Tech Manual TL Series - yourkinetico.com · TL Series Technical Manual Rev. 11/2010 Kinetico...

Tech Manual TL Series

Models: TL 2000 TL 4000 TL 6000 TL 8000

TL Series Technical Manual

Rev. 11/2010 Kinetico Incorporated Corporate Headquarters Newbury, Ohio 44065 440-564-9111 Product No. 8304H

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Table of Contents

1.0 General Information About this Manual ........................................................................................................................ 3 Reverse Osmosis Technology ..................................................................................................... 5 The Kinetico TL RO Product Line ................................................................................................ 6 Applications .................................................................................................................................. 7 System Sizing .............................................................................................................................. 10

2.0 Equipment Specifications System Configuration ................................................................................................................... 12 Operating Specifications .............................................................................................................. 15 Component Functionality ............................................................................................................. 16 System Controller ......................................................................................................................... 19 System Configuration ................................................................................................................... 19

3.0 Installation Getting Started ............................................................................................................................. 21 Pre-installation Review ................................................................................................................ 21 TL RO Installation ........................................................................................................................ 21 Unpacking .................................................................................................................................... 22 Skid Positioning ............................................................................................................................ 22 Plumbing Hook-ups ...................................................................................................................... 23 Electrical Hook-up- 230V ............................................................................................................. 23 Electrical Hook-up- 208V ............................................................................................................. 24 Buck-Boost Transformer Wiring ................................................................................................... 25 Determining the TL Series Revision ............................................................................................ 26 Transformer Recommendations .................................................................................................. 27 Atmospheric Tanks Installation .................................................................................................... 28 High Level & Repressurizer Installation ....................................................................................... 29 Captive Air (Bladder) Tank Installation ........................................................................................ 31

4.0 Operation and Maintenance Normal Operating Procedures ..................................................................................................... 32 System Commissioning ............................................................................................................... 32 Long Term System Shutdowns .................................................................................................... 34 System Sanitization...................................................................................................................... 35 Start-up Procedures, Repressurizer ............................................................................................ 37 System Maintenance.................................................................................................................... 37 Conductivity Monitor Calibration .................................................................................................. 38 Membrane Replacement .............................................................................................................. 39 Pump & Motor Maintenance ........................................................................................................ 41 System Alarms ............................................................................................................................. 42 Troubleshooting ........................................................................................................................... 43

5.0 Parts ................................................................................................................................. 46

6.0 Drawing ............................................................................................................................ 48

7.0 System Log ...................................................................................................................... 49



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About this Manual This manual will cover information needed for the proper installation and operation of your Kinetico TL Series Commercial Reverse Osmosis System. We have also included information regarding the frequently asked questions about reverse osmosis systems. This information may be more technical in nature, but provides further insight to the continued operation of this equipment to its highest standards. This manual will use various icons to help highlight issues that are relevant to the safe operation of this equipment. The following icons will be used as described:

General information regarding the application of this product will be highlighted by this icon. This will include technical specifications and expected operational results.

Lock out electrical power. Use appropriate lockout procedures when servicing. Maintain safe pressure. This sign indicates the safe operating pressure range. Consult Maintenance Section. Refer to the maintenance section for specific instructions.

Consult Equipment Specifications Section. Refer to the equipment specifications section for specific instructions.

Consult MSDS Sheets

A caution icon will be used to present any information that may hold a potential hazard or concern during the installation, use or maintenance of this product. Should this information not be followed, it may result in damage of this equipment and its surroundings.

Electrical shock or electrocution hazard. Pinch point or crushing hazard. Chemical hazard



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The warning icon will be used to present any information that may result in a severe hazard or concern during the installation, use or maintenance of this product. Should this information not be followed, it may result in severe physical harm.

Stay Clear. Do Not Touch. No Access. Only properly trained and authorized persons can enter area or open panel.

Any tools or materials required during the installation, use or maintenance of this equipment will be preceded by this icon. Using these specific tools will minimize time and effort. Not using the proper tool may result in damage to this equipment, its surroundings or even physical harm.

If there are any additional questions pertaining to this equipment, please contact your local Kinetico Dealer for further assistance.



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Reverse Osmosis Technology In the early 1960’s, the use of reverse osmosis (RO) began its commercial debut. Before this time, the technology had been used by the U.S. military for the purification of water for troops. Since its introduction into the market, RO has continued to gain popularity. RO technology offers the finest level of filtration available. The RO membrane acts as a barrier to dissolved salts and inorganic molecules, as well as organic molecules with a molecular weight greater than approximately 100. Water molecules, on the other hand, pass freely through the membrane creating a purified product stream. The applications for RO are diverse and include desalination of sea water or brackish water for drinking purposes, food and beverage processing, purification of home drinking water and many others. Utilizing RO prior to Ion Exchange (IX) for the production of ultra high water qualities dramatically reduces operating costs and regeneration frequency of the IX system. Pressures associated with RO systems can range from 40 psi for tap water systems to 1,000 psi for sea water desalination systems.

Concentrated Solution Dilute Solution

Semipermeable Membrane

Concentrated Solution Dilute Solution

Figure 1

RO technology is not new. The process of osmosis is actually found in nature and in the human body. In this application human membranes allow nutrients or waste products to pass in and out of the blood stream. “Semipermeable” means that the membrane is permeable to some species and not permeable to others. Most semipermeable membranes allow water to pass through and not other molecules or ions. Figure 1 shows a concentrated solution will increase in volume as water from the dilute solution permeates through the membrane. In this fashion, the concentrations on either side of the membrane become equal, even though the volumes are not. This dilution relationship can be quantified by the rise in the height of the salt solution. This height will increase until the pressure of the column of water (salt solution) is so high that the force of this water column stops the water flow. The equilibrium point of this water column height in terms of water pressure against the membrane is called osmotic pressure.

Semipermeable Membrane

Concentrated Solution Dilute Solution Concentrated Solution Dilute Solution

Pressure

Figure 2

Reverse osmosis (Figure 2) is created if a force is applied to this column of water. Thus the direction of water flow through the membrane can be reversed. This is the basis of the term reverse osmosis. This reversed flow produces “permeate” water from the salt solution, since the membrane does not permit most salt to pass through it. The typical rejection of a semipermeable membrane is over 95%. This means that it will reject 95% of the salts and let 5% pass through.



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The Kinetico TL RO Product Line Kinetico’s Industrial Reverse Osmosis product line is designed to serve both Domestic and International customers. As shown in table below the TL Series is available in both a 50 and 60 Hz configuration. The capacity of Kinetico’s TL Series systems will accommodate daily flow requirements up to 5.5 gpm. System feature for the TL Series include:

Integrated Circuit board Controller Digital Permeate Quality Display (Conductivity) Permeate Flow Meter

A number of accessories are also available with the TL Series systems including:

Carbon Filters Backwashing Filters Softeners Storage Tanks

For further information regarding these products, please contact your local Kinetico Dealer.

Model Name TL-2000 TL-4000 TL-6000 TL-8000

Part Numbers

60 Hz 7507B 7508B 7509B 7510B

50 Hz 8510B 8511B 8514B 8515B

Rated* Daily Production 2,000 gpd 4,000 gpd 6,000 gpd 8,000 gpd

Rated* Daily Production 7,572 lpd 15,144 lpd 22,717 lpd 30,289 lpd

Membrane Type Thin Film Composite

Number of Membranes 1 2 3 4* Based on feed TDS of 500 mg/l and a water temperature of 77 o F



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Applications From A to Z there are a variety of applications for the TL RO product line. Some ideas on how and where these applications can be found have been provided. Further detail of these application ideas will be available through case studies prepared for each market. Market Applications Dental Office Instrument Feed Water -- Dental instruments represent a

large investment at many dental offices. These tools require high quality water to operate properly. RO water is an excellent choice to maintain the operation of this equipment.

Autoclave Feed Water -- Many dental offices are now

equipped with their own sterilization equipment, the autoclave. This device sterilizes dental instruments through the use of heat and pressure. As part of its operation, feed water to the system is required. RO water is ideal due to its low TDS and provides for reduced operational wear on the autoclave.

Drinking Water -- Any dental office will have drinking water

sources. Along with the other applications listed, one central RO system may be appropriate to meet all water treatment needs.

Grocery Stores Bottled Water Stations -- Many grocers will offer stocked

bottled water as well as refillable bottling locations. These “pay-by-the-gallon” tap locations can be supplied by a TL RO.

Produce Misting -- Most grocers use misters to keep their

fresh produce hydrated. The water used in these misters will have an effect on the quality and freshness of the produce. Providing an RO feed to these misters can greatly improve the quality and longevity of their fresh produce -- a benefit that is sure to be noticed by their customer.

Hydroponics/Greenhouses Nutrient feed water -- In both hydroponics and conventional

greenhouses, the quality of water being fed to the plants should be of a consistent, high quality. By using RO feed water, this will standardize the makeup. RO quality water becomes an even greater need should the facility be located where the feed water supply has a high TDS. Under these conditions, the output of the harvest can be greatly increased by reducing the TDS of the water by using an RO system.

Hospitals Autoclave Feed Water Reagent Grade Pretreatment Water -- Many hospitals will

have their own analytical laboratory where many tests are completed. RO water can be used to produce water for use in these analytical tests.

Laboratory Reagent Grade Pretreatment Water -- Many laboratories

use portable or disposable deionization tanks to produce



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ultra-pure qualities of water. RO water will greatly increase the gallons produced from these types of DI systems.

Car Washes Final Spot-Free Rinse Water -- Both self-serve and

automatic car washes will offer a “spot-free” rinse cycle. The TL RO is an excellent choice for these applications, as the water quality produced by the TL RO typically contains less than 25 mg/l of dissolved solids (the maximum TDS contamination level that will accommodate a spot-free rinse).

Whole House R.O. TDS Reduction -- In areas where feed water TDS is over

1,000 mg/l, additional water treatment is required to accommodate national drinking water standards (1997 code). RO systems can provide purification to this standard.

Office Buildings Drinking Water Manufacturing Facilities Final Spot-Free Rinse Chemical Bath Makeup -- Many manufacturing facilities

add large volumes of water to their chemical baths to make up for water lost by evaporation or drag-out. Using high quality water significantly reduces the risk of bath contamination from untreated water.

Parts Cleaning -- Many chemical cleaning formulations

require purified rinse water following the cleaning process. By using water with low TDS, the chemical cleaning agents can work more effectively.

Schools/Universities Drinking Water Reagent Grade Laboratory Pretreatment Water Restaurants Steamers -- Low TDS RO water is preferred for use in this

equipment. With untreated water, maintenance on this equipment is very high. This is caused by the TDS contaminants from the raw water that concentrate in the steamers. Prolonged operation with typical raw water will eventually damage these units.

Insta-hots -- In the preparation of many foods, the addition

of hot water via an instant hot water delivery system is used. By pretreating this water to RO quality, it will improve the taste of the food.

Cooking -- As recommended for home use, cooking with

RO water will enrich the natural flavor of food. This quality improvement can be a valuable asset for restaurants striving for the finest cuisine.

Drinking Water Food Processing Rinse Water -- Many food handling standards now require

pretreatment of rinse water. This may include softening, reverse osmosis or sterilization.



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Printing Cooling Water Makeup Ink additive -- Many high volume printers such as

newspapers, require high purity water to be used with the quick-drying printing press inks.

Gas Stations Drinking Water Car Wash / Spot-Free Rinsing



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System Sizing In sizing the TL RO, the output production is given based on the model number (i.e. TL-2000 = 2000 gallons per day). However, this output production is based on average system operating conditions, and depending on some factors, the output production can change significantly.

Factors that must be examined include: Temperature Inlet TDS (osmotic pressure) Average Permeate Pressure System Operating Pressure

Temperature conversions: (35°F = 1.6°C), (45°F=7.2°C), (55°F=12.7°C), (65°F=18.3°C), (75°F=23.8°C)

Example 1: TL RO Size: TL-6000 Water Temperature: 65 °F Storage Tank: Atmospheric Tank TDS: 1500 Use the TLRO Capacity Chart for Atmospheric Storage Tanks. Follow up the x-axis at 1500 TDS until it meets the 65 °F temperature line. Follow this point across to the Y-axis to get the capacity %. The capacity % is approximately 65%. So the TL 6000 will produce 65% of its rated capacity or (6000gpd x .65)= 3900gpd.

TLRO Capacity Chart for Atmospheric Storage

20%

30%

40%

50%

60%

70%

80%

90%

100%

0 500 1000 1500 2000 2500 3000

Inlet TDS (ppm)

Cap

acit

y

35 Deg F

45 Deg F

55 Deg F

65 Deg F

75 Deg F



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Note: Chart above is based on a captive air (bladder) tank with a 30/50 pressure switch. Temperature conversions: (35°F = 1.6°C), (45°F=7.2°C), (55°F=12.7°C), (65°F=18.3°C), (75°F=23.8°C) Example 2: TL RO Size: TL-2000 Water Temperature: 45 °F Storage Tank: Bladder Type Tank TDS: 1000 Use the TLRO Capacity Chart for Bladder Storage Tanks. Follow up the x-axis at 1000 TDS until it meets the 45 °F temperature line. Follow this point across to the Y-axis to get the capacity %. The capacity % is approximately 27%. So the TL-2000 will produce 27% of its rated capacity or (2000gpd x .27)= 540gpd.

TLRO Capacity Chart for Bladder Tank

10.0%

15.0%

20.0%

25.0%

30.0%

35.0%

40.0%

45.0%

50.0%

55.0%

0 500 1000 1500 2000 2500 3000

Inlet TDS (ppm)

Cap

acit

y

35 Deg F

45 Deg F

55 Deg F

65 Deg F

75 Deg F



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EQUIPMENT SPECIFICATIONS

System Configuration Depending on the inlet characteristics of your water, additional components may be required with your TL Series Reverse Osmosis System. The configuration of these accessories along with their functionality has been listed. Should you require further information regarding this equipment, please contact your local Kinetico Dealer.

Backwashing Filter The TL RO uses a 5-micron cartridge filter for total suspended solids (TSS) removal. If this filter becomes frequently blocked, additional filtration may be required. Kinetico offers a wide range of backwashing filters using a variety of media. Depending on the type of solids in the water, the appropriate media may be matched for your application. Kinetico’s laboratory can test for the TSS content of feed water if it is not known. This will help determine the type of pre-filter required. High levels of TSS can cause fouling of the TL RO’s membrane, thus reducing both the quality and quantity of the TL RO’s permeate water.

Carbon Filter A carbon filter is used to protect the TL RO’s membrane from organic fouling or from chlorine degradation. Both these types of fouling can seriously damage the TL RO’s membrane(s). With chlorine degradation, the membrane is slowly damaged. This type of damage is irreversible.

The maximum influent level of chlorine to the TL RO is 0.05 mg/l. Prolonged exposure to excessive levels of chlorine will cause membranes to be destroyed. At this point, the only remedy would be to replace the membranes.

Softener If hardness levels exceed 4 gpg (68.4 mg/l as CaCO3), scaling will occur within the TL RO’s membrane(s). Calcium and magnesium are the two primary constituents leading to scale build up on the RO’s membrane(s). To prevent this scaling, a softener can be used to remove calcium and magnesium from the water. A chemical descalent may be substituted for pre-softening the water in some applications. However, some chemical additives may result in a poorer quality of permeate water from the TL RO. Also, the uses of various chemical additives are controlled under regulatory standards.

TL Series Reverse Osmosis System The TL RO uses reverse osmosis technology to reduce the total level of dissolved solids in a feed stream. The system uses spiral wound RO membranes for production of permeate water. The permeate water from the system typically exhibits a 95% or better reduction of the total dissolved solids level (TDS) from the feed water. The reject water contains the concentrated minerals that have not been permitted to pass through the membrane. The TL RO also features a permeate flush. This permeate flush extends the operating life of the system’s membranes by flushing the entire feed side of the membrane with high quality permeate water before its idling mode.

Feedwater Flow(High Pressure)

Permeate

Concentrate

MembranePermeate Spacer

Feedwater Spacer



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Holding Tank If the average permeate flow rate of the TL RO can not meet peak demands, a holding tank is used to collect the water, allowing for higher, intermittent demands to be accommodated.

The permeate water is not pressurized from the TL RO. Alternative holding tank configurations such as a pressurized bladder tank is possible, however it will affect the rated daily production of the system due to the back pressure on the TL RO in this configuration. Also, special attention must be made to the size and number of pressure vessels and set point for the pressure switch that will control the units operation. More on this topic is discussed within the options section.

* Empty Weight

Repressurizer Pump Since the water being stored in the holding tank is at atmospheric pressure, a repressurizer pump assembly is used to make up to 50 psi for the delivery of the water. This pump assembly is also used to supply water back to the TL RO for the permeate flush on this system.

Model Number Rated Size Diameter Height Weight* Capacity to low level7495 300 gal. (1,136 l) 35" (88.9 cm) 80" (203.2 cm) 85 lbs. (39 Kg) 225 gal. (852 l)7496 550 gal. (2,082 l) 48" (121.9 cm) 83" 210.8 cm) 120 lbs. (54 Kg) 413 gal. (2,414 l)7497 850 gal. (3,218 l) 48" (121.9 cm) 120" (304.8 cm) 190 lbs. (86 kg) 638 gal. (2,840 l)7498 1,000 gal. (3,786 l) 64" 162.6 cm) 84" (213.4 cm) 205 lbs. (93 Kg) 750 gal. (2840 l)7499 1,500 gal. (5,679 l) 64" (162.6 cm) 123" (312.4 cm) 300 lbs. (136 Kg) 1125 gal. (4259 l)

Atmospheric Storage Tank AccessoriesPart Number Description

8319 Level Control TL/TI10210 Repressurizer Asy, TL/TI-B, 230 volt / 1HP9837 Bulkhead Kit, CRO7535 Switch, Float N/C (float only- Low Level for TL-RO)7552 Switch, Float N/O (float only-High Level for TL-RO)7534 Weight Cord, 3" x 2 1/4" (Weight only- High Level Weight for TL-RO)7553 Weight Cord, 3" x 5 1/2" (Weight only- Low Level Weight for TL-RO)7549 Clamp, Tubing - Ratchet

Filter AccessoriesPart Number Description

7477 5 micron Replacement Cartridge 20"

MiscellaneousPart Number Description

3814 Wrench, Slimline Filter Sump



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Operating Specifications General operating parameters for the TL RO product line have been listed in the table below. These specifications have been provided to express the required conditions for the operation of this system. If there are other parameters that you may be concerned about, please contact your local Kinetico Dealer for further operating or performance data.

Exceeding the conditions in the table below may inhibit performance or could cause the system to be permanently damaged.

To assure that these factors are being met, a yearly water analysis is recommended to keep track of your influent water quality. This can be a beneficial tool in recognizing changes in your inlet water supply. If the inlet supply does change, please contact your area Kinetico Dealer. Modifications to the system or additional equipment may be required to maintain peak operation efficiency of your system.

60 HZ Operating Specifications *Production rates based at 500 TDS, 50% water recovery and 77F

Model T-2000 T-4000 T-6000 T-8000Dimensions (LxWxH) 22" x 20" x 54" 22" x 20" x 54" 22" x 20" x 54" 22" x 20" x 54"*Production Rate gallons/day (gpd) 2,000 4,000 6,000 8,000*Production Rate liters/day (lpd) 7,572 15,144 22,717 30,289Inlet Flow Rate gallons/minute 2.8 5.6 8.3 11.1Inlet Flow Rate liters/minute 10.5 21.0 31.6 42.1Membrane Type Thin Film Low E Thin Film Low E Thin Film Low E Thin Film Low ENumber of Membranes 1 2 3 4Rejection Rate typical 92% - 98% 92% - 98% 92% - 98% 92% - 98%Recovery Ratio 50% 50% 50% 50%Prefilter 20", 5 micron 20", 5 micron 20", 5 micron 20", 5 micronPump submersible submersible submersible submersibleMotor (Domestic 60 Hz) 0.75 hp 0.75 hp 0.75 hp 0.75 hpFeed Valve solenoid valve solenoid valve solenoid valve solenoid valveFeed Water

Pressure psi 15 - 50 15 - 50 15 - 50 15 - 50Pressure bar 1.07 - 3.55 1.07 - 3.55 1.07 - 3.55 1.07 - 3.55

Temperatureo F 35 - 90 35 - 90 35 - 90 35 - 90

Temperatureo C 1.7 - 32.2 1.7 - 32.2 1.7 - 32.2 1.7 - 32.2

pH SU 4 - 10 4 - 10 4 - 10 4 - 10Hardness (max.) gpg as CaCO 3 4 4 4 4

Iron (max.) ppm as Fe 0.2 0.2 0.2 0.2Chlorine (max.) ppm as Cl 2 0.05 0.05 0.05 0.05

Total Dissolved Solids (max.) ppm as CaCO 3 3,000 3,000 3,000 3,000

Operating Pressure psi 95 - 125 95 - 125 95 - 125 95 - 125Normal Operating Pressure psi 105 105 105 105Product Water Storage Tank atmospheric atmospheric atmospheric atmosphericPower - Domestic System volts 208-240 208-240 208-240 208-240

(frequency) hertz 60 60 60 60Full Load Current w/o Rep Amps 8A 8A 8A 8AFull Load Current w/ 1 HP Rep Amps 16A 16A 16A 16A

Fitting ConnectionsInlet diameter 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPTPermeate diameter 1/2" tubing 1/2" tubing 1/2" tubing 1/2" tubingDrain diameter 1/2" tubing 1/2" tubing 1/2" tubing 1/2" tubing

Permeate FlushPressure psi 30 - 50 30 - 50 30 - 50 30 - 50Pressure bar 2.13 - 3.55 2.13 - 3.55 2.13 - 3.55 2.13 - 3.55Volume gallons 5 10 15 20Volume liters 18.9 37.9 56.8 75.7



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50 HZ Operating Specifications

*Production rates based at 500 TDS, 50% water recovery and 77F

Model T-2000 T-4000 T-6000 T-8000

Dimensions (LxWxH) 22" x 20" x 54" 22" x 20" x 54" 22" x 20" x 54" 22" x 20" x 54"

*Production Rate gallons/day (gpd) 2,000 4,000 6,000 8,000

*Production Rate liters/day (lpd) 7,572 15,144 22,717 30,289

Inlet Flow Rate gallons/minute 2.8 5.6 8.3 11.1

Inlet Flow Rate liters/minute 10.5 21.0 31.6 42.1

Membrane Type Thin Film Low E Thin Film Low E Thin Film Low E Thin Film Low E

Number of Membranes 1 2 3 4

Rejection Rate typical 92% - 98% 92% - 98% 92% - 98% 92% - 98%

Recovery Ratio 50% 50% 50% 50%

Prefilter 20", 5 micron 20", 5 micron 20", 5 micron 20", 5 micron

Pump submersible submersible submersible submersible

Motor (International 50 Hz) 1.5 hp 1.5 hp 1.5 hp 1.5 hp

Feed Valve solenoid valve solenoid valve solenoid valve solenoid valve

Feed Water

Pressure psi 15 - 50 15 - 50 15 - 50 15 - 50

Pressure bar 1.07 - 3.55 1.07 - 3.55 1.07 - 3.55 1.07 - 3.55

Temperatureo F 35 - 90 35 - 90 35 - 90 35 - 90

Temperatureo C 1.7 - 32.2 1.7 - 32.2 1.7 - 32.2 1.7 - 32.2

pH SU 4 - 10 4 - 10 4 - 10 4 - 10

Hardness (max.) gpg as CaCO 3 4 4 4 4

Iron (max.) ppm as Fe 0.2 0.2 0.2 0.2

Chlorine (max.) ppm as Cl 2 0.05 0.05 0.05 0.05

Total Dissolved Solids (max.) ppm as CaCO 3 3,000 3,000 3,000 3,000

Operating Pressure psi 95 - 125 95 - 125 95 - 125 95 - 125

Normal Operating Pressure psi 105 105 105 105

Product Water Storage Tank atmospheric atmospheric atmospheric atmospheric

Power - Domestic System volts 208-240 208-240 208-240 208-240

(frequency) hertz 50 50 50 50

Full Load Current w/o Rep Amps 10.6A 10.6A 10.6A 10.6A

Full Load Current w/ 1 HP Rep Amps 18.6A 18.6A 18.6A 18.6A

Fitting Connections

Inlet diameter 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT

Permeate diameter 1/2" tubing 1/2" tubing 1/2" tubing 1/2" tubing

Drain diameter 1/2" tubing 1/2" tubing 1/2" tubing 1/2" tubing

Permeate Flush

Pressure psi 30 - 50 30 - 50 30 - 50 30 - 50

Pressure bar 2.13 - 3.55 2.13 - 3.55 2.13 - 3.55 2.13 - 3.55

Volume gallons 5 10 15 20

Volume liters 18.9 37.9 56.8 75.7



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Component Functionality The TL RO is comprised of various components.. A brief description has been provided for each of these major components. The illustration helps depict the physical location of these components on the TL RO, while the flow schematic shows the flow path through the system.

Inlet The inlet to the system is located adjacent to the filter housing. This connection is 3/4” NPT. Prefilter A 5 micron prefilter is used to trap suspended solids before entering the TL RO. This filter acts as a safeguard for protection of the system’s pump and membranes.

Operating the unit without a filter in the filter housing will increase the potential for membrane fouling and damage.

Feed Solenoid Valve A brass, normally closed (NC) solenoid valve is used to shut flow off to the system during shutdown or alarm conditions. Panel-Mounted 0-160 psi Pressure Gauge The pressure gauge labeled “Feed Pressure” shows the feed pressure after the filter. The required inlet pressure to the system is 30 psi. Low Pressure Switch The low pressure switch is used to shut the system down if an inadequate feed pressure is present. The set point for the pressure switch is 12 psi (0.7 bar). The switch is located behind the Inlet pressure gauge.

Do not operate the system with this safety device bypassed.

Pump-in-Tube The pump-in-tube provides pressure to the TL RO as required for proper operation. The use of this pump style is a design advantage that also provides extraordinarily quiet operation compared to typical pumps being used. Depending on the model of your system, typical operating pressure should be at 95 to 125 psi for the TL-RO’s. See Table 3 for details. The pump-in-tube assembly is identified by its length and conduit connection. Panel-Mounted 0-160 psi Pressure Gauge The gauge labeled “Pump Pressure” on the panel, shows the pressure of the water after the pump-in-tube assembly.



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Membrane Housing / Membrane Each membrane housing holds one 4” x 40” (10.12cm x 101.16cm) Thin Film Composite (TFC) membrane. There are between one and four membrane housings used in the TL RO product line. (see table pg. 16) The operating efficiency of this membrane is affected by operating pressure, quality of the inlet water and water temperature. Conductivity Probe The conductivity probe is used to measure the product water quality of the RO. This probe is designed to operate specifically with the conductivity meter in the control box. 0.5-5 gpm Flow Meter The panel-mounted flow meter indicates the flow of the permeate water from the system. Depending on the model and feed water conditions, flow rate can vary from 1.25 to 5.5 gpm (4.7 to 21 lpm). Pump Pressure Regulator A back pressure regulator is used to adjust and regulate the feed pressure. This valve should be adjusted so that the system operates at peak performance. Concentrate Flow Control Assembly The concentrate flow control is used to regulate the recovery of the system. This assembly consists of the housing, screen and disc. The TL RO Systems are designed to operate at a 50% recovery efficiency (at standard operating conditions).

Screen/Filter Disc Housing



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Drain Connection The drain connection is a 1/2” hose quick-connect fitting, located on the right side of the skid. Permeate Connection The permeate connection is a 1/2” hose quick-connect fitting, located on the right side of the skid. This line should be plumbed to an atmospheric storage tank. Permeate Rinse Solenoid Valve This electric normally closed solenoid valve is used to flush the membrane prior to a system shutdown. A pressurized supply line from the permeate storage tank is required for the permeate flush to work properly. Panel The panel includes instrumentation pertinent to the operation of the system. This information includes:



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System Controller The TL RO is operated by a microprocessor controller designed to enhance the operation of small to medium commercial and industrial reverse osmosis systems. The controller is used to operate the TL RO efficiently and safely. The controller monitors pressure and float switches and provides time delays to prevent false system shutdowns. Pump control relays are provided to operate a single phase auxiliary pump motors up to 1 HP @208 - 240 volt. Motors larger than 1 HP can be controlled when the unit is used in conjunction with an additional motor starter. The panel indicators show the status of the control system. Switches on the front panel are provided to allow easy control of the System Power, RO Pump and Auxiliary Pump.

Controls and Indicators Tank Full Lamp -- When lit, the RO pump is shut down due to storage tank full. Everclean Rinse Lamp -- When lit, the membrane flush control relay is energized. Water Quality Lamp -- Lit green on acceptable water quality; lit red when the conductivity exceeds the allowable high limit. Conductivity Display -- Displays the actual conductivity (selectable) reading in microsiemens. Low Pressure Lamp – Lit red when pressure drops below 12 psi for more then 15 second. Alarm Lamp – Is lit red when an alarm condition such as low feed pressure or high conductivity occurs. RO Pump Lamp -- Lighted when the RO pump control relay is energized. RO Pump Switch -- Turns system on or enables automatic RO operation. AUX Lamp -- Lighted when the auxiliary pump control relay is energized. AUX Switch -- Enables the auxiliary pump control relay. Reset Switch -- Resets the system when it is shut down on low feed pressure or high conductivity.

System Configuration There are 8 Jumpers on the base controller that vary the time delays for the RO system. See base controller below for location of these jumpers. By placing these jumpers on the various pins the time delay is changed. Time Delays (see chart below for location of jumpers) Aux Restart – Controls time to start the Repressurizer pump after reaching aux float level if one is connected to the controller (field installed). High Level Storage Tank Reset- Controls time delay to start the RO System after float is tripped. Membrane Flush- Controls the time for a membrane flush. Pump Start Delay- Controls time delay between opening inlet solenoid valve and starting the system pump. Atmospheric Storage Tank The TL RO can be operated with either an atmospheric storage tank, or pressurized storage tank. The system’s default settings are for an atmospheric storage tank set-up. With this configuration, the “High level storage tank reset” is set to 15 minutes. This means, that when the high level float in the tank drops below its energized position, the system waits 15 minutes before restarting. Pressure Tank Configuration A time delay on the high tank level would cause problems if the unit is used with a pressure switch and pressurized storage tank. To change the high tank delay to 5 seconds install jumpers on pins 7 & 8.



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Example: The standard pin setting for an atmospheric storage tank type system would be jumpers at the following locations:

Jumpers on pin 1, 3, 5, 7 -Aux Restart = 30 seconds

Function Time 1 2 3 4 5 6 7 8AUX Restart 5 sec. X X

15 sec. X** 30 sec. X

60 sec.High Level Storage Tank Reset 5 sec. X X

300 sec. X** 900 sec. X

1800 sec.Membrane Flush 5 sec. X X

120 sec. X** 300 sec. X

600 sec.Pump Start Delay 5 sec. X X

15 sec. X** 30 sec. X

60 sec.* X- Denotes Installed Jumper** - Denotes Standard Settings

Jumper Setting*

Jumpers



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INSTALLATION

Getting Started The following procedures have been developed to assist during the installation of your TL RO System.

The installation of this TL RO should be performed by a qualified service person with an understanding of local and regional codes that may affect the installation requirements.

Pre-installation Review Before beginning the installation of the TL RO system, confirm system configuration to be installed, and components that have been ordered. Please review TL RO system specification sheet that includes required components. Review of the customer’s facility is also recommended, especially critical operating data that could effect the operation of the system:

Water Pressure Water pressure to the TL RO system will effect the maximum flow permitted by the system. The TL RO system will not operate if the inlet pressure fluctuates below a dynamic pressure of 30 psi. This minimum pressure must be maintained to the system at all times. Should the pressure fluctuate below this level, a booster pump may be required.

Temperature Ambient temperature must be maintained above 32°F (0°C). Freezing temperatures will cause breakage of equipment and void all warranties. Water Temperature Inlet water temperature must be maintained between 35°F and 90°F to prevent damage to the system’s membranes.

System Location The unit must be installed indoors. Failure to comply with this requirement can cause significant damage to the system and will create a safety concern.

TL RO Installation

Tools and Installation Materials Since the TL RO process high quality water, plumbing runs on the process, purge and drain outlets should all be completed with PVC piping. Copper and galvanized pipe will be chemically attacked by the permeate water.

Teflon® Tape Fitting Sealant 1/2” Tubing Plastic Tube Cutter Flat head screwdriver (medium)



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Phillips head screwdriver (medium and small) Multimeter Wire strippers/cutters PVC pipe cutters PVC Piping and PP Tubing (see TL RO specification sheet for detailed pipe and tubing requirements) PVC cement PVC pipe hangers PVC Isolation / By-pass Valves Additional 316 SS pressure gauges PVC or steel conduit

Unpacking 1) Remove the box covering the TL RO. 2) Unbolt TL RO frame from pallet attached to the box. 3) Remove TL RO from the pallet. 4) Inspect unit for possible shipping damage: -broken fittings -loose hoses or tubing -dents or scratches 5) Remove additional material from crate: -Additional copy of manual -Prefilter Cartridge -Assembly components package 6) Check all connections and mounting bolts. Tighten as necessary as they may become loose during

shipment. Check that all unions are tighten. 7) Check all tubing and mounting bolts. Tighten as necessary as they may become loose during shipping. 8) Install feet to the bottom of the unit. They are installed in the same holes that were used to mount the TL

RO to the pallet. 9) Install the prefilter cartridge into the filter housing.

Skid Positioning The TL RO can be moved by forklift, pallet jack or two-wheeler. The skid weights nearly 300 lbs. (empty weight) and caution should be used whenever moving the equipment. Move the TL RO Assembly to the location of its installation. Make sure the area meets the following requirements: Indoors. Level. Dry. Access to drain. Access to electrical hookup. Access to adequate water supply. After moving the unit to the installation site, select an area where the unit can serviced from the front and sides. When installing next to a wall, leave a minimum of a 12” access path to allow service to the back of the unit. Leave a minimum of 12” on both sides of the system. This will allow for easy removal of membranes, should they need to be changed. 36” access in front of the system is required due to the electrical control box.



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Plumbing Hook-ups 1) Connect the feed water line to the inlet of

the TL RO (1). This requires a 3/4” NPT male pipe adapter.

2) Connect the permeate water line using 1/2” tubing (2). This connection should lead to an atmospheric holding tank or directly to your supply line (see start-up instructions before operation of this system).

3) Before starting the system, move the permeate line to the drain to flush the preservatives from the membranes.

4) Connect the drain water line using 1/2” tubing (3). This connection should be made to a drain in compliance with the local codes or requirements of your area.

5) Connect permeate flush line to permeate flush solenoid valve (4). This connection should be plumbed from the pressurized side of the permeate feed line.

When making these plumbing connections, it is recommended to install a system by-pass using adequately sized ball valves.

Electrical Hook-up – 230 Volt Single Phase After installing the skid connections, bring power to the TL RO skid. Single phase power is required. The system will be configured to run at one of the following line voltages:

230VAC, 60 Hz, 1 phase Without Repressurization Pump (TL RO only) Full Load Current: 8A Required Branch Circuit Device: 250V/10A Fuse (RK5 TD) With Optional 1 HP Repressurization Pump (TL RO and 1 HP Pump) Full Load Current: 16.9A Required Branch Circuit Device: 250V/25A Fuse (RK5 TD) Branch Circuit Conductor: #12 AWG (75C) Cu Minimum Equipment Grounding Conductor: #12 AWG (75C) Cu Minimum

Fusible and lockable disconnect switch with a minimum rating of 250 VAC/30A and including class R rejection mechanism must be installed within 50 feet of this equipment. The disconnect switch must be visible from this equipment.

230VAC, 50 Hz, 1 phase Without Repressurization Pump (TL RO only) Full Load Current: 10.6A Required Branch Circuit Device: 250V/17.5A Fuse (RK5 TD) With Optional 1 HP Repressurization Pump (TL RO and 1 HP Pump) Full Load Current: 18.6A Required Branch Circuit Device: 250V/30A Fuse (RK5 TD) Branch Circuit Conductor: 4mm2 HØ5RR #12 AWG (75C) Cu Minimum

(1)

(2)

(3)

(4)



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Equipment Grounding Conductor: 4mm2 HØ5RR #12 AWG (75C) Cu Minimum Fusible and lockable disconnect switch with a minimum rating of 250 VAC/30A and including class R rejection mechanism must be installed within 50 feet of this equipment. The disconnect switch must be visible from this equipment.

Tools and Materials Required for Electrical Install Fused Disconnect (See Table 7) Voltmeter Flexible or Rigid 1/2” conduit #12 AWG (75C) Cu Minimum Conductors #12 AWG (75C) Cu Minimum Green Conductors Wire Cutters/Strippers Flathead Screwdriver Conduit Sealtight Connectors

Use a multimeter to confirm power to be supplied to TL RO is proper voltage. After confirming voltage of the source power, shut off that power line, and confirm it is de-energized with the multimeter. It is also recommended to use a lock-out kit on the power supply to prevent it from being energized during installation connections.

1) Wiring must be done by a qualified electrician and must follow all local and appropriate codes. 2) This unit must be connected to a dedicated disconnect. That disconnect should be within 50 feet (15

meters) of the equipment and within visible site. The disconnect must be fusable and lockable with a minimum rating of 250 VAC/30A.

3) The disconnect should use UL Class RK5 TD (or equivalent). (Fuses must be sized accordingly see information above.) From the disconnect, run three #12 AWG conductors within 1/2” conduit to the TL RO (two leads plus equipment ground - must be green).

4) The use of a grounded conduit is not suitable for proper equipment grounding. Please use a separate #12 AWG grounding conductor for this purpose.

5) Connect #12 AWG conductors to L1 and L2 terminals. 6) Connect #12 AWG ground wire to the grounding bar. 7) Connect high tank level float (N/O) lead to the terminals marked “System Float” on the system’s circuit

board. 8) Connect low tank level float (N/C) lead to the terminals marked “Aux Float” on the system’s circuit board. 9) Connect repressurization pump leads to AUX terminals. 10) Plug any unused holes within the electrical enclosure with the metal clip plugs included with this package.

Electrical Hook-up -- 208 Volt Single Phase 60 HZ

The TL Series RO systems are designed for 230 V, 60 Hz, single phase power. When only 208V, 60 Hz, single phase power is present, a means of “boosting the voltage from 208V to 230V is required. Standard isolation-type transformers will work, however Kinetico Incorporated recommends the use of an autotransformer. A “buck-boost” or “autotransformer” is an economical way to convert 208 V single phase to 230 V single phase. The autotransformer (buck-boost transformer), when properly sized, is a more efficient, smaller, lighter, and less costly way to make minor voltage changes. They are designed to raise the voltage by a small amount, typically 5 to 20%. Buck-boost transformer nameplates can cause confusion. The nameplates depict their operation as isolation transformers, not when configured as autotransformers. Therefore, the primary voltage, secondary voltage, and KVA rating listed on the transformer nameplate are not the primary voltage, secondary voltage and KVA rating of the auto-connected configuration (autotransformer configuration).



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Here is an example. One of the transformers Kinetico Incorporated recommends using is an Acme T-1-81051. The nameplate for this transformer says:

Primary Voltage: 120 x 240 Secondary Voltage: 12/24 KVA Rating: 0.5 KVA

However, when used to boost 208 V to 230 V, this transformer has the following ratings:

Primary Voltage: 208 V Secondary Voltage: 230 V KVA Rating: 5.5 KVA

The improved performance results from the way the transformer is wired. When the transformer is auto-connected, the KVA rating of the transformer depends on the amount of voltage boost (or buck). All of the recommended transformers for the TL series have been sized to account for motor starting currents. Buck-Boost Transformer Wiring The following figure shows how to wire a Buck-Boost Transformer as an autotransformer.

230 V Out

208 V In

120/240 x 12/24 VBuck-Boost Transformer

(Autotransformer)

WARNING!! NEC Code, Article 450-4(a) prohibits fusing in the shunt winding of the autotransformer. Refer to all national and local electrical codes when fusing the

transformer.



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Determining the TL Series Revision The transformer must be sized to the TL series unit and possible accessories. TL units before revision B used a 1½ HP feed pump and an optional 1 HP repressurization pump. TL units revision B and later use a ¾ HP feed pump and an optional 1 HP repressurization pump. To determine the unit revision, examine the TLRO dataplate. The dataplate is located on the Pump-In-Tube Assembly, and looks similar to this:

Revision B and later units have a Full Load Current without the repressurization pump of 8.0A. Units prior to Revision B, have a Full Load Current without the repressurization pump of 13.1A.



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Transformer Recommendations After determining the TL series configuration, and version, refer to the following table for the recommended Buck-Boost transformer. When using a Buck-Boost transformer from a different manufacturer, make sure the transformer is rated as listed below. NOTE: These transformers will also work when connected before the main disconnect box on an HP unit.

TLRO before revision B without repressurizer

Manufacturer Manufacturer P/N Transformer Rating:Acme T-1-81051 Single Phase

Dongan 85-M025 120/240 PrimarySquare D 500SV43B 12/24 Secondary

GE 9T51B108 0.5 kVAJefferson Electric 216-1131-000 Dry Type

TLRO before revision B with 1 HP repressurizer


Dongan 85-M030 120/240 PrimarySquare D 750SV43F 12/24 Secondary


TLRO revision B or later without repressurizer




TLRO revision B or later with 1 HP repressurizer






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Atmospheric Tank Installation

Tools and Installation Materials 1/2” Tubing 1” Plastic Piping Teflon® Tape Pipe Sealant 1 1/4” Threaded Male Adapter for Pump Inlet 1” Threaded Male Adapter for Pump Outlet Plastic Pipe Cleaner Plastic Pipe Cement Plastic Pipe Cutter

Use both Teflon tape and pipe sealant on all threaded connections. For Plastic connections, make sure fittings are first cleaned, then glued. For tubing connections, plastic tubing should be cut straight with a sharp blade. These procedures will minimize leaks at the connections.

Tank Connection The figure at right shows the tank connection assembly. Connect 1/2” tubing connector to 1/2” x 1” reducer bushing. Connect adaptor to outlet of 1” NPT Tee. To other outlet of Tee, connect 1” short nipple. Connect nipple to 1” NPT Ball Check. To common inlet of tee, connect 1” short nipple. To nipple, connect 1” true union ball valve. To other end of ball valve, connect 1” short nipple. Disassemble the true union ball valve with the nipple. Make the connection from this nipple to the tank. Reassemble ball valve.



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High Level Control Refer to figure at right. Assemble the float switch components to the top of the tank. Place the level control switch with the cord in the tank through the manway. Guide the cord out of the tank through the bulkhead, nipple, tee and the cord grip. Tighten in place as shown in Repressurizer Installation section. Thread the HEPA filter horizontally onto the 3/8” nipple in the TEE. Disconnect all power to the TL RO System. Open the door on the front of the system. Route the cord into the TL RO Control box using another cord grip. Connect the wiring to the “System Float” terminals as shown on the electrical wiring diagram.

Repressurizer Installation (Domestic 60HZ Models Only)

Tools and Installation Materials Flexible or solid conduit Conduit fittings #12 AWG Conductors (black, red and green) 1” Threaded Male Pipe Adapter for Pump Outlet

1) Make sure level floats are installed in atmospheric tank. 2) Disconnect all power to the TL RO System. 3) Open the door on the front of the system. 4) Confirm using voltmeter that power has been disconnected to the TL RO system. 5) Route the #12 conductors through protective conduit from the pressure switch on the repressurizer to the

controller. 6) Connect the wires as shown on the electrical schematic. 7) Connect the wires to the pressure switch. 8) The green wire must be connected between the pressure switch and the ground bar inside the electrical

control box. 9) Install 1” (minimum) plastic pipe from the ball check valve to the 1” NPT inlet of the repressurization

pump. 10) Install the TEE fitting to the 1” outlet of the pump. 11) Connect one side of the TEE to the flush solenoid valve located at the top back side of the primary

membrane. (Figure Below.) 12) Connect the other side of the TEE to the customer service outlet. 13) It is recommended that a plastic ball valve be installed at the pump outlet before plumbing to any post-

filtration.



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Important: Connect a ¾” overflow line from the top of the tank to the drain.

Install OverflowLine to drain

TO “System Float”TLRO Controller



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Captive Air (Bladder) Tank Installation In some applications a captive air style (bladder) tank may be used instead of an atmospheric tank. When installing a captive air style tank with a TLRO a reverse acting pressure switch and relief valve are required. The pressure switch is set at 30/50 to turn the TLRO on at 30psi and shut if off at 50psi. Important: The relief valve is used as a safety in case the pressure switch fails. The relief valve is set at 100psi to open up and allow pressure to relieve from the tank. The relief line is run to the drain. 1. The #10284 Pressure Switch spring is set so that the turn on pressure is 30psi and the turn off is 50psi.

(Note: The 30/50 setting is standard if a different switch setting is required the spring on the switch must be adjusted).

2. Connect 2 conductor cable (2 wires) to the normally open contacts on the #10284 Pressure Switch. This is a low voltage contact so the wire conductor size can vary (normally between 14 and 20 gauge).

3. Run the 2 conductor cable into the TLRO control panel and connect to the contacts on the controller marked ‘System Float’.

4. Adjust the jumper settings on the TLRO Controller so that the TLRO starts making water immediately after the pressure switch turns on at 30psi (no delay). Install a jumper on pins 7 and 8 (see System Controller section for changing the jumper settings).

Permeate from TLRO

#10284 Pressure Switch N/O Rev Act

#7916 Pressure Relief Valve (Run relief line to drain)

#7483 Pressure Tank 80 Gallon w/bladder

Permeate out to process



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OPERATION AND MAINTENANCE

Normal Operating Procedures During the normal operation of the TL RO system, a few items are required to be checked daily. The reliable upkeep with these items will maintain the operation of the TL RO to its highest standards.

Daily Start-up/Shutdown The equipment will run in an automatic mode, shutting itself off each time a high level is achieved in the storage tank. With the automatic control, the pump will shut off first. Just after this occurs, the flush solenoid valve will open, thus initiating the permeate flush. This rinse flushes the membrane with permeate water, minimizing the possibility of membrane fouling.

Daily Log On the back page of this manual, a daily log has been provided. Photocopy this template and use it for recording the system’s daily performance. By recording various system characteristics each day, this will help in any future troubleshooting of the equipment. It is also necessary to keep a daily performance log to show changing performance characteristics of the TL RO. These changes may be the result of membrane fouling. With accurate logs kept on performance, timely cleaning of the membranes will insure maximum membrane life. The parameters included on the daily log sheet are:

Date Feed Pressure Pump Pressure Permeate Flow Rate Water Quality Comments

Routine Maintenance Filter Maintenance If the inlet feed pressure is not above 30 psi during operation (dynamic pressure at the inlet flowrate), the system will shut down due to low feed pressure. In this situation, it is most probable that the cartridge filter requires replacement.

Check the daily log for changes in the inlet pressure. One can predict the life of the prefilter before its use has become over-exhausted by using the daily log as a preventative maintenance tool.

Membrane Cleaning To determine if the membrane requires cleaning, review of the daily log is required. If the permeate of the system has decreased by more than 25%, or if the permeate quality has risen by more than 50%, the membranes may require cleaning. Please refer to the maintenance section for further details on membrane cleaning.

System Commissioning (Initial Start-up) The start-up procedures for the equipment should be followed if:

-It is the first time the unit is being put into operation. -The equipment has been moved. -The unit has been shut down for an extended period of time (a few weeks).



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After completing these start-up procedures, the normal operating procedure should be followed. Make sure unit has been properly installed by reviewing the installation section.

Recommended Start-up Tools 1/2” Tubing Tube Cutter Portable Conductivity Meter Temporarily connect permeate line to drain using 1” hose. This will be used to flush the membranes of any preservatives before commissioning the system.

1) Temporarily connect permeate line to drain using 1/2” tubing. 2) Open feed water valve slowly to pressurize the system. 3) Check unit for leaks. 4) Tighten any connections exhibiting leaks. 5) Do not use a pipe wrench to tighten plastic pipe connections. This may result in damage of the pipe,

causing a rupture in the plumbing assembly. 6) Turn on disconnect switch. 7) Energize system by toggling “Feed Pump” switch on front panel. This will activate the pump. The pump

may shut down a number of times while the system purges itself of air. 8) Reset the system if it has shut down due to this low pressure signal by pushing the reset button on the

front panel (must hold in for 2.5 seconds). 9) Repeat resetting the system until the pump runs automatically. (It may take 2 -3 resets to purge the air.) 10) If after three attempts the system still fails to reach an adequate operating pressure, it may be necessary

to assist bleeding the air out of the system.

First shut off the pump, then system power. Decouple the tube connection for the pressure

gauge line at the top of the membrane assembly. 11) After pump is running in the automatic mode, observe

pressure gauges. 12) Do not exceed 140 psi on the pump pressure gauge and

do not run the pump dry. These conditions will damage the system.

13) While the system is running, turn the pump pressure regulator until the pump pressure reads 105psi for the TL-RO.

14) After 10 minutes of operation, the membranes should be adequately flushed of any preservatives.

15) Take a sample of the permeate water, measuring conductivity using a portable monitor. Compare this reading to the reading of the conductivity display.

16) If this reading is different by more than 100 Ms/cm, the conductivity meter may require calibration (see service and maintenance section on System Controller).

17) Shut the system down, including pump, system and disconnect switch. 18) Connect permeate line to the storage tank 19) Reconnect disconnect. 20) Engage system power toggle. 21) Engage system pump. 22) Do not engage AUX toggle at this time. 23) At this time, permeate water should begin filling the storage tank.



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Long Term System Shutdowns If the system is to be non-operational for more than 5 days:

Allow system to completely fill RO storage tank and perform a permeate flush. Connect the permeate line to drain.

Premix the specified volume of 1% sodium bisulfite (by weight) and water in a container. Open the housing, remove the filter cartridge and fill the housing with the bisulfite solution. (note- sodium bisulfite should be food grade, not cobalt activated) . Completely open regulator valve. Start the RO system by turning the switch upward. If the system shuts down press the alarm reset button (hold button for 2.5 seconds).

Wait 30 seconds, then shut-off system, by pressing the feed pump switch down.

Long Term Start-ups Temporary connect the permeate outlet to the drain with 1/2” hose. Turn power on to unit.

Turn on RO system on. Readjust regulator valve to preset rates.

Next, wait for 5 minutes while the system begins its operational cycle. Record data including filter differential, pressure pump pressure, inlet quality, and outlet quality. Flush permeate to drain for 10 minutes. Check permeate conductivity, when it returns to normal operation point, return RO to service.

Membrane Preservation In cases were the RO system is shut down for long periods it is recommended that the membranes are preserved in a solution containing 1% sodium bisulfite. The 1% sodium bisulfite solution will provide protection from biological growth.

While working with the preservative chemicals, please follow the appropriate local and national codes for chemical handling procedures to insure safety during this operation. This includes protective eyewear and gloves.

Disconnect and lockout/tagout power to the system.



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Close Feed water supply Close Drain, Recirculation and Permeate Ball Valves. Depressurize the system at the bag filter assembly. Premix the specified volume of 1% sodium bisulfite (by weight) and water in a container. Open the housing, remove the filter bag and fill the housing with the bisulfite solution. (note- sodium bisulfite should be food grade, not cobalt activated) After closing the housing, Close filter, open all ball valves. Reconnect power to the system. Turn on system power by pressing reset control power pushbutton. Direct permeate line to drain Operate system for 15 minutes. Repeat dosing step. After second dosing step, reconnect the permeate line to its original configuration. The system has now been preserved and can be restarted at a later date.

System Sanitation If bacteria or mold has infected the RO system, sanitation of the system is required. There are several compatible biocides that can be used with type FT 30 membranes. Please consult supplier instructions for specific use of biocides. FT 30 Compatible Brand Name Biocides:

Biocide Maximum Concentration (20-25C)

Supplier

Bioclean 882 .2% Argo Scientific C-68 .09% Betz Kathon GC/ICP .15% Rohm and Haas Nalco 2593 .15% Nalco Monarch Soak 40 5% Monarch Chemical Filtrapure Membrane Preservative 1% Monarch Chemical Before preparing water for consumption with your new system, it is recommended the entire system be sanitized. It is also recommended that this procedure be repeated at least every 12 months if bacteriological concerns are prevalent in your area.

While working with the sanitization chemicals, please follow the appropriate chemical handling procedures to insure safety during this operation. This includes protective eyewear and gloves.

Disconnect and lockout / tag out power to the system.



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Close Feed water supply Depressurize the system at the cartridge filter assembly. Premix the specified volume of bisulfite and water in a container. Open the housing, remove the filter cartridge and fill the housing with the bisulfite solution. After closing the housing, Turn on system power. Direct permeate line to drain Operate system for 15 minutes. Repeat dosing step. After second dosing step, reconnect the permeate line to its original configuration. The system has now been sanitized and can be restarted.

Atmospheric Storage Tank Sanitization

Tank Size Volume of Bleach (5 1/4% Sodium Hypochlorite)300 gallons 250 Milliliters 8 Ounces550 gallons 450 Milliliters 15 Ounces850 gallons 650 Milliliters 22 Ounces

1000 gallons 770 Milliliters 26 Ounces1500 gallons 1250 Milliliters 40 Ounces

System Size Volume of Iron Out or SodiumBisulfite

Volume of Water

2000 4 Ounces 200 Milliliters4000 8 Ounces 200 Milliliters6000 12 Ounces 200 Milliliters8000 16 Ounces 200 Milliliters



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Start-up Procedures, Repressurizer Pump Based on the completion of the TL RO start-up, the storage tank should be filling with permeate water. Start-up of the repressurization pump can commence once the tank has filled about halfway.

Check proper installation of the repressurization pump. Prime pump by disconnecting tube fitting on the pump casing. When water flows out, reconnect. Turn on the power to the repressurization pump by toggling the AUX switch on the TL RO panel. Immediately check pump pressure gauge for rising pressure in the Amtrol tank. If pressure does not begin to rise steadily toward 50 psi (3.4 bar) within 15 seconds, turn of the power at the AUX switch. If the unit is not shut down, pump damage will result. If the pump does not reach pressure, check the following items: Is the bulkhead valve at the base of the tank open? Is the water level in the tank above pump? (More than 12” (30.5 cm) from bottom of tank.) Has the unit been properly installed? Repeat Priming Steps. When the pressure tank reaches 50 psi (3.4 bar), the pump will continue to operate on a 30/50 (2 – 3.4 bar) psi cycle, provided the AUX switch is left on. Check for plumbing leaks.

System Maintenance

System Controller The TL RO uses an internal microprocessor controller to enhance the operation of the system. This microprocessor is equipped with a number of control devices that allow the electric components of the TL RO to be operated via this control device. Some of the controls included on the controller are listed:

Pump Motor Wiring Due to the nature of the pump design, it is not recommended to have any service done on the internal components. The pump-in-tube can be ordered as a complete assembly for replacement in the field. Should for any reason the pump assembly be removed from its housing, it is critical that this be done while the assembly is in a horizontal position. If removal is attempted while the unit is still mounted to the RO frame, a hazardous safety concern will arise due to the weight, position and placement of the housing.

Input Signal Wiring The “Low Feed” pressure switch – N/C switch, opens with pressure > 12psi. The “Tank Full” switch – N/O switch, closes with an “up” float position. “Tank Low” switch – N/C, opens when level exceeds float setting. Closed signal with low tank level.



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Membrane Flush Relay A relay to control membrane flush is provided. This relay has a normally open contact that closes to provide membrane flush. The connections for membrane flush are pre-wired.

Inlet Solenoid Relay The inlet solenoid relay is utilized to control the inlet solenoid independent of the RO pump. This relay operates immediately when the RO controller power switch is turned on and initiates a 30 sec. time delay before starting the RO pump (time delay is adjustable). The solenoid valve is 240 VAC.

Conductivity Sensor The Conductivity sensor cable connects to terminal marked as follows:

WHT –White Wire BLK – Black Wire GRN – Green Wire RED – Red Wire SHLD – Sheild wire, no insulation

Conductivity Monitor Calibration The TL RO microprocessor is calibrated at the factory and normally does not require calibration. However, after extended use calibration may be required.

Required Tools External Quality Meter Small Screwdriver Standard Sample of Solution

To calibrate the unit, the conductivity sensor must be connected to the unit, and the unit must be powered up for at least 15 minutes before calibration is attempted. Place a small screwdriver into the POT switch and turn the POT slowly to adjust the conductivity up or Down.

Membrane Cleaning Please consult your local Kinetico Dealer for assistance in cleaning of the RO membranes.



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Membrane Replacement Should the membrane require replacement or cleaning, the membrane will need to be removed from the vessel.

1) Depressurize system. 2) Grasp locking ring on the membrane housing by the

raised portion of the ring, and gently compress the ring inward so that it separates from its internal track.

3) Remove the end cap of the membrane by pulling the attached connection. The cap is held in place by an o-ring seal and may be tight.

4) With the top end cap removed, use a small pair of pliers to help grab the internal membrane. DO NOT pull from the center pipe, instead grasp from the surrounding plastic honeycomb.

5) Pull the membrane straight out of the vessel. 6) Membrane insertion is directional. Do not install against

the brine seal. Silicone is recommended on the brine seal to help insure a proper seal and to simplify the membrane insertion.

7) Insert new or cleaned membranes back into the vessel. 8) Make sure the membrane is completely down and in

place within the vessel. 9) Replace the end cap, fitting the top over the center pipe

of the membrane. 10) Replace the locking ring, making sure it is secure within

the groove at the top of the membrane vessel. A click will be heard when installed correctly. Rotate the clip two revolutions to verify it is properly seated.

11) Failure to follow these instructions could result in severe personal injury and property damage.

12) Reattach tube fittings. 13) Restart the system.

Filter Should the system frequently shut down due to low pressure, it is likely that the system’s prefilter requires replacement.

1) Shut down the system. 2) Gently rotate the bottom portion of the filter housing

counterclockwise.

o-ring end cap lockini

membrane

housing



Page - 40

3) Remove the old cartridge filter. 4) Insert a new filter cartridge. 5) Hand tighten the filter housing back to the RO system.

Solenoid Valves Occasionally debris may become trapped within the orifice in the permeate flush solenoid valve causing it to leak or not operate properly.

1) Disconnect and Lockout / Tag out power to the system. 2) Depressurize the system. 3) After removing the screws located on the valve, carefully

separate the electric actuator from the body of the valve. 4) Be mindful of the spring which sets within the housing,

used to keep the valve closed. 5) Clear the internal port using water, air or a towel. 6) Reassemble the valve making sure to apply equal

pressure on the screws around the valve. 7) Restart the system.

Pressure Gauges 1) Depressurize the system. 2) Loosen 1/4” NPT x TUBE fitting on back of gauge. 3) Loosen and remove mounting brackets from back side of

front panel. 4) Remove gauge through front of the panel. 5) Replace with new gauge. 6) Restart system.

Pressure Regulator Replacement Valve 1) Depressurize the system. 2) Remove the tubing from the back side of the pressure

regulator assembly. 3) Remove the handle from the pressure regulator. 4) Using a flathead screwdriver, loosen the four front bolts

of the pressure regulator. 5) Slip the assembly off of the back of the system. 6) Inset new pressure regulator. 7) Connect the flow control to the top brass fitting of the

new regulator. 8) Place regulator against front panel, and fasten bolts. 9) Replace remaining tubing connections to regulator. Leaking Valve 1) With the pressure regulator removed, tighten the internal

bolts that compress the internal diaphragm. 2) Reinstall pressure regulator, connecting tube fittings and

tightening the front plate bolts.

Flush solenoid valve

Feed solenoid valve



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Flow Disc It is possible to change the recovery rates on the TL RO system. This can be done by changing the flow disc size contained within the brass flow control assembly. By changing the recovery percentage of the system, it is vitally important to analyze the inlet stream coming to the RO, and calculate the maximum recovery possible based on the feed parameters. Also, the higher the recovery, the more quickly the membrane will become fouled and require cleaning or replacement. 1) Depressurize the system. 2) Unscrew the flow control body (1) from the hose connection side

(2). As this opens, the inside components will become visible. 3) Remove the filter (3), and clean it with water or air. 4) Remove the flow disc (4), and replace it with the appropriate disc.

(see Table 9) 5) Replace the clean filter, and reattach the body of the flow control

back to hose connection.

Pump & Motor Maintenance Under certain circumstances it may be necessary to service the pump or the motor. The pump and motor are housed in the long pump vessel housing.

Important: Disconnect and Lockout / Tag out power to the system. Depressurize the system. Important: The Pump & Motor Vessel Housing must first be removed from the TLRO frame before the Pump & Motor can be serviced.

1. Disconnect the inlet and outlet plumbing on the top and the bottom of the Pump Vessel

Housing. 2. Disconnect the power and ground leads from the motor from inside the TLRO control

box. 3. Remove the upper and lower clamps from the vessel housing holding the pump vessel

housing to the frame. 4. Remove the vessel housing from the frame and place the pump vessel on the floor or a

bench. 5. Grasp the locking ring on the pump housing by the raised portion of the ring and gently

compress the ring inward so that it separates from its internal track. 6. Remove the top end cap of the pump vessel by pulling the attached connection. The cap

is held in place by an o-ring seal and may be tight. 7. Pull the pump and motor out of the vessel. 8. Remove plastic wire protector from the side of the pump. 9. Disassemble the pump from the motor by unscrewing the 4 nuts that hold pump and

motor together.

Part Number GPM LPM TL 2000 TL 4000 TL 6000 TL 80007413 0.3 1.1 82% - - -7415 0.6 2.3 70% 82% - -8262 1.3 4.9 52% 68% 76% -10243 1.4 5.3 50% 67% 75% 80%8384 2.5 9.5 36% 53% 62% 69%10244 2.8 10.6 33% 50% 60% 66%8490 3.8 14.4 27% 42% 52% 59%10245 4.15 15.7 25% 40% 50% 57%8491 5 18.9 22% 36% 45% 52%10246 5.5 20.8 20% 34% 43% 50%

Reject Flow Rate Recovery

1

2

3

4



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10. Examine the pump and motor for any defects, including worn or broken shaft, check rotation by hand of the pump and motor shafts.

11. Replace any defective components. 12. Reassemble the pump and motor. 13. Add silicone grease between the pump coupler and the motor shaft. This will reduce

wear between pump and motor. 14. Tighten the 4 nuts that hold the pump to the motor in a staggered pattern (similar to the

installation of a tire on a car. Tighten the 4 nuts to a torque of 5 ft/lbs. 15. Insert the pump and motor back into the pump vessel housing, it may be necessary to

stand the pump vessel housing up so that the o-ring slides into place. Be careful not to pinch fingers in between the vessel and cap.

16. Replace the locking ring, make sure it is secure within the groove at the top of the membrane vessel. A click will be heard when installed correctly. Rotate the clip two revolutions to verify it is properly seated.

17. Failure to follow these instructions could result in severe personal injury and property damage.

18. Reattach the pump vessel housing to the TLRO frame. Rest the bottom of the pump vessel housing on the metal frame support. Then secure the clamps to the pump vessel housing.

19. Reattach the hose connections. 20. Reconnect the pump power and ground inside the TLRO control panel 21. Restart the system.

System Alarms All switch inputs are constantly monitored by the RO controller. If a switch input becomes active, a time delay is initiated to prevent false shutdown of the RO Pump or AUX Pump.

Low Feed Pressure When low feed pressure becomes active, the time delay is started. If the input remains active until the delay times out, then the RO pump will be shut down and the red “Low Pressure” lamp will light. The operator can reset the system by pressing the reset switch (hold for 2.5 seconds). If the alarm condition is clear, the pump will restart. If a low pressure alarm shuts the system down, a 15 minute automatic reset timer is activated. If the reset button is not pushed before this timer goes out, the system will reset itself if the alarm condition is clear. If the alarm condition is not clear, the system will reset the automatic timer until the condition is cleared.

High Tank Level When the “Tank Full” input becomes active, a time delay is started and the green “Tank Full” lamp will light. If the input remains active until the delay times out, the RO pump will shut down to prevent overflow of the storage tank. When the tank level drops and the “Tank Full” input clears, a second time delay is started. When this delay times out, the RO pump is then restarted. This delay allows the level in the tank to drop and prevent unnecessary cycling of the RO pump. When the RO unit is shut down due to a tank full condition, pressing the reset switch starts a five minute tank full override.

Low Tank Level When the “Tank Low” input becomes active, a time delay is started. If the input remains active until the delay times out, the AUX pump will shut down to prevent the AUX pump from running dry. When the tank level rises and the tank low input clears, a second time delay is started. When the delay times out, the AUX pump is then started. This delay allows the water level in the tank to rise and prevent unnecessary cycling of the AUX Pump.



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Troubleshooting

System dead -- Control Power “ON” Light is “OFF” Incoming power was interrupted Make sure incoming branch circuit is on, then press reset

control power push button. Blown Fuse Make sure incoming branch circuit is powered on all three

phases. Turn off TL RO disconnect Open Enclosure Remove each fuse one at a time. Check continuity of fuse Replace with new fuse only after determining why the fuse

blew.

RO Pump Never Starts No power Use guidelines from “System dead”. Heater pack tripped on motor starter (Intl.) Examine heater pack, it heater pack is tripped, examine

heater pack setting. Heater pack should be set to 125% of the motor’s nameplate’s FLA. Reset heater unit

Feed pump power switch is off Make sure feed pump power switch is in the up position. System does not need to make water yet If the tank full light is energized, the system does not need to

make water. Make sure the system float is in the down position, then wait for the appropriate time delay (factory default is 15 minute delay)

High level float incorrect The system will begin running with an open contact from the

high level float. Check wiring and continuity of switch in off and on position.

Feed Tank Overflows Level float malfunction Check placement of high level float. Float should engage

contact before water level reaches top of tank. Inlet solenoid valve not shutting Shut system down. After completion of permeate flush

cycle, check permeate line. No water should be flowing. If a flow is present, isolate system, and check inlet solenoid valve.



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Poor Quality Inlet TDS too high Check inlet TDS. TL RO is designed to operate with a ~

98% rejection. For high TDS applications, reset poor quality alarm to higher setting.

Permeate flush not operating Cycle system through permeate flush, check flush time, and

volume to reject during flush. Check reject quality at end of flush, should be RO quality.

System not operating within specifications Confirm system operating parameters. System should run at

provided permeate, recycle and reject flow rates. Brine seal leak Check permeate conductivity for each housing. If one or

some show poor readings, service membranes. Conductivity probe not calibrated Check outlet quality to portable meter. Calibrate permeate

quality meter if necessary. Chlorine damage to membranes Check inlet chlorine levels, residual less than 0.05 mg/l is

required to prevent thin film composite membrane deterioration.

System Not Consistently Running Low pressure alarm Feed pressure too low. Check inlet PSI while system is

running. System will shutdown if feed psi is below 15 psi. Check cartridge filter – replace if pressure loss exceeds 5

psi. System leak – check and repair. Low Permeate flow Water temperature is low. Membranes are fouled. Membranes fouled Check system log for history, if consistent declining

production is found, clean membranes. Consult your Kinetico dealer for appropriate cleaning procedures and chemicals.

Confirm system operating parameters. Float switch not operating properly Check operation of high level switch . .

Frequent Membrane Cleaning Required Recovery too high Depending upon water chemistry, a 65% system recovery is

recommended as maximum. For source water high in silt, silica or organics, a reduced recovery % is recommended.

Ineffective cleaning solution Silica treatment requires caustic cleaners that are heater to

90 oF for maximum effectiveness. Hardness contamination is cleaned with acid chemistries.



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Improper cleaning procedures Temperature, flow rate, time and chemistry must all be

matched to specific foulant being cleaned. Improper procedure will result in poor cleaning cycles.

Damaged membranes Replace membranes

Poor Production Volume System not operating within specifications Confirm system operating parameters. System should run at

provided permeate, recycle and reject flow rates. Cold Temperature Inlet temperature less than 77oF. Fouled membranes Check permeate quality. Low pump pressure The TL-RO systems are designed to permeate projected

volumes at a pump pressure of 105 psi. and a temperature at least 77oF. Check if pump pressure yields less than 110 psi.

Inlet quality changes Analyze RO feed for Chlorine, harness and temperature.



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PARTS

Electrical Components Part Number 2000 4000 6000 8000Pressure Switch, low 9866 1 1 1 1Fuse, 1/4"x 1 1/4", 3A/250v, Time delay (60hz units) 9863 2 2 2 2Panel, Back Plate 9850 1 1 1 1Plug, Solenoid, Conn 4 Pin 59867 2 2 2 2Solenoid Vlv, 1/2" Permeate Flush (220v) 8480 1 1 1 1Solenoid Vlv, 3/4" Inlet (220v) 8493 1 1 1 1Controller, TLRO-1 Rev-A 9853A 1 1 1 1Controller, Retrofit Kit TLRO (Upgrade from ROTrol) 9869 - - - -Conductivity, Probe 61318 1 1 1 1Overload, Contactor (50hz units) 8415 1 1 1 1Contactor, Motor (50hz units) 8414 1 1 1 1Fuse, 1/4"x1 1/4",.3A/250V,Time delay 9864 2 2 2 2Fused Terminal 9863 1 1 1 1Transformer, 380-415 VAC/3 Phase (50hz units) 8412 1 1 1 1

Plumbing Components Part Number 2000 4000 6000 8000Check Valve, 1/2" NPT Brass 8286 1 1 1 1Cartridge Filter, 5 Micron 367 1 1 1 1Check Valve, 1/2" NPT PVC 51995 1 1 1 1Filter Housing, 3/4" NPT 8494 1 1 1 1Pressure Regulator with Bracket 8790 1 1 1 1Flow Regulator body 8260 1 1 1 1Flow Regulator Screen 7680 1 1 1 1Flow Disc, 1.25 GPM TL-1800 8383 - - - -Flow Disc, 1.4 GPM TL-2000 10243 1 - - -Flow Disc, 2.5 GPM TL-3600 8384 - - - -Flow Disc, 2.8 GPM TL-4000 10244 - 1 - -Flow Disc, 3.75 GPM TL-5400 8490 - - - -Flow Disc, 4.1 GPM TL-6000 10245 - - 1 -Flow Disc, 5.0 GPM TL-7200 8491 - - - -Flow Disc, 5.5 GPM TL-8000 10246 - - - 1Gauge, Liquid-Filled 0-160 PSI 8307A 2 2 2 2Meter, Flow Permeate .5 to 5.0 GPM 8257 1 1 1 1



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2000 4000 6000 8000Miscellaneous Hardware Part Number 2000 4000 6000 8000Clamp, Fiberglass 8758 4 6 8 10Caster, Self Adjusting 8280 4 4 4 4Cord Grip 7541 2 2 2 2Wrench, Slimline 3814 1 1 1 1

2000 4000 6000 8000Pump Components Part Number 2000 4000 6000 8000Vessel, Pump and Tube 8521 1 1 1 1Pump, 3/4 HP (for 60 HZ units) 10287 1 1 1 1Motor, 3/4 HP (for 60 HZ units) 10288A 1 1 1 1Pump, 1.5 HP (for 50 HZ units) 10821 1 1 1 1Motor, 1.5 HP (for 50 HZ units) 10820A 1 1 1 1Wire Harness Asy. 3 Wire (50/60 HZ) 8780 1 1 1 1

2000 4000 6000 8000Membrane Components Part Number 2000 4000 6000 8000Membrane, 4" x 40" XLE 10230 1 2 3 4Vessel, Membrane 4" x 40" TL-2000 & 4000 8588 1 2 3 4

2000 4000 6000 8000Documentation Part Number 2000 4000 6000 8000Tech Manual 8304H 1 1 1 1



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50 and 60 Hz System (Note: Feed pump for 50 HZ is 1.5 HP)



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System Log



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Date

TECH MANUAL TL SERIES REVERSE OSMOSIS

2010, Kinetico Incorporated Product No. 8304H

Tech Manual TL Series - yourkinetico.com · TL Series Technical Manual Rev. 11/2010 Kinetico...

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