COMMPRO XPRO-2500D Commercial Reverse Osmosis System User Manual

COMMPRO XPRO-2500D Commercial Reverse Osmosis System

Please read this manual carefully before the installing the system.

Introduction

Please read this entire service guide prior to beginning installation.

The CommPro Series commercial reverse osmosis system has been designed for quick and simple installation and maintenance. By carefully reading this instruction manual and following the operational guidelines you will insure a successful installation and reliable operation. Routine maintenance is essential to the longevity and performance of the system.

CONDITIONS FOR OPERATION

Min..
Feed Temperature| 40°F| Max TDS ppm| 2,000
Max. Ambient Temperature| 120°F| Max. Hardness GPG ^^| 1
Min. Ambient Temperature| 40°F| Max. pH (Continuous)| 11
Max. Feed Pressure PSI| 85| Min. pH (Continuous)| 3
Min. Feed Pressure PSI| 45| Max. pH(Cleaning 30 Min.)| 12
Max. Operating Pressure PSI| 150| Min. pH (Cleaning 30 Min.)| 2
Max. SDI Rating| <3| |

Test Parameters: Static pressure test for 5 minutes.
^ Appropriate filtration must be installed in order to prevent premature membrane fouling.
^^ Scale prevention measures must be taken to prolong membrane life.

CAUTION

• Do not use this system where the water is microbiologically unsafe or of unknown quality.
• Adequate pretreatment must be installed to remove organic and inorganic contaminants that may lead to membrane fouling.
• Disconnect the electrical power and turn off feed water supply before servicing the unit
• Never allow the pump to run dry.
• Do not run the system with waste or recycle valves fully closed.

Specifications

COMMPRO MODEL#| XPRO-2500D| XPRO-5000D| XPRO-7500D| XPRO-10000D| XPRO-1500 0D
---|---|---|---|---|---
Sy stem Design
Treatment Configuration| Single Pass| Single Pass| Single Pass| Single Pass| Single Pass
Feed Water Quality| TDS < 2,000| TDS < 2,000| TDS < 2,000| TDS < 2,000| TDS < 2,000
Recovery with Recycle| 35%-50%| 35%-50%| 50%-75%| 50%-75%| 50%-75%
Rejection and Flow Rates
Nominal Salt Reduction| 98.50%| 98.50%| 98.50%| 98.50%| 98.50%
Permeate Flow Rate| 1.8 gpm| 3.5 gpm| 5.4 gpm| 7.1 gpm| 10.5 gpm
Concentrate Flow Rate| 2.0 gpm| 3.2 gpm| 4.5 gpm| 6.0 gpm| 8.0 gpm
Concentrate Recycle Flow Rate| Up to 2.0 gpm| Up to 2.0 gpm| Up to 5.0 gpm| Up to 5.0 gpm| Up to 5.0 gpm
Water Connections
Feed Connection| 3/4” CTS QC| 3/4” CTS QC| 1” CTS QC| 1” CTS QC| 1” CTS QC
Permeate Connection| 1/2” QC| 1/2” QC| 3/4” QC| 3/4” QC| 3/4” QC
Concentrate Connection| 1/2” QC| 1/2” QC| 3/4” QC| 3/4” QC| 3/4” QC
Membrane Elements
Membrane Quantity| 1| 2| 3| 4| 6
Membrane Size| 4” x 40”| 4” x 40”| 4” x 40”| 4” x 40”| 4” x 40”
Booster Pumps
Pump Type| Multi-Stage| Multi-Stage| Multi-Stage| Multi-Stage| Multi-Stage
Motor HP| 1/2 HP| 3/4 HP| 1 HP| 1.5 HP| 1.5 HP
RPM @ 60 HZ| 3450| 3450| 3450| 3450| 3450
Electrical Specifications
Standard Voltage| 110 1ph 60hz| 110 1ph 60hz| 220v 1ph 60hz| 220v 1ph 60hz| 220v 1ph 60hz
Safety Factor (SF) Amps| 12.4| 14.5| 9| 13| 13
**Weight and Dems***
Shipping Weight| 135lb| 150lb| 225 lbs.| 240 lbs.| 255 lbs.
Approx. Dimensions (L x W x H)| 27” x 25” x 56”| 27” x 25” x 56”| 30” x 35” x 56”| 30” x 35” x 56”| 30” x 35” x 56”

*Based on internal testing, actual results may vary.

Operating Parameters

Test Parameters: Static pressure test for 5 minutes.
^ Appropriate filtration must be installed in order to prevent premature membrane fouling.
^^ Scale prevention measures must be taken to prolong membrane life.

System Diagrams

1. DM-2 ***** INLINE DUAL TDS METER

2. CHIP-V RO CONTROLLER; VERTICAL

3. AFM-055 PANEL FLOWMETER C/W CONTROL

4. PG-100-PC PANEL MOUNT GAUGE; 0-100 PSI

5. S211YF02NPEG5 FEED SOLENOID; 3/4″ N/C 120VAC

6. PSEI012826E JG 3/4″ CTS X 3/4″ NPT MALE CONNECTOR, BLACK

7. PFM-055 PANEL FLOWMETER

8. **40L30N-1W * 4″X40″ CODELINE FRP VESSEL; 300PSI; EP; WH
   MH-4040SS.C **** 4X40 SS PRESSURE VESSEL

9. PG-300-PC PANEL MOUNT GAUGE; 0-300 PSI

10. 150233 20″ BIG BLUE HOUSING BL/BK W/PR

11. FF-36″ FALCON 3/4×3/4 FPT; SS FLEX CONN; 36″L

• Deluxe models only (2600-D & 5200-D)
  ** Basic models only (2600-B & 5200-B)
  

  12. **95880505 * 5FBT05C4 – 5GPM; 1/2 HP 120V; PUMP AND MOTOR
      95880710 ** 7FBT07C4** – 7GPM; 3/4 HP 120V; PUMP AND MOTOR

  13. WPS-4-4MF-3-7-30-15 LOW PRESSURE SWITCH; 30-15 PSI

  14. ACV15 PRODUCT CHECK VALVE; 1/2″ FPT

  15. S211YF02NPDG4 * FLUSH SOLENOID; 1/2″ N/C 120V
      

Items Not Shown:

x) C-4010 DIN CONNECTOR (required for all solenoid valves)
x) 1227868-V-BB VX05-20″ BB 5M SEDIMENT CARTRIDGE
x) 3056683 MEMBRANE AK-90LE; 4X40; HR;ULE; 2800GPD; 110PSI
x) 144368 SW-4; WRENCH FOR 20″ BB

Deluxe models only (2600-D & 5200-D)
Single membrane units (2600-B & 2600-D)
**** Dual membrane systems** (5200-B & 5200-D)

System Installation Instructions

1. Feed Water Supply
   The 3/4″ CTS push to connect fitting for the feed water supply is connected to the solenoid on the inlet side of the pre-filter.
   NOTE : Minimum line size for the feed line is 3/4″ with a minimum pressure of 45 PSI not to exceed 85 PSI.
   
   To Connect

   • Cut the pipe square, removing all burrs and sharp edges.

   • Insert pipe fully into fitting.

   • Turn locking cap quarter turn clockwise to locked position; an audible click will be heard; indicator marks will be aligned.
     
     To Disconnect

   • Depressurize the system.

   • Turn locking cap quarter turn counter-clockwise.

   • Depress collet against fitting and remove the pipe.
     
     

2. Permeate (Product Water) Connection
   Locate the 1/2″ O.D. push to connect fitting connected to the check valve located on the outlet (top) side of the permeate water flow meter.
   The permeate line should be connected to the storage tank by 1/2″ O.D. poly tubing or other suitable material.

3. Concentrate (Waste Water) Connection
   The 1/2″ O.D. push to connect fitting is connected to the outlet of the flowmeter labelled “Concentrate”.
   Run the drain line in 1/2″ O.D. tubing to an open drain, ensuring that the drain is free and unobstructed.
   Drain connection to be made in accordance to local plumbing codes.

   • Secure connections are simple
     
     cut the tube square and push past the o-ring to the tube stop

   • Tube is secured in position
     
     Disconnection is just as easy

   • Push collet against body
     
     Slide tube out of fitting

4. Auto-Flush Drain Connection (Deluxe Models Only)
   The 1/2″ O.D. push to connect fitting for the auto-flush is on the outlet of the 1/2″ flush solenoid.
   Run this drain to an open drain via a 1/2″ O.D. drain line.
   This drain  needs to be separate from the 1/2″ concentrate drain line.

5. Tank Level Control
   All CommPro-Series systems are prewired for a tank level control (not included).
   Tank level control needs to be a normally closed switch (open connection in the tank full position shut the system down). 5′ of wiring is included with the system.
   NOTE: Tank level control needs to only act as a dry contact.
   

6. Pretreatment Lockout
   CommPro-Series systems are also wired for pretreatment lockout, allowing the system to be shut down while critical equipment installed ahead of it is backwashed/regenerated. 5′ of system wire is attached to the system controller and can be connected to either a micro switch or relay installed on the pretreatment equipment.
   The lockout wire needs to be connected to the terminals on the micro switch or relay that provide an open contact in the service position and a closed contact while in backwash.
   NOTE: Pretreatment lockout does NOT need to be installed. If it is not required simply leave the two leads unconnected.

7. Electrical
   CommPro-Series systems are wired for 110 VAC 60 HZ. A suitable 15 amp dedicated circuit needs to be provided. If required, have a licensed electrician install a suitable power outlet at the install location.

Membrane Loading Instructions

CommPro-Series systems are shipped without the membrane installed in the membrane pressure vessels. Membranes are left in their original packaging increasing the time frame the system can sit before installation.

NOTE: Membranes must be loaded correctly. The brine seal on the membrane needs to be on the same side of the membrane housing as the feed water connection. For ease of service, all membrane vessels on CommPro-Series are plumbed so that they are fed from the top allowing the membranes to also be loaded from the top.

Please refer to the loading procedure below for initial installation and future replacement of the membranes.

1. End Cap Removal
   A) Basic Models with Stainless Membrane Housings (2600-B & 5200-B)
   Remove the red locking clip from the push to connect fitting and remove tubing.
   Remove the two bolts holding the upper band clamp together.
   Gently pull up on the black plastic cap to remove it from the stainless housing.
   
   B) Deluxe Models with Codeline Membrane Housings (2600-D & 5200-D)
   Remove the red locking clip from the push to connect fitting and remove tubing.
   Using your forefinger in the end of the tab of the retaining ring, lift it up and out of the groove in the shell.
   Remove the ring from the groove in the shell by rotating your finger behind the ring as it continues to exit the groove.
   Thread a 1/2″ threaded pipe nipple into the center port and carefully rock the head assembly to release the seal.
   Once the seal is broken, pull straight outward to remove the head assembly from the vessel.
   

2. Membrane Installation
   Carefully remove membrane from the packaging. Note which end of the membrane that the brine seal is installed on as the membrane will need to be installed so that this is at the top of the vessel.
   With a smooth and constant motion, push the membrane into the housing. You will feel some resistance as the membrane product tube seals into the bottom end cap.
   Install the end caps back into the housing and reconnect any fittings that had been disconnected.

NOTE: Should it be necessary to lubricate any of the seals or o-rings, a food grade silicon based product can be used. Never use petroleum based lubricants.

NOTE: Membranes must be flushed for at least 30 minutes prior to be being used. During this time all permeate must be discarded

System Startup

1. Divert permeate water to the drain temporarily.
2. Fully open the concentrate adjustment valve by turning it counter-clockwise.
3. Fully close the concentrate recycle adjustment valve by turning it clockwise.
4. Turn on the feed water supply to the system and connect the power. The TANK FULL light should be flashing green indicating that the system is power on and in STANDBY.
5. Touch a finger to the power button (this is a capacitive switch that only requires contact) to take the unit out of standby.
6. Adjust concentrate and recycle valves to the desired flows and operating pressure.
7. Allow the system to run for 30 minutes and carefully inspect all connections for leaks.
8. After 30 minutes, connect permeate to the storage tank and check the tank float by manually moving it to the high position.
   

Operation and Maintenance

1. Pre-Filter Pressure Gauges 0 – 100 PSI
   The pre-filter in and pre-filter out gauges show the feed water pressure before and after the pre-filter when the system is running. If a pressure differential of 10-15 PSI is present it would indicate that the pre-filter requires changing.
   
   These gauges are installed after the feed water solenoid and should show zero PSI when the system is shut down or in standby.

2. Pump Pressure Gauge 0 – 300 PSI
   The pump pressure gauge shows the discharge pressure of the multi stage pump. While the system is operating you can make adjustments to this by opening or closing the concentrate or recycle needle valves.
   Changes in feed water pressure and membrane production may affect the pump pressure and require periodic adjustments.
   NOTE: Maximum pump pressure for the CommPro-Series system is 150 PSI.
   

3. System Flow Meters
   All ProComm-Series models are equipped with three flow meters: Concentrate (waste), Concentrate Recycle and Permeate (product). The concentrate flow meter includes an adjustable valve allowing the operator to control the flow of water to drain.
   The concentrate recycle flow meter also includes an adjustable valve. This allows for a portion of the waste water to be reintroduced in to the raw water feed at the inlet of the multi-stage pump.
   The Permeate flow meter shows how much product water is being produced. It is not adjustable but controlled by operating conditions (raw water quality, temperature, and system operating pressure).
   

4. RO System Controller
   CommPro-Series systems include the CHIP system control. This operates all electrical components on the unit including:

   • Pump start delay
   • Low pressure protection
   • Tank level control
   • Pretreatment lockout
   • Auto flush (on deluxe models)
     System status is displayed on the front panel by a series of LED lights.
     The capacitive touch button toggles the unit between service and standby mode.
     

5. RO System Controller Electrical Connection
   NOTE : The system must be disconnected from the 120v power before opening the control box. It may be necessary to consult a qualified electrician before attempting repair or service.
   

6. DM-2 Inline TDS Monitor
   SPECIFICATIONS
   TDS Range: 0-9990 ppm
   Resolution: 0-999: 1 ppm
   1000-9990: 10 ppm (indicated by a blinking ‘x10’ icon – multiply the reading by10)
   Accuracy: +/-2% (of the reading)
   Conversion Factor: NaCl (avg. of 0.5)
   Factory Calibration: 342 ppm NaCl (digital calibration)
   Sensor Cable Length: 46” (116.8 cm) (including sensor)
   Power Source: 2 x AA batteries
   Auto Shut-Off: After 3 minutes
   Battery Life: Approximately 2 years
   Base Unit Dimensions: 4.6 x 2.6 x 0.7 in (11.6 x 6.8 x 1.8 cm)
   Base Unit Weight: 7.9 oz (224.3 g) (including batteries)

Usage

1. Press the “POWER” button
2. To display the TDS level of the feed (tap) water, press the IN button. To display the TDS level of the product (filtered) water, press the OUT button.
3. The displayed TDS will be most accurate after approximately 10 seconds.
4. Determining filter effectiveness depends on your particular system. For an RO system, for example, compare the IN water TDS levels with the OUT water TDS.
5. If the “x10” icon appears, then the TDS level is above 999 ppm. Therefore, multiply the reading by 10. For example, if the display shows 143 ppm with the ‘x10’ icon, the actual TDS level is1430 ppm. (If the ‘x10’ icon does not appear, the reading on the display is the actual TDS level.)
6. Turn off the unit. (It will automatically shut off after 3 minutes to conserve battery power).
   

Changing the Batteries

If the batteries are low, when the unit is turned on, you will see 6AE(bat) for three seconds.

1. To replace the batteries, unscrew the four metal screws on the rear of the unit and remove the back panel.
2. Remove the batteries. 3. Replace both batteries with two fresh AA batteries. Ensure the polarity is correct.
3. Close the back panel and replace the screws. You will not need to recalibrate.

TROUBLESHOOTING

1. The sensor cable is unplugged. Open the back panel and connect the cable securely.

display (out of range)|

1. The water is out of the monitor’s TDS range.

Incorrect readings|

1. Re-calibrate the monitor.
2. Change the batteries.

display (low batteries)|

1. Change the batteries.

The “OUT” reading is higher than the “IN” reading|

1. Check your connections. The sensors may be reversed.

CommPro Limited Warranty

Water Industries warrants its CommPro-Series Reverse Osmosis system to be free from defects in materials and workmanship under normal use within the operating parameters  listed below. For a period of one year from the date of purchase CommPro will repair or replace any part of the Reverse Osmosis System with the exception of the filters, membrane and  battery.

Conditions of Warranty

The above warranty shall not apply to any part of the CommPro Reverse Osmosis System that is damaged because of neglect, misuse, alteration, accident, misapplication, physical damage, fouling, and/or scaling of the membrane by minerals, bacterial attack, sediment or damage caused by fire, freezing, hot water, or an Act of God.

CommPro assumes no warranty liability in connection with this Reverse Osmosis System other than as specified herein. Water Industries shall not be liable for consequential damages due to the use of CommPro products.

Warranty Service

Warranty service will be provided CommPro under the following conditions:

1. Contact your local Water Industries dealer, who will obtain return authorization instructions from CommPro.
2. Ship the unit or part freight prepaid to Water Industries Warehouse for warranty evaluation or service. The unit must be returned in the original carton or packaged to prevent possible damage. Systems or parts covered under warranty shall be repaired  (or, at our option, replaced) and returned without charge.

Conditions for Operation of TFC – Thin Film Composite Membrane
Used in the CommPro-Series

Source Water Supply – TFC

Community / Private| Bacteriologically Safe
System Pressure min/max| 45 / 85 psi
Temperature| 40º / 85º F
pH Range| 3.0 to 11.0
Maximum supply TDS level| 2000 mg/L
Turbidity| < 1.0 net turbidity (NTU)

Chemical Parameters – TFC

Hardness (CaCo3)| < 1 GPG
Iron (Fe)| < 0.1 mg/L
Manganese (Mn)| < 0.05 mg/L
Hydrogen Sulfide (H2S)| 0.00 mg/L

Operating Limits

Maximum Pressure| 150 PSI

References

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