions.
6. Check the new pressure drop.
7. If pressure drop is correct restart the plant using the starting procedure given.

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 02-09-0186 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

8. If pressure drop does not reach originally values, the inside material must be renewed
(see maintenance).

6. MAINTENANCE

6.1. GENERAL

When carrying out maintenance on the pump, follow the following instructions:

 The maintenance will be performed only by qualified personnel

equipped with suitable clothing and safety equipment.

 Always ensure that the pump is isolated from the power line: the power
switch must be locked in the open position and the fuses removed. The
necessary measures will be taken to prevent an involuntary return of
voltage. A sign should be placed in the area where electrical insulation
runs and in the startup device. This sign will be similar to the one
shown:

DANGER
DO NOT CONNECT
STAFF WORKING

 The equipment must be stopped before being touched for any reason.
Ensure that all closure elements are regulated so that a fluid return can
not occur.
 The equipment and the pipes to which it is connected must not be under
pressure when acting upon it.
 Ensure repositioning all safety guards that have been removed during
maintenance, prior to starting the equipment.

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6.2. ROUTINE MAINTENANCE

It is strongly recommended that a plant operating log is maintained to record the running hours
and operating parameters of the various items of equipment and any maintenance comments. A
list of operating parameters that should be recorded is given in the Annex.

Many routine maintenance requirements are dependent on such variables as running times,
operating conditions, etc. and should be reviewed from time to time in the light of operating
experience.

The following points should be noted:

General

The product flow during the first hour of operation of a new or replacement membrane must be
discharged to waste/sample.

The permeate flow during the first 30 minutes of operation after filling with preservative or a
cleaning operation must be discarded to waste.

The flow rate and differential pressure logged in the first 25 to 48 hours of operation must be
recorded as a reference on which to judge the cleaning requirements for the membrane.

Conductivity measuring cell

The measuring cell incorporates electrode surfaces of monel metal. For correct operation these
electrode surfaces must make good contact with the water being monitored and this can only
occur if the electrode surfaces are free from grease and scaling.

Before placing a cell into service, or if the readings obtained are at variance with observations
from samples taken, clean the electrode surfaces.

Switch off the main switch and take out circuit breakers

Plug out electrical connection. With the cell electrical wire free, unthread from the manifold.

With a soft fine paper clean the electrodes.

Assembly in inverse order tightening carefully.

Daily
 Visually inspect the plant, check for any leaks, signs of faulty
operation (for example, oscillating pressure indications or
General excessive noise from pumps), or any mechanical damage.
 Complete the plant log.

 Cartridge filter should be removed if the pressure differential

Cartridge filters across the filters has increased 1 bar (as maximum 2 bar). Filter
cannot be cleaned.

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 02-09-0186 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Three-Monthly

 Clean the membrane following the instruction given in this

Reverse Osmosis
manual. This operation must be carried out at least three-times
Unit
per year to maintain product water quality.

NOTE

Depending on the operating conditions, membrane cleaning may be required more frequently.
The requirement for cleaning is indicated either by a drop of 10% in product quantity, a
noticeable increase in product conductivity, or an increase of 15% in the pressure differential
across the membrane. The flow rate and pressures logged in the first 25 to 48 hours of
operation being used as reference values.

Six-Monthly

 Switch off the main switch and take out its fuses.
 Plug out electrical connection. With the cell electrical wire free,
Conductivity unthread from the manifold.
measuring cell
 With a soft fine paper clean the electrodes.
 Assembly in inverse order tightening carefully.

High pressure switch  Check that the unit high pressure switch works properly and trips
the unit.

CAUTION
Before working on any electrical system, the power supply must be
isolated.

 Clean the control panel interior

 Check the electrical connections for tightness and security. .
 Check the pump contactors for freedom of movement and for
excessive burning or pitting of the contacts.
Control panel
 Visually check all wiring, components and insulation for
deterioration.
 Measure and record the electrical continuity (earth) between the
control panel and the ship's structure. The readings should not
be greater than 0.05 Ohms.
 Measure and record the resistance (insulation) between the
terminals and earth. The reading should be greater than 1
MegOhm.

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 02-09-0186 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

CAUTION
Before working on any electrical system, the power supply must be
isolated.

 Clean the interior of the motor terminal box.

 Check the electrical connections for tightness and security.
 Visually check all wiring, components and insulation for
deterioration.
 Insulation resistance check
 Measure insulation resistance before commissioning and when
winding dampness is suspected.
 Resistance, measured at 25ºC, shall exceed the reference
value, i.e.
Pump motors
 10 Mohm (measured with 500 V dc Megger)

WARMING
Windings should be discharged immediately after measurement to avoid
risk of electric shock.

 Insulation resistance reference value is halved for each 20ºC

rise in ambient temperature.
 If the reference resistance value is not attained, the winding is
too damp and must be oven dried. Oven temperature should be
90ºC for 12 16 hours followed by 105ºC for 6-8 hours.
 Drain hole plugs, if fitted, must be removed during heating.
 Windings drenched in seawater normally need to be rewound.

 To prevent a total and disastrous breakdown, we recommend a

High pressure pump pump inspection after max. 4000 hours-at which any worn parts
must be replaced. See Annex for pump service intervals.

6.3. MEMBRANE CLEANING PROCEDURE

In normal operation, the membrane in reverse osmosis elements can become fouled by mineral
scale, biological matter, colloidal particles and insoluble organic constituents. Deposits build up
on the membrane surfaces during operation until they cause loss in water output, loss of salt
rejection or both.

Elements should be cleaned whenever the normalised product water output drops by 10% of
the flow rate recorded during the first 25 to 48 hours of operation, or when the salt content
(conductivity reading) of the product water rises noticeably.

It should be noted that the water output will drop, by about 3% per degree Celsius, as the feed
water temperature decreases. This is normal and does not indicate product fouling. A
malfunction in the pre-treatment, pressure control, or pump can also cause a drop in product
water output or an increase in salt passage. If a problem occurs, these causes should be
considered. The element may not require cleaning.

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Safety Precautions

1. When using any chemical substance it is essential to follow the correct safety practices.
Contact the chemical supplier or manufacturer for detailed information about safety,
handling and disposal (technical information is included on this manual).

2. When preparing cleaning solutions, ensure that all chemicals are dissolved and well
mixed before circulating the solution to the elements.

3. After cleaning, it is desirable to flush the elements with good quality chlorine-free water
at a minimum temperature of 20°C. Product water is recommended, but pre-filtered feed
water may be used provided that there is no corrosion problem in the piping system.

Care should be taken to flush the cleaning solution from the elements before resuming
normal operating pressures and flows. Despite this precaution, cleaning chemicals will
be present on the product side of the membrane after cleaning. The product water must
be diverted to discharge for at least 30 (thirty) minutes, or a longer period until the water
is clear, when starting up after cleaning.

4. Check table in the Technical Specification of the membranes manufacturer for pH range
and temperature limits during cleaning.

5. The flow direction through the elements must not be reversed.

Chemical Quantities

Acid cleaners are used to remove inorganic precipitates including iron, while alkaline cleaners
are used to remove organic fouling, including oil.

Sulphuric acid should not be used because of the risk of calcium sulphate precipitation.

Commercial laundry detergents cannot be approved because the specific chemical constituents
are unknown.

Preferably, reverse osmosis product water should be used for the cleaning solutions, but pre-
filtered raw water will also work in most cases. Raw water can be highly buffered, so a larger
amount of the acid or alkaline may be needed to achieve the desired pH value, which is about 2
for acid cleaning or about 11 for alkaline cleaning.

Alkaline Cleaning Solutions (For removal of organic fouling)

Chlorine-free product water should be used to make up a 1,0 – 2,0% with solution of
PermaClean 99 which may be adjusted to pH 11 by the addition of sodium hydroxide.

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 02-09-0186 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

The cleaning solution should be circulated through the elements at a temperature of 25 - 30°C
at a flow rate and pressure designated. Intermittent circulation and soaking of the membrane for
a total of 3 - 5 hours is recommended.

Foaming may be expected in some designs of CIP tank and pipe-work.

This cleaning cycle may have to be repeated in the case of heavily fouled membranes, and it is
recommended that the cleaning is carried out at the maximum temperature allowed by the
membrane manufacturer.

Before returning the system to service the operator must ensure that any residual cleaning
product is removed from the membrane surface by thorough flushing. This may be done by
monitoring the pH of the concentrate until it returns to same pH as the influent water.

Acid Cleaning Solutions (For removal of inorganic fouling)

Cleaning solutions should be prepared with chlorine free product water to give a 4% w/w
solution, or 1 kg of PermaClean 77 to every 25 kg of water. As PermaClean 77 is buffered the
cleaning solution will stabilize at pH – 3,6.

The cleaning time depends on the amount of fouling present but is usually completed within two
to three hours. If the cleaning solution becomes red / brown in color it must be changed as it
has become exhausted. The PermaClean 77 cleaning solution should always be neutralized
with alkali and discarded after use.

Before returning the system to service the operator must ensure that any residual cleaning
product is removed from the membrane surfaces by thorough flushing. This may be done by
monitoring the pH of the concentrate until it returns to the same pH as the influent water.

Module preparation

Unit must be correctly aligned to produce the adequate flow circulation.

1. Stop the plant following the indications described in this manual.

2. Following the safety precautions, thoroughly mix the required quantity of chemicals into
the Chemical Tank. If necessary, top up with fresh, chlorine free, process water from
storage.
3. Close the brine discharge valve (6) and open the cleaning outlet valve (7).
4. Open chemical cleaning pump intake valve from cleaning tank.
5. Start the chemical cleaning pump and circulate the cleaning solution around the system.

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 02-09-0186 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

6. After a period of circulation, stop the pump and allow the membranes to soak. A soak
period of about one hour is normally sufficient. For difficult fouling an extended soak
period of 10 to 15 hours may be beneficial.

NOTE Check the pH level during acid cleaning. The acid is consumed when it dissolves
inorganic precipitates so, if the pH increases by more than 0.5 pH units, add more acid.

7. Reverse the setting of the cleaning valves and pump the remaining chemicals in the
chemical tank to waste.
8. Refill the chemical tank two or three times with chlorine free water and flush to waste.

NOTE If chlorine free water is not available, use the normal plant start sequence to flush the
membrane array with clean sea water for five minutes at a low pressure before returning
the plant to service.

9. Start the system as described in the starting procedure.

CAUTION The product water must be diverted to discharge for the first 30 (thirty) minutes of
operation to ensure that all traces of the cleaner are removed from the product water
side.

10. When conditions are seen to be stable, check the plant for correct operation and record
the cleaning operation and the current operating conditions as described.

6.4. MEMBRANE HANDLING AND PRESERVATION

General

Membrane elements should be handled in such a way that biogrowth and change in membrane
performance during long-term storage, shipping, or system shut-downs is prevented. The
elements should preferably be stored and shipped outside the pressure vessels and loaded into
the pressure vessels just prior to start-up.

In using biocide solutions as membrane preservations, follow accepted safety practices. Always
wear eye protection. Consult the relevant Material Safety Data Sheets as supplied by the
manufacturer of the chemicals.

Preservation

New elements are shipped in a standard preservation solution containing 1% sodium bisulphite
and 20% propylene glycol. All these elements have been tested by quality control, soaked in the
mentioned solution for one hour, drained, and bagged into a double plastic bag. The inner bag
is made out of an oxygen barrier material.

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Bisulphite provides protection from biological growth, propylene glycol provides protection from
freeze damage and has additional preserving properties.

Any element that has been used and removed from the pressure vessel for storage or shipping,
must be preserved in a preservation solution. Use a mixture of 1% (by weight) of sodium
bisulphite – food grade, not cobalt activated – and 20% (by weight) propylene glycol. Glycol can
be omitted when freezing temperatures can be excluded. Soak the element for one hour in the
solution, allow to drip out and seal it into an oxygen barrier plastic bag. We recommend re-using
the original bag or original spare bags available from Dow. Do not fill the plastic bag with the
preservation solution – the moisture in the element is sufficient, and leaking bags might create a
problem during transport. Identify the element and the preservation solution on the outside of
the bag.
Instead of sodium bisulphite, formaldehyde can be used as preservation solution at 0.5 to 3.0%
(by weight) concentration. 0.5% is sufficient when no biofilm is on the membrane.
Formaldehyde is a more effective biocide than bisulphite and is not decomposed by oxygen. On
the other hand, formaldehyde handling requires more precautions due to its suspected
carcinogenicity. Please follow the relevant safety regulations about this product.

Elements must be in use for at least six hours before formaldehyde is used as a biocide. If the
elements are exposed to formaldehyde before being in use for this period of time, a loss in flux
may result.

Aldehydes other than formaldehyde do not affect the membrane rejection, but the water
permeability may be markedly decreased. Therefore, no other aldehydes are recommended as
preservation solution components.

There is a fully approved biocides list which can also be used as membrane preservatives. They
do not affect the membrane performance, but their biocidal efficiency cannot be guaranteed.

Re-wetting of dry elements

Elements that have dried out after use may irreversibly lose water permeability. Re-wetting
might be successful with one of the following methods:

 Soak in 50/50% ethanol/water or propanol/water for 15 min.

 Pressurize the element at 10 bar (150 PSI) and close the permeate port for 30 min. Take
care that the permeate port is reopened before the feed pressure is released.
 Soak the element in 1% HCl or 4% HNO3 for 1-100 hours.

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Storage

 Please follow these guidelines for storage of FILMTEC elements:

 Store cool inside a building or warehouse and not in direct sunlight.
 Temperature limits: -4°C to +45°C (22° to 113°F). New dry elements will not be affected
by temperatures below -4°C (22°F). Elements stored in 1% sodium bisulfite/20%
propylene glycol will freeze below -4°C, but as the ice crystals are soft, the membrane
will not be damaged.
 Keep new elements in their original packaging.
 Storage time of dry elements is unlimited.
 Elements preserved in bisulphite/glycol should be visually inspected for biological growth
every three months. When the preservation solution appears to be not clear, or after six
months, the element should be removed from the bag, soaked in a fresh preservation
solution and repacked.
In case no equipment for re-preservation (fresh solution, clean environment, bag sealing
device) is available, the elements can be left in their original packaging for up to 12
months. When the elements are then loaded into the pressure vessels, they should be
cleaned with an alkaline cleaner before the plant is started up. Ensure conservation
conditions also for membranes loaded into the pressure vessels.
 The pH of the preservation solution must never drop below pH 3. A pH decrease can
occur when bisulphite is oxidized to sulphuric acid.
This precaution is especially important for seawater membranes (SW30 and SW30HR),
because the salt rejection of those membranes will be affected at low pH storage.
Therefore, the pH of the bisulphite preservation solution should be spot checked at least
every 3 months. A new preservation is mandatory when the pH is 3 or lower.
 Elements stored in formaldehyde do not need frequent observation. The preservation
solution should be renewed after 12 months.

Shipping

When membrane elements have to be shipped, they must be preserved with a preservation
solution.

Make sure that:

 The plastic bag does not leak.

 The element is properly identified.
 The preservation solution is correctly labelled.

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We recommend using the original packaging with the polystyrene foam cushions to protect the
element from mechanical damage. The product tube ends of elements of size < 8" are
especially endangered.

Disposal

Used FILMTEC elements can be disposed of as municipal waste, provided:

 No preservation solution or other hazardous liquid is contained in the element.

No depositions of hazardous substances are on the membranes (e.g. elements used in waste
water treatment).

6.5. REVERSE OSMOSIS MODU LES

See enclosed annex for pressure vessels at the end of the manual..

6.6. INSTRUMENTATION / CONTROL

HIGH PRESSURE AND LOW PRESSURE CUT-OUT SWITCHES

Adjustment

Adjust the switches by rotating the adjusting nut on the top of the switch body.

Clockwise rotation decreases the pressure setting, anti-clockwise rotation increases the setting.
The sections of pipework, or the pressure vessel, should be pressurized to the required setting
pressure. Switch settings can then be checked by increasing or decreasing the pressure acting
on the switch, while monitoring the switch terminals.

To set a switch to operate on rising pressure, rotate the adjusting nut until the switch is on.

To set a switch to operate on a falling pressure, rotate the adjusting nut until the switch is on
and then turning the nut clockwise until the switch resets.

Maintenance

Other than external cleaning and visual inspection, the switches should require no routine
maintenance.

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LOW PRESSURE SWITCH HIGH PRESSURE SWITCH

LOW PRESSURE RELIEF VALVE

The unit is supplied with two bronze relief valves of 1/2"*3/4". One for the overboard brine
discharge set at 5 bar (g) and the other one to the permeate discharge circuit set at 4 bar (g).

They are constructed with a 90º angle, with full nozzle and long stroke, closed bonnet and
mechanism of closure actuated by direct-actions helicoidal spring.

Connections screwed according to DIN-259 or ANSI B-2.1.

Design for all type of application and services for industry, adequate for steam, air water, gases,
vapours, and all kind of liquids.

See Annex, Technical Data Sheet.

HIGH PRESSURE RELIEF VALVE

A stainless steel valve of 1/2" * 3/4", adjusted at 75 bar (g), is threat on the H.P. Pump outlet
manifold.

It is constructed with a 90º angle, with full nozzle and long stroke, closed bonnet and
mechanism of closure actuated by direct-actions helicoidal spring.

Connections screwed according to DIN-259 or ANSI B-2.1.

Design for all type of application and services for industry, adequate for steam, air water, gases,
vapours, and all kind of industrial liquids.

See Annex, Technical Data Sheet.

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PRESURE REGULATING VALVE

The pressure regulating valve is a stainless steel 316 needle valve. This valve is designed to
set the system operating pressure and is adjusted to suit the operating conditions and to give a
maximum product flow. If this flow cannot be obtained without tripping the High Pressure Alarm,
then check the system to determine the cause, the membranes may require cleaning.

CONDUCTIVITY MEASURING CELL

The conductivity measuring cell incorporates electrode surfaces of monel. For correct operation
these electrode surfaces must make good contact with the water, this can only occur if the
electrode surfaces are clean and free from grease.

Correctly cleaned electrode surfaces are easily identified by dipping them in clean water and
then holding up to the light. Rapid drying areas, or contraction of the surface moisture indicate
that the washing procedure must be repeated.

The frequency of cleaning must be judged by comparison of the salinometer readings with
those obtained by a portable salinometer on water samples taken from the sample point, until a
pattern of regular cleaning is established, this should then be added to the normal routine
maintenance schedule.

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ELECTRONIC CONDUCTIVITY CONTROLLER

Terminal connections and wiring are as shown on the electrical drawings. Ensure that any
replacement instrument is correctly rated for the supply voltage.

In order to select the desired alarm set point, rotate the set point control knob, situated in the
salinometer box front side, until it lines up with the desired set point mark (see enclosed data
sheet).

SALINITY ALARM VALUE

ALARM SET KNOB POSITION
P.P.M NaCl
1 30
2 60
3 120
4 170
5 320
6 360
7 400
8 450
9 700
10 900

From time to time verify the alarm system. Rotate the set point control until the point at which
the alarm lamp lights red. Check that the bilge solenoid valve is opened and the remote high
salinity alarm is activated.

When the water purity level is worse than the alarm set point, the salinometer activates the
alarm relay. In this moment, the solenoid valves are de-energised and dump valve opens,
meanwhile tank solenoid valve is closed. When water quality is better than alarm set value, the
solenoid valves are energised.

The salinometer recalibration must be done as follows:

 The salinity indicator should be at approximately mechanical zero with power off. If not,
turn the external knob in the indicator with a screwdriver until the zero will be marked by
the needle.
 Clean the salinity cell electrodes, as was described.
 Controller (salinometric unit) calibration is accomplished by rotating the meter calibrates
control on the PC board (inside the box), so that the meter reads correctly. Cell test
resistor simulates the appropriate input, and it's applied across the cell electrodes. It is
available from factory.

34
 02-09-0186 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

SOLENOID VALVES

Solenoid Temperature

The valve coils are designed for continuous duty service. When the solenoid is
energised for a long period the solenoid gets too hot to be comfortably touched. This is
a safe operating condition. Any excessive heating will be indicated by smoke and an
odour of burning.

Preventive Maintenance

CAUTION

Before servicing a valve isolate it from the supply voltage and line pressure; that is, shut
down the plant.

Periodic cleaning is desirable. The intervals should be judged by the operation of the
valves; when a valve operates sluggishly, there is excess leakage, or excessive noise,
the valve should be cleaned. By noting the time intervals a regular maintenance period
can be chosen to prevent problems, this should then be added to the normal routine
maintenance schedule.

Coil Replacement

CAUTION

Before servicing a valve isolate it from the supply voltage and line pressure; that is, shut
down the plant.

The solenoid must be fully assembled before use. The housing and internal parts are
part of and complete the magnetic circuit. Place an insulating washer at each end of the
coil, if required.

35
 02-09-0186 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

1. Remove the screw 7. Take out complete connector.

2. Unthread coil nut 11. Take out coil 12.
3. Reassemble in the reverse order of disassembly, paying careful attention to the
exploded view provided for parts identification.

Valve Disassembly

CAUTION

De-pressurise the valve and isolate the electrical power supply before working on the valves.

1. Disassemble the valve using the exploded view to identify the parts
2. Remove coil (as it was described).
3. Remove the four bonnet screws (10), valve bonnet (3), disc holder subassembly, disc
holder spring (13), diaphragm/spring sub-assembly and body gasket.
4. All parts are now accessible for cleaning or replacement. If any worn or damaged parts
are found, replace all the items supplied in the spare parts kit for the best results.

Valve Re-assembly
36
 02-09-0186 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

1. Re-assemble in the reverse order of disassembly.

2. Replace the valve bonnet and bonnet screws. Tighten the bonnet screws in a diagonal
pattern to a torque of 19,8 +/-2,8 Nm (175 +/-25 inch-pounds).
3. After maintenance operate the valve a few times to check its correct operation.

6.7. CARTRIDGE FILTER

The cartridge filter extracts solid particles down to a size of 50 microns (first group) and to a size
of 5 microns (second group). In operation the pores in the filter cartridge material become
blocked with these particles. When the differential pressure across the filter increases by 1 bar
(max. 2 bar of pressure drop) compared with the figure initially logged, as indicated on the
pressure gauges, the filter element should be replaced. The cartridge elements cannot be
cleaned.

The seals should be replaced at annual intervals, if not changed when the filter elements are
replaced.

To change the element:

See annex enclosed at the end of this manual.

7. PARTS LIST RECOMMENDED

See Annex.

37
 02-09-0186 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

8. ANNEX

0960D0104001 GENERAL ARRANGEMENT

09-0232-05 PIPING & INSTRUMENTS DIAGRAM

18-0249-02 ELECTRICAL & TERMINATION DIAGRAM

18-0264-33 WIRING DIAGRAM

09-0244-22 SPARE PARTS

18-0265-22 ELECTRICAL PANEL SPARE PARTS

06-12-0062 TECHNICAL DATA HIGH PRESSURE PUMP

02-12-0188 INSTRUCTION MANUAL HIGH PRESSURE PUMP

06-20-0047 TECHNICAL DATA ELECTRICAL MOTOR HIGH PRESSURE PUMP

02-20-0191 INSTRUCTION MANUAL ELECT. MOTOR HIGH PRESSURE PUMP

06-35-0251 PERMEATE AND BRINE RELIEF VALVE (LOW PRESSURE)

06-35-0257 HIGH PRESSURE RELIEF VALVE

02-44-0189 INSTRUCTION MANUAL PRESSURE VESSELS

44-0003-01 DRAWING PRESSURE VESSELS

02-25-0190 INSTRUCTION MANUAL CARTRIDGE FILTER

06-25-0252 TECHNICAL DATA MEMBRANES

02-25-0194 MEMBRANE CLEANING PROCEDURES

11-09-0001 RECORD DATA SHEET

38
 1 2 3 4 5 6

1000mm 90 - 45 LIFTING LUG LIFTING LUG 45 - 90 1422

5 6
3
A

A A A

B
C
4
1331

1060
890
D

740
540

540
335
606 394 928
74,5

60 1900
1000 300
2200
B B

785*
SERVICE AREA

300
2200
LEYENDA/KEY
ITEM DESCRIPTION FLANGE SIZE 1050 1050
A ENTRADA AGUA SALADA / SEA WATER INLET DIN 2576 ND 40
1
B SALIDA PERMEADO / PERMEATE OUTLET DIN 2576 ND 25
C SALIDA SALMUERA / BRINE OUTLET DIN 2576 ND 40
D ENTRADA QUIMICA / CHEMICAL INLET DIN 2576 ND 40
E SALIDA QUIMICA / CHEMICAL OUTLET DIN 2576 ND 40

FOUNDATION FRAME

1000

960
LEYENDA/KEY

C ITEM DESCRIPTION FIXING HOLES C

1 WOUND FILTER CARTRIDGE 5
2 WOUND FILTER CARTRIDGE 50
6x 12
3 PUMP GROUP
4 PRESSURE VESSELS 2
5 INSTRUMENTAL PANEL
6 ELECTRICAL PANEL

400
785*
500

REVISION HISTORY
REV DESCRIPTION DATE APPROVED
0 10/04/2014 VMA
MADE BY DATE NORM/STANDARS PROJECT NAME
15,00 MMR 07/04/2014 Vahana Aryan & Vahana Arjun
A(1:4) CENTER OF GRAVITY DATE
UNE-EN 22768-C
CHECKED BY
EMPTY WEIGHT 650kg
20

LIFTING DLT 07/04/2014 REFERENCE NO GEFICO PROJECT PROJECT NO

OPERATIONAL WEIGHT 1050kg DATE
APPROVED BY

SERVICING SPACES VMA 07/04/2014

UNITS: mm 0960D0104001 090/15 JM1401/JM1402
40

MAINTENANCE SPACES DESCRIPTION

D D

Gefico GENERAL ARRANGEMENT

* MEMBRANE DISASSEMBLY SPACE. IF IT'S 1:20 0960D0104001 0 1 /1 A3
NOT AVAILABLE, PRESSURE VESSELS CAN www.gefico.com
BE REMOVED FOR MEMBRANE DISASSEMBLY SCALE DRAWING NO REV. SHEET NO FORMAT
NOTICE:
THIS DRAWING HAS NOT BEEN PUBLISHED AND IS THE SOLE PROPERTY OF GEFICO ENTERPRISE AND IS LENT TO THE BORROWER FOR HIS CONFIDENTIAL USE ONLY AND IN CONSIDERATION OF THE LOAN OF THIS
DRAWING, THE BORROWER PROMISES AND AGREES TO RETURN IT UPON REQUEST AND AGREES THAT IT SHALL NOT BE REPRODUCED, COPIED, LENT OR OTHERWISE DISPOSED OF DIRECTLY OR INDIRECTLY AND NOT USED
IN ANY WAY DETRIMENTAL TO THE INTEREST OF THIS COMPANY.
1 2 3 4 5 6
 1 2 3 4 5 6
R.O. UNIT 1
CONTROL Pretreatment Power supply, 75W CONTROL Post-treat. Power supply, 75W
BOX
dosing unit BOX

dosing unit
(connect to control box)
TERMINAL DESCRIPTION
TK (connect to control box) TK
L.L. antiscaling 230V/60Hz/1ph L.L.
chlorination Pulse signal input
DOSING DOSING
(connect directly to pump)
1
PUMP PUMP

Incoming Power supply (3+GND)x25mm2

Power supply
440V/60Hz/3ph Supplied by Client
2 POWER SUPPLY: 440V/60Hz/3ph (CABLE SUPPLIED BY CLIENT)
3
Flowmeter (F3) Pulse signal Cable sensor 4

A M
3~
Chemical Cleaning
pump
Power supply, 2,2kW
440V/60Hz/3ph
(4m length) 5
6
7
HIGH PRESSURE PUMP
A
(3+GND)x2,5mm2
M Booster Power supply, 3kW
8 BOOSTER PUMP (CABLE SUPPLIED BY CLIENT)
pump
CONTROL
Post-treat.
Power supply, 75W 3~ 440V/60Hz/3ph
9
BOX (connect to control box)
TK dosing unit 11
Power supply Incoming Power supply L.L.
pH adjust.
4-20mA signal input
12 R.O. UNIT INTERLOCK TO CHEMICAL BOARD (CABLE SUPPLIED BY TVME)
(3+GND)x6mm2 DOSING (connect directly to pump)
440V/60Hz/3ph Supplied by Client PUMP
13
14 CHEMICAL PUMP ON CHEMICAL BOARD INTERLOCK (CABLE SUPPLIED BY TVME)

15IN
Control signal, 4-20mA 2x1,0mm2 16RET
KM20 N/O TO CHEMICAL SWITCHBOARD UNIT (CABLE SUPPLIED BY TVME)

(active output) shielded 17IN

Signal converter Power supply, 4,2W 18RET
KM10 N/O TO CHEMICAL SWITCHBOARD UNIT (CABLE SUPPLIED BY TVME)

CHEMICAL MODULE (AZ1) pH sensor signal

19
HIGH PRESSURE SWITCH
(input) 20
21
22
LOW PRESSURE SWITCH
DESCRIPTION TERMINAL 23
Cable sensor 24
SOLENOID VALVE TO WATER TANK
1 pH sensor (PH) (5m length)
23
POWER SUPPLY: 440V/60Hz/3ph (CABLE SUPPLIED BY CLIENT) 2
24
SOLENOID VALVE TO BILGE
3
26
4
CHEMICAL PUMP (CABLE SUPPLIED BY CLIENT)
5
(2+GND)x2,5mm2
27 SALINITY CELL
28
6
(2+GND)x1,5mm2 29
7
DOSING PUMP, pre-treatment (CABLE SUPPLIED BY TVME)
8
30 REMOTE GENERAL ALARM (CABLE SUPPLIED BY TVME)

(2+GND)x1,5mm2 31
9
DOSING PUMP, post-treatment 1 (CABLE SUPPLIED BY TVME)
10
32
REMOTE RUNNING INDICATION (CABLE SUPPLIED BY TVME)
(2+GND)x1,5mm2 33
11
DOSING PUMP, post-treatment 2 (CABLE SUPPLIED BY TVME)
12 GROUND
(2+GND)x1,5mm2
11A
SIGNAL CONVERTER, post-treatment 2 (CABLE SUPPLIED BY TVME)
12A

B B
1x1,5mm2
13
RO UNIT 1 & 2 KM20 N/O IN (PRE-TREAT.) (CABLE SUPPLIED BY TVME)
14
1x1,5mm2
1x1,5mm2
15
RO UNIT 1 & 2 KM20 N/O RETURN (PRE-TREAT.) (CABLE SUPPLIED BY TVME)
16
1x1,5mm2
1x1,5mm2
17
RO UNIT 1 & 2 KM10 N/O IN (POST1-TREAT.) (CABLE SUPPLIED BY TVME)
18
1x1,5mm2

17A
RO UNIT 1 & 2 KM10 N/O IN (POST2-TREAT.) (CABLE SUPPLIED BY TVME)
18A 1x1,5mm2
19
RO UNIT 1 & 2 KM10 N/O RETURN (POST1-TREAT.) (CABLE SUPPLIED BY TVME)
20
1x1,5mm2

19A
RO UNIT 1 & 2 KM10 N/O RETURN (POST2-TREAT.) (CABLE SUPPLIED BY TVME)
20A
COM
25 COM
1x1,5mm2
COM Pre-Treat.
LOW LEVEL SWITCH PRE-TREATMENT (CABLE SUPPLIED BY TVME)
25B
MAX
MAX Tank R.O. UNIT 2
26 MIN Level
MIN 1x1,5mm2
26B
COM
27
27B COM COM
Post-Treat.1 TERMINAL DESCRIPTION
LOW LEVEL SWITCH POST-TREATMENT 1 (CABLE SUPPLIED BY TVME)
28 MAX MAX
Tank
Level 1
28B MIN MIN Power supply Incoming Power supply (3+GROUND)x25mm2
29 COM
COM 440V/60Hz/3ph Supplied by Client
2 POWER SUPPLY: 440V/60Hz/3ph (CABLE SUPPLIED BY CLIENT)
COM Post-Treat.2 3
29B
LOW LEVEL SWITCH POST-TREATMENT 2 (CABLE SUPPLIED BY TVME)
30 MAX
MAX
Tank 4
30B MIN MIN Level 5 HIGH PRESSURE PUMP
6
31
7
REMOTE GENERAL ALARM (CABLE SUPPLIED BY TVME) 32 M Booster Power supply, 3kW
(3+GND)x2,5mm2
8 BOOSTER PUMP (CABLE SUPPLIED BY CLIENT)
33 pump
3~ 440V/60Hz/3ph
9
34
CHEMICAL PUMP REMOTE RUNNING INDICATION (CABLE SUPPLIED BY TVME)
35
11
R.O. UNIT INTERLOCK TO CHEMICAL BOARD (CABLE SUPPLIED BY TVME)
12
36
RO UNIT 1 & 2 KM20 N/C IN (BOOSTER PUMP) (CABLE SUPPLIED BY TVME)
37
13
CHEMICAL PUMP ON CHEMICAL BOARD INTERLOCK (CABLE SUPPLIED BY TVME)
14
38
RO UNIT 1 & 2 KM20 N/O RETURN (BOOSTER PUMP) (CABLE SUPPLIED BY TVME) 15IN
KM20 N/O TO CHEMICAL SWITCHBOARD UNIT
C C
39 (CABLE SUPPLIED BY TVME)
16RET
40
RUNNING INDICATION FOR R.O. UNITS 1 & 2 (CABLE SUPPLIED BY TVME)
41
17IN
KM10 N/O TO CHEMICAL SWITCHBOARD UNIT (CABLE SUPPLIED BY TVME)
18RET
GROUND 19
HIGH PRESSURE SWITCH
20
21
22
LOW PRESSURE SWITCH
23
24
SOLENOID VALVE TO WATER TANK
23
24
SOLENOID VALVE TO BILGE
26
27 SALINITY CELL
28
29
30 REMOTE GENERAL ALARM (CABLE SUPPLIED BY TVME)
31
32
33
REMOTE RUNNING INDICATION (CABLE SUPPLIED BY TVME)

GROUND

MADE BY DATE
REFERENCES Notes: FID 29/07/2015
NORM/STANDARS PROJECT NAME

DATE UNE-EN 22768-C Vahana Aryan & Vahana Arjun

ELECTRICAL AND TERMINATION DIAGRAM CHECKED BY
FID 29/07/2015
CABLE SUPPLIED BY CLIENT APPROVED BY DATE
REFERENCE N O GEFICO PROJECT PROJECT N O
REF. DESCRIPTION DRAWING No. MHI 29/07/2015 UNITS: mm 17694 090/15 JM1401/JM1402
17694 RO unit AQE-60D 18-0249-02 CABLE SUPPLIED BY TMVE
D Gefico
DESCRIPTION
D
17693 Chemical Module 18-0250-02
CABLE SUPPLIED BY GEFICO WIRING DIAGRAM
INSTALLED BY SHIPYARD Pol. O Acevedo - CERCEDA
A CORUÑA - 15185 S/E 18-0264-33 1 1/1 A3
Tfno: +34-981250111
Fax: +34-981258439
E.mail: gefico@gefico.com SCALE DRAWING N O REV. SHEET N O FORMAT
CLIENT POWER SUPPLY SPECIFIED, REFERENCES INCLUDED, CABLE INSTALLED BY GEFICO
1 22/09/2015 MHI NOTICE:
SCOPE OF SUPPLY OF CABLES UPDATED THIS DRAWING HAS NOT BEEN PUBLISHED AND IS THE SOLE PROPERTY OF GEFICO ENTERPRISE AND IS LENT TO THE BORROWER FOR HIS CONFIDENTIAL USE ONLY AND IN CONSIDERATION OF THE LOAN OF THIS
GEFICO SCOPE OF SUPPLY DRAWING, THE BORROWER PROMISES AND AGREES TO RETURN IT UPON REQUEST AND AGREES THAT IT SHALL NOT BE REPRODUCED, COPIED, LENT OR OTHERWISE DISPOSED OF DIRECTLY OR INDIRECTLY AND NOT USED
REV DESCRIPTION DATE APPROVED BY IN ANY WAY DETRIMENTAL TO THE INTEREST OF THIS COMPANY.

1 2 3 4 5 6
 A B C D

P1

P2

1 V1 1

V2

2 V4 2

V5

28

35

P1

3 3
F2

23
FP1
F1
FP2

V6

V7
A
V3

V9
SAL1

4 4

14

V8
5 5

REV DESCRIPTION DATE APPROVED BY

REVISION HISTORY
MADE BY DATE PROJECT NAME
NORM/STANDARS
LFA 25/09/2015 Vahana Aryan & Vahaha Arjun
CHECKED BY DATE UNE-EN 22768 mk
LFA 25/09/2015 GEFICO PROJECT PROJECT N O
APPROVED BY DATE
MHI 25/09/2015 UNITS: mm 18463 090/15 JM1401/JM1402
DESCRIPTION

Gefico SPARE PARTS REVERSE OSMOSIS AQE-60D

6 6
Pol. O Acevedo - CERCEDA
S/E 09-0244-22 1/6 A3
Tfno: +34-981250111
Fax: +34-981258439
E.mail: gefico@gefico.com SCALE REV. FORMAT
NOTICE:
THIS DRAWING HAS NOT BEEN PUBLISHED AND IS THE SOLE PROPERTY OF GEFICO ENTERPRISE AND IS LENT TO THE BORROWER FOR HIS CONFIDENTIAL USE ONLY AND IN CONSIDERATION OF THE LOAN OF
THIS DRAWING, THE BORROWER PROMISES AND AGREES TO RETURN IT UPON REQUEST AND AGREES THAT IT SHALL NOT BE REPRODUCED, COPIED, LENT OR OTHRWISE DISPOSED OF DIRECTLY OR
INDERECTLY, NOT USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF THIS COMPANY.

A B C D
 A B C D

2 PB

1 1

B
2 28 2

42

43 49

C
3 OI SW
3

7
25 46

27 43 C 47
26
B

4 4

11

48

5 5

REV DESCRIPTION DATE APPROVED BY

REVISION HISTORY
MADE BY DATE PROJECT NAME
NORM/STANDARS
LFA 25/09/2015 Vahana Aryan & Vahaha Arjun
CHECKED BY DATE UNE-EN 22768 mk
LFA 25/09/2015 GEFICO PROJECT PROJECT N O
APPROVED BY DATE
MHI 25/09/2015 UNITS: mm 18463 090/15 JM1401/JM1402
DESCRIPTION

Gefico SPARE PARTS REVERSE OSMOSIS AQE-60D

6 6
Pol. O Acevedo - CERCEDA
S/E 09-0244-22 2/6 A3
Tfno: +34-981250111
Fax: +34-981258439
E.mail: gefico@gefico.com SCALE REV. FORMAT
NOTICE:
THIS DRAWING HAS NOT BEEN PUBLISHED AND IS THE SOLE PROPERTY OF GEFICO ENTERPRISE AND IS LENT TO THE BORROWER FOR HIS CONFIDENTIAL USE ONLY AND IN CONSIDERATION OF THE LOAN OF
THIS DRAWING, THE BORROWER PROMISES AND AGREES TO RETURN IT UPON REQUEST AND AGREES THAT IT SHALL NOT BE REPRODUCED, COPIED, LENT OR OTHRWISE DISPOSED OF DIRECTLY OR
INDERECTLY, NOT USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF THIS COMPANY.

A B C D
 A B C D

1 1

D E

2 2

49 29
D

3 3

51

PA
54 E VSA

43 53

44

42 45

44
4 4

53

52

47

48
V19

5 5
11

REV DESCRIPTION DATE APPROVED BY

REVISION HISTORY
MADE BY DATE PROJECT NAME
NORM/STANDARS
LFA 25/09/2015 Vahana Aryan & Vahaha Arjun
CHECKED BY DATE UNE-EN 22768 mk
LFA 25/09/2015 GEFICO PROJECT PROJECT N O
APPROVED BY DATE
MHI 25/09/2015 UNITS: mm 18463 090/15 JM1401/JM1402
DESCRIPTION

Gefico SPARE PARTS REVERSE OSMOSIS AQE-60D

6 6
Pol. O Acevedo - CERCEDA
S/E 09-0244-22 3/6 A3
Tfno: +34-981250111
Fax: +34-981258439
E.mail: gefico@gefico.com SCALE REV. FORMAT
NOTICE:
THIS DRAWING HAS NOT BEEN PUBLISHED AND IS THE SOLE PROPERTY OF GEFICO ENTERPRISE AND IS LENT TO THE BORROWER FOR HIS CONFIDENTIAL USE ONLY AND IN CONSIDERATION OF THE LOAN OF
THIS DRAWING, THE BORROWER PROMISES AND AGREES TO RETURN IT UPON REQUEST AND AGREES THAT IT SHALL NOT BE REPRODUCED, COPIED, LENT OR OTHRWISE DISPOSED OF DIRECTLY OR
INDERECTLY, NOT USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF THIS COMPANY.

A B C D
 A B C D

1 1

28

2 2

18 35

3 3
1 F

V10
G

24

4 4

34

5 5
V19

REV DESCRIPTION DATE APPROVED BY

REVISION HISTORY
MADE BY DATE PROJECT NAME
NORM/STANDARS
LFA 25/09/2015 Vahana Aryan & Vahaha Arjun
CHECKED BY DATE UNE-EN 22768 mk
LFA 25/09/2015 GEFICO PROJECT PROJECT N O
APPROVED BY DATE
MHI 25/09/2015 UNITS: mm 18463 090/15 JM1401/JM1402
DESCRIPTION

Gefico SPARE PARTS REVERSE OSMOSIS AQE-60D

6 6
Pol. O Acevedo - CERCEDA
S/E 09-0244-22 4/6 A3
Tfno: +34-981250111
Fax: +34-981258439
E.mail: gefico@gefico.com SCALE REV. FORMAT
NOTICE:
THIS DRAWING HAS NOT BEEN PUBLISHED AND IS THE SOLE PROPERTY OF GEFICO ENTERPRISE AND IS LENT TO THE BORROWER FOR HIS CONFIDENTIAL USE ONLY AND IN CONSIDERATION OF THE LOAN OF
THIS DRAWING, THE BORROWER PROMISES AND AGREES TO RETURN IT UPON REQUEST AND AGREES THAT IT SHALL NOT BE REPRODUCED, COPIED, LENT OR OTHRWISE DISPOSED OF DIRECTLY OR
INDERECTLY, NOT USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF THIS COMPANY.

A B C D
 A B C D

VSP

1 1

36

I
2 2

3 3

I
H
29 CBA
4 4

BA

5 AFBA 5

BA

REV DESCRIPTION DATE APPROVED BY

REVISION HISTORY
MADE BY DATE PROJECT NAME
NORM/STANDARS
LFA 25/09/2015 Vahana Aryan & Vahaha Arjun
CHECKED BY DATE UNE-EN 22768 mk
LFA 25/09/2015 GEFICO PROJECT PROJECT N O
APPROVED BY DATE
MHI 25/09/2015 UNITS: mm 18463 090/15 JM1401/JM1402
DESCRIPTION

Gefico SPARE PARTS REVERSE OSMOSIS AQE-60D

6 6
Pol. O Acevedo - CERCEDA
S/E 09-0244-22 5/6 A3
Tfno: +34-981250111
Fax: +34-981258439
E.mail: gefico@gefico.com SCALE REV. FORMAT
NOTICE:
THIS DRAWING HAS NOT BEEN PUBLISHED AND IS THE SOLE PROPERTY OF GEFICO ENTERPRISE AND IS LENT TO THE BORROWER FOR HIS CONFIDENTIAL USE ONLY AND IN CONSIDERATION OF THE LOAN OF
THIS DRAWING, THE BORROWER PROMISES AND AGREES TO RETURN IT UPON REQUEST AND AGREES THAT IT SHALL NOT BE REPRODUCED, COPIED, LENT OR OTHRWISE DISPOSED OF DIRECTLY OR
INDERECTLY, NOT USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF THIS COMPANY.

A B C D
 A 2 3 B 4 C 5 D 6
PARTS LIST
ITEM QTY PART NUMBER DESCRIPTION
1 1 15246 HIGH PRESSURE PUMP DISCHARGE MANIFOLD
2 1 15245 HIGH PRESSURE S.S MAINFOLD
FP2 1 18020
FP1 1 18021
1 1
PB 1 10071 PRESSURE SWITCH
T 1 16705 DIGITAL THERMOMETER
7 9 10499 HEXAGONAL NIPPLE 1"
V4 1 10492 NEEDLE VALVE 1" AISI 316L
V5 1 12475 BALL VALVE G1" (H) AISI-316
V19 2 10636 CHECK VALVE 1'' (F) AISI 316
11 3 10496 ADAPTOR 1'' S.S.
VSA 1 12528 SAFETY VALVE
V9 1 12375 SOLENOID VALVE 1" BRASS
14 1 15238 MANIFOLD 60x60x80 BRONZE
V8 1 12557 SOLENOID VALVE 1'' BRASS
VSP 1 12529 PERMEATE RELIEF VALVE
SAL1 1 10074 SALINITY CELL OSMOSIS
18 1 10621 MOTOR ABB 3 PHASE 18,5KW
2 2
CBA 1 10619 PUMP COUPLING HUB
AFBA 1 10617 PUMP FLEXIBLE COUPLING
AFBA 1 10618 SPIDER FLEXIBLE COUPLING
BA 1 10452 HIGH PRESSURE PUMP
23 4 10622 SILENT BLOCK
24 1 16274 PROBE THERMOMETER DN50 G1/2"(H) - G1/2"(M)
25 1 15374 REDUCTION 1/2" - 1'' F-F S.S.
26 1 14221
27 1 10465 COUPLING 11/2"(DN40)
28 1 18309 HOSE L=2360mm HG -HG 1" AISI-316
29 1 18416 HOSE L:970mm R-R 1" INOX
F2 1 14329 FLOWMETER 2" 500-6300 L/H
F1 1 14327 FLOWMETER 2", 2-14 M3/H
P1 6 10602 PRESSURE GAUGE 1/4"(M)
3 P2 2 10603 PRESSURE GAUGE 1/4"(F) 3
34 9 10039 CLAMP AFS-50
35 2 10410 CLAMP AFS-40
36 2 13523 CLAMP AFS-32
PA 1 10107 PRESSURE SWITCH
V2 1 12034 BALL VALVE DN25 PVC-U
V1,V3,V6,V7 4 12039 BALL VALVE DN40 PVC-U
V10 1 12117 CHECK VALVE DN25 PVC-U
OI 3 16770 PRESSURE VESSEL
42 2 15965 BRINE PIPE
43 5 10465 COUPLING 11/2"(DN40)
44 4 10418 HOSE CLAMP 37-40 S.S.
45 2 12736 POLYESTER REINFORCED PVC HOSE OD38 , ID 30
46 1 15374 REDUCTION 1/2" - 1'' F-F S.S.
4 47 1 10499 HEXAGONAL NIPPLE 1" 4
48 1 14221
49 1 18417 HOSE L=620mm HG -HG 1" AISI-316
SW 3 15198 MEMBRAME
51 3 12030 UNION DN25 PVC-U
52 1 12025 TEES 90 32 PVC-U
53 4 18341 HOSE CONNECTOR D32
54 2 12019 ELBOW 90 32 PVC-U

5 5

REV DESCRIPTION DATE APPROVED BY

REVISION HISTORY
MADE BY DATE PROJECT NAME
NORM/STANDARS
LFA 25/09/2015 Vahana Aryan & Vahaha Arjun
CHECKED BY DATE UNE-EN 22768 mk
LFA 25/09/2015 GEFICO PROJECT PROJECT N O
APPROVED BY DATE
MHI 25/09/2015 UNITS: mm 18463 090/15 JM1401/JM1402
DESCRIPTION

Gefico SPARE PARTS REVERSE OSMOSIS AQE-60D

6 6
Pol. O Acevedo - CERCEDA
S/E 09-0244-22 6/6 A3
Tfno: +34-981250111
Fax: +34-981258439
E.mail: gefico@gefico.com SCALE REV. FORMAT
NOTICE:
THIS DRAWING HAS NOT BEEN PUBLISHED AND IS THE SOLE PROPERTY OF GEFICO ENTERPRISE AND IS LENT TO THE BORROWER FOR HIS CONFIDENTIAL USE ONLY AND IN CONSIDERATION OF THE LOAN OF
THIS DRAWING, THE BORROWER PROMISES AND AGREES TO RETURN IT UPON REQUEST AND AGREES THAT IT SHALL NOT BE REPRODUCED, COPIED, LENT OR OTHRWISE DISPOSED OF DIRECTLY OR
INDERECTLY, NOT USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF THIS COMPANY.

A B C D
 1 2 3 4 5 6

13 33 68

A A

14

24 19

32

B B

69

19 69

29
24

40

C C

34

REV DESCRIPTION DATE APPROVED BY

REVISION HISTORY
MADE BY DATE PROJECT NAME
NORM/STANDARS
MMR 04/08/2015
CHECKED BY DATE
D MMR 04/08/2015 D
GEFICO PROJECT PROJECT NO
APPROVED BY DATE
MHI 04/08/2015 UNITS: mm 17694
DESCRIPTION

Gefico SPARE PARTS MAIN SWITCHBOARD

Pol. O Acevedo - CERCEDA

Tfno: +34-981250111
S/E 18-0265-22 0 1/4 A3
Fax: +34-981258439
E.mail: gefico@gefico.com SCALE REV. FORMAT
NOTICE:
THIS DRAWING HAS NOT BEEN PUBLISHED AND IS THE SOLE PROPERTY OF GEFICO ENTERPRISE AND IS LENT TO THE BORROWER FOR HIS CONFIDENTIAL USE ONLY AND IN CONSIDERATION OF THE LOAN OF
THIS DRAWING, THE BORROWER PROMISES AND AGREES TO RETURN IT UPON REQUEST AND AGREES THAT IT SHALL NOT BE REPRODUCED, COPIED, LENT OR OTHRWISE DISPOSED OF DIRECTLY OR
INDERECTLY, NOT USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF THIS COMPANY.
1 2 3 4 5 6
 1 2 3 4 5 6

18 17 16 15 68 33

A A

53

23 22 21 20 28 27 26 25

52

32
B B

69

20 21 22 23

69

53

28 27 26 25

30 31
C C

39

36 35

REV DESCRIPTION DATE APPROVED BY

REVISION HISTORY
MADE BY DATE PROJECT NAME
NORM/STANDARS
MMR 04/08/2015
CHECKED BY DATE
D MMR 04/08/2015 D
GEFICO PROJECT PROJECT NO
APPROVED BY DATE
MHI 04/08/2015 UNITS: mm 17694
DESCRIPTION

Gefico SPARE PARTS MAIN SWITCHBOARD

Pol. O Acevedo - CERCEDA
S/E 18-0265-22 0 2/4 A3
Tfno: +34-981250111
Fax: +34-981258439
E.mail: gefico@gefico.com SCALE REV. FORMAT
NOTICE:
THIS DRAWING HAS NOT BEEN PUBLISHED AND IS THE SOLE PROPERTY OF GEFICO ENTERPRISE AND IS LENT TO THE BORROWER FOR HIS CONFIDENTIAL USE ONLY AND IN CONSIDERATION OF THE LOAN OF
THIS DRAWING, THE BORROWER PROMISES AND AGREES TO RETURN IT UPON REQUEST AND AGREES THAT IT SHALL NOT BE REPRODUCED, COPIED, LENT OR OTHRWISE DISPOSED OF DIRECTLY OR
INDERECTLY, NOT USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF THIS COMPANY.
1 2 3 4 5 6
 1 2 3 4 5 6

7 6 4 5 74 9

A A
8

65

11

61

62 12 67 7

B B
10 7
64

63
64 75

56 57 58 59 60 37 41

55

C 54 C
38

51

43 42 45 44 48 47 76 49 50

REV DESCRIPTION DATE APPROVED BY

REVISION HISTORY
MADE BY DATE PROJECT NAME
NORM/STANDARS
MMR 04/08/2015
CHECKED BY DATE
D MMR 04/08/2015 D
GEFICO PROJECT PROJECT NO
APPROVED BY DATE
MHI 04/08/2015 UNITS: mm 17694
DESCRIPTION

Gefico SPARE PARTS MAIN SWITCHBOARD

Pol. O Acevedo - CERCEDA
S/E 18-0265-22 0 3/4 A3
Tfno: +34-981250111
Fax: +34-981258439
E.mail: gefico@gefico.com SCALE REV. FORMAT
NOTICE:
THIS DRAWING HAS NOT BEEN PUBLISHED AND IS THE SOLE PROPERTY OF GEFICO ENTERPRISE AND IS LENT TO THE BORROWER FOR HIS CONFIDENTIAL USE ONLY AND IN CONSIDERATION OF THE LOAN OF
THIS DRAWING, THE BORROWER PROMISES AND AGREES TO RETURN IT UPON REQUEST AND AGREES THAT IT SHALL NOT BE REPRODUCED, COPIED, LENT OR OTHRWISE DISPOSED OF DIRECTLY OR
INDERECTLY, NOT USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF THIS COMPANY.
1 2 3 4 5 6
 1 2 3 4 4 3 5 2 6 1
PARTS LIST
ITEM QTY PART NUMBER DESCRIPTION
1 1 14824 ARMARIO METAL ENCLOSURE
2 1 10667 CANALETA SLOTTED TRUNKING
3 3 10665 CANALETA SLOTTED TRUNKING
4 1 10136 BASE RELE SOCKET RELAY
5 2 17227 RELE RELAY
6 1 10147 SALINOMETRIC UNIT
8 1 10666 CANALETA SLOTTED TRUNKING
9 4 13886 BASE RELE SOCKET RELAY
10 1 10140 CONTACTOR CONTACTOR
11 4 13885 RELE RELAY
12 1 17769 CIRCUIT BREAKER THERMAL-MAGNETIC
13 1 18281 CARATULA STICK
14 1 11022 PILOTO BLANCO COMPLETO WHITE PILOT COMPLETE
A 15 1 11023 CUERPO PILOTO BLANCO WHITE PILOT BODY A
16 1 11009 CUERPO PILOTO BLANCO WHITE PILOT BODY
17 1 11010 DIODO LUMINOSO BLANCO WHITE LIGHT EMISSION DIODE
18 1 11008 CABEZA PILOTO BLANCO WHITE PILOT LIGHT
19 6 11020 PILOTO ROJO COMPLETO RED PILOT COMPLETE
20 1 11021 CUERPO PILOTO ROJO RED PILOT BODY
21 1 11006 CUERPO PILOTO ROJO RED PILOT BODY
22 1 11007 DIODO LUMINOSO ROJO RED LIGHT EMISSION DIODE
23 1 11005 CABEZA PILOTO ROJO RED PILOT LIGHT
24 2 16323 PILOTO VERDE COMPLETO GREEN PILOT COMPLETE
25 1 16324 CUERPO PILOTO VERDE GREEN PILOT BODY
26 1 13748 CUERPO PILOTO VERDE GREEN PILOT BODY
27 1 13749 DIODO LUMINOSO VERDE GREEN LIGHT EMISSION DIODE
28 1 13747 CABEZA PILOTO VERDE GREEN PILOT LIGHT
29 2 10157 PULSADOR COMPLETO PUSH BUTTON COMPLETE
30 1 17288 CUERPO PULSADOR PUSH BUTTON BODY
31 1 11011 CABEZA PULSADOR PUSH BUTTON HEAD
32 1 13518 AMPERIMETRO AMMETER
33 1 10159 SALINOMETRO SALINITY INDICATOR
34 1 14268 PULSADOR RESET COMPLETO RESET PUSH BUTTON COMPLETE
35 1 13751 CABEZA PULSADOR RESET RESET PUSH BUTTON
36 1 17244 CUERPO INTERRUPTOR SWITCH BODY
37 1 18292 CUERPO INTERRUPTOR V5 SWITCH BODY V5
38 1 18293 TERMINAL SHROUDS
39 1 18295 CONTRAPLACA ENCLAVAMIENTO DOOR INTERLOCK
40 1 18296 MANETA GIRATORIA ROTARY HANDLE
41 1 14287 ALARGADOR DE EJE SHAFT EXTENSION
42 1 15337 PRENSA VTEC GLAND VTEC
B 42.6 1 15337-001
B
42.7 1 15337-003
44 1 15336 PRENSA VTEC GLAND VTEC
44.6 1 15336-001
44.7 1 15336-003
47 1 15333 PRENSA VTEC GLAND VTEC
47.6 1 15333-002
47.7 1 15333-003
49 10 15331 PRENSA VTEC GLAND VTEC
49.3 1 15331-001
49.4 1 15331-003
54 2 18311 ELEVADOR CARRIL MOUNTING BRACKET
55 2 17919 BORNA TOPE END CLAMP
56 3 14817 BORNA TERMINAL BLOCK
57 3 14818 BORNA TERMINAL BLOCK
58 3 14819 BORNA TERMINAL BLOCK
59 12 14820 BORNA TERMINAL BLOCK
60 1 18315 BORNA TERMINAL BLOCK
61 1 18316 CIRCUIT BREAKER THERMAL
62 1 18318 CIRCUIT BREAKER THERMAL
63 1 18322 CONTACTOR CONTACTOR
64 2 10137 CONTACTOR CONTACTOR
65 1 18323 TRANSFORMADOR TRANSFORMER
67 1 10135 DISYUNTOR CIRCUIT BREAKER
68 1 10819 CONTADOR HORARIO HOUR METER
69 2 15646 TAPON CAP
70 1 18349 CABLE TIERRA GROUND WIRE
71 1 18350 CABLE NEGRO BLACK WIRE
72 1 18351 CABLE BLANCO WHITE WIRE
73 1 18352 CABLE AZUL BLUE WIRE
74 1 17228 ALARM RELAY
75 1 18440 TRANSFORMADOR TRANSFORMER
C 76 1 18441 GLAND CAP C

REV DESCRIPTION DATE APPROVED BY

REVISION HISTORY
MADE BY DATE PROJECT NAME
NORM/STANDARS
MMR 04/08/2015
CHECKED BY DATE
D MMR 04/08/2015 D
GEFICO PROJECT PROJECT NO
APPROVED BY DATE
MHI 04/08/2015 UNITS: mm 17694
DESCRIPTION

Gefico SPARE PARTS MAIN SWITCHBOARD

Pol. O Acevedo - CERCEDA

Tfno: +34-981250111
S/E 18-0265-22 0 4/4 A3
Fax: +34-981258439
E.mail: gefico@gefico.com SCALE REV. FORMAT
NOTICE:
THIS DRAWING HAS NOT BEEN PUBLISHED AND IS THE SOLE PROPERTY OF GEFICO ENTERPRISE AND IS LENT TO THE BORROWER FOR HIS CONFIDENTIAL USE ONLY AND IN CONSIDERATION OF THE LOAN OF
THIS DRAWING, THE BORROWER PROMISES AND AGREES TO RETURN IT UPON REQUEST AND AGREES THAT IT SHALL NOT BE REPRODUCED, COPIED, LENT OR OTHRWISE DISPOSED OF DIRECTLY OR
INDERECTLY, NOT USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF THIS COMPANY.
1 2 3 4 5 6
 06-12-0062

MAKING MODERN LIVING POSSIBLE

Data sheet

APP pumps
APP 5.1-10.2

ro-solutions.com
 06-12-0062

Data sheet APP pumps - APP 5.1-10.2

Table of Contents 1. General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2. Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4. Flow at different rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

5. Power requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6. Inlet pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

7. Temperature and corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

7.1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

8. Noise level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

9. Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

10. Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
10.1 APP pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
10.2 Complete unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

11. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
11.1 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
11.2 Open-ended systems with water supply from tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
11.3 Open-ended system with direct water supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
11.4 RO system with APP pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

12. Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
12.1 Periodic maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
12.2 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1. General information APP 5.1, APP 6.5, APP 7.2, APP 8.2 and APP 10.2 All parts included in the APP pumps are designed
pumps are designed to supply low viscosity and to provide long service life, i.e. long service life
corrosive fluids under high pressure, e.g. in with a constantly high efficiency and minimum
seawater reverse osmosis filtration applications of service required.
and for high pressure salt water pumping.
The pumps are fixed displacement pumps in
The APP pumps are based on the axial piston which the flow is proportional to the number of
principle enabling a very light and compact revolutions of the input shaft and the pump
design, and they are designed so that lubrication displacement, regardless of any counter-pressure.
of the moving parts in the pumps is provided by
the fluid itself. No oil lubrication is thus required.

1 2 3 4 5 6

1: Shaft sealing
2: Mounting flange
3: Bleeding plugs
4: Retaining ring
5: Piston/shoe
6: Valve plate
7: Swash plate
8: Cylinder barrel
9: Spring
10: Port plate
11: Connecting flange
12: Housing with bearing

7 8 9 10 12 11

2 521B0851 / DKCFN.PD.013.FB3.02 / 10.2012

 06-12-0062

Data sheet APP pumps - APP 5.1-10.2

2. Benefits • One of the smallest and lightest pumps on • Long service life. Danfoss guarantees
the market. 8,000 hours maintenance-free operation.
• Can be powered by a combustion engine • All parts of the pump are made of non-
provided that a special coupling is used. corrosive materials e.g. Duplex (SAF 2205/
• Generates insignificant pulsations in the EN1.4462) and Super Duplex (SAF 2507/
pressure line. EN1.4410) stainless steel and carbon
• No preventive maintenance required (no reinforced PEEK.
periodic service like e.g. change of lubricant • High efficiency.
and wearing parts).

3. Technical data Code number 180B3005 180B3006 180B3007 180B3008 180B3010

APP pumps APP 5.1 APP 6.5 APP 7.2 APP 8.2 APP 10.2
Geometric displace- cm3/rpm 50 63 70 80 100
ment
in3/rpm 3.05 3.84 4.27 4.88 6.10

Flow m3/h 5.0 6.4 7.2 8.2 10.2

(1800 rpm) 1)
gpm 22.0 28.2 31.7 36.1 44.9

Min. pressure 2)
bar 20 20 20 20 20

psi 290 290 290 290 290

Max. pressure, cont. 3) bar 80 80 80 80 80

psi 1160 1160 1160 1160 1160

Max. pressure, bar 100 100 100 100 100

intermittent 4)
psi 1450 1450 1450 1450 1450

Max. speed cont. 5) rpm 1800 1800 1800 1800 1800

Min. speed cont. rpm 700 700 700 700 700

Power requirement at kW 13.7 17.3 19.2 21.7 27.4

80 bar and 1800 rpm
hp 18.4 23.2 25.7 29.1 36.7

Weight kg 30 30 30 30 30

lb 66 66 66 66 66

1)
Typical average flow at 80 bar.
2)
For lower pressure, please contact Danfoss RO Solutions Sales Organization.
3)
For higher pressure, please contact Danfoss RO Solutions Sales Organzation.
4)
Intermittent pressure is acceptable for less than 10 seconds per minute.
5)
For speeds above 1500 rpm the APP pump must be boosted at a pressure of 2-5 bar
(29-72.5 psi).

521B0851 / DKCFN.PD.013.FB3.02 / 10.2012 3

 06-12-0062

Data sheet APP pumps - APP 5.1-10.2

4. Flow at different rpm Using the diagram shown below, it is easy to

select the APP pump which fits the application
best if the flow required and the rotation speed
(rpm) of the pump are known.

12,00

10,00 APP10.2
APP8.2
8,00
APP7.2
m /h

6,00 APP6.5
3

APP5.1
4,00

2,00

0,00
600 800 1000 1200 1400 1600 1800 2000
rpm

Furthermore, this diagram shows that the flow

can be changed by changing the rotation speed
of the pump. The flow/rpm ratio is constant, and
the “desired “ flow can be obtained by changing
the rotation speed to a corresponding value.
Thus, the required rpm can be determined as:

Desired flow × Rated rpm

Required rpm =
Rated flow

5. Power requirements Pump Flow Pressure rpm Calc.

model factor
60 bar 70 bar 80 bar
l/min m3/h gpm 870 psi 1015 psi 1160 psi
APP 5.1 66 4.0 17.4 8.3kW 9.7 kW 11.1 kW 1460 475.2
APP 5.1 79 4.7 20.9 10.0 kW 11.7 kW 13.4 kW 1752 475.2
APP 6.5 83 5.0 22.0 10.5 kW 12.3 kW 14.0 kW 1460 475.2
APP 6.5 100 6.0 26.4 12.6 kW 14.7 kW 16.8 kW 1752 475.2
APP 7.2 93 5.6 24.6 11.6 kW 13.5 kW 15.5 kW 1470 480.6
APP 7.2 112 6.7 29.5 13.9 kW 16.3 kW 18.6 kW 1764 480.6
APP 8.2 106 6.4 28.1 12.7 kW 14.8 kW 16.9 kW 1470 502.2
APP 8.2 128 7.7 33.7 15.3 kW 17.8 kW 20.3 kW 1764 502.2
APP 10.2 133 8.0 35.1 16.0 kW 18.7 kW 21.4 kW 1470 496.2
APP 10.2 159 9.6 42.1 19.3 kW 22.5 kW 25.7 kW 1764 496.2

The power requirements can be determined using one of the following guiding equations:

l/min × bar 16.7 × m3/h × bar 0.26 × gpm × psi

Required power = [kW] or [kW] or [kW]
Calc. factor Calc. factor Calc. factor

1 hp = 0.75 kW
1 kW = 1.34 hp
1 gpm = 3.79 l/min
1 l/min = 0.26 gpm
1 m3/h = 4.40 gpm
1 gpm = 0.23 m3/h

4 521B0851 / DKCFN.PD.013.FB3.02 / 10.2012

 06-12-0062

Data sheet APP pumps - APP 5.1-10.2

6. Inlet pressure Water supply to the APP pump is either made

from a tank placed above the pump or directly
from a feed pump. The pressure at the pump
inlet (I) must be in the range: 0.5 - 5 bar
(7.3 - 72.5 psi).

7. Temperature and 7.1 Operation

corrosion
Fluid temperature: The chart below illustrates the corrosive
+3° C to +50° C (+37.4° F to 122° F) - dependent resistance of different types of stainless steel
on the NaCl concentration related to NaCl concentration and temperature.

All critical parts of the APP pump are made of

Ambient temperature: SAF 2507. If the APP pump is operated at high
+3° C to +50° C (+37.4° F to 122° F) salinity, always flush the pump with fresh water
at operation stop in order to minimise the risk of
crevice corrosion.

NaCI vs. temperature

80 º C Duplex
70
Super Duplex
60

50
316L
40

30

20 -
100 1000 10 000 100 000 CI
ppm
160 1600 16000 160000 NaCI
ppm

7.2 Storage

Storage temperature: Antefreeze protection is required at tempera-

-40° C to +70° C (+37.4° F to 122° F) – provided tures below 2° C. Danfoss recommends using
that the APP pump is drained of fluid and Dowcal N from Dow Chemical Company or
stored ”plugged”. Chillsafe mono propylene glycol from Arco
Chemical Company.

8. Noise level The chart indicates the noise level in dB(A)

measured at a distance of 1 m from the APP
pump in a reverberation room.

Type 60 bar (580 psi) 60 bar (580 psi) 80 bar (2000 psi) 80 bar (2000 psi)
1500 rpm 1800 rpm 1500 rpm 1800 rpm
APP 5.1 74 79 73 78
APP 6.5 74 79 73 78
APP 7.2 74 79 73 78
APP 8.2 74 79 73 78
APP 10.2 74 79 73 78

Generally, noise will be reduced if speed is It is therefore very important that the APP pump
reduced and vice versa. Use flexible hoses in is mounted correctly on a frame with vibration
order to minimize vibrations and noise. absorber to minimize vibrations and noise.

Since the APP pump is typically mounted on a

bell housing or frame, the noise level can only be
determined for the complete unit (system).

521B0851 / DKCFN.PD.013.FB3.02 / 10.2012 5

 06-12-0062

Data sheet APP pumps - APP 5.1-10.2

The noise level is influenced by:

• The speed of the pump, high rpm create
more noise than low rpm
• Rigid mounting of the pump generates
more noise than flexible mounting
• Pipe mounting direct to the pump
increases the noise level compared to a
flexible hose

9. Filtration As water has very low viscosity, the APP pumps For more information on the importance of
have been designed with very narrow clearance proper filtration, please consult our publication
in order to control internal leakage rates and “Filtration” (code number 521B0861), which also
improve component performance. Therefore it is will provide you with an explanation of filtration
important that the inlet water is filtered properly definitions and a guidance on how to select the
to minimize the wear of the pump. right filter.

The main filter must have a filtration efficiency of

99.98% at 10 μm. We recommend that you use
precision depth filter cartridges rated 10μm abs.
ß10>5000 (equivalent to a filtration efficiency of
99.98%). Bag filters and string wound filter
cartridges typically have only 90% filtration
efficiency. This means that for each 100,000 parti-
cles reaching the filter, 10,000 particles pass
through it compared to only 20 particles in a
filter with an efficiency of 99.98%.

10. Dimensions 10.1 APP pump

6 521B0851 / DKCFN.PD.013.FB3.02 / 10.2012

 06-12-0062

Data sheet APP pumps - APP 5.1-10.2

Description APP 5.1 and APP 10.2

C Bleeding M6, Hexagon AF = 5 mm
D Parallel key, DIN 6885 mm 10 × 8 × 45
inches 0.39 × 0.31 × 1.77
I Inlet connection M42 x 1.5 x 13 mm (0.51 inch) depth
O Outlet connection M42 x 1.5 x 13 mm (0.51 inch) depth
Pump mounting flange 125 A2

10.2 Complete unit

Pump A (mm) B (mm) C (mm) D (mm) E (mm) F (mm) IEC Electric motor
APP 5.1 350 437 160 254 210 498 11 kW, HUC2 160 M-4
APP 6.5 350 437 160 254 254 542 15 kW, HUC2 160 L-4
APP 7.2 350 437 160 254 254 542 15 kW, HUC2 160 L-4
APP 8.2 350 473 180 279 241 578 18.5 kW, HUC2 180 M-4
APP 10.2 350 473 180 279 279 616 22 kW, HUC2 180 L-4
APP 10.2 400 513 200 318 305 659 30 kW, HUC2 200 L-4

For inlet and outlet connections data, see “Accessories catalogue” (521B0903).

521B0851 / DKCFN.PD.013.FB3.02 / 10.2012 7

 06-12-0062

Data sheet APP pumps - APP 5.1-10.2

11. Installation 11.1 Mounting To ensure easy mounting of the flexible coupling
The figure below illustrates how to mount the without using tools, the tolerances must be
APP pump and connect it to an electric motor/ dimensioned accordingly.
combustion engine.
Note: Any axial and/or radial loads on the shaft
A: Flexible coupling must be avoided
B: Bell housing
C: Motor shaft

If alternative mounting is required, please The APP pump should be connected to the rest
contact Danfoss Sales Organization for further of the plant with a flexible hoses.
information.

Min. 3 mm

A B C

11.2 Open-ended systems with water supply

from tank
In order to eliminate the risk of cavitation, a
positive inlet pressure should always be main-
tained by observing the following guidelines:

1. Place the tank (1) above the APP pump inlet

(water level in tank should always be above
the pump).

2. Place a filter (2) in the water supply line in

front of the tank.

3. Dimension the inlet line (3) with minimum

pressure drop (large internal diameter,
minimum length of pipe, avoid bends and
fittings with small internal diameter).

11.3 Open-ended system with direct water

supply
In order to eliminate the risk of cavitation, a
positive inlet pressure is always to be maintained
at min. 0.5 bar (7.3 psi) and max. 5 bar (72.5 psi).

1. Place the filter (1) in the water supply line in

front of the APP pump.

2. Place a monitoring pressure switch (2) set

at min. 1 bar (14.5 psi) between filter and
pump inlet. The monitoring switch must
stop the pump at pressures lower than 1
bar (14.5 psi) At speeds above 1500 rpm -
use 2 bar (29 psi) as set point.

8 521B0851 / DKCFN.PD.013.FB3.02 / 10.2012

 06-12-0062

Data sheet APP pumps - APP 5.1-10.2

11.4 RO system with APP pump

1. For easy system bleeding and flushing, 5. In order to eliminate the risk of damage
apply a bypass non-return valve (1) in and cavitation, a positive pressure at the
parallel with the APP pump. inlet (4) is always to be maintained at min.
0.5 bar (7.3 psi) and max. 5 bar (72.5 psi).
2. Place an inlet filter (2) in front of the APP At speeds above 1500 rpm the pressure at
pump (3). Please consult section 9, the inlet of the APP pump must be min.
“Filtration” for guidance on how to select 2 bar (29 psi).
the right filter. Throughly clean pipes and
flush system prior to start-up. 6. Use flexible hoses (5) to minimize vibra-
tions and noise.
3. Place a monitoring pressure switch (6) set
at min. 1 bar between filter and pump inlet. 7. Install a safety valve (7) in order to avoid
The monitoring switch must stop the pump system damage as the APP pump creates
at pressures lower than 1 bar (14.5 psi). pressure and flow immediately after
Above 1500 rpm - use 2 bar (29 psi) as set startup, regardless of any counter-pressure.
point.

4. Dimension the inlet line to obtain mini-

mum pressure loss (large flow, minimum
pipe length, minimum number of bends/
connections, and fittings with small
pressure losses).

1
7
2 3
5 4 5 Permeate
Feed APP

6
M

Brine

12. Service Provided that the APP pump has been running The shaft sealing in the APP pump is made of
according to the Danfoss specifications on Hastelloy C. At high TDS and high water temper-
pre-filtration, pressure, and rotation speed, ature, the service life of the shaft sealing will be
Danfoss guarantees minimum 8,000 hours reduced. For these applications it is recom-
operation, however max. 18 months from date of mended to replace the shaft sealing after approx.
sale. 4,000 hours operation.

To prevent a total and disastrous breakdown,

Danfoss recommends a pump inspection after 12.1 Periodic maintenance
max. 8,000 hours – at which any worn parts must Water acts as lubricant in the APP pump. Thus
be replaced. there is no oil in the pump.

Note: It is always recommended to replace By operation below the curve for SAF 2507 in the
pistons and shaft sealing if another service- figure in section 7.1, no parts are expected to be
free period is to be obtained. replaced within the first 8,000 hours of opera-
tion.

If the pistons are not replaced, more frequent

inspection is recommended. 12.2 Repair
In case of irregular function of the APP pump,
The APP pump is made of Duplex/Super Duplex please contact the Danfoss RO Solutions Sales
materials with fine corrosion properties. Organisation.
However, it is always recommended to flush the
APP pump when the system is shut down.

521B0851 / DKCFN.PD.013.FB3.02 / 10.2012 9

 06-12-0062

Data sheet APP pumps - APP 5.1-10.2

Danfoss A/S
High Pressure Pumps
DK-6430 Nordborg
Denmark

Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice.
This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed.
All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.

10 521B0851 / DKCFN.PD.013.FB3.02 / 10.2012

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 06-20-0047

ABB Motors and Generators

EU ­ MEPS

Motor data sheet

M3AA 180 MLA 4

Definition Data Unit Remarks

Product code 3GAA 182 031­**G

Voltage code D

Type/Frame M3AA 180 MLA 4

Design CENELEC

Efficiency class IE2

Rated output PN 18.5 kW

Rated voltage UN 400 VD ± 5 % (IEC 60034­1)

Rated frequency fN 50 Hz ± 2 % (IEC 60034­1)

Rated speed nN 1477 r/min

Rated current IN 34.5 A

Starting current IS /IN 7.2

Nominal torque TN 119 Nm

Locked rotor torque Tl/ TN 2.6

Maximum torque Tb / TN 2.9

Efficiency ­ full load 100% 91.87 % Acc. to IEC 60034­2­1

Efficiency ­ 75% 92.82 %

Efficiency ­ 50% 92.63 %

Power factor ­ full load 100% 0.84

Bearing DE/NDE 6310­2Z/C3 6209­2Z/C3

Sound pressure level LP A dB 62 dB(A) +3dB(A)

Moment of inertia J = ¼ GD2 kgm2 0.17 kg­m²

Weight 146 kg

All data subject to tolerances in accordance with IEC. Data subject to changes.
 06-20-0047

ABB Motors and Generators

EU ­ MEPS

Motor data sheet

M3AA 180 MLA 4

Running performance chart

Efficiency Current Power Factor

All data subject to tolerances in accordance with IEC. Data subject to changes.
 06-20-0047

ABB Motors and Generators

EU ­ MEPS

Motor data sheet

M3AA 180 MLA 4

Starting performance chart information

IMotor 400V TMot 400V

All data subject to tolerances in accordance with IEC. Data subject to changes.
 02-20-0191

Low voltage motors

Installation, operation, maintenance and safety manual

More languages – see web site www.abb.com/motors&generators > Motors > Document library
02-20-0191
 02-20-0191

Low voltage motors

Installation, operation, maintenance and safety manual

Contents Page

1. Introduction..................................................................................................................................5
1.1 Declaration of Conformity.....................................................................................................5
1.2 Validity..................................................................................................................................5
2. Safety considerations..................................................................................................................5
3. Handling........................................................................................................................................6
3.1 Reception check...................................................................................................................6
3.2 Transportation and storage...................................................................................................6
3.3 Lifting...................................................................................................................................6
3.4 Motor weight........................................................................................................................6
4. Installation and commissioning..................................................................................................7
4.1 General.................................................................................................................................7
4.2 Motors with other than ball bearings.....................................................................................7
4.3 Insulation resistance check...................................................................................................7
4.4 Foundation...........................................................................................................................7
4.5 Balancing and fitting coupling halves and pulleys..................................................................7
4.6 Mounting and alignment of the motor...................................................................................8
4.7 Radial forces and belt drives.................................................................................................8
4.8 Motors with drain plugs for condensation.............................................................................8
4.9 Cabling and electrical connections........................................................................................8
4.9.1 Connections for different starting methods............................................................9
4.9.2 Connections of auxiliaries......................................................................................9
4.10 Terminals and direction of rotation........................................................................................9
5. Operation ...................................................................................................................................10
5.1 General...............................................................................................................................10

Low voltage motors manual, 3GZF500730-85 Rev F 02-2015 | ABB Motors and Generators 3
 02-20-0191

6. Low voltage motors in variable speed operation...................................................................11

6.1 Introduction........................................................................................................................11
6.2 Winding insulation...............................................................................................................11
6.2.1 Selection of winding insulation for ABB converters...............................................11
6.2.2 Selection of winding insulation with all other converters.......................................11
6.3 Thermal protection..............................................................................................................11
6.4 Bearing currents.................................................................................................................11
6.4.1 Elimination of bearing currents with ABB converters............................................11
6.4.2 Elimination of bearing currents with all other converters.......................................12
6.5 Cabling, grounding and EMC..............................................................................................12
6.6 Operating speed.................................................................................................................12
6.7 Motor in variable speed applications...................................................................................12
6.7.1 General...............................................................................................................12
6.7.2 Motor loadability with AC_8_ _ – series of converters with DTC control................12
6.7.3 Motor loadability with AC_5_ _ – series of converter............................................12
6.7.4 Motor loadability with other voltage source PWM-type converters.......................12
6.7.5 Short time overloads...........................................................................................13
6.8 Rating plates......................................................................................................................13
6.9 Commissioning the variable speed application....................................................................13
7. Maintenance...............................................................................................................................14
7.1 General inspection..............................................................................................................14
7.1.1 Standby motors...................................................................................................14
7.2 Lubrication.........................................................................................................................14
7.2.1 Motors with permanently greased bearings.........................................................14
7.2.2 Motors with regreasable bearings........................................................................15
7.2.3 Lubrication intervals and amounts.......................................................................15
7.2.4 Lubricants...........................................................................................................17
8. After Sales Support....................................................................................................................18
8.1 Spare parts.........................................................................................................................18
8.2 Dismantling, re-assembly and rewinding.............................................................................18
8.3 Bearings.............................................................................................................................18
9. Environmental requirements.....................................................................................................18
10. Troubleshooting.........................................................................................................................19
11. Figures........................................................................................................................................21

4 ABB Motors and Generators | Low voltage motors manual, 3GZF500730-85 Rev F 02-2015
 02-20-0191

1. Introduction 2. Safety considerations

The motor is intended for installation and use by qualified
NOTE!
personnel, familiar with health and safety requirements and
These instructions must be followed to ensure
national legislation.
safe and proper installation, operation and
maintenance of the motor. They should be brought Safety equipment necessary for the prevention of accidents
to the attention of anyone who installs, operates at the installation and operating site must be provided in
or maintains the motor or associated equipment. accordance with local regulations.
The motor is intended for installation and use by
qualified personnel, familiar with health and safety
requirements and national legislation. Ignoring these WARNING!
instructions may invalidate all applicable warranties. Emergency stop controls must be equipped with
restart lockouts. After emergency stop a new start
command can take effect only after the restart
1.1 Declaration of Conformity lockout has been intentionally reset.

The conformity of the end product according to Directive

2006/42/EC (Machinery) has to be established by the
commissioning party when the motor is fitted to the Points to be observed:
machinery. 1. Do not step on the motor.
2. The temperature of the outer casing of the motor
1.2 Validity may be hot to the touch during normal operation and
especially after shut-down.
These instructions are valid for the following ABB electrical 3. Some special motor applications may require additional
machine types, in both motor and generator operation: instructions (e.g. when supplied by frequency
converter).
series MT*, MXMA,
4. Observe rotating parts of the motor.
series M1A*, M2A*/M3A*, M2B*/M3B*, M4B*, M2C*/M3C*,
M2F*/M3F*, M2L*/M3L*, M2M*/M3M*, M2Q*, M2R*/M3R*, 5. Do not open terminal boxes while energized.
M2V*/M3V*
in frame sizes 56 - 450.

There is a separate manual for e.g. Ex motors ‘Low voltage

motors for explosive atmospheres: Installation, operation
and maintenance and safety manual (3GZF500730-47)

Additional information is required for some machine types

due to special application and/or design considerations.

Additional manual is available for the following motors:

– roller table motors
– water cooled motors
– smoke extraction motors
– brake motors
– motors for high ambient temperatures
– motors in marine applications for mounting on open deck
of ships or offshore units

Low voltage motors manual, 3GZF500730-85 Rev F 02-2015 | ABB Motors and Generators 5
 02-20-0191

3. Handling Lifting eyebolts must be tightened before lifting. If needed,

the position of the eyebolt can be adjusted using suitable
washers as spacers.
3.1 Reception check
Ensure that proper lifting equipment is used and that the
Immediately upon receipt, check the motor for external sizes of the hooks are suitable for the lifting lugs.
damage (e.g. shaft-ends, flanges and painted surfaces)
and, if found, inform the forwarding agent without delay. Care must be taken not to damage auxiliary equipment and
cables connected to the motor.
Check all rating plate data, especially voltage and winding
connections (star or delta). The type of bearing is specified Remove eventual transport jigs fixing the motor to the
on the rating plate of all motors except the smallest frame pallet.
sizes.
Specific lifting instructions are available from ABB.
In the case of a variable speed drive application check
the maximum loadability allowed according to frequency
stamped on the motor’s second rating plate. WARNING!
During lifting, mounting or maintenance work, all
necessary safety considerations shall be in place
3.2 Transportation and storage and special attention to be taken that nobody will be
The motor should always be stored indoors (above subject to lifted load.
–20 °C), in dry, vibration-free and dust-free conditions.
During transportation, shocks, falls and humidity should
be avoided. In other conditions, please contact ABB. 3.4 Motor weight
Unprotected machined surfaces (shaft-ends and flanges) The total motor weight can vary within the same frame size
should be treated against corrosion. (center height) depending on different output, mounting
arrangement and auxiliaries.
It is recommended that shafts are rotated periodically by
hand to prevent grease migration. The following table shows estimated maximum weights
for machines in their basic versions as a function of frame
Anti-condensation heaters, if fitted, are recommended to material.
be used to avoid water condensing in the motor.
The actual weight of all ABB’s motors, except the smallest
The motor must not be subject to any external vibrations at frame sizes (56 and 63), is shown on the rating plate
standstill so as to avoid causing damage to the bearings.
Frame size Aluminum Cast iron Add.
Motors fitted with cylindrical-roller and/or angular contact for brake
bearings must be fitted with locking devices during Weight kg Weight kg
transport. 56 4.5 - -
63 6 - -
3.3 Lifting 71 8 13 5
80 14 20 8
All ABB motors above 25 kg are equipped with lifting lugs 90 20 30 10
or eyebolts. 100 32 40 16
112 36 50 20
Only the main lifting lugs or eyebolts of the motor should be
132 93 90 30
used for lifting the motor. They must not be used to lift the
160 149 130 30
motor when it is attached to other equipment.
180 162 190 45
Lifting lugs for auxiliaries (e.g. brakes, separate cooling 200 245 275 55
fans) or terminal boxes must not be used for lifting the 225 300 360 75
motor. Because of different output, mounting arrangements 250 386 405 75
280 425 800 -
and auxiliary equipment, motors with the same frame may
315 - 1700 -
have a different center of gravity.
355 - 2700 -
Damaged lifting lugs must not be used. Check that 400 - 3500 -
eyebolts or integrated lifting lugs are undamaged before 450 - 4500 -
lifting.
If the motor is equipped with a separate fan, contact ABB
for the weight.

6 ABB Motors and Generators | Low voltage motors manual, 3GZF500730-85 Rev F 02-2015
 02-20-0191

4. Installation and commissioning

WARNING! WARNING!
Disconnect and lock out before working on the To avoid risk of electrical shock, the motor frame
motor or the driven equipment. must be grounded and the windings should be
discharged against the frame immediately after each
measurement.
4.1 General
All rating plate values must be carefully checked to ensure If the reference resistance value is not attained, the
that the motor protection and connection will be properly winding is too damp and must be oven dried. The oven
done. temperature should be 90 °C for 12-16 hours followed by
105 °C for 6-8 hours.
4.2 Motors with other than If fitted drain hole plugs must be removed and closing
ball bearings valves must be opened during heating. After heating, make
sure the plugs are refitted. Even if the drain plugs are fitted,
Remove transport locking if employed. Turn the shaft of the it is recommended to disassemble the end shields and
motor by hand to check free rotation, if possible. terminal box covers for the drying process.

Windings drenched in seawater normally need to be

Motors equipped with roller bearings:
rewound.
Running the motor with no radial force applied to the shaft
may damage the roller bearing due to “sliding”, 4.4 Foundation
Motors equipped with angular contact bearing: The end user has full responsibility for preparation of the
foundation.
Running the motor with no axial force applied in the right
direction in relation to the shaft may damage the angular Metal foundations should be painted to avoid corrosion.
contact bearing.
Foundations must be even and sufficiently rigid to
withstand possible short circuit forces.
WARNING!
For motors with angular contact bearings the axial They must be designed and dimensioned to avoid the
force must not by any means change direction. transfer of vibration to the motor and vibration caused by
resonance. See figure below.

The type of bearing is specified on the rating plate.

Ruler

Motors equipped with regreasing nipples:

When starting the motor for the first time, or after long
storage, apply the specified quantity of grease. Note! Height difference shall
not exceed ± 0,1mm referred
See section “7.2.2 Motors with re-greasable bearings” for to any other motor foot
more details.

When fitted in a vertical position with the shaft pointing

downwards, the motor must have a protective cover
to prevent foreign objects and fluid from falling into the
ventilation openings. This task can also be achieved by Foot location
a separate cover not fixed to the motor. In this case, the
motor must have a warning label.

4.3 Insulation resistance check 4.5 Balancing and fitting

Measure insulation resistance before commissioning and
when winding dampness is suspected.
coupling halves and pulleys
As standard, balancing of the motor has been carried out
Insulation resistance, corrected to 25 °C, may not in any using half key.
cases be below 1 MΩ (measured with 500 or 1000 VDC).
The insulation resistance value is halved for each 20 °C Coupling halves or pulleys must be balanced after
increase in temperature. Figure 1 can be used for the machining the keyways. Balancing must be done in
insulation correction to the desired temperature. accordance with the balancing method specified for the
motor.

Low voltage motors manual, 3GZF500730-85 Rev F 02-2015 | ABB Motors and Generators 7
 02-20-0191

Coupling halves and pulleys must be fitted on the shaft by 4.8 Motors with drain plugs
using suitable equipment and tools which do not damage
the bearings and seals. for condensation
Never fit a coupling half or pulley by hammering or Check that drain holes and plugs face downwards. In
removing it by using a lever pressed against the body of the vertical position mounted motors, the drain plugs may be in
motor. horizontal position.

Motors with sealable plastic drain plugs are delivered in an

4.6 Mounting and alignment open position. In very dusty environments, all drain holes
should be closed.
of the motor
Ensure that there is enough space for free airflow around
the motor. It is recommended to have a clearance between
4.9 Cabling and electrical
the fan cover and the wall etc. of at least ½ of the air connections
intake of the fan cover. Additional information may be
found from the product catalog or from the dimension The terminal box on standard single speed motors normally
drawings available on our web pages: www.abb.com/ contains six winding terminals and at least one earth
motors&generators. terminal.

Correct alignment is essential to avoid bearing, vibration In addition to the main winding and earthing terminals, the
and possible shaft failures. terminal box can also contain connections for thermistors,
heating elements or other auxiliary devices.
Mount the motor on the foundation using the appropriate
bolts or studs and place shim plates between the Suitable cable lugs must be used for the connection of all
foundation and the feet. main cables. Cables for auxiliaries can be connected into
their terminal blocks as such.
Align the motor using appropriate methods.
Motors are intended for fixed installation only. Unless
If applicable, drill locating holes and fix the locating pins into otherwise specified, cable entry threads are metric. The IP
position. class of the cable gland must be at least the same as those
of the terminal boxes.
Mounting accuracy of coupling half: check that clearance
b is less than 0.05 mm and that the difference a1 to a2 is Certified conduit hub or cable connector has to be used at
also less than 0.05 mm. See figure 2. the time of installation.

Re-check the alignment after final tightening of the bolts or

studs. NOTE!
Cables should be mechanically protected and
Do not exceed permissible loading values for bearings as clamped close to the terminal box to fulfill the
stated in the product catalogs. appropriate requirements of IEC/EN 60079-0 and
local installation standards.
Check that the motor has sufficient airflow. Ensure that no
nearby objects or direct sunshine radiate additional heat to
the motor.
Unused cable entries must be closed with blanking
For flange mounted motors (e.g. B5, B35, V1), make sure elements according to the IP class of the terminal box.
that the construction allows sufficient air flow on the outer
surface of the flange. The degree of protection and diameter are specified in the
documents relating to the cable gland.

4.7 Radial forces and belt drives WARNING!

Belts must be tightened according to the instructions of the Use appropriate cable glands and seals in the cable
supplier of the driven equipment. However, do not exceed entries according to the type and diameter of the
the maximum belt forces (i.e. radial bearing loading) stated cable.
in the relevant product catalogs.

Earthing must be carried out according to local regulations

WARNING! before the motor is connected to the supply voltage.
Excessive belt tension will damage bearings and can
cause shaft damage. The earth terminal on the frame has to be connected to
PE (protective earth) with a cable as shown in Table 5 of
IEC/EN 60034-1:

8 ABB Motors and Generators | Low voltage motors manual, 3GZF500730-85 Rev F 02-2015
 02-20-0191

Minimum cross-sectional area of protective Direct-on-line starting (DOL):

conductors Y or D winding connections may be used.
Cross-sectional area of phase Minimum cross-sectional area For example, 690 VY, 400 VD indicates Y-connection for
conductors of the installation, of the corresponding protective 690 V and D-connection for 400 V.
S, [mm2] conductor, SP, [mm2]
4 4 Star/Delta (Wye/Delta) starting (Y/D):
6 6
10 10
The supply voltage must be equal to the rated voltage of
16 16
the motor when using a D-connection.
25 25
Remove all connection links from the terminal block.
35 25
50 25 Other starting methods and severe starting
70 35 conditions:
95 50 In cases where other starting methods e.g. converter or
120 70 soft starter will be used in the duty types of S1 and S2, it
150 70 is considered that the device is “isolated from the power
185 95 system when the electrical machine is running” as in the
240 120 standard IEC 60079-0 and thermal protection is optional.
300 150
400 185
4.9.2 Connections of auxiliaries
In addition, earthing or bonding connection facilities on
the outside of electrical apparatus must provide effective If a motor is equipped with thermistors or other RTDs
connection of a conductor with a cross-sectional area of at (Pt100, thermal relays, etc.) and auxiliary devices, it is
least 4 mm2. recommended they be used and connected by appropriate
means. For certain applications, it is mandatory to use
The cable connection between the network and motor thermal protection. More detailed information can be found
terminals must meet the requirements stated in the in the documents delivered with the motor. Connection
national standards for installation or in the standard diagrams for auxiliary elements and connection parts can
IEC/EN 60204-1 according to the rated current indicated be found inside the terminal box.
on the rating plate.
The maximum measuring voltage for the thermistors is
2.5 V. The maximum measuring current for Pt100 is 5 mA.
NOTE!
Using a higher measuring voltage or current may cause
When the ambient temperature exceeds +50 °C,
errors in readings or a damaged temperature detector.
cables having permissible operating temperature
of +90 °C as minimum shall be used. Also all other The insulation of thermal sensors fulfills the requirements of
conversion factors depending on the installation basic insulation.
conditions shall be taken into account while sizing
the cables.

Ensure that the motor protection corresponds to the

4.10 Terminals and direction
environment and weather conditions. For example, make of rotation
sure that water cannot enter the motor or the terminal
boxes. The shaft rotates clockwise when viewing the shaft face at
the motor drive end, and the line phase sequence - L1, L2,
The seals of terminal boxes must be placed correctly in L3 - is connected to the terminals as shown in figure 3.
the slots provided to ensure the correct IP class. A leak
could lead to penetration of dust or water, creating a risk of To alter the direction of rotation, interchange any two
flashover to live elements. connections on the supply cables.

If the motor has a unidirectional fan, ensure that it rotates in

4.9.1 Connections for different starting the same direction as the arrow marked on the motor.
methods
The terminal box on standard single speed motors normally
contains six winding terminals and at least one earth
terminal. This enables the use of DOL- or Y/D –starting.

For two-speed and special motors, the supply connection

must follow the instructions inside the terminal box or in the
motor manual.

The voltage and connection are stamped on the rating

plate.

Low voltage motors manual, 3GZF500730-85 Rev F 02-2015 | ABB Motors and Generators 9
 02-20-0191

5. Operation
5.1 General
The motors are designed for the following conditions unless
otherwise stated on the rating plate:

– Motors are to be installed in fixed installations only.

– Normal ambient temperature range is from –20 °C to
+40 °C.
– Maximum altitude is 1000 m above sea level.
– The variation of the supply voltage and frequency may
not exceed the limits mentioned in relevant standards.
Tolerance for supply voltage is ±5 %, and for frequency
±2 % according to the figure 4 (EN / IEC 60034-1,
paragraph 7.3, Zone A). Both extreme values are not
supposed to occur at the same time.

The motor can only be used in applications for which

it is intended. The rated nominal values and operation
conditions are shown on the motor rating plates. In
addition, all requirements of this manual and other related
instructions and standards must be followed.

If these limits are exceeded, motor data and construction

data must be checked. Please contact ABB for further
information.

WARNING!
Ignoring any instructions or maintenance of the
apparatus may jeopardize safety and thus prevent
the use of the motor.

10 ABB Motors and Generators | Low voltage motors manual, 3GZF500730-85 Rev F 02-2015
 02-20-0191

6. Low voltage motors in variable speed operation

6.1 Introduction 6.2.2 Selection of winding insulation with
all other converters
This part of the manual provides additional instructions for
motors used in frequency converter supplies. The motor The voltage stresses must be limited below accepted limits.
is intended to operate from a single frequency converter Please contact the system supplier to ensure the safety of
supply and not motors running in parallel from one the application. The influence of possible filters must be
frequency converter. Instructions given by the converter taken into account while dimensioning the motor.
manufacturer shall be followed.

Additional information may be required by ABB to decide

on the suitability for some motor types used in special
6.3 Thermal protection
applications or with special design modifications. Most of the motors covered by this manual are equipped
with PTC thermistors or other type of RTD’s in the stator
windings. It is recommended to connect those to the
6.2 Winding insulation frequency converter. Read more in chapter 4.9.2.

Variable speed drives create higher voltage stresses

than the sinusoidal supply on the winding of the motor.
Therefore, the winding insulation of the motor as well as
6.4 Bearing currents
the filter at the converter output must be dimensioned Insulated bearings or bearing constructions, common
according following instructions. mode filters and suitable cabling and grounding methods
must be used according to the following instructions and
6.2.1 Selection of winding insulation for using table 6.1.
ABB converters
6.4.1 Elimination of bearing currents with
In the case of ABB e.g. AC_8_ _-series and AC_5_ _-series
single drives with a diode supply unit (uncontrolled DC
ABB converters
voltage), the selection of winding insulation and filters can In case of ABB frequency converter e.g. AC_8_ _- and
be made according to table 6.1. AC_5_ _-series with a diode supply unit, the methods
according to table 6.1 must be used to avoid harmful
bearing currents in motors.

PN < 100 kW PN ≥ 100 kW or PN ≥ 350 kW or

IEC315 ≤ Frame size ≤ IEC355 IEC400 ≤ Frame size ≤ IEC450
UN ≤ 500 V Standard motor Standard motor Standard motor
+ Insulated N-bearing + Insulated N-bearing
+ Common mode filter
500V >UN ≤ 600V Standard motor Standard motor Standard motor
+ dU/dt –filter (reactor) + dU/dt –filter (reactor) + Insulated N-bearing
OR + Insulated N-bearing + dU/dt –filter (reactor)
Reinforced insulation OR + Common mode filter
Reinforced insulation OR
+ Insulated N-bearing Reinforced insulation
+ Insulated N-bearing
+ Common mode filter
500V >UN ≤ 600V Standard motor Standard motor Standard motor
(cable length > 150 m) + Insulated N-bearing + Insulated N-bearing
+ Common mode filter

600V >UN ≤ 690V Reinforced insulation Reinforced insulation Reinforced insulation

+ dU/dt –filter (reactor) + dU/dt –filter (reactor) + Insulated N-bearing
+ Insulated N-bearing + dU/dt –filter (reactor)
+ Common mode filter
600V >UN ≤ 690V Reinforced insulation Reinforced insulation Reinforced insulation
(cable length > 150 m) + Insulated N-bearing + Insulated N-bearing
+ Common mode filter

Table 6.1 Selection of winding insulation for ABB converters

Please contact ABB for more information on resistor braking and converters with controlled supply units.

Low voltage motors manual, 3GZF500730-85 Rev F 02-2015 | ABB Motors and Generators 11
 02-20-0191

NOTE!
6.7 Motors in variable speed
Insulated bearings which have aluminum oxide applications
coated inner and/or outer bores or ceramic rolling
elements are recommended. Aluminum oxide
6.7.1 General
coatings shall also be treated with a sealant to
prevent dirt and humidity penetrating into the porous With ABB’s frequency converters, the motors can be
coating. For the exact type of bearing insulation, see dimensioned by using ABB’s DriveSize dimensioning
the motor’s rating plate. Changing the bearing type program. The tool is downloadable from the ABB website
or insulation method without ABB’s permission is (www.abb.com/motors&generators).
prohibited. For application supplied by other converters, the motors
must be dimensioned manually. For more information,
6.4.2 Elimination of bearing currents with please contact ABB.
all other converters The loadability curves (or load capacity curves) are based
The user is responsible for protecting the motor and driven on nominal supply voltage. Operation in under or over
equipment from harmful bearing currents. Instructions voltage conditions may influence on the performance of the
described in chapter 6.4.1 can be used as guideline, but application.
their effectiveness cannot be guaranteed in all cases.
6.7.2 Motor loadability with AC_8_ _ – series
6.5 Cabling, grounding and EMC of converters with DTC control
The loadability curves presented in Figures 5a - 5d are
To provide proper grounding and to ensure compliance
valid for ABB AC_8_ _-series converters with uncontrolled
with any applicable EMC requirements, motors above
DC-voltage and DTC-control. The figures show the
30 kW shall be cabled by shielded symmetrical cables and
approximate maximum continuous output torque of the
EMC glands, i.e. cable glands providing 360° bonding.
motors as a function of supply frequency. The output
Symmetrical and shielded cables are highly recommended torque is given as a percentage of the nominal torque of
also for smaller motors. Make the 360° grounding the motor. The values are indicative and exact values are
arrangement at all the cable entries as described in the available on request.
instructions for the glands. Twist the cable shields into
bundles and connect to the nearest ground terminal/bus
NOTE!
bar inside the terminal box, converter cabinet, etc.
The maximum speed of the motor and application
may not be exceeded!
NOTE!
Proper cable glands providing 360° bonding must
be used at all termination points such as motor, 6.7.3 Motor loadability with AC_5_ _ – series
converter, possible safety switch, etc. of converter
The loadability curves presented in Figures 6a - 6d are
valid for AC_5_ _ -series converters. The figures show
For motors of frame size IEC 280 and above, additional
the approximate maximum continuous output torque of
potential equalization between the motor frame and the
the motors as a function of supply frequency. The output
driven equipment is needed, unless both are mounted on
torque is given as a percentage of the nominal torque of
a common steel base. In this case, the high frequency
the motor. The values are indicative and exact values are
conductivity of the connection provided by the steel
available on request.
base should be checked by, for example, measuring the
potential difference between the components.
NOTE!
More information about grounding and cabling of variable
The maximum speed of the motor and application
speed drives can be found in the manual “Grounding and
may not be exceeded!
cabling of the drive system” (Code: 3AFY 61201998).

6.7.4 Motor loadability with other voltage

6.6 Operating speed source PWM-type converters
For speeds higher than the nominal speed stated on the For other converters, with uncontrolled DC voltage and
motor’s rating plate or in the respective product catalog, minimum switching frequency of 3 kHz (200…500 V), the
ensure that either the highest permissible rotational speed dimensioning instructions as mentioned in chapter 6.7.3
of the motor or the critical speed of the whole application is can be used as guidelines. However, it shall be noted that
not exceeded. the actual thermal loadability can also be lower. Please
contact the manufacturer of the converter or the system
supplier.

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 02-20-0191

NOTE!
6.9 Commissioning the variable
The actual thermal loadability of a motor may be speed application
lower than shown by guideline curves.
The commissioning of the variable speed application must
6.7.5 Short time overloads be done according to the instructions of the frequency
converter and local laws and regulations. The requirements
ABB motors can usually be temporarily overloaded as well and limitations set by the application must also be taken
as used in intermittent duties. The most convenient method into account.
to dimension such applications is to use the DriveSize tool.
All parameters needed for setting the converter must be
6.8 Rating plates taken from the motor rating plates. The most often needed
parameters are:
The usage of ABB’s motors in variable speed applications
do not usually require additional rating plates. The – nominal voltage
parameters required for commissioning the converter – nominal current
can be found from the main rating plate. In some special – nominal frequency
applications, however, the motors can be equipped with – nominal speed
additional rating plates for variable speed applications. – nominal power
Those include the following information:

– speed range NOTE!

– power range In case of missing or inaccurate information, do not
– voltage and current range operate the motor before ensuring correct settings!
– type of torque (constant or quadratic)
– and converter type and required minimum switching
frequency. ABB recommends using all the suitable protective features
provided by the converter to improve the safety of the
application. Converters usually provide features such as
(names and availability of features depend on manufacturer
and model of the converter):

– minimum speed
– maximum speed
– acceleration and deceleration times
– maximum current
– maximum torque
– stall protection

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 02-20-0191

7. Maintenance 2. The bearing must be greased while rotating the shaft

every year (to be reported). If the motor has been
provided with roller bearing at the driven end, the
WARNING! transport lock must be removed before rotating the
Voltage may be connected at standstill inside the shaft. The transport locking must be remounted in case
terminal box for heating elements or direct winding of transportation.
heating. 3. All vibrations must be avoided to prevent a bearing from
failing. All instructions in the motor instruction manual for
commissioning and maintenance have to be followed.
The warranty will not cover the winding and bearing
7.1 General inspection damages if these instructions have not been followed.
1. Inspect the motor at regular intervals, at least once a
year. The frequency of checks depends on, for example,
the humidity level of the ambient air and on the local 7.2 Lubrication
weather conditions. This can initially be determined
experimentally and must then be strictly adhered to.
2. Keep the motor clean and ensure free ventilation WARNING!
airflow. If the motor is used in a dusty environment, Beware of all rotating parts!
the ventilation system must be regularly checked and
cleaned.
3. Check the condition of shaft seals (e.g. V-ring or radial WARNING!
seal) and replace if necessary. Grease can cause skin irritation and eye
inflammation. Follow all safety precautions specified
4. Check the condition of connections and mounting and
by the manufacturer of the grease.
assembly bolts.
5. Check the bearing condition by listening for any unusual
noise, vibration measurement, bearing temperature, Bearing types are specified in the respective product
inspection of spent grease or SPM bearing monitoring. catalogs and on the rating plate of all motors, except
Pay special attention to bearings when their calculated smaller frame sizes.
rated life time is coming to an end.
Reliability is a vital issue for bearing lubrication intervals.
When signs of wear are noticed, dismantle the motor, ABB uses mainly the L1 -principle (i.e. that 99 % of the
check the parts and replace if necessary. When bearings motors are certain to make the life time) for lubrication.
are changed, replacement bearings must be of the same
type as those originally fitted. The shaft seals have to be
replaced with seals of the same quality and characteristics 7.2.1 Motors with permanently greased
as the originals when changing bearings. bearings
Bearings are usually permanently greased bearings of 1Z,
In the case of the IP 55 motor and when the motor
2Z, 2RS or equivalent.
has been delivered with a plug closed, it is advisable to
periodically open the drain plugs in order to ensure that As a guide, adequate lubrication for sizes up to 250 can
the way out for condensation is not blocked and allows be achieved for the following duration, according to L1.
condensation to escape from the motor. This operation For duties with higher ambient temperatures, please
must be done when the motor is at a standstill and has contact ABB. The informative formula to change the
been made safe to work on. L1 values roughly to L10 values: L10 = 2.0 x L1.

7.1.1 Standby motors

If the motor is in standby for a longer period of time on
a ship or in other vibrating environment the following
measures have to be taken:

1. The shaft must be rotated regularly every 2 weeks (to

be reported) by means of starting up of the system. In
case a start-up is not possible, for any reason, at least
the shaft has to be turned by hand in order to achieve
a different position once a week. Vibrations caused by
other vessel's equipment will cause bearing pitting which
should be minimized by regular operation/hand turning.

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 02-20-0191

Duty hours for permanently greased bearings at ambient Regreasing while the motor is at a standstill
temperatures of 25 °C and 40 °C are: If it is not possible to re-grease the bearings while the
motors are running, lubrication can be carried out while the
Duty hours Duty hours motor is at a standstill.
Frame size Poles at 25° C at 40° C – In this case, use only half the amount of grease and then
56 2 52 000 33 000 run the motor for a few minutes at full speed.
56 4-8 65 000 41 000 – When the motor has stopped, apply the rest of the
63 2 49 000 31 000 specified amount of grease to the bearing.
63 4-8 63 000 40 000 – After 1-2 running hours, close the grease outlet plug or
71 2 67 000 42 000 closing valve, if fitted.
71 4-8 100 000 56 000 B. Automatic lubrication
80-90 2 100 000 65 000
80-90 4-8 100 000 96 000 The grease outlet plug must be removed permanently with
100-112 2 89 000 56 000 automatic lubrication or open closing valve, if fitted.
100-112 4-8 100 000 89 000
ABB recommends only the use of electromechanical
132 2 67 000 42 000
systems.
132 4-8 100 000 77 000
160 2 60 000 38 000 The amount of grease per lubrication interval stated in the
160 4-8 100 000 74 000 table should be multiplied by three if a central lubrication
180 2 55 000 34 000 system is used. When using a smaller automatic re-grease
180 4-8 100 000 70 000 unit (one or two cartridges per motor) the normal amount of
200 2 41 000 25 000 grease can be used.
200 4-8 95 000 60 000 When 2-pole motors are automatically re-greased, the note
225 2 36 000 23 000 concerning lubricant recommendations for 2-pole motors in
225 4-8 88 000 56 000 the Lubricants chapter should be followed.
250 2 31 000 20 000
250 4-8 80 000 50 000 The used grease should be suitable for automatic
lubrication. The automatic lubrication system deliverer and
Data is valid up to 60 Hz. the grease manufacturer’s recommendations should check.

7.2.2 Motors with regreasable bearings Calculation example of amount of grease for
automatic lubrication system
Lubrication information plate and general lubrication Central lubrication system: Motor IEC M3_P 315_ 4-pole in
advice 50 Hz network, re-lubrication interval according to Table is
If the motor is equipped with a lubrication information plate, 7600 h/55 g (DE) and 7600 h/40g (NDE):
follow the given values.
(DE) RLI = 55 g/7600h*3*24 = 0,52 g/day
Greasing intervals regarding mounting, ambient
temperature and rotational speed are defined on the (NDE) RLI = 40 g/7600*3*24 = 038 g/day
lubrication information plate.
Calculation example of amount of grease for single
During the first start or after a bearing lubrication a automation lubrication unit (cartridge)
temporary temperature rise may appear, approximately 10 (DE) RLI = 55 g/7600h*24 = 0,17 g/day
to 20 hours.
(NDE) RLI = 40 g/7600*24 = 0,13 g/day
Some motors may be equipped with a collector for old
grease. Follow the special instructions given for the RLI = Re-lubricaion interval, DE = Drive end, NDE = Non drive end
equipment.

A. Manual lubrication 7.2.3 Lubrication intervals and amounts

Regreasing while the motor is running Lubrication intervals for vertical motors are half of the values
– Remove grease outlet plug or open closing valve if fitted. shown in the table below.
– Be sure that the lubrication channel is open.
As a guide, adequate lubrication can be achieved for the
– Inject the specified amount of grease into the bearing.
following duration, according to L1. For duties with higher
– Let the motor run for 1-2 hours to ensure that all excess
ambient temperatures please contact ABB. The informative
grease is forced out of the bearing. Close the grease
formula to change the L1 values roughly to L10 values is L10
outlet plug or closing valve, if fitted.
= 2.0 x L1, with manual lubrication.

The lubrication intervals are based on a bearing operating

temperature of 80 °C (ambient temperature +25 °C).

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 02-20-0191

Higher speed operation, e.g. in frequency converter

NOTE!
applications, or lower speed with heavy load will require
An increase in the ambient temperature raises the
shorter lubrication intervals.
temperature of the bearings correspondingly. The
interval values should be halved for a 15 °C increase
in bearing temperature and may be doubled for a WARNING!
15 °C decrease in bearing temperature. The maximum operating temperature of the grease
and bearings, +110 °C, must not be exceeded.
The designed maximum speed of the motor must
not be exceeded.

Amount
Frame 3600 3000 1800 1500 1000 500-900
of grease kW kW kW kW
size r/min r/min r/min r/min r/min r/min
g/bearing
Ball bearings, lubrication intervals in duty hours
112 10 all 10 000 13 000 all 18 000 21 000 all 2 5 000 all 28 000
132 15 all 9 000 11 000 all 17 000 19 000 all 23 000 all 26 500
160 25 ≤ 18,5 9 000 12000 ≤ 15 18 000 21 500 ≤ 11 24 000 all 24 000
160 25 > 18,5 7 500 1 0000 > 15 15 000 18 000 > 11 22 500 all 24 000
180 30 ≤ 22 7 000 9 000 ≤ 22 15 500 18 500 ≤ 15 24 000 all 24 000
180 30 > 22 6 000 8 500 > 22 14 000 17 000 > 15 21 000 all 24 000
200 40 ≤ 37 5 500 8 000 ≤ 30 14 500 17 500 ≤ 22 23 000 all 24 000
200 40 > 37 3 000 5 500 > 30 10 000 12 000 > 22 16 000 all 20 000
225 50 ≤ 45 4 000 6 500 ≤ 45 13 000 16 500 ≤ 30 22 000 all 24 000
225 50 > 45 1 500 2 500 > 45 5 000 6 000 > 30 8 000 all 10 000
250 60 ≤ 55 2 500 4 000 ≤ 55 9 000 11 500 ≤ 37 15 000 all 18 000
250 60 > 55 1 000 1 500 > 55 3 500 4 500 > 37 6 000 all 7 000
2801) 60 all 2 000 3 500 - - - - - - -
2801) 60 - - - all 8 000 10 500 all 14 000 all 17 000
280 35 all 1 900 3 200 - - - -
280 40 - - all 7 800 9 600 all 13 900 all 15 000
315 35 all 1 900 3 200 - - - -
315 55 - - all 5 900 7 600 all 11 800 all 12 900
355 35 all 1 900 3 200 - - - -
355 70 - - all 4 000 5 600 all 9 600 all 10 700
400 40 all 1 500 2 700 - - - -
400 85 - - all 3 200 4 700 all 8 600 all 9 700
450 40 all 1 500 2 700 - - - -
450 95 - - all 2 500 3 900 all 7 700 all 8 700

Roller bearings, lubrication intervals in duty hours

160 25 ≤ 18,5 4 500 6 000 ≤ 15 9 000 10 500 ≤ 11 12 000 all 12 000
160 25 > 18,5 3 500 5 000 > 15 7 500 9 000 > 11 11 000 all 12 000
180 30 ≤ 22 3 500 4 500 ≤ 22 7 500 9 000 ≤ 15 12 000 all 12 000
180 30 > 22 3 000 4 000 > 22 7 000 8 500 > 15 10 500 all 12 000
200 40 ≤ 37 2 750 4 000 ≤ 30 7 000 8 500 ≤ 22 11 500 all 12 000
200 40 > 37 1 500 2 500 > 30 5 000 6 000 > 22 8 000 all 10 000
225 50 ≤ 45 2 000 3 000 ≤ 45 6 500 8 000 ≤ 30 11 000 all 12 000
225 50 > 45 750 1 250 > 45 2 500 3 000 > 30 4 000 all 5 000
250 60 ≤ 55 1 000 2 000 ≤ 55 4 500 5 500 ≤ 37 7 500 all 9 000
250 60 > 55 500 750 > 55 1 500 2 000 > 37 3 000 all 3 500
2801) 60 all 1 000 1 750 - - - - - - -
2801) 70 - - - all 4 000 5 250 all 7 000 all 8 500
280 35 all 900 1 600 - - - -
280 40 - - all 4 000 5 300 all 7 000 all 8 500
315 35 all 900 1 600 - - - -
315 55 - - all 2 900 3 800 all 5 900 all 6 500
355 35 all 900 1 600 - - - -
355 70 - - all 2 000 2 800 all 4 800 all 5 400
400 40 all - 1 300 - - - -
400 85 - - all 1 600 2 400 all 4 300 all 4 800
450 40 all - 1 300 - - - -
450 95 - - all 1 300 2 000 all 3 800 all 4 400
1)
M3AA

16 ABB Motors and Generators | Low voltage motors manual, 3GZF500730-85 Rev F 02-2015
 02-20-0191

7.2.4 Lubricants The following greases can be used for high speed cast iron
motors but not mixed with lithium complex greases:

WARNING! - Klüber Klüber Quiet BQH 72-102 (polyurea base)

Do not mix different types of grease. - Lubcon Turmogrease PU703 (polyurea base)
Incompatible lubricants may cause bearing damage.
If other lubricants are used, check with the manufacturer
that the qualities correspond to those of the above
When re-greasing, use only special ball bearing grease with mentioned lubricants. The lubrication intervals are based
the following properties: on the listed high performance greases above. Using other
greases can reduce the interval.
– good quality grease with lithium complex soap and with
mineral- or PAO-oil
– base oil viscosity 100-160 cST at 40 °C
– consistency NLGI grade 1.5 - 3 *)
– temperature range –30 °C - +120 °C, continuously

*) A stiffer end of scale is recommended for vertical

mounted motors or in hot conditions.

The above mentioned grease specification is valid if the

ambient temperature is above –30 °C or below +55 °C,
and the bearing temperature is below 110 °C; otherwise,
consult ABB regarding suitable grease.

Grease with the correct properties is available from all major

lubricant manufacturers.

Admixtures are recommended, but a written guarantee

must be obtained from the lubricant manufacturer,
especially concerning EP admixtures, that admixtures do
not damage bearings or the properties of lubricants at the
operating temperature range.

WARNING!
Lubricants containing EP admixtures are not
recommended in high bearing temperatures in frame
sizes 280 to 450.

The following high performance greases can be used:

– Mobil Unirex N2 or N3 (lithium complex base)
– Mobil Mobilith SHC 100 (lithium complex base)
– Shell Gadus S5 V 100 2 (lithium complex base)
– Klüber Klüberplex BEM 41-132 (special lithium base)
– FAG Arcanol TEMP110 (lithium complex base)
– Lubcon Turmogrease L 802 EP PLUS
(special lithium base)
– Total Multiplex S2 A (lithium complex base)
– Rhenus Rhenus LKZ 2 (lithium complex base)

NOTE!
Always use high speed grease for high speed 2-pole
motors where the speed factor is higher than
480,000 (calculated as Dm x n where Dm = average
bearing diameter, mm; n = rotational speed, r/min).

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 02-20-0191

8. After Sales Support 9. Environmental

requirements
8.1 Spare parts
Most of ABB’s motors have a sound pressure level not
Unless otherwise stated, spare parts must be original parts
exceeding 82 dB (A) (± 3 dB) at 50 Hz.
or approved by ABB.
Values for specific motors can be found in the relevant
When ordering spare parts, the motor serial number, full
product catalogs. At 60 Hz sinusoidal supply, the values are
type designation and product code, as stated on the rating
approximately 4 dB(A) higher compared to 50 Hz values
plate, must be specified.
stated in the product catalogs.

For sound pressure levels at frequency converter supplies,

8.2 Dismantling, re-assembly please contact ABB.
and rewinding When motor(s) need to be scrapped or recycled,
Rewinding should always be carried out by qualified repair appropriate means, local regulations and laws must be
shops. followed.

Smoke venting and other special motors should not be

rewound without first contacting ABB.

8.3 Bearings
Special care should be taken with the bearings.

These must be removed using pullers and fitted by heating

or using special tools.

Bearing replacement is described in detail in a separate

instruction leaflet available from the ABB Sales Office.

Any directions placed on the motor, such as labels, must

be followed. The bearing types indicated on the rating plate
must not be changed.

NOTE!
Any repair by the end user, unless expressly
approved by the manufacturer, releases the
manufacturer from responsibility to conformity.

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 02-20-0191

10. Troubleshooting
These instructions do not cover all details or variations
in equipment nor provide information for every possible
condition to be met in connection with installation,
operation or maintenance. Should additional information be
required, please contact the nearest ABB Sales Office.

Motor troubleshooting chart

Your motor service and any troubleshooting must be
handled by qualified persons who have the proper tools
and equipment.

TROUBLE CAUSE WHAT TO DO

Motor fails to start Blown fuses Replace fuses with proper type and rating.
Overload trips Check and reset overload in starter.
Improper power supply Check to see that power supplied agrees with motor rating plate
and load factor.
Improper line connections Check connections against diagram supplied with motor.
Open circuit in winding or Indicated by humming sound when switch is closed. Check for loose
control switch wiring connections and ensure that all control contacts are closing.
Mechanical failure Check to see if motor and drive turn freely.
Check bearings and lubrication.
Short circuited stator
Poor stator coil connection Indicated by blown fuses. Motor must be rewound.
Remove end shields and locate fault.
Rotor defective Look for broken bars or end rings.
Motor may be overloaded Reduce load.
Motor stalls One phase may be open Check lines for open phase.
Wrong application Change type or size. Consult equipment supplier.
Overload Reduce load.
Low voltage Ensure the rating plate voltage is maintained. Check connection.
Open circuit Fuses blown. Check overload relay, stator and push buttons.
Motor runs and Power failure Check for loose connections to line, fuses and control.
then dies down
Motor does not Not applied properly Consult equipment supplier for proper type.
accelerate up to Voltage too low at motor terminals Use higher voltage or transformer terminals or reduce load.
nominal speed because of line drop Check connections. Check conductors for proper size.
Starting load too high Check the motor’s starts against “no load”.
Broken rotor bars or loose rotor Look for cracks near the rings. A new rotor may be required, as
repairs are usually temporary.
Open primary circuit Locate fault with testing device and repair.

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 02-20-0191

TROUBLE CAUSE WHAT TO DO

Motor takes too Excessive load Reduce load.
long to accelerate Low voltage during start Check for high resistance. Make sure that an adequate cable size
and/or draws high is used.
current
Defective squirrel cage rotor Replace with new rotor.
Applied voltage too low Correct power supply.
Wrong rotation Wrong sequence of phases Reverse connections at motor or at switchboard.
direction
Motor overheats Overload Reduce load.
while running Frame or ventilation openings may be Open vent holes and check for a continuous stream of air
full of dirt and prevent proper ventilation from the motor.
of motor
Motor may have one phase open Check to make sure that all leads and cables are well connected.
Grounded coil Motor must be rewound.
Unbalanced terminal voltage Check for faulty leads, connections and transformers.
Motor vibrates Motor misaligned Realign.
Weak support Strengthen base.
Coupling out of balance Balance coupling.
Driven equipment unbalanced Rebalance driven equipment.
Defective bearings Replace bearings.
Bearings not in line Repair motor
Balancing weights shifted Rebalance rotor.
Contradiction between balancing of Rebalance coupling or rotor.
rotor and coupling (half key - full key)
Poly phase motor running single phase Check for open circuit.
Excessive end play Adjust bearing or add shim.
Scraping noise Fan rubbing end shield or fan cover Correct fan mounting.
Loose on bedplate Tighten holding bolts.
Noisy operation Air gap not uniform Check and correct end shield fits or bearing fits.
Rotor unbalance Rebalance rotor.
Hot bearings Bent or sprung shaft Straighten or replace shaft.
Excessive belt pull Decrease belt tension.
Pulleys too far away from shaft Move pulley closer to motor bearing.
shoulder
Pulley diameter too small Use larger pulleys.
Misalignment Correct by realignment of the drive.
Insufficient grease Maintain proper quality and amount of grease in bearing.
Deterioration of grease or lubricant Remove old grease, wash bearings thoroughly in kerosene and
contaminated replace with new grease.
Excess lubricant Reduce quantity of grease, bearing should not be more than half full.
Overloaded bearing Check alignment, side and end thrust.
Broken ball or rough races Replace bearing, clean housing thoroughly first.

20 ABB Motors and Generators | Low voltage motors manual, 3GZF500730-85 Rev F 02-2015
 02-20-0191

11. Figures
100
Key
50
X-axis: Winding temperature, Celsius Degrees

Y-axis: Insulation Resistance Temperature Coefficient,

ktc
10 1) To correct observed insulation resistance, Ri,
to 40 °C multiply it by the temperature coefficient
5 ktc. Ri 40 °C = Ri x

1.0

0.5

1)
0.1

0.05

-10 0 10 20 30 40 50 60 70 80 90 100

Figure 1. Diagram illustrating the insulation resistance dependence from the temperature and how to correct the
measured insulation resistance to the temperature of 40 °C.

a1 b

a2

Figure 2. Mounting of half-coupling or pulley

Low voltage motors manual, 3GZF500730-85 Rev F 02-2015 | ABB Motors and Generators 21
 02-20-0191

Figure 3. Connection of terminals for main supply

Y
1.10

Key
X axis frequency p.u.
Y axis voltage p.u.
1.05 1 zone A
2 zone B (outside zone A)
1.03 3 rating point
1
3
1.09
X
0.95 0.98 1.00 1.02
2

0.93

0.95

0.90

Figure 4. Voltage and frequency deviation in zones A and B

22 ABB Motors and Generators | Low voltage motors manual, 3GZF500730-85 Rev F 02-2015
 02-20-0191

Guideline loadability curves with converters with DTC control

Figure 5a. Conventer with DTC control, 50 Hz, Figure 5b. Conventer with DTC control, 60 Hz,
temperature rise B temperature rise B

Figure 5c. Conventer with DTC control, 50 Hz, Figure 5d. Conventer with DTC control, 60 Hz,
temperature rise F temperature rise F

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 02-20-0191

Guideline loadability curves with other voltage source PWM type

Figure 6a. Other voltage source PWM type converter, Figure 6b. Other voltage source PWM type converter,
50 Hz, temperature rise B 60 Hz, temperature rise B

Figure 6c. Other voltage source PWM type converter, 50 Figure 6d. Other voltage source PWM type converter,
Hz, temperature rise F 60 Hz, temperature rise F

24 ABB Motors and Generators | Low voltage motors manual, 3GZF500730-85 Rev F 02-2015
 06-35-0251

N.P C DENOMINACION MATERIAL NP C DENOMINACION MATERIAL

1 1 PIE ROSCADO Bronce RG-5
2 1 CAMPANA Bronce RG-5
3
4 1 CAPUCHON Latón
5 1 OBTURADOR Bronce RG-5
6 1 CIERRE P.T.F.E.
7 1 TUERCA Y ARANDELA Latón
8 1 BOLA Inox Aisi-304
9 1 P.MUELLE INF. Latón
10 1 P.MUELLE SUP. Latón
11 1 EJE Latón
12 1 RESORTE Acero EN 10270-1-SH
13
14 ** SAL.CONDENSAD. 1/4" H Gas B.S.P.
15 1 TUERCA REGUL. Latón
16
17 1 TORNILLO REGUL. Latón Temperatura Màxima a 10 Kg. de Presión: 240ºC
18
19 Temperatura Mínima: -15ºC
20
21 Apertura Total Instantánea (A.I.T.)
22
ENTRADA SALIDA A B C D PRESION PESO 23
Rosca M Gas B.S.P. Rosca H Gas B.S.P. MIN. MAX. 24 Opcional: Cierre VITÓN, máximo: PN-12 y 180ºC

3/8" 1/2" 145 40 33 10 0,5 Kg 10 kg 25

1/2" 1/2" 155 45 33 13 0,5 Kg 10 kg 26
1/2" 3/4" 175 45 37 13 0,5 Kg 10 kg 27
3/4" 3/4" 180 50 37 18 0,5 Kg 10 kg FECHA NOMBRE NIQUELADO Revisión " 1 "
3/4" 1" 195 55 39 18 0,5 Kg 10 kg PROYECTO 15/03/1985 Juan Solano ACABADO PINTADO Fecha: 29-01-2014
1" 1" 195 55 39 23 0,5 Kg 10 kg DIBUJO 14/11/1990 Juan Solano NATURAL Por: JM Peig
1" 1"1/4 205 60 43 22 0,5 Kg 10 kg CONFECCIÓN 10/05/2004 JM Peig PN-16 Nº PLANO

1"1/4 1"1/4 205 60 43 29 0,5 Kg 10 kg Válv. Seguridad "ALPER" c/PTFE Fig. 396 aP
 06-35-0251

N.P C DENOMINACION MATERIAL NP C DENOMINACION MATERIAL

1 1 PIE ROSCADO Bronce RG-5
2 1 CAMPANA Bronce RG-5
3
4 1 CAPUCHON Latón
5 1 OBTURADOR Bronce RG-5
6 1 DISCO DE CIERRE P.T.F.E.
7 1 TUERCA Y ARANDELA Latón
8 1 BOLA Inox Aisi-304
9 1 P.MUELLE INF. Latón
10 1 P.MUELLE SUP. Latón
11 1 EJE Latón
12 1 RESORTE Acero EN10270-1-SH
13
14 ** 1 SAL.CONDENSAD. 1/4" H Gas B.S.P.
15 1 TUERCA REGUL. Latón
16
17 1 TORNILLO REGUL. Latón Temperatura Màxima a 10 Kg. de Presión: 240ºC
18
19 Temperatura Mínima: -15ºC
20
21 Apertura Total Instantánea (A.I.T.)
22
ENTRADA SALIDA A B C D PRESION PESO 23
Rosca M Gas B.S.P. Rosca H Gas B.S.P. MIN. MAX. 24 Opcional: Cierre VITÓN, máximo: PN-12 y 180ºC

1"1/4 1"1/2 220 70 55 30 0,5 Kg 10 kg 25

1"1/2 1"1/2 225 70 55 36 0,5 Kg 10 kg 26
1"1/2 2" 255 85 60 37 0,5 Kg 10 kg 27
2" 2" 255 85 60 41 0,5 Kg 10 kg FECHA NOMBRE NIQUELADO Revisión: " 1 "
2" 2"1/2 280 95 75 47 0,5 Kg 10 kg PROYECTO 15/03/1985 Juan Solano ACABADO PINTADO Fecha: 29-01-2014
2"1/2 3" 320 105 90 60 0,5 Kg 10 kg DIBUJO 14/11/1990 Juan Solano NATURAL Por: JM Peig
3" 4" 400 140 120 74 0,5 Kg 10 kg CONFECCIÓN 10/05/2004 JM Peig PN-16 Nº PLANO

4" 4" 410 140 120 93 0,5 Kg 10 kg Válv. Seguridad "ALPER" c/PTFE Fig. 396 bP
06-35-0257
06-35-0257
06-35-0257
06-35-0257
 02-44-0189

USER’S GUIDE
80E Series
Fiberglass Pressure Vessels
For Reverse Osmosis

MODEL - 80E30 MODEL – 80E45

300 450
PSI PSI

MODEL – 80E60 MODEL – 80E100 MODEL – 80E120

600 1000 1200
PSI PSI PSI

All information included in this publication is based on the latest information available at the
time of printing. Pentair reserves the right to make changes at any time without prior notice and
without incurring any obligation whatsoever. Photocopying of this publication by authorized
original equipment manufacturers who have purchased directly from Pentair, or by persons using
the materials for legitimate educational purposes, is approved by Pentair. Otherwise all copyright
protection afforded by the law applies.

Chardon, Ohio. Phone: 440-286-4116
Fax: 440-286-7432

Goa, India. Phone: 91-832-2883300
Fax: 91-832-2883312

Ontario, California
Shanghai, China
New Delhi, India

Dubai,
U.A.E.
Milan, Italy
NSW, Australia
Product Bulletin 523004
www.codeline.com

Updated: Nov- 2014

 02-44-0189

Preface

The 80E Series

Family of Vessels

The CodeLine® 80E Series is a standardized family of fiberglass pressure vessels

designed for the continuous, long-term use as housings for reverse osmosis membrane
elements. Any make of eight-inch nominal diameter spiral-wound element is easily
accommodated.
The 80E Series includes five models of different pressure ratings. They are unified in
design and have maximum number of parts in common. Each model has the
appropriate strength and materials of construction to provide years of continuous use in
typical service when properly maintained.
Each model is available in lengths to house, from one to eight, 40-inch long elements
and two, four or five 60-inch long elements.
The 80E Series is designed and built in accordance with the engineering standards of the
Boiler and Pressure Vessel Code of the American Society of Mechanical Engineers
(ASME Code). A vessel marked with an ASME Code stamp is accepted worldwide as
being built to the highest standards of safety.
Each model in the CodeLine® 80E Series has passed rigorous ASME Code qualification
tests which require that the vessels do not burst at less than six times their design
pressure. Safe use is further assured in that vessels will not fail catastrophically;
overpressure is relieved by weeping through the fiberglass shell. Also, every production
vessel is hydro-tested to verify structural integrity.
While undertaking regular maintenance/repair/replacement of a pressure vessel it may
be necessary to remove the pressure vessel from the bank. Also ensure sufficient spares
are available for replacement. Care must be taken in installation/removal of the vessel
to avoid damage to the shell. Damage to the shell can result in catastrophic failure and
possible injury to personnel. Any corrections or recommendation for improvement for
this manual should be addressed to:
CodeLine® Division
Pentair Water India Pvt. Ltd.
L/52-55, Verna Industrial Area,
Verna, Goa – 403722, INDIA
Tel: +91-832-2883300
Fax: +91-832-2883312
 02-44-0189

CONTENTS

SECTION 1 OPERATION / MAINTENANCE GUIDE OM-1

• Safety Precautions…………………………………… OM-2
• Installation Notes……………………………………. OM-3
• Pre-pressurization Checklist……………………….. OM-4
• Component Identification
• 80E30………………………………………………….. OM-5
• 80E45 / 60 / 100 / 120………………………………. OM-5A
• Opening the Vessel………………………………….. OM-6
• Replacing Elements…………………………………. OM-8
• Closing Vessel……………………………………….. OM-11
• Head Rebuilding
• 80E30………………………………………………….. OM-15
• 80E45 / 60 / 100 / 120………………………………. OM-17
• Preventive Maintenance …………………………….. OM-24
• Troubleshooting……………………………………… OM-25

Note: Due to difference in design of the 80E port retainers, some pages
in this guide apply either to the 80E30, 80E45/60 or the 80E100/120
models only. Pages are headed accordingly. Pages not headed apply to
all 80E models.

SECTION 2 INSTALLATION GUIDE I-1

• Handling and Receiving…………………………….. I-2
• Mounting Shell………………………………………. I-3
• Piping Connection…………………………………… I-5

SECTION 3 APPLICATION GUIDE A-1

• Suitability for Intended Use………………………… A-2
• Elasticity and Mounting Requirements……………. A-3
• Corrosion……………………………………………… A-4
• Safety………………………………………………….. A-5

SECTION 4 APPENDIX APX-1

• Limited Warranty…………………………………….. APX-2
• Registration Card…………………………………….. APX-3
 02-44-0189

80E SERIES
USER’S GUIDE

MODEL – 80E30
300
PSI

MODEL – 80E45 MODEL – 80E60

450 600
PSI PSI

MODEL – 80E100 MODEL – 80E120

1000 1200
PSI PSI

DANGER – High Pressure Device

This vessel may cause loss of life, severe bodily harm, Misuse, incorrect assembly or use of damaged or
and / or property damage if not correctly installed, corroded components can result in high-velocity
operated and maintained. Read and understand all release of the end closure.
guidelines given in this bulletin before attempting to We recommend that only a qualified mechanic,
open, operate or service this vessel. experienced in servicing high-pressure hydraulic
Failure to follow these guidelines and observe every systems, open, close and service this vessel.
precaution may result in malfunction and could
result in catastrophic failure.

This section is a guide to proper operation and For information on application and installation,
maintenance of CodeLine® 80E Series pressure refer to 80E Series Application and Installation
vessels. Good industrial practice must be used in sections.
applying this information to assure safe vessel use. For technical specifications and dimensions, refer
These guidelines are not intended to relieve the user to the Engineering Drawing of each specific
from full responsibility for correct operation and model.
maintenance of the vessels. The information in all sections must be carefully
adhered to in order for the vessels to provide safe,
long service life for which it is designed.
 02-44-0189

OPERATION AND MAINTENANCE GUIDE

Proper vessel handling and installation are important to safe use and long vessel life. The
guidelines outlined herein should be carefully followed; however, they are intended only
as guidelines and 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 the CodeLine® for clarification.

TABLE OF CONTENTS

• Safety Precautions………………………………… OM-2

• Installation Notes…………………………………. OM-3
• Pre-pressurization Checklist…………………….. OM-4
• Component Identification
• 80E30……………………………………………….. OM-5
• 80E45/60/100/120……………………………….. OM-5A
• Opening the Vessel……………………………….. OM-6
• Replacing Elements………………………………. OM-8
• Closing Vessel…………………………………….. OM-11
• Head Rebuilding
• 80E30………………………………………………. OM-15
• 80E45 / 60 / 100 / 120…………………………… OM-17
• Preventive Maintenance ………………………... OM-24
• Troubleshooting………………………………….. OM-25

OM-1
 02-44-0189

SAFETY PRECAUTIONS

DO
• Read, understand and follow every part of this section. Failure to take every
precaution may void warranty and could result in catastrophic failure.

• Install in an area where water leakage resulting from a vessel or piping

malfunction would not damage sensitive or expensive equipment, such as
electronic components.

• Verify that head locking components are properly placed and secured.
• Inspect end closures regularly, replace deteriorated components and correct
causes of corrosion.

• Follow membrane element manufacturer’s recommendations for loading

elements into vessel (see Replacing Elements on page OM-8).

DO NOT
• Operate vessel at pressures in excess of specific rating or temperatures over
120oF. (See vessel information chart on page OM-3).

• Service any component until you verify that vessel pressure is fully relieved
from the vessel.
• Use corroded components. Use of such components may result in
catastrophic failure.

• Pressurize vessels without element in place, unless permeate ports are

plugged properly.

• Pressurize vessel until after visually inspecting to insure that the retaining
ring is correctly installed in the stainless steel groove in the vessel.
• Tolerate leaks or allow end closures to be routinely wetted in any way.

• Use excessive silicone lubricant or allow petroleum or silicon based products

to come in contact with the membrane element during installation or
maintenance. (DO NOT USE PETROLEUM PRODUCTS ON NORYL
COMPONENTS).
• Use vessel at negative pressure.

OM-2
 02-44-0189

INSTALLATION NOTES

Even though your vessel may have been installed Vessels must be installed correctly to
by others, there are a few quick checks on instal- ensure safe use and long service life.
lation you should make before use.

Vessel mounted on horizontal support frame using compliant black

urethane saddles; hold-down straps tightened just snug.

Vessel free to expand under pressure; shell not clamped rigidly in place;
piping to vessel ports not made with rigid connections.

Vessel not used in any way to support other components, such as piping
manifolds hanging from ports.

WARNING

FAILURE TO ALLOW EXPANSION

IN DIAMETER OR LENGTH WILL
RESULT IN VESSEL DAMAGE.

If you have any questions about the installation of the vessels in your unit, contact
your supplier. For installation guidelines, refer to the 80E Series Installation
Guide.

VESSEL INFORMATION CHART

80E30 80E45 80E60 80E100 80E120
MAX OPERATING
300 450 600 1000 1200
PRESSURE (PSI)
OPERATING
20oF – 120oF
TEMPERATURE RANGE
TEST PR ASME(1.1X) 330 495 660 1100 1320
(PSI) CE (1.5X) 450 675 900 1500 1800
PROTOTYPE MIN. BURST
1800 2700 3600 6000 7200
PRESSURE (PSI)
ENGINEERING DRAWING
NUMBER 99111 99112 99109 99108 99110
80E SERIES USER
GUIDE NUMBER 523004

OM-3
 02-44-0189

PRE-PRESSURIZATION CHECKLIST

DANGER – High Pressure Device

This vessel may cause loss of life, severe bodily could result in catastrophic failure.
harm, and / or property damage if not correctly Misuse, incorrect assembly or use of damaged or
installed, operated and maintained. Read and corroded components can result in high-velocity
understand all guidelines given in this bulletin release of the end closure.
before attempting to open, operate or service this We recommend that only a qualified mechanic,
vessel. experienced in servicing high-pressure hydraulic
Failure to follow these guidelines and observe systems, open, close and service this vessel.
every precaution may result in malfunction and

This checklist is an operational aid intended to augment detailed guidelines given in the 80E Series
Operation and Maintenance Guide.
Note that the checklist alone does not include all the details needed for safe vessel operation. Use the
checklist each time any service operation is carried out to ensure that each step is completed before
pressurizing the vessel.
MEMBRANE ELEMENTS HEAD ASSEMBLY INTERLOCK
Installed per manufacturer’s recommendation. Locking groove at each end of the shell is clean,
Feed flow direction correctly noted and elements free of corrosion and / or delamination with
correctly oriented. outboard face of groove true and is in sound
Column of elements centered inside shell. condition.
All components in as-new condition, clean and
ELEMENT INTERFACE free of damage or corrosion.
Adapters installed at both ends of element Retaining ring is fully seated in the retaining ring
column. groove.
Thrust ring installed downstream from element PIPING CONNECTIONS
column. Properly secured.
Leak free.
HEAD
All components in as-new condition clean and
free of damage or corrosion.
All components are properly assembled with
new, freshly lubricated seals.
Port retainer for feed/concentrate port in correct
position.
Port nut snug - 80E45 / 60 (Note: left-hand
thread)
Permeate port snap ring installed – 80E30
Head marked with proper pressure rating for
Assembled by:__________________________ Date of Assembly:_________________________
Checked by:____________________________ Date of Inspection:_________________________
The following vessels listed by serial number below were serviced under this checklist:
_____________ _____________ _____________ _____________ ____________
_____________ _____________ _____________ _____________ ____________
OM-4
 02-44-0189

COMPONENT IDENTIFICATION
● 80E30 ●
BOTH ENDS ARE IDENTICAL
EXCEPT ITEM 16
-DOWNSTREAM ONLY-

End closure component identification

Dwg Part
Qty. Part Name Materials/Remarks
Ref Number
SHELL
ORDER Filament wound epoxy/glass composite SS – Head
1 1 Shell Length
SECTION locking groove, integrally wound in place
HEAD
2 2 51050 Bearing Plate 6061-T6 aluminium alloy-hard anodized
3 2 96003 Sealing Plate Engineering Thermoplastic
4 2 50607 Feed/Conc Port 316L Stainless Steel
5 4 45247 Port Retainer 304 Stainless Steel
6 2 50608 Permeate Port Engineering Thermoplastic
7 2 96000 Head Seal Ethylene Propylene, O-Ring (442)
8 4 45312 Port Seal Ethylene Propylene, O-Ring (225)
HEAD INTERLOCK
9 2 47336 Retaining Ring 316 Stainless Steel
VESSEL SUPPORT
10 *2 52169 Saddle Engineering Thermoplastic
11 *2 45042 Strap Assy 304 Stainless Steel-PVC cushion
12 4 46265 Strap Screw 5/16-18 UNC, 18-8 Stainless Steel
ELEMENT INTERFACE
13 2 A/R Adapter Engineering Thermoplastic
14 4 A/R PWT Seal Ethylene Propylene, O-Ring
15 2 52245 Adapter Seal Ethylene Propylene, O-Ring
16 1 45069 Thrust Ring Engineering Thermoplastic
* 3 each furnished with length code 4 - 7

OM-5
 02-44-0189

COMPONENT IDENTIFICATION
● 80E45 / 60, 80E100 / 120 ●

BOTH ENDS ARE IDENTICAL

EXCEPT ITEM 17
-DOWNSTREAM ONLY-

2 7

10

End closure component identification

Dwg Qty.
Part Number Part Name Materials/Remarks
Ref Per
SHELL
Filament wound epoxy/glass composite – SS Head locking
1 1 ORDER SECTION Shell Length
groove, integrally wound in place
HEAD
80E45 : 51051
2 2 80E60: 51052 Bearing Plate 6061-T6 aluminium alloy-hard anodized
80E100/120 : 47317
3 2 96003 Sealing Plate PVC Thermoplastic
80E45/60 : 50567 For 80E45/60 – 316L Stainless Steel, Two piece set
4 2 Feed/Conc Port
80E100/120 : 50556 For 80E100/120 – Super Duplex SST
Port Retainer
5 4 45090 CF8M Cast SS, Two-piece set
Set
80E45/60: 50569
6 2 Permeate Port Engineering Thermoplastic
80E100/120 : 50558
7 2 45066 Port Nut Engineering Thermoplastic
8 2 96000 Head Seal Ethylene Propylene, O-Ring
9 4 45312 Port Seal Ethylene Propylene, O-Ring
HEAD INTERLOCK
10 2 47336 Retaining Ring 316 Stainless Steel
VESSEL SUPPORT
11 *2 52169 Saddle Engineering Thermoplastic
12 *2 45042 Strap Assy 304 Stainless Steel-PVC cushion
13 4 46265 Strap Screw 5/16-18 UNC, 18-8 Stainless Steel
ELEMENT INTERFACE
14 2 A/R Adapter Engineering Thermoplastic
15 4 A/R PWT Seal Ethylene Propylene, O-Ring
16 2 52245 Adapter Seal Ethylene Propylene, O-Ring
17 1 45069 Thrust Cone Engineering Thermoplastic
* 3 each furnished with length code 4 -7

OM-5A
 02-44-0189

OPENING VESSEL
Step-By-Step Guide
NOTE WARNING
Read all guidelines in this section
DO NOT ATTEMPT TO SERVICE ANY
before attempting to open the vessel.
COMPONENT WITHOUT FIRST VERIFYING
THAT VESSEL PRESSURE IS FULLY
RELIEVED FROM THE VESSEL.
STEP 1 RELIEVE PRESSURE ATTEMPTING TO REMOVE ANY
1. Shut off all sources of pressure and relieve COMPONENT BEFORE PRESSURE IS
pressure from the vessel, following the System RELIEVED MAY RESULT IN EXPLOSIVE
manufacturer’s recommendation. RELEASE OF THE HEAD.

STEP 2 DISCONNECT PERMEATE PORT

STEP 4 REMOVE HEAD RETAINING RING
1. Disconnect and remove permeate piping from 1. No special tools are required for this operation.
the permeate port of the vessel. Engage your fore finger in the end tab of the
retaining ring, lift if up and out of the stainless
STEP 3 EXAMINE END CLOSURE
steel groove in the shell.
1. Examine end closure of vessel for corrosion. If
2. Remove the retaining ring from the stainless
any is evident, proceed as follows:
steel groove in the shell. This is accomplished
A. Loosen any deposits with a small wire brush by running your fingers behind the retaining
and/or a medium grade piece of Scotchbrite®.
ring as it continues to exit the groove.
3. If the retaining ring is difficult to remove, try
soaking with a warm release agent such as
LPSTM or WD40TM, being careful to avoid any
contamination of a membrane element. Take
care to avoid hitting or levering against the
vessel, as this could result in delamination.

Loosening Deposits

B. Flush away loosened deposits with clean

water.
CAUTION

Corroded products can cause difficulty

in removing the head and / or other
components. Do not attempt to remove
components until all apparent corrosion
is removed.

Removing the retaining ring from the groove

OM-6
 02-44-0189

2. Remove the retaining ring from the stainless

steel groove in the shell. This is accomplished by
running your finger behind the retaining ring as
it continues to exit the groove.

Head assembly removal – by hand

NOTE

If vessel has been in service for

sometime, head may be difficulty to
Removing the retaining ring from the groove remove. For assistance in head removal,
80E Series head tool (p/n 94101) is
STEP 5 REMOVE HEAD available from CodeLine®.

CAUTION STEP 5B REMOVAL USING HEAD TOOL

Do not strike or apply undue force on

1. The Head Removal Tool (P/N 94101) is made up
ports to remove heads.
of 3 components:
a) Plate b) Bolt c) Nut with handle Grip
STEP 5 REMOVAL BY HAND
2. Hold the plate against the face of the vessel with
1. Gently tap the Head Assembly with a rubber the Feed/Concentrate port projecting out of the
mallet. hole provided on the plate, engage the bolt of the
2. Grasp feed/concentrate port and pull head head puller in the 1” FNPT connection of the
straight out. A sharp forceful tug may be permeate port.
required to start head assembly moving. 3. Run the Nut with the handle grip on the head
3. If the head seal remains in the vessel bore, it puller bolt and continue to tighten the nut till the
should be removed at this time. head comes out.

Repeat above procedure for the opposite end of the Repeat the procedure for the opposite end of the
vessel. vessel.

NOTE

It may be helpful to rock head slightly

to break head seal bond.

Removing Head Assembly using Head Tool

OM-7
 02-44-0189

REPLACING ELEMENTS

NOTE

Read all parts of this section before

replacing elements. These procedures are
provided for general information only.
Elements should be installed in accordance
with the element manufacturer’s
recommendations.

WARNING

DO NOT ATTEMPT TO SERVICE ANY COMPONENT

WITHOUT FIRST VERIFYING THAT VESSEL PRESSURE IS
FULLY RELIEVED FROM THE VESSEL.
MAKE SURE THAT THE CENTRAL (PERMEATE) TUBE
OF MEMBRANE ELEMENT STACK IS CONNECTED TO
THE PERMEATE PORTS INSIDE BOTH END OF VESSEL,
USING THE ADAPTERS SUPPLIED. PRESSURIZING
VESSEL WITHOUT ELEMENTS AND BOTH ADAPTERS
INSTALLED COULD RESULT IN CATASTROPHIC
FAILURE.
DO NOT SCRATCH OR DAMAGE THE VESSEL BORE
WHEN REMOVING OR INSTALLING ELEMENTS.

PRELIMINARY STEPS
DO NOT PROCEED WITH STEP BY STEP
INSTRUCTIONS UNTIL….
1. All pressure has been relieved from the vessel,
following system manufacturer’s
recommendations.
2. Both heads have been removed from vessel
following step by step instructions in Opening
Vessel.

STEP 1 REMOVE ELEMENT INTERFACE

HARDWARE
Thrust Ring Adapter
1. Remove thrust ring from downstream end.
2. Remove adapters from elements at each end.

OM-8
 02-44-0189

3. Examine membrane element surfaces for any

STEP 2 ELEMENT REMOVAL
imperfection which could scratch the vessel
1. Remove elements from vessel following element
bore. Pay particular attention to edges of anti-
manufacturer’s instructions. Clean off any
telescopic device (ATD/brine seal carrier). If
excess lubricant from vessel inside diameter
any defects are found which cannot easily be
before removing elements. Elements must be
corrected, contact the element manufacturer for
removed in direction of feed flow.
corrective action.
4. Using an approximate 50% mixture of glycerine
in water, lubricate the inside of the vessel. This
WARNING may best be accomplished using a suitably sized
swab soaked in the mixture. This procedure will
DO NOT PRESSURIZE VESSEL ease membrane element loading and reduce
WITHOUT ELEMENTS INSTALLED chance of scratching the vessel bore.
OR OTHERWISE OPERATE VESSEL
WITH PERMEATE PORT PRESSURE
IN EXCESS OF 125 PSI*. OPERATION
IN EXCESS OF THIS PRESSURE
COULD RESULT IN CATASTROPHIC
PORT FAILURE.

NOTE

A record of element serial numbers and

Examine bore for scratches
locations should be made and checked
during loading.
NOTE

If the brine seal is not installed on

element and element supplier does not
specify otherwise, a brine seal should
STEP 3 ELEMENT LOADING be placed on upstream end of elements.
1. Flush out vessel with clean water to remove all Open side of seal must face upstream.
dust and debris.
2. Examine inside diameter of the vessel for
5. Load the first element into upstream end of the
scratches or imperfections that may affect
vessel. Leave a few inches of the element
sealing capability of head or element seals.
projecting from the vessel to facilitate
Corrosion deposits or other foreign matter,
interconnection to next element.
including any excess lubricant, should be
6. Apply O-lube sparingly to O-ring of
removed as described in Closing Vessel, Step 1
interconnector (amount of O-lube should be
on page OM-12.
sufficient to give a luster to the O-ring. Excess
O-lube must be removed to prevent possibility
of element contamination).
* PVC Permeate Port
7. Assemble the interconnector to the loaded
element.

OM-9
 02-44-0189

CAUTION

Maintain element alignment carefully

during assembly process. Do not allow
element weight to be supported by
interconnector.
Misalignment can result in damage to
interconnectors or permeate tubes or to
element outer surface.

Installing thrust ring

8. Line up the next element to be loaded and
assemble it to the interconnector already
assembled on first element.
9. Push both elements into the vessel until a few NOTE
inches are projecting from the vessel. Repeat
loading process until all elements are installed. Ensure thrust ring is clean before
installation.
Thrust ring required no orientation;
STEP 4 INSTALL ELEMENT INTERFACE simply push into shell.
HARDWARE For step-by-step instructions on vessel
1. Assemble adapter to element permeate tube at closure, refer to the Closing Vessel,
each end of the vessel. page OM-12.

WARNING

PRESSURIZING VESSEL WITHOUT

BOTH ADAPTERS INSTALLED
COULD RESULT IN CATASTROPHIC
FAILURE.

2. Install thrust ring at downstream end.

CAUTION

Install the thrust ring at the

downstream end. Serious damage may
result if thrust ring is not installed in
correct location.

OM-10
 02-44-0189

CLOSING THE VESSEL

NOTE

Read all guidelines in this section before

attempting to close the vessel.

WARNING

CHECK THE HEAD ASSEMBLY FOR

CORROSION AS DESCRIBED IN THE HEAD
REBUILDING SECTION. CORRODED PARTS
CAN RESULT IN CATASTROPHIC FAILURE.
KEEP PORT NUT SNUG. (80E45/60,
80E100/120 ONLY – NUT HAS LEFT HAND
THREAD). IF NUT LOOSENS,
FEED/CONCENTRATE PORT RETAINERS
MAY FALL OUT OF POSITION RESULTING
IN CATASTROPHIC RELEASE OF PORT.
DO NOT PRESSURIZE THE VESSEL UNTIL
AFTER VISUALLY INSPECTING TO ENSURE
THAT RETAINING RING IS FULLY SEATED.

PRELIMINARY STEPS
DO NOT PROCEED UNTIL….
1. Elements and adapters have been installed in
vessel following guidelines in Replacing
Elements.
2. Head has been checked for correct component
assembly by following step-by-step instructions
in Head Rebuilding.
3. Vessel has been shimmed to prevent movement
of the membrane elements if required. See page
OM-27 of the troubleshooting section for a
description of when shimming is required.
Cleaning vessel inside surface
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 medium or finer grade of ScotchbriteTM
and a mild soap solution clean each end of the
vessel liner surface up to 8” in from each end of
vessel.
B. Rinse away all loosened deposits from shell
inside surface.

OM-11
 02-44-0189

2. Inspect vessel inside surface for scratches or STEP 3 INSTALL HEAD

other damage which could cause leaks. Vessels
that leak must be replaced. NOTE

In some installations it may be

CAUTION
advisable to tighten a system-required
Never attempt to repair a fiberglass permeate port nipple or fitting into
permeate port before head is assembled
shell. into the vessel.

STEP 2 SHELL AND HEAD SEAL

LUBRICATION
1. Work O-ring lubricant into shell area behind the
retaining ring groove and approximately ½”
into the vessel I.D. (See figure 3).
2. Ensure entire head seal is covered with a thin
CAUTION
layer of O-ring lubricant, with no dirt or dust
contamination. Do not overtighten a component into
thermoplastic permeate port more than
NOTE one turn past hand tight.

Glycerin is a commercially available

lubricant that will not foul membranes. STEP 3A INSTALLATION OF HEAD
However, silicone lubricant will better ASSEMBLY
assist correct performance and ease 1. Align any previously placed index marks on
head assembly, installation and head assembly and vessel body. This will ensure
removal. Do not use petroleum based correct alignment for port connections. Do not
lubricants. rotate head assembly after insertion into vessel
as this may cause head seal to become detached.
2. Hold head assembly square to axis of shell and
slide it straight in until a slight resistance is felt.
3. Using both hands, firmly push head in as far as it
will go (a sharp, forceful thrust may be necessary to
push head seal into vessel bore.) When head is in
correct position, entire retaining ring groove will be
exposed.

Figure 3

NOTE

Any remaining lubricant should be

cleaned from vessel before applying
fresh lubricant.

Installing head assembly – by hand

OM-12
 02-44-0189

CAUTION 3. Continue until the entire retaining ring is

installed in the groove.
If head is allowed to rock side to side 4. Verify that the retaining ring is fully seated in the
during installation, head seal may groove before proceeding.
become detached.

STEP 3B INSTALLATION USING TOOL

1. Align any previously placed index marks on
head assembly and vessel body. This will ensure
correct alignment for port connections. Do not
rotate head assembly after insertion into vessel
as this may cause head seal to become detached.
2. Hold the head assembly square to axis of the
shell and slide it straight in until a slight
resistance is felt.
3. Slide tool (p/n 50733) into shell just behind the Installing retaining ring
head.
4. Tap tool alternating around circumference with a
dead-blow hammer until retaining ring groove WARNING
is fully exposed.
RETAINING RING MUST BE CORRECTLY
5. Remove tool by pulling straight out. Do not INSTALLED. INCORRECT ASSEMBLY OR
rotate. INSTALLATION CAN RESULT IN
EXPLOSIVE HEAD FAILURE.

STEP 5 RECONNECT PORTS

NOTE

Using teflon tape or anaerobic sealant on all

threaded connections will help ensure a
leak-free assembly.

Installing head assembly - using head insertion tool

1. Reconnect piping manifold to the vessel.

STEP 4 INSTALL INTERLOCK CAUTION

1. With the head assembly installed in shell, place
the tip of the head retaining ring in the stainless Do not tighten a component into
thermoplastic permeate port more than one
steel groove.
turn past hand tight.
2. Begin pushing the retaining ring into the groove
as you rotate your hand around the I.D. of the
shell.

OM-13
 02-44-0189

STEP 6 PRE-PRESSURIZATION CHECKS

It is vitally important that the following checks be
carried out before any attempt is made to
pressurize the vessel.
It is recommended that the Pre-pressurization
Checklist (Page OM-4) be used to systematically
verify that all steps have been performed.

HEAD ASSEMBLY
Verify that…
1. Head assembly is in good condition, with no
evidence of damage or corrosion. See the
sections on Head Rebuilding and Maintenance.
2. Port nut is snug (80E45/60, 80E100/120 left-
handed thread) or snap ring is in position
(80E30).
3. Port retainers are correctly installed.
4. Retaining ring is seated in groove.

MEMBRANE ELEMENTS
Verify that…
1. Elements are installed in the vessel.
2. Element adapters are installed at each end of
vessel.
3. Thrust ring is installed at downstream end of
vessel.

PIPING CONNECTIONS
1. Check all piping connections to ensure that they
will provide a leak-free seal.

STEP 7 PRESSURIZATION

WARNING

DO NOT PRESSURIZE VESSEL

WITHOUT ELEMENTS INSTALLED.

1. After following the above pre-pressurization

checks, pressurize vessel in accordance with the
element manufacturer’s specifications.
2. Vessels should be filled slowly to assist trapped
air to escape.
3. Vessels should be pressurized slowly to avoid
damage to membrane elements and vessel
components.

OM-14
 02-44-0189

HEAD REBUILDING – 80E30 ONLY

Step-By-Step Guide

NOTE

Read all guidelines in this section

before attempting to rebuild the head.
Head Rebuilding should be performed in a clean work area. Dust
or dirt on O-rings or other parts can scratch inner surfaces and
cause leakage.

WARNING
DO NOT SERVICE ANY COMPONENT UNTIL YOU VERIFY THAT
PRESSURE IS FULLY RELIEVED FROM THE VESSEL.
REPLACE ANY COMPONENTS NOT IN “AS-NEW” CONDITION.
REUSING CORRODED OR DAMAGED COMPONENTS CAN RESULT
IN CATASTROPHIC FAILURE.
SNAP RINGS MUST BE FULLY SEATED AT BOTTOM OF GROOVES
PROVIDED. INCORRECT ASSEMBLY CAN RESULT IN
CATASTROPHIC RELEASE OF PORT.

Permeate
Port Retaining
Ring
Feed/
Concentrate
Port Port Seal

Port Head Seal

Retainer

Bearing Plate

Sealing Plate

Head component identification (80E30) – head disassembled

OM-15
 02-44-0189

● 80E30 ONLY ●
PRELIMINARY STEPS 2. Remove permeate port by pressing out from
Do not proceed with step by step guidelines until.. small end.
1. All pressure has been relieved from the vessel,
following system manufacturer’s
recommendations.
2. Head has been removed from the vessel
following guidelines in Opening Vessel.

TO DISASSEMBLE HEAD

NOTE

Refer to pages OM-5 and OM-16 for

head component identification.
Pressing out permeate port

CAUTION STEP 2 REMOVE SEALING PLATE

1. Hold feed/concentrate port and bearing plate
It is recommended that safety glasses be stationary and rotate sealing plate slightly to break
worn during removal of snap ring. seal. Remove sealing plate.

STEP 3 REMOVE FEED/CONCENTRATE PORT

STEP 1 REMOVE PERMEATE PORT
1. Remove snap ring using snap ring pliers.
1. Remove snap ring using snap ring pliers.

Snap ring removal using snap ring pliers

Snap ring removal with pliers
NOTE

If necessary, ports may be tapped with 2. Remove feed/concentrate port from bearing
a rubber mallet to ease removal. plate.

Steps for rebuilding the heads of the 80E30

continue on OM-20

OM-16
 02-44-0189

HEAD REBUILDING – 80E45/60, 80E100/120 ONLY

Step-By-Step Guide

NOTE

Read all guidelines in this section

before attempting to rebuild the head.
Head Rebuilding should be performed in a clean work area. Dust
or dirt on O-rings or other parts can scratch inner surfaces and
cause leakage.

WARNING
DO NOT SERVICE ANY COMPONENT UNTIL YOU VERIFY THAT
PRESSURE IS FULLY RELIEVED FROM THE VESSEL.
REPLACE ANY COMPONENTS NOT IN “AS-NEW” CONDITION.
REUSING CORRODED OR DAMAGED COMPONENTS CAN RESULT
IN CATASTROPHIC FAILURE.
UPON REASSEMBLY, PORT NUT MUST BE SNUG (LEFT HAND
THREAD). IF NUT LOOSENS, FEED/CONCENTRATE PORT
RETAINERS MAY FALL OUT OF POSITION RESULTING IN
CATASTROPHIC RELEASE OF PORT.

Permeate
Port
Retaining
Port Nut Ring

Feed/
Concentrate
Port Head Seal

Port
Retainer
Port Seal

Bearing Plate

Sealing Plate

Head component identification (80E45/60, 80E100/120) – head disassembled

OM-17
 02-44-0189

● 80E45/60, 80E100/120 ONLY ●

PRELIMINARY STEPS 2. Remove permeate port by pressing out from
TO DISASSEMBLE HEAD threaded end.
Do not proceed with step by step guidelines until..
1. All pressure has been relieved from the vessel,
following system manufacturer’s
recommendations.
2. Head has been removed from the vessel
following guidelines in Opening Vessel.

NOTE

Refer to pages OM-5A and OM-18 for

head component identification.
Pressing out permeate port
STEP 1 REMOVE PERMEATE PORT STEP 2 REMOVE SEALING PLATE
1. Remove port nut by unscrewing left-hand 1. Hold feed/concentrate port and bearing plate
thread. stationary and rotate sealing plate slightly to
break seal. Remove sealing plate.

STEP 3 REMOVE FEED/CONCENTRATE PORT

1. Press long, exposed end of feed/concentrate port
further into bearing plate to free the port
retainer set.
2. First remove port retainer set (2 pieces), then
feed/concentrate port from bearing plate.

Removing port nut (Left-hand threaded)

NOTE

If necessary, ports may be tapped with

a rubber mallet to ease removal. Removing port retainer set

Steps for rebuilding the heads of the 80E45/60,

80E100/120 continue on OM-20

OM-18
 02-44-0189

● ALL MODELS●
STEP 4 REMOVE SEALS CAUTION
1. Carefully remove 3 seals from the sealing plate.
Read all guidelines in this section before
making decisions on component structural
or corrosion problems and treatment.
This section is intended only to provide
guidelines in dealing with corrosion or
component damage. In combination with
good industrial practice, these guidelines
provide a basis for safe system operation.
Any condition not covered in this section
should be referred to CodeLine®.
Corrosion in this context includes metal
oxidation products and mineral deposits.

Removing Seals
THE FOLLOWING EXAMPLES INDICATE
WHEN REPLACEMENT IS REQUIRED.
A. FEED/CONCENTRATE PORT bent or distorted
NOTE
B. PERMEATE PORT or NUT stripped or
A small screwdriver or similar tool may overstrained.
be used to remove O-rings. However, C. PERMEATE PORT internal thread stripped or
do not damage the sealing plate overstrained.
surfaces in any way or leakages may D. BEARING PLATE dented or distorted or with
result. anodizing removed (possibly from being
It is recommended that all seals be dropped or hit).
replaced each time the heads is E. SEALING PLATE cracked, distorted or with
assembled. sealing area damaged.
It is recommended that on 80E30 F. RETAINING RING bent or damaged.
vessels, the snap ring be replaced each
time head is assembled. Any other detail consideration to be a potential
problem should be referred to CodeLine®.

COMPONENT CLEANING AND NOTE

EXAMINATION
STEP 1 WASH COMPONENTS Alternate materials are available for
1. Wash all components in fresh water. high corrosion environments. Call
2. Blow components dry with compressed air, if CodeLine for information.
available.
STEP 3 EVALUATING CORRODED METAL
STEP 2 INITIAL COMPONENT INSPECTION
COMPONENTS
1. Examine all components for any damage that
This procedure applies to the following parts:
could affect structural strength or sealing
A. Retaining Ring
properties.
B. Bearing Plate
2. Replace any parts considered to be structurally
C. Feed/Concentrate port
unacceptable.
D. Port Retainers

OM-19
 02-44-0189

STEP 4 REMOVING DEPOSITS FROM

CAUTION PLASTIC
This procedure is to be used on any
CAUTION
corroded metal parts. If this fails to
bring any component to “as-new” The following procedure should be
standards, the part must be replaced. used on all plastic components
contaminated by mineral deposits or
other foreign matter. If any component
1. Examine all components for corrosion. For any cannot be brought to “as-new”
components not in “as-new” condition, proceed standards, it must be replaced.
as follows:
A. Loosen any large deposits with small wire This procedure applied to the following
brush. components:
B. Place components in shallow container of A. Port Nut (80E45/60/100/120 only)
soapy water and scrub entire surface with B. Permeate Port
medium grade ScotchbriteTM until all corrosion C. Sealing Plate
is removed. D. Adapter
C. Rinse components clean with fresh water.
D. Blow components dry with compressed air, if 1. Examine all plastic components for mineral
available. deposits or other foreign matter. If any are
E. Re-examine components for damage that found, proceed as follows:
could affect structural strength or sealing A. Place components in shallow container of
properties. Any components not in “as-new” soapy water and scrub entire surface with
condition must be replaced. medium grade ScotchbriteTM until all foreign
F. Inspect components for any condition that matter is removed.
may have promoted corrosion, (e.g. gouged B. Rinse components clean with fresh water.
anodizing, inappropriate material selection, etc. C. Blow components dry with compressed air, if
available.
D. Re-examine components for any damage that
could affect structural strength or sealing
properties. Any component not in “as-new”
NOTE condition must be replaced.

Damage to anodized or plated parts

may be temporarily sealed with epoxy
paint while waiting for replacement
parts. NOTE

If any components are cracked,

softened or discolored this may indicate
a chemical resistance problem. These
components must be replaced.
Alternate materials may be required in
these applications.

OM-20
 02-44-0189

TO REASSEMBLE HEAD 2. Install port seals in sealing plate .

WARNING

HEAD MUST BE CAREFULLY

ASSEMBLED FOLLOWING THESE
INSTRUCTIONS.
INCORRECT ASSEMBLY CAN RESULT
IN CATASTROPHIC FAILURE.

CAUTION

Use Parker Super-O-LubeTM sparingly

on all seals each time the head is
assembled. Excessive lubricant may Installing port seals
foul membrane.

STEP 2 INSTALL FEED/CONCENTRATE PORT

NOTE
1. Hold the bearing plate so that the counter bore in
It is recommended that all seals be the off center hole is facing toward you. From
replaced each time the head is the other side, insert the smaller, machined end
assembled. A seal replacement kit is of the stainless steel feed/concentrate port
available from your supplier. through the off-center hole.

STEP 1 LUBRICATE AND INSTALL SEALS

1. Cover each seal with a thin, even layer of O-ring
lubricant.

NOTE

Glycerine is a commercially available

lubricant that will not foul membranes.
However, silicone lubricant, correctly
used, will better assist correct
performance and ease head assembly
and disassembly. Do not use petroleum Installing feed/concentrate port
based lubricants.

NOTE

Steps for rebuilding the head of the

80E30 only continue on page OM-23.
Steps for rebuilding the head of the
80E45/60, 80E100/120 continue on
page OM-24.

OM-21
 02-44-0189

● 80E30 ONLY●
CAUTION

It is recommended that safety glasses be

worn during installation of snap ring.

2. Install snap ring into groove in feed/concentrate

port using snap ring pliers.

Permeate port being inserted

WARNING

SNAP RING MUST BE FULLY

SEATED AT BOTTOM OF GROOVE
PROVIDED. INCORRECT ASSEMBLY
Port being fitted using snap ring pliers CAN RESULT IN CATASTROPHIC
FAILURE.
STEP 3 INSTALL SEALING PLATE
1. With its larger diameter facing the bearing plate,
press the sealing plate onto the machined end of NOTE
the feed/concentrate port.
2. Rotate sealing plate until the two center holes are Head rebuilding of the 80E30 is now
aligned. complete.

STEP 4 INSTALL PERMEATE PORT

1. From sealing plate side, insert threaded end of
permeate port through bearing/sealing plate
combination. Press firmly until permeate port
bottoms on sealing plate.
2. Install snap ring into groove on outer end of
permeate port using snap ring pliers.

OM-22
 02-44-0189

● 80E45/60, 80E100/120 ONLY●

(Cont’d from page OM-22)
2. Install the port retainer set into the groove in the STEP 4 INSTALL PERMEATE PORT
machined end of the feed/concentrate port. Pull 1. From sealing plate side, insert threaded end of
port back until retaining ring set bottoms in permeate port through bearing/sealing plate
bearing plate recess. combination. Press firmly until permeate port
bottoms on sealing plate.

Installing permeate port

Installing port retaining set
2. Thread port nut (left-hand thread) onto permeate
port. Tighten until snug.

STEP 3 INSTALL SEALING PLATE

1. Hold these components together so that the WARNING
retaining ring set remains firmly seated. With its WITH THE PORT NUT TIGHTENED,
larger diameter facing the bearing plate, press THE SEALING PLATE MUST SIT
the sealing plate onto the machined end of the FLUSH AGAINST THE BEARING
feed/concentrate port. PLATE. IF ANY GAP IS EVIDENT,
2. Rotate sealing plate until the two center holes are THE COMPONENTS HAVE NOT
aligned. BEEN ASSEMBLED CORRECTLY.
INCORRECT ASSEMBLY CAN RESULT
IN CATASTROPHIC FAILURE.

NOTE

Head rebuilding of the 80E45/60,

80E100/120 is now complete.

OM-23
 02-44-0189

PREVENTIVE MAINTENANCE

Corrosion prevention is essential for the maintenance of safe operating

conditions and to ease membrane element servicing.

Attention to the points listed below will enhance long-term safe

operation and will ease servicing.

For suggestions on cleaning corrosion deposits from the vessel inside

surface, refer to Closing Vessel.

For suggestions on cleaning corrosion deposits from head components,

refer to Head Rebuilding.

PREVENTION CHECKLIST
End closures. Inspect for components that may
have deteriorated. Replace as needed.

Keep external head assembly components as dry

as possible.

Do not tolerate leaks.

Ensure that protective coatings are intact. Exposed

metal may promote corrosion.

CAUTION

Any leakage indicated a potentially dangerous

condition. Failure to eliminate leakage may
void the warranty and could result in vessel
failure.

OM-24
 02-44-0189

TROUBLESHOOTING

This section is intended only to provide guidelines for dealing with problems that might
arise while working with CodeLine® pressure vessels.

These guidelines are not in any way a replacement for the good industrial practice required
to ensure safe operation. We recommend that only a qualified mechanic experienced in
servicing high pressure hydraulic systems carry out the following tasks.

PRELIMINARY INSPECTION
Inspect the vessel at each end for corrosion which CAUTION
may interfere with head assembly removal. If When applying penetrating fluid, be
corrosion is evident, proceed as follows: careful to avoid element contamination.
1. Loosen any deposits with a small wire brush
and /or a medium grade piece of ScotchbriteTM.
RETAINING RING
1. Will not release from groove and or bearing
plate:
A. Apply penetrating fluid (such as WD-40TM or
LPS-1TM) around retaining ring at the retaining
ring groove and bearing plate interfaces.

Loosening Deposits

2. Flush away loosened deposits with clean water.

3. Proceed with instructions given in Opening
Vessel section. Applying penetrating fluids

DIFFICULTY IN OPENING VESSEL B. Use a cushioned mallet or hammer in

conjunction with a wood block to tap the face
NOTE of the bearing plate and retaining ring.
C. Again attempt to remove the retaining ring.
Recommendations listed below are
intended only as a guide. If the head
assembly is still difficult to remove after
all recommendations have been
followed, call CodeLine for technical
assistance.

OM-25
 02-44-0189

SUDDEN DROP IN 4. Remove the head and slide some spacers over
PERMEATE QUALITY the end of the adapter that fits into the permeate
If a system is started and stopped frequently and port. Add enough spacers so that when the head is
no provision is made to raise the pressure slowly, installed, it is not possible to install the retaining
movement of the membrane column may damage ring in the groove. This will normally require 2 to 3
O-ring seals and reduce permeate quality. spacers.

If the quality of the permeate suddenly drops off,

and poor membrane performance is not suspected,
remove the head per instructions in the User’s
Guide (See OPENING VESSEL section on pages
OM-6 through OM-7). Remove the adapters from
each end of the vessel. Remove the PWT seals from
the adapters and the adapter seal from each of the
permeate ports. Inspect these O-ring seals carefully
for breakage or other damage. If the seals have
rolled out of the groove, or are damaged, this may
indicate excessive movement is occurring during
startup and shutdown. To overcome this problem,
the vessel should be shimmed to minimize this
movement. Follow the procedure for shimming as
given below: Sliding spacers onto adapter

SHIMMING
5. Remove one spacer at a time until it is just
Shimming is accomplished by placing spacers
possible to install the retaining ring in the shell
between the adapters and the hub on the permeate
groove with the head in place.
port on the up-stream end of the vessel. When
6. Remove the head and reinstall the adapter seal
done properly, shimming will prevent excessive
and head seal.
movement of the membrane elements and the
7. Now close the vessel according to the VESSEL
adapters, thus preventing potential damage of the
CLOSING section which begins on page OM-11.
O-ring seals. The spacers used for shimming are
shaped like a plastic washer and are 0.20 inches
thick.
The suggested procedure for shimming is as
follows:
1. With the membrane properly loaded, install the
adapters and place the thrust ring in the
downstream end of the vessel. (See
REPLACING ELEMENTS section on pages OM-
8 through OM-08).
2. Install a head in the downstream end of the
vessel following Steps 1 through 4 of the
section entitled CLOSING VESSEL on page
OM-11).
3. Remove the adapter seal and head seal from the
remaining head. Install the head far enough into
the upstream end of the vessel so that you can
place a locking ring segment in the locking ring
groove. This will assure that there is no
interference in any of the components and
establish the force required to seat the head.
OM-26
 02-44-0189

INSTALLATION GUIDE

Proper vessel handling and installation are important to safe use and long vessel life.
These guidelines outlined herein should be carefully followed; however, they are
intended only as guidelines and 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 Installation Guide section.
Should any information in this guide not agree with the system supplier’s instructions,
call the CodeLine® for clarification.

TABLE OF CONTENTS

• Handling and Receiving.……………………………I-2

• Mounting Shell……………………………………….I-3
• Piping Connections…………………………………..I-5

I-1
 02-44-0189

HANDLING AND RECEIVING

Fibreglass reinforced plastic (FRP) pressure vessels are extremely rugged and durable.
They are designed for safe, long-term service when they are handled and installed
properly. However, damage to the vessel shell or related components from improper
handling or installation could result in malfunction or catastrophic failure while in
service. Therefore, exercise the following precautions whenever handling vessels.

1. Never lift or move a vessel by placing anything inside it. The vessel is durable
and ideally suited to its purpose, but it can be permanently damaged by careless
handling.
2. Be careful not to scratch the inside wall of the shell, especially in the sealing area
inboard of retaining ring groove near each end.
3. DO NOT drop vessel or allow it to hit hard on the ground or against other objects.
4. DO NOT apply undue stress to the shell.
5. Before using a forklift to handle the vessel, pad the forks to lessen the chance of
damaging the shell. Severe scratched or gouging of the vessel can result in failure
of the vessel wall.
6. DO NOT allow undue stress to act on the Feed/Concentrate port, which might
cause impact damage to port area, leading to leakage. Do not use the
Feed/Concentrate port or the permeate port as a tool to lift the pressure vessel or
as a support to manifolds. Manifolds should be self-supporting.

NOTE ON IMPACT DAMAGE

Exterior vessel damage can lead to early vessel failure. Damage received in shipment
should be reported to the shipping company immediately upon receipt. Minor damage
such as scratched that go no deeper than the paint may be acceptable. Call CodeLine®
Customer Service for advice if in doubt.

I-2
 02-44-0189

MOUNTING SHELL

This section is concerned with the mounting of 80E Series pressure vessels only.

These guidelines must be integrated with any additional procedures required for specific
installation.

Installation Guidelines:
2. Provide adequate room for servicing at both ends of vessel. Elements are installed
from the upstream end, pushed through towards the downstream end and,
eventually, removed from downstream end.
3. Follow all applicable handling guidelines. (Page I-2)
4. Position each vessel on its mounting frame such that it is centered between
headers.

NOTE

It is important that each vessel be placed to minimize any strain on the tubing
which connects a vessel to a header. Normally each vessel should be placed
such that dimension from the vessel retaining ring groove to U-bend/header
connection point be equal at both ends. However, if U-bends are not
symmetrical at both ends, the vessel may need to be positioned off center such
that connections can be made easily, without undue strain, at both ends of the
vessel.

1. Mount vessel on urethane saddles positioned in line with pre-drilled frame holes
for -1 through -5 vessels. The holes should be drilled at approximate centre span
‘S’. For -6, -7, -7.5 and -8 vessels, holes should be drilled within 10” to 30” from
ends of vessel and a third saddle and strap, should be placed at mid span. These
dimensions are shown on the corresponding engineering drawing.

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.

I-3
 02-44-0189

5. Place mounting straps over 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 rum up to
the frame finger tight.
8. Using a wrench, tighten mounting bolts one additional full turn. This should
result in 25-50 lbs-in. of torque.

CAUTION

To avoid damage to vessel shell

DO NOT over-tighten mounting nuts.

I-4
 02-44-0189

PIPING CONNECTIONS

The following are suggested guidelines to ensure that the vessel is allowed to expand and
is easily serviced.

1. Support the header independently; support the branch with the header and
the vessel.
2. Include an expansion loop in the branch connection to allow for:
A. Elastic growth in vessel length
B. Thermal growth in vessel length
C. Sagging of the vessel (which can occur even when supported at
recommended span)
3. The recommended branch connection is a U-bend pipe with flexible
connections at each end, or a flexible hose.
4. The total weight of the branch connection and fittings should not exceed 16
lbs. for feed/concentrate and 8lbs. for permeate port for 80E Series vessels.

I-5
 02-44-0189

APPLICATION GUIDE

This Application Guide, together with the Installation Guide and the Operation and
Maintenance Guide, outlines the general conditions for safe use of 80E Series pressure
vessels. Because of the considerable risk inherent in high pressure systems, it is the
purchaser’s responsibility to evaluate carefully each specified application to ensure that
the 80E vessel selected is appropriate to that application.

CodeLine® 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.

TABLE OF CONTENTS

• Suitability for Intended Use…………………………A-2

• Elasticity and Mounting Requirements…………….A-3
• Corrosion…………..…………………………………..A-4
• Safety…………………………………………………...A-5

A-1
 02-44-0189

SUITABILITY FOR INTENDED USE

80E Series RO pressure vessels are designed for continuous, long-term use as housings for
reverse osmosis membrane elements. Models are available for 300, 450, 600, 1000 and 1200
PSI. Any make of eight inch nominal diameter spiral wound element is easily
accommodated.
In an RO system there is considerable potential for catastrophic failure, with consequent
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 CodeLine® pressure vessel for other than its intended application will void the
warranty.

CodeLine® 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.

A-2
 02-44-0189

ELASTICITY AND MOUNTING REQUIREMENTS

Mounting design must allow for the 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 0.20 inch in diameter
and up to 0.007 inch per foot in length. A six-element vessel, for example, would expand
approximately 0.150 inch 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 is sufficient)
3. U-bolts should 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 branch connection is a U-bend pipe with flexible
connections at each end, or a flexible hose.
5. Do not hard plumb either end of the vessel.
6. Support the header independently; support the branch with the header and the
vessel.
7. Include an expansion loop in the branch connection to allow for:
A. Elastic growth under pressure
B. Thermal growth in vessel length
C. Sagging of the vessel (which occurs even when supported at two points at
recommended span)
8. The total weight of branch connection and fittings should not exceed 16 lbs for
feed/concentrate ports and 8 lbs for the permeate port for 80E 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.

A-3
 02-44-0189

CORROSION

Considerations relating to corrosion are an important factor in vessel application.

Corrosion can result in catastrophic failure and/or cause difficulty in removing head
components from the shell. Correct component material selection is essential for safe long-
term use. Although the process fluid is the main consideration, external environmental
conditions should also be taken into account.
All reasonable precautions should be taken to protect head assemblies from external
wetting, particularly in corrosive atmospheres (e.g. salt water areas or acidic atmospheres
such as near lead acid battery arrays, etc.) Leaks from vessel or nearby components which
allow head parts to be routinely wetted should not be tolerated.
The typical list of CodeLine® pressure vessel components on pages OM-5 & 5A shows the
standard material of construction of each part. An evaluation of the possibility of
corrosion damage to metal head interlock components is of critical importance. Alternate
materials are available on request.

A-4
 02-44-0189

SAFETY

CAUTION

Pressure vessels may cause loss of life, severe bodily harm or property damage
if not correctly installed, operated and maintained.

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 catastrophic failure. Although each 80E 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 120oF.

Overpressure 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 the 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).

A-5
 44-0003-01

DWG PART
QTY DESCRIPTION MATERIAL
REF NUMBER
SHELL

ORDER Filament Wound Epoxy/Glass composites-Head

01 1 SHELL
SECTION locking grooves integrally wound in place.

HEAD
6061-T6 Aluminium Alloy-Hard Anodized as per
02 2 47317 Bearing Plate
ASME SB-221/SB-209.
03 2 96003 Sealing Plate Engineering Thermoplastic.

04 2 50556 Feed/Conc Port UNS S32750 #

05 2 45090 Port Retainer Set CF8M Cast SS, Two-piece set.

06 2 50558 Permeate Port Engineering Thermoplastic.

07 2 45066 Port Nut Engineering Thermoplastic.

08 2 96000 Head Seal Ethylene Propylene - O Ring.

09 4 45312 Port Seal Ethylene Propylene - O Ring.

HEAD INTERLOCK

10 2 47336 Retaining Ring 316 Stainless Steel

VESSEL SUPPORT

11 *2 52169 Saddle Engineering Thermoplastic.

12 *2 45042 Strap Assy. 304 Stainless Steel - PVC cushion

13 4 46265 Strap screw. 5/16-18 UNC, 18-8 Stainless Steel.

ELEMENT INTERFACE

14 2 A/R Adapter Engineering Thermoplastic.

15 4 A/R PWT Seal Ethylene Propylene - O - Ring

16 2 52245 Adapter seal Ethylene Propylene - O - Ring

17 1 45069 Thrust Ring Engineering Thermoplastic.

* 3 Each Furnished With Length Code 4, 5, 6, 7 & 8.

 44-0003-01

RATING: PRECAUTIONS: ORDERING:

DESIGN PRESSURE……………...1000 PSI at 120°F DO…read, understand and follow all Using the chart below, please check the Please note that we require your
(6.89 Mpa @ 49°C) instructions; failure to take every precaution features you require and fax them with membrane brand and model number
MIN.OPERATING TEMP……...………………..20°F will void warranty and may result in vessel your purchase order to our customer when ordering. If this information is not
(-7°C) failure service department for expedited initially available, you may provide it at
FACTORY TEST PRESSURE………CE / ASME DO…mount the shell on horizontal members at processing. a later date by checking the appropriate
1500 / 1100 PSI span “S” using complaint vessel supports For optional materials and/or features box below.
(10.34Mpa) / (7.58 MPa) furnished; tighten hold down straps just snug not listed below, please consult factory
BURST PRESSURE……..………………….6000 PSI DO…provide overpressure protection for vessel for pricing and availability.
(41.4 MPa) set at not more than 105% of design pressure
DO…inspect end closures regularly; replace VESSEL LENGTH CODE – please check one
INTENDED USE: components that have deteriorated and
correct causes of corrosion MODEL 80E100
-1
-2
-3
-4
-5
-6
-7
-8
The CodeLine Model 80E100 Fiberglass RO Pressure
Vessel is designed for continuous, long term use as MEMBRANE BRAND AND MODEL – please check one and fill in information
housing for reverse osmosis membrane elements to
DO NOT… make rigid piping connections to
desalt typical sea waters at pressures up to 1000 psi.
Please supply adapters for the following membrane brand and specific model
ports or clamp vessel in any way that resists
Any make of eight-inch nominal diameter spiral- Brand_________________________Model_______________________
growth of fiberglass shell under pressure;
wound element is easily accommodated; the
∆DIA = 0.015 in. (0.4mm) and ∆L = 0.2 in.
appropriate interfacing hardware for the element CERTIFICATION REQUIRED
(5mm) for a length code –8 vessel
specified is furnished with the vessel.  ASME Stamped and National Board Registered (please consult factory for pricing)
DO NOT… hang piping manifolds from ports or
The CodeLine Model 80E100 is designed in use vessel in any way to support other  CE Marked
components; branch connection piping may
accordance with the engineering standards of the
be simply supported between the header and  Standard, Certified by Pentair water.
Boiler and Pressure Vessel Code of the American
Society of Mechanical Engineers (ASME Code). At port; maximum weight of branch piping;
feed/concentrate – 16 lbs (7.3 kg); permeate
small additional cost, vessels can be inspected during EXTERIOR FINISH – please check one
– 8 lbs (3.6 kg)
construction by an ASME Authorized inspector and
ASME Code stamped. DO NOT… operate vessel at pressures and
Standard – white high-gloss polyurethane coating.
temperatures in excess of its rating
Option – optional colors are available for 50 or more vessels per order.
DO NOT… operate vessel without permeate Call factory for pricing details.
The CodeLine Model 80E100 must be installed,
operated and maintained in accordance with the listed ports internally connected with a complete
set of elements and interconnecting MATERIAL OPTIONS
precautions and good industrial practice to assure safe
hardware
operation over a long service life.  Standard – All materials as per drawing 99108 on the first page.
DO NOT… operate vessel with permeate
pressure in excess of 125 psi at 120°F  Customer specified materials: -
The high performance reinforced plastic shell must be
(0.86 MPa @ 49°C) (Please consult the factory, as these options will affect pricing and vessel lead-time.)
allowed to expand under pressure; undue restraint at
support points or piping connections can cause leaks DO NOT… overtighten the connection to the
permeate port (hand-tighten plus one-quarter
to develop in the shell. The end closure, incorporating
turn, check for leaks)
close fitting, interlocking metal components, must be
kept dry and free of corrosion; deterioration can lead DO NOT… tolerate leaks or allow end closures
to be routinely wetted in any way For complete information on proper use of
to catastrophic mechanical failure of the head. this vessel please refer to the 80E series
DO NOT… pressurize vessel until double-
checking to verify that the retaining ring is USER’S GUIDE Bulletin 523004.
The end closures, incorporating close-fitting,
completely inside the groove
interlocking metal components, must be kept dry and
DO NOT… work on any component until first
free of corrosion; deterioration can lead to catastrophic
mechanical failure of the heads. verifying that pressure is relieved from
vessel
DO NOT… operate at pH levels below 3 or
Pentair Water will assist the purchaser in determining
the suitability of this standard vessel for their specific above 10
operating conditions. The final determination
however, including evaluation of the standard material
of construction for compatibility with the specific
corrosive environment, shall be the responsibility of
the purchaser.

Specifications are subject to change without notice.

DWG.No. 99108-Q © Pentair Water Page 2 of 2

 02-25-0190

ABCDE

FTPV FILTER HOUSINGS

ASSEMBLY, START UP,

AND MAINTENANCE INSTRUCTIONS

MO-D-40.04.10.01 Rev.08 Date.- 07/05/12 Technical Office Dpt.

Written by: Approved by:

A. BLÁZQUEZ F.GARCIA
Quality assurance Technical Manager

Fluytec,s.a. Cº Sakoni, 18 48950 Erandio.- Vizcaya.- Spain

Telf+34.94.4676150 Fax.+34.94.4676153 e-mail.- info@fluytec.com web-site.- www.fluytec.com
Page 1 / 10
 02-25-0190

1.- WORKING PRINCIPLE

The raw liquid flows into the equipment through upper flange / solvent socket
union number 1 to the upper raw liquid chamber. It goes through the filtering
cartridges where deep filtration takes place. The filtered product goes through the
internal support core of the filtering cartridges longitudinally until it reaches the lower
chamber (filtered liquid), going out from the equipment through flange / solvent
socket union number 2.

(Models 12FTPV, 20FTPV y 35FTPV) (Models 3FTPV, 4FTPV y 6FTPV)

2.- DESCRIPTION
The FTPV series has been designed to be fitted with cartridges of Ø60 mm. (2.36
inches) and different heights depending on the model.

The construction material is PVC; the tightening bars are made of Stainless Steel
AISI316. In models 3FTPV, 4FTPV and 6FTPV, the tightening bar is encapsulated in a
PVC tube.
The heel springs for the cartridges are made of plastic coated Stainless Steel. The
union joints are made of rubber (EPDM or equivalent).

The design pressure (maximum in operation) for these vessels is 6 bar (Test Pressure
9 bar), for normal use at ambient temperature.

Fluytec,s.a. Cº Sakoni,18 48950 Erandio.- Vizcaya.- Spain

Telf.+34.94.4676150 Fax.+34.94.4676153 e-mail.- info@fluytec.com web-site.- www.fluytec.com

MO-D-40.04.10.01 Rev.08 Page 2 / 10 Date.- 07/05/12 Technical Office Dpt.

 02-25-0190

(Models 12FTPV, 20FTPV y 35FTPV) Models 3FTPV, 4FTPV y 6FTPV)

* Filtering elements. Cartridges 10 P.P.

* Spring 9 S.S. Plastified
* Nipple “Tetón” 8 P.V.C.
2 O-rings. Joints 7 EPDM
** Bolts / Screw rods 6 AISI316
** Nuts 5 AISI316
** Washer 4 AISI316
1 Set upper flat cap 3 P.V.C.
1 Central body Shell 2 P.V.C.
1 Lower body with outlet flange 1 P.V.C.
Quantity Denomination Mark Material

* Nº according to model. As many as cartridges.

** Nº according to model

Fluytec,s.a. Cº Sakoni,18 48950 Erandio.- Vizcaya.- Spain

Telf.+34.94.4676150 Fax.+34.94.4676153 e-mail.- info@fluytec.com web-site.- www.fluytec.com

MO-D-40.04.10.01 Rev.08 Page 3 / 10 Date.- 07/05/12 Technical Office Dpt.

 02-25-0190

3.- ASSEMBLY

3.1.- ANCHORAGE
3.1.1.- Models 3FTPV, 4FTPV y 6FTPV do not need to be anchored to the floor.
3.1.2.- Models 12FTPV and 20FTPV do not need to be anchored to the floor.
However, should one decide to do so, the system is by means of 2 ó 3
pieces “escuderas” type with 180º-120º screwing these pieces to the floor
and to the lower part of the filter as in the fig.
3.1.3.- Model 35FTPV incorporates a lower bottom plate with 4 holes of 14mm Ø for
anchoring to in a bottom plate of 600mm Ø the floor.

Model 20FTPV Model 35FTPV

3.2.- CONNECTIONS

3.2.1.- FILTER HOUSINGS MODELS 3FTPV, 4FTPV AND 6FTPV

Models 3FTPV, 4FTPV y 6FTPV allow the inlet and outlet to be at any angle each
other. Only the heights which are invariable must be maintained.
INLET/OUTLET 3FTPV.- DN32 (solvent socket union PVC Øext.40)
INLET/OUTLET 4FTPV.- DN40 (solvent socket union PVC Øext.50)
INLET7OUTLET 6FTPV.- DN50 (solvent socket union PVC Øext.63)

Fluytec,s.a. Cº Sakoni,18 48950 Erandio.- Vizcaya.- Spain

Telf.+34.94.4676150 Fax.+34.94.4676153 e-mail.- info@fluytec.com web-site.- www.fluytec.com

MO-D-40.04.10.01 Rev.08 Page 4 / 10 Date.- 07/05/12 Technical Office Dpt.

 02-25-0190

The inlet is taken in the upper tube (intake) and the outlet in the lower tube.
Models 3FTPV and 4 FTPV have the intake in the upper lid, and in model 6FTPV in the
main body or ferrule. For its assembly, loosen the upper closure nut and rotate the
head (models 3FTPV and 4 FTPV) or the central body (model 6FTPV), until it is aligned
with the intake pipe.

The benchmarks for the height of the ferrules (inlet and outlet) must be respected,
unless important modifications are made to the filters. A graft with an intake for a vent
and a security valve should be installed in the upper intake pipe. This should be
carried out by the installer.

Also, a TE (junction) must be installed in the outlet pipe with a valve in order to
empty the filter.

3.2.2.- FILTER HOUSINGS MODELS 12FTPV, 20FTPV Y 35FTPV

Filter housings of the 12FTPV, 20FTPV and 35FTPV series are provided with flanges in
the Inlet/Outlet tube to be connected to their corresponding pipelines.

INLET/OUTLET 12FTPV.- Flange DN80 PN10 (Pipe PVC Øext.90)

INLET/OUTLET 20FTPV.- Flange DN100 PN10 (Pipe PVC Øext.110)
INLET/OUTLET 35FTPV.- Flange DN125 PN10 (Pipe PVC Øext.140)

Generically these models have the inlet/outlet pipe oriented at 0º.

Fluytec,s.a. Cº Sakoni,18 48950 Erandio.- Vizcaya.- Spain

Telf.+34.94.4676150 Fax.+34.94.4676153 e-mail.- info@fluytec.com web-site.- www.fluytec.com

MO-D-40.04.10.01 Rev.08 Page 5 / 10 Date.- 07/05/12 Technical Office Dpt.

 02-25-0190

For model 35FTPV, the customer should specify in the Purchase Order any kind of
different orientation as it is impossible to change this when the filter housing is finished.

Models 12FTPV and 20FTPV allow an orientation of the inlet/outlet tubes at 0º, 90º,
180º and 270º between them. If the angle of the tubes are changed after the
equipment has been supplied, the following operations should be carried out:

TURN TO 180º: Remove the upper lid, extract the central tube, turn it 180º and
replace it.

TURN 90º OR 270º: Remove the upper lid and external fixation rods, extract the
central tube, and fix the rods in the previously un-used drill holes (the intermediate
false bottom has doubled the number of drill holes to rods), place the central tube in
the desired position and close with the upper lid.

The inlet is taken through the upper flange and outlet in the lower flange.

The benchmarks in height of the tubes must be respected unless important

modifications are made to the filter.

The upper lid is provided with a central intake of 1/2" BSP female threaded for the
air drain and a threaded reducing nipple male-female 1/2" to 3/4" is connected to
this intake. The air drain and security valve are installed in this point.

If this last reducing nipple is eliminated, the installation could be carried out
starting from ½” instead of ¾” BSP threaded.

RECOMMENDATIONS
It is necessary to install two valves (inlet/outlet) as close as possible to the filter for
its isolation. It is recommended that a by pass and a manometer are installed at the
inlet and outlet of the filters (or differential manometer) in order to read the pressure
drop which enables us to know the clogging range of the filtering elements.

We strongly recommend that the assembly of the above mentioned components

is carried out once the filter is secured and fixed.

NOTE.- For the fitting and removal of the cartridges, it should be taken into
account that a minimum clearance is needed of at least the length of the cartridge
(from the upper lid to the ceiling)

In order to facilitate assembly, we recommend that the customer indicates in the

purchase order both the orientation of the tubes and the foreseen connection of the
air drain for the planned installation.

4.- STARTING UP
Once the filter has been fixed and connected, proceed to the installation of the
filtering cartridges as follows:

Fluytec,s.a. Cº Sakoni,18 48950 Erandio.- Vizcaya.- Spain

Telf.+34.94.4676150 Fax.+34.94.4676153 e-mail.- info@fluytec.com web-site.- www.fluytec.com

MO-D-40.04.10.01 Rev.08 Page 6 / 10 Date.- 07/05/12 Technical Office Dpt.

 02-25-0190

 Dismount the upper lid using an adequate tool for the corresponding nut,
depending on the model of filter as shown in pictures 1 and 2.

Picture 1 Picture 2

 Open the cartridge boxes and remove the protective plastic cover.

 Remove the upper lid and introduce the cartridges in such way the lower part
at the cartridge fits over the guide tube on false bottom plate. See detail of
the drawing, page 8. Picture 3.

Picture 3

 Once the cartridges are in place, proceed to position the centring plate, by
lightly pressing it as far as it can go. It is very important to check that all the
cartridges are lined up and at equal height (see detail number 2 in the
drawing and picture 4).

Picture 4

 In the upper part of each cartridge, place the nipples “teton” (solid PVC
piece), so that the plain surface of the ring faces the external part of the
cartridge (the cutting ring in contact with the wound part of the cartridge).
See detail 3 of the drawing and picture 5.

Fluytec,s.a. Cº Sakoni,18 48950 Erandio.- Vizcaya.- Spain

Telf.+34.94.4676150 Fax.+34.94.4676153 e-mail.- info@fluytec.com web-site.- www.fluytec.com

MO-D-40.04.10.01 Rev.08 Page 7 / 10 Date.- 07/05/12 Technical Office Dpt.

 02-25-0190

Picture 5
 Place the springs. See picture 6.

Picture 6

 Place the lid.

 Screw the closure nuts.

 The torque to be applied on the closure bolts and nuts is written in the
following sticker attached to the vessel

We recommend that all the nuts are put in place and lightly tightened before
being fully tightened using a dynamometric spanner. Our experience
indicates that in a high number of installed filters, the torque is excessive.
Lower torque will lead only to light liquid leaks and this can easily be solved,
by depressurization of the filter and then tightening again.

Fluytec,s.a. Cº Sakoni,18 48950 Erandio.- Vizcaya.- Spain

Telf.+34.94.4676150 Fax.+34.94.4676153 e-mail.- info@fluytec.com web-site.- www.fluytec.com

MO-D-40.04.10.01 Rev.08 Page 8 / 10 Date.- 07/05/12 Technical Office Dpt.

 02-25-0190

Excessive torque will cause damage to the joint and if it is too heavy or
unequal can lead to the breakage of the upper lid or even the housing itself.

 Once the filter housing is closed, proceed to the opening of the inlet/outlet
valves and to the draining of the air content in the filter housing.

 Once the pressure of the filter is stable, proceed to manometer readings at

the inlet/outlet, and the difference between them will be the pressure drop at
clean filter.

 The filter can be used until the difference of the pressure between
manometers and the pressure increase at “clean filter” reaches the
recommended level for the substitution or cleaning of the cartridges.

 NOTES: Maximum allowed differential pressure in the filter is 2 bar, the

cartridges must be replaced when this pressure increase is reached (In
general, the cartridges should be replaced when reaching 0’8-1’5 bar).

 It is recommended that the valves are not open too quickly (if they are ball
valves and manual operated, they can be opened almost instantaneously),
so avoiding ram shocks in the filter.

5.- MAINTENANCE
These filters do not need any maintenance except the substitution of the cartridges
when clogged. However, we recommend the following operations:

 Visual Inspection of the closure o-rings joints whenever the filter is opened,
substituting them once a year.

 Keep the screw areas of the closure rods covered with protective Vaseline,
graphite, grease or similar lubricating material.

Furthermore, it is not possible to predict the lifetime of the filter cartridge, which
depends on the raw water parameters and the performance and characteristics of the
pre-treatment before reach the filter cartridges.

Fluytec,s.a. Cº Sakoni,18 48950 Erandio.- Vizcaya.- Spain

Telf.+34.94.4676150 Fax.+34.94.4676153 e-mail.- info@fluytec.com web-site.- www.fluytec.com

MO-D-40.04.10.01 Rev.08 Page 9 / 10 Date.- 07/05/12 Technical Office Dpt.

 02-25-0190

Fluytec,s.a. Cº Sakoni,18 48950 Erandio.- Vizcaya.- Spain

Telf.+34.94.4676150 Fax.+34.94.4676153 e-mail.- info@fluytec.com web-site.- www.fluytec.com

MO-D-40.04.10.01 Rev.08 Page 10 / 10 Date.- 07/05/12 Technical Office Dpt.

 06-25-0252

Product Information

DOW™ FILMTEC™ Membranes

DOW™ FILMTEC™ SW30HR LE-440i Seawater Reverse Osmosis Element with iLEC™
Interlocking Endcaps
Features Dow Water & Process Solutions offers various premium seawater reverse osmosis (RO)
elements designed to reduce capital and operation cost of desalination systems. DOW™
FILMTEC™ products combine excellent membrane quality with automated precision fabrication,
taking system performance to unprecedented levels.

The DOW™ FILMTEC™ SW30HRLE-440i element offers sustainable lower lifecycle cost for
medium and high salinity feedwaters by combining high rejection and low energy performance
with the highest active area and thickest feed spacer of the Dow membranes. Benefits of the
DOW FILMTEC™ SW30HR LE-440i element include:
• Enables systems to be designed and operated to either lower operating cost through
reduced energy consumption, or to decrease capital cost through higher productivity at
lower operating fluxes.
• High NaCl and boron rejection to help meet World Health Organization (WHO) and other
drinking water standards.
• The highest guaranteed active area of 440 ft2 (41 m2) permits lowest system cost by
maximizing productivity and enables accurate and predictable system design and operating
flux.
• The combination of highest active area with thickest feed spacer (28 mil) allows low
cleaning frequency and high cleaning efficiency.
• Utilization of the distinct iLEC™ interlocking endcaps that help reduce system operating
costs and the risk of o-ring leaks that can cause poor water quality (See Form No. 609-
00446 for information on cost-saving benefits).
• Sustainable high performance over the operating lifetime of the element, because oxidative
treatments are not used in membrane production. This is one reason DOW FILMTEC
elements are more durable and may be cleaned more effectively over a wider pH range (1-
13) than most other RO elements, which use oxidative treatments.
• Effective use in permeate staged seawater desalination systems without impairing the
performance of the downstream stage.
Product Specifications
Part Active area Maximum operating Permeate flow Stabilized boron Minimum salt Stabilized salt
Product number ft2 (m2) pressure psig (bar) rate gpd (m3/d) rejection % rejection % rejection %
SW30HR LE-440i 440 (41) 1,200 (83) 8,200 (31) 92 99.65 99.80
1. The above values are normalized to the following conditions: 32,000 ppm NaCl, 5 ppm boron, 800 psi (5.5 MPa), 77°F (25°C), pH 8, 8% recovery.
2. Permeate flows for individual elements may vary +/-15%.
3. Product specifications may vary slightly as improvements are implemented.
4. Active area guaranteed +/-5%. Active area as stated by Dow Water & Process Solutions is not comparable to the nominal membrane area figure often stated by some
element suppliers. Measurement method described in Form No. 609-00434.
B
A
Figure 1

D DIA C DIA

Feed Fiberglass Outer Wrap

U-Cup Brine Seal End Cap Brine Permeate
Dimensions – inches (mm)
Product Feed spacer (mil) A B C D
SW30HR LE-440i 28 40 (1,016) 40.5 (1,029) 7.9 (201) 1.125 (29)
1. Refer to Dow Design Guidelines for multiple-element systems. 1 inch = 25.4 mm
2. Elements fit nominal 8-inch (203 mm) I.D. pressure vessel
3. Individual iLEC elements measure 40.5 inches (1,029 mm) in length (B). The net length (A) of iLEC elements when connected is 40 inches (1,016 mm).
Page 1 of 2 ™® Trademark of The Dow Chemical Company ("Dow") or an affiliated company of Dow Form No. 609-03001-1009
 06-25-0252

Operating Limits • Membrane Type Polyamide Thin-Film Composite

• Maximum Operating Temperaturea 113°F (45°C)
• Maximum Element Pressure Drop 15 psig (1.0 bar)
• pH Range, Continuous Operationa 2 - 11
• pH Range, Short-Term Cleaning (30 min.)b 1 - 13
• Maximum Feed Silt Density Index (SDI) SDI 5
• Free Chlorine Tolerancec <0.1 ppm
a. Maximum temperature for continuous operation above pH 10 is 95°F (35°C).
b. Refer to Cleaning Guidelines in Form No. 609-23010.
c. Under certain conditions, the presence of free chlorine and other oxidizing agents will cause premature membrane failure.
Since oxidation damage is not covered under warranty. Dow recommends removing residual free chlorine by pretreatment
prior to membrane exposure. Please refer to technical bulletin 609-22010 for more information.

Important Proper start-up of reverse osmosis water treatment systems is essential to prepare the membranes for
Information 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.
Before initiating system start-up procedures, membrane pretreatment, loading of the membrane
elements, instrument calibration and other system checks should be completed.
Please refer to the application information literature entitled “Start-Up Sequence” (Form No. 609-
02077) for more information.
Operation Avoid any abrupt pressure or cross-flow variations on the spiral elements during start-up, shutdown,
Guidelines cleaning or other sequences to prevent possible membrane damage. During start-up, a gradual
change from a standstill to operating state is recommended as follows:
• Feed pressure should be increased gradually over a 30-60 second time frame.
• Cross-flow velocity at set operating point should be achieved gradually over 15-20 seconds.
• Permeate obtained from first hour of operation should be discarded.
Please refer to the product technical manual.
General • Keep elements moist at all times after initial wetting.
Information • If operating limits and guidelines given in this bulletin are not strictly followed, the limited warranty
will be null and void. Refer to DOW™ FILMTEC™ Reverse Osmosis and Nanofiltration Element
Three-Year Prorated Limited Warranty (Form No. 609-35010)
• To prevent biological growth during prolonged system shutdowns, it is recommended that
membrane elements be immersed in a preservative solution.
• The customer is fully responsible for the effects of incompatible chemicals and lubricants on
elements.
• Maximum pressure drop across an entire pressure vessel (housing) is 50 psi (3.4 bar).
• Avoid static permeate-side backpressure at all times.
DOW™ FILMTEC™ Membranes Notice: The use of this product in and of itself does not necessarily guarantee the removal of cysts and pathogens from water.
For more information about DOW Effective cyst and pathogen reduction is dependent on the complete system design and on the operation and maintenance of
FILMTEC membranes, call the Dow the system.
Water & Process Solutions business: Notice: No freedom from any patent owned by Dow or others is to be inferred. Because use conditions and applicable laws
North America: 1-800-447-4369 may differ from one location to another and may change with time, Customer is responsible for determining whether products
Latin America: (+55) 11-5188-9222 and the information in this document are appropriate for Customer’s use and for ensuring that Customer’s workplace and
Europe: (+32) 3-450-2240 disposal practices are in compliance with applicable laws and other governmental enactments. The product shown in this
Pacific: +60 3 7958 3392
literature may not be available for sale and/or available in all geographies where Dow is represented. The claims
Japan: +813 5460 2100
made may not have been approved for use in all countries. Dow assumes no obligation or liability for the information in
China: +86 21 2301 9000
this document. References to “Dow” or the “Company” mean The Dow Chemical Company and its consolidated
http://www.dowwatersolutions.com
subsidiaries unless otherwise expressly noted. NO WARRANTIES ARE GIVEN EXCEPT FOR ANY LIMITED
PERFORMANCE WARRANTY SET FORTH HEREIN; ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS
FOR A PARTICULAR PURPOSE ARE EXPRESSLY EXCLUDED.

Page 2 of 2 ™® Trademark of The Dow Chemical Company ("Dow") or an affiliated company of Dow Form No. 609-03001-1009
 02-25-0194

Tech Fact

DOW FILMTEC™ Membranes

Cleaning Procedures for DOW FILMTEC FT30 Elements

The following are general recommendations for cleaning DOW FILMTEC™ FT30 elements.
More detailed procedures for cleaning a reverse osmosis (RO) system are typically included
in the operating manual provided by the system supplier. It should be emphasized that
frequent cleaning is not required for a properly designed and properly operated RO system
however, because of the FT30 membrane’s distinct combination of pH range and
temperature resistance, cleaning may be accomplished very effectively.

Cleaning In normal operation, the membrane in reverse osmosis elements can become fouled by
Requirements mineral scale, biological matter, colloidal particles and insoluble organic constituents.
Deposits build up on the membrane surfaces during operation until they cause loss in
normalized permeate flow, loss of normalized salt rejection, or both.

Elements should be cleaned when one or more of the below mentioned parameters are
applicable:
• The normalized permeate flow drops 10%
• The normalized salt passage increases 5 - 10%
• The normalized pressure drop (feed pressure minus concentrate pressure)
increases 10 - 15%

If you wait too long, cleaning may not restore the membrane element performance
successfully. In addition, the time between cleanings becomes shorter as the membrane
elements will foul or scale more rapidly.

Differential Pressure (∆P) should be measured and recorded across each stage of the array
of pressure vessels. If the feed channels within the element become plugged, the ∆P will
increase. It should be noted that the permeate flux will drop if feedwater temperature
decreases. This is normal and does not indicate membrane fouling.

A malfunction in the pretreatment, pressure control, or increase in recovery can result in

reduced product water output or an increase in salt passage. If a problem is observed, these
causes should be considered first. The element(s) may not require cleaning. A computer
program called FTNORM is available from DW&PS for normalizing performance data of
DOW FILMTEC™ RO membranes. This program can be used to assist in determining when
to clean and can be downloaded from our web site (www.dowwaterandprocess.com).

Page 1 of 7 ™® Trademark of The Dow Chemical Company ("Dow") or an affiliated company of Dow Form No. 609-23010-0211
 02-25-0194

Safety Precautions 1. When using any chemical indicated here in subsequent sections, follow accepted safety
practices. Consult the chemical manufacturer for detailed information about safety,
handling and disposal.
2. When preparing cleaning solutions, ensure that all chemicals are dissolved and well
mixed before circulating the solutions through the elements.
3. It is recommended the elements be flushed with good-quality chlorine-free water (20°C
minimum temperature) after cleaning. Permeate water or deionized water are
recommended. Care should be taken to operate initially at reduced flow and pressure to
flush the bulk of the cleaning solution from the elements before resuming normal
operating pressures and flows. Despite this precaution, cleaning chemicals will be
present on the permeate side following cleaning. Therefore, the permeate must be
diverted to drain for at least 30 minutes or until the water is clear when starting up after
cleaning.
4. During recirculation of cleaning solutions, the maximum temperature must not be
exceeded. The maximum allowed temperature is dependent on pH and membrane
type. Table 1 contains information on the maximum allowed temperatures.
5. For elements greater than six inches in diameter, the flow direction during cleaning
must be the same as during normal operation to prevent element telescoping, because
the vessel thrust ring is installed only on the reject end of the vessel. This is also
recommended for smaller elements. Equipment for cleaning is illustrated below.

Cleaning System
Flow Diagram

Page 2 of 7 ™® Trademark of The Dow Chemical Company ("Dow") or an affiliated company of Dow Form No. 609-23010-0211
 02-25-0194

Suggested The equipment for cleaning is shown in the Cleaning System Flow Diagram. The pH of
Equipment cleaning solutions used with FILMTEC™ elements can be in the range of 1 to 13 (see
Table 1), and therefore non-corroding materials should be used in the cleaning system.

1. The mixing tank should be constructed of polypropylene or fiberglass-reinforced plastic

(FRP). The tank should be provided with a removable cover and a temperature gauge.
The cleaning procedure is more effective when performed at a warm temperature, and it
is recommended that the solution be maintained according to the pH and temperature
guidelines listed in Table 1. It is not recommended to use a cleaning temperature below
20°C because of the very slow chemical kinetics at low temperatures. In addition,
chemicals such as sodium lauryl sulfate might precipitate at low temperatures. Cooling
may also be required in certain geographic regions, so both heating/cooling requirements
must be considered during the design. A rough rule of thumb in sizing a cleaning tank is
to use approximately the empty pressure vessels volume and then add the volume of the
feed and return hoses or pipes. For example, to clean ten 8-inch diameter pressure
vessels with six elements per vessel, the following calculations would apply:
A. Volume in Vessels
V1 = πr2L
= 3.14 (4 in) 2 (20 ft) (7.48 gal/ft3) / (144 in2/ft2)
V1 = 52 gal/vessel (0.2 m3)
V10 = 52 x 10 = 520 gal (1.97 m3)

B. Volume in Pipes, assume 50 ft. length total 4" Sch 80 pipe

Vp = πr2L
= 3.14 (1.91 in) 2 (50 ft) (7.48 gal/ft3) / (144 in2/ft2)
= 30 gals (0.11 m3)
Vct = V10 + Vp = 520 + 30 = 550 gal.

Therefore, the cleaning tank should be about 550 gals (2.1 m3).

2. The cleaning pump should be sized for the flows and pressures given in Table 2,
making allowances for pressure loss in the piping and across the cartridge filter. The
pump should be constructed of 316 SS or nonmetallic composite polyesters.
3. Appropriate valves, flow meters, and pressure gauges should be installed to adequately
control the flow. Service lines may be either hard piped or hoses. In either case, the
flow rate should be a moderate 10 ft/sec (3 m/sec) or less.

Cleaning Elements There are six steps in the cleaning of elements:

In Situ
1. Make up cleaning solution.
2. Low-flow pumping. Pump mixed, preheated cleaning solution to the vessel at conditions
of low flow rate (about half of that shown in Table 2) and low pressure to displace the
process water. Use only enough pressure to compensate for the pressure drop from
feed to concentrate. The pressure should be low enough that essentially no or little
permeate is produced. A low pressure minimizes redeposition of dirt on the membrane.
Dump the concentrate, as necessary, to prevent dilution of the cleaning solution.
3. Recycle. After the process water is displaced, cleaning solution will be present in the
concentrate stream. Then recycle the concentrate and permeate to the cleaning
solution tank and allow the temperature to stabilize. Measure the pH of the solution
and adjust the pH if needed.

Page 3 of 7 ™® Trademark of The Dow Chemical Company ("Dow") or an affiliated company of Dow Form No. 609-23010-0211
 02-25-0194

Table 1. pH range and

temperature limits
during cleaning

Max Temp Max Temp Max Temp Max Temp

Element type 50°C (122°F) pH range 45°C (113°F) pH range 35°C( 95 °F) pH range 25°C (77°F) pH range
BW30, BW30LE, LE, XLE, Please contact Dow for 1 - 10.5 1 - 12 1 - 13
TW30, TW30HP, NF90, LC assistance
SW30HR, SW30HR LE, Please contact Dow for 1 - 10.5 1 - 12 1 - 13
SW30XLE, SW30 assistance
NF200, NF270 Not allowed 3 - 10 1 - 11 1 - 12
SR90 Not allowed 3 - 10 1 - 11 1 - 12

Table 2. Recommended
feed flow rate per pressure
vessel during high flow
rate recirculation

Feed Pressure¹ Element Diameter Feed Flow Rate per Pressure Vessel
(psig) (bar) (inches) (gpm) (m3/hr)
20-60 1.5-4.0 2.5 3-5 0.7-1.2
20-60 1.5-4.0 4² 8-10 1.8-2.3
20-60 1.5-4.0 6 16-20 3.6-4.5
20-60 1.5-4.0 8 30-40 6.-9.1
20-60 1.5-4.0 8³ 35-45 8.0-10.2
1. Dependent on number of elements in pressure vessel.
2. 4-inch full-fit elements should be cleaned at 12-14 gpm (2.7-3.2 m3/hr).
3. For full-fit and 440 sq. ft. area elements.

4. Soak. Turn the pump off and allow the elements to soak. Sometimes a soak period of
about 1 hour is sufficient. For difficult fouling an extended soak period is beneficial; soak
the elements overnight for 10-15 hours. To maintain a high temperature during an
extended soak period, use a slow recirculation rate (about 10 percent of that shown in
Table 2).
5. High-flow pumping. Feed the cleaning solution at the rates shown in Table 2 for 30-60
minutes. The high flow rate flushes out the foulants removed from the membrane surface
by the cleaning. If the elements are heavily fouled, a flow rate which is 50 percent higher
than shown in Table 2 may aid cleaning. At higher flow rates, excessive pressure drop
may be a problem. The maximum recommended pressure drops are 15 psi per element
or 50 psi per multi-element vessel, whichever value is more limiting. Please note that the
15 psi per element or the 50 psi per multi-element vessel should NOT be used as a
cleaning criteria. Cleaning is recommended when the pressure drop increases 15%.
Pressure drop above 50 psi in a single stage may cause significant membrane damage.
6. Flush out. RO permeate or deionized water is recommended for flushing out the cleaning
solution. Prefiltered raw water or feed water should be avoided as its components may
react with the cleaning solution: precipitation of foulants may occur in the membrane
elements. The minimum flush out temperature is 20°C.

Page 4 of 7 ™® Trademark of The Dow Chemical Company ("Dow") or an affiliated company of Dow Form No. 609-23010-0211
 02-25-0194

Cleaning Tips 1. It is strongly recommended to clean the stages of the RO or NF system separately.
This is to avoid having the removed foulant from stage 1 pushed into stage 2 resulting
in minimal performance improvement from the cleaning. If the system consists of 3
stages, stage 2 and stage 3 should also be cleaned separately.
For multi-stage systems, while each stage should be cleaned separately, the flushing
and soaking operations may be done simultaneously in all stages. Fresh cleaning
solution needs to be prepared when the cleaning solution becomes turbid and/or
discolored. High-flow recirculation, however, should be carried out separately for each
stage, so the flow rate is not too low in the first stage or too high in the last. This can be
accomplished either by using one cleaning pump and operating one stage at a time, or
by using a separate cleaning pump for each stage.

2. The fouling or scaling of elements typically consists of a combination of foulants and

scalants, for instance a mixture of organic fouling, colloidal fouling and biofouling.
Therefore, it is very critical that the first cleaning step is wisely chosen. FilmTec
strongly recommends alkaline cleaning as the first cleaning step. Acid cleaning should
only be applied as the first cleaning step if it is known that only calcium carbonate or
iron oxide/hydroxide is present on the membrane elements.

Acid cleaners typically react with silica, organics (for instance humic acids) and biofilm
present on the membrane surface which may cause a further decline of the membrane
performance. Sometimes, an alkaline cleaning may restore this decline that was
caused by the acid cleaner, but often an extreme cleaning will be necessary. An
extreme cleaning is carried out at pH and temperature conditions that are outside the
membrane manufacturer’s guidelines or by using cleaning chemicals that are not
compatible with the membrane elements. An extreme cleaning should only be carried
out as a last resort as it can result in membrane damage.

If the RO system suffers from colloidal, organic fouling or biofouling in combination with
calcium carbonate, then a two- step cleaning program will be needed: alkaline cleaning
followed by an acid cleaning. The acid cleaning may be performed when the alkaline
cleaning has effectively removed the organic fouling, colloidal fouling and biofouling.

3. Always measure the pH during cleaning. If the pH increases more than 0.5 pH units
during acid cleaning, more acid needs to be added. If the pH decreases more than 0.5
pH units during alkaline cleaning, more caustic needs to be added.

4. Long soak times. It is possible for the solution to be fully saturated and the foulants
can precipitate back onto the membrane surface. In addition, the temperature will drop
during this period, therefore the soaking becomes less effective. It is recommended to
circulate the solution regularly in order to maintain the temperature (temperature should
not drop more than 5°C) and add chemicals if the pH needs to be adjusted.

5. Turbid or strong colored cleaning solutions should be replaced. The cleaning is

repeated with a fresh cleaning solution.

6. If the system has to be shutdown for more than 24 hours, the elements should be
stored in 1% w/w sodium metabisulfite solution.

Page 5 of 7 ™® Trademark of The Dow Chemical Company ("Dow") or an affiliated company of Dow Form No. 609-23010-0211
 02-25-0194

Effect of pH on In addition to applying the correct cleaning sequence (alkaline cleaning step first), selecting the
foulant removal correct pH is very critical for optimum foulant removal. If foulant is not successfully removed,
the membrane system performance will decline faster as it is easier for the foulant to deposit on
the membrane surface area. The time between cleanings will become shorter, resulting in
shorter membrane element life and higher operating and maintenance costs.

Most effective cleaning allows longer system operating time between cleanings and results in
the lowest operating costs.

Figure 1 and 2 below show the importance of the selecting the right pH for successful cleaning.

Figure 1. Effect of pH on the removal of calcium carbonate

2 .5
Relative change permeate flow

1 .5

0 .5

0
2 % c itric HCl @ pH H C l@ p H 2 , H C l@ p H 1 , H C l@ p H 1 ,
a c id @ p H 4 , 2 .5 , 3 5 C 35C 25C 35C
40C

R e c o m m e n d e d C le a n in g C o n d itio n s

L e s s E ffe c tiv e M o re E ffe c tiv e

Calcium carbonate is best removed by cleaning with hydrochloric acid at pH 1-2.

Figure 2. Effect of pH on the removal of biofouling

18

16
Relative change permeate flow

14

12
10
2% STPP + 0.8%
8 NaEDTA@35C
6
4

0
pH 10 pH 11 pH 12

Less Effective More Effective

Biofouling is best removed by cleaning at pH 12.

Page 6 of 7 ™® Trademark of The Dow Chemical Company ("Dow") or an affiliated company of Dow Form No. 609-23010-0211
 02-25-0194

Cleaning Table 3 lists suitable cleaning chemicals. Acid cleaners and alkaline cleaners are the standard
Chemicals cleaning chemicals. The acid cleaners are used to remove inorganic precipitates including iron,
while the alkaline cleaners are used to remove organic fouling including biological matter.
Sulfuric acid should never used for cleaning because of the risk of calcium sulfate precipitation.
Reverse osmosis permeate or deionized water should be used for the preparation of cleaning
solutions.

Table 3. Simple
cleaning solutions
for FT30 membrane
Cleaner
0.1% (W) NaOH 0.1% (W) NaOH 0.2% (W) 1.0% (W) 0.5% (W) 1.0% (W)
and 1.0% (W) and 0.025% (W) HCI, 25°C and Na2S2O4, 25°C H3PO4 , 25 °C NH2SO3H , 25°C
Na4EDTA, pH Na-DSS, pH 12, pH 1 - 2 and pH 5 and and pH 3 - 4
12, 35°C max. 35°C max. pH 1 - 2
Foulant

Inorganic Salts (for example, CaCO3) Preferred Alternative Alternative

Sulfate Scales (CaSO4, BaSO4) OK
Metal Oxides (for example, iron) Preferred Alternative Alternative
Inorganic Colloids (silt) Preferred
Silica Alternative Preferred
Biofilms Alternative Preferred
Organic Alternative Preferred
The temperatures and pH listed in table 3 are applicable for BW30, BW30LE, LE, XLE, TW30, TW30HP, SW30HR,
SW30HR LE , SW30XLE, SW30 and NF90 membrane elements. For more information regarding the allowed
temperatures and pH for cleaning, please refer to table 1.

Notes:
1. (W) denotes weight percent of active ingredient.
2. Foulant chemical symbols in order used: CaCO3 is calcium carbonate; CaSO4 is calcium sulfate; BaSO4 is barium sulfate.
3. Cleaning chemical symbols in order used: NaOH is sodium hydroxide; Na4EDTA is the tetra-sodium salt of ethylene
diamine tetraacetic acid and is available from Dow under the trademark VERSENE™ 100 and VERSENE 220 crystals;
Na-DSS is sodium salt of dodecylsulfate; Sodium Laurel Sulfate; HCI is hydrochloric acid (Muratic Acid); H3PO4 is
phosphoric acid; NH2SO3H is sulfamic acid; Na2S2O4 is sodium hydrosulfite.
4. For effective sulfate scale cleaning, the condition must be caught and treated early. Adding NaCl to the cleaning solution
of NaOH and Na4EDTA may help as sulfate solubility increases with increasing salinity. Successful cleaning of sulfate
scales older than 1 week is doubtful.
5. Citric Acid is another cleaning alternative for metal oxides and calcium carbonate scale. It is less effective (see also
figure 1 of this document). It may contribute to biofouling especially when it is not properly rinsed out.

DOW FILMTEC™ Membranes

For more information about DOW
NOTICE: The use of this product does not necessarily guarantee the removal of cysts and pathogens from water. Effective cyst
FILMTEC membranes, call the Dow and pathogen reduction is dependent on the complete system design and on the operation and maintenance of the system.
Water & Process Solutions business: NOTICE: No freedom from any patent owned by Dow or others is to be inferred. Because use conditions and applicable laws
North America: 1-800-447-4369 may differ from one location to another and may change with time, Customer is responsible for determining whether products
Latin America: (+55) 11-5188-9222 and the information in this document are appropriate for Customer's use and for ensuring that Customer's workplace and
Europe: (+32) 3-450-2240 disposal practices are in compliance with applicable laws and other government enactments. The product shown in this
Pacific: +60 3 7958 3392
literature may not be available for sale and/or available in all geographies where Dow is represented. The claims made may not
www.dowwaterandprocess.com
have been approved for use in all countries. Dow assumes no obligation or liability for the information in this document.
References to “Dow” or the “Company” mean the Dow legal entity selling the products to Customer unless otherwise expressly
noted. NO WARRANTIES ARE GIVEN; ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE ARE EXPRESSLY EXCLUDED.

Page 7 of 7 ™®* Trademark of The Dow Chemical Company ("Dow") or an affiliated company of Dow Form No. 609-23010-0211
RECORD DATA SHEET

MODEL: INSTALLATION: SERIAL NUMBER:

FEED PUMP FILTERS FEED SEA WATER PERMEATE

FEED SAND FILTER HIGH
FP1 FP2
PUMP DISC FILTER S.W. FEED PRESS
FLOW PRESS. SALINITY
TEMP FLOW
INLET OUTLET INLET OUTLET INLET OUTLET INLET OUTLET IN OUT (Lpm) (bar) (ppm)
DATE HOUR (ºC ) (Lpm)
(bar) (bar) (bar) (bar) (bar) (bar) (bar) (bar) (bar) (bar)

11-09-0001