GE Merlin Manual

GE Infrastructure
Water and Process Technologies
Merlin™
Point of Use
Drinking Water System
Installation and Maintenance Manual

2
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SAFETY GUIDES 3
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SAFETY GUIDES
Read and follow all steps and guides carefully before installing and
using your reverse osmosis system.
Do not use this product to make safe drinking water from non-potable
water sources. Do not use the system on microbiologically unsafe
water, or water of unknown quality without adequate disinfection
before or after the system.
This reverse osmosis system contains replaceable components
(membrane elements). These components are critical for the effective
reduction of total dissolved solids and specific contaminants that are
listed in the Product Data Sheet.
The Merlin drinking water system does not have a monitoring device
for contaminants. To verify that the system is performing satisfactorily
the product water should be tested periodically by the system’s
installing dealer every six months. See the back cover of this manual
for the installing dealer’s contact information.
Consult yourlocal public works department for plumbing and sanitation
codes. Follow your local codes if they differ from this manual.
The reverse osmosis system works on water pressures of 40 psi
(2.8 bar) minimum to 80 psi (5.5 bar) maximum. Water pressure can
be reduced by installing a pressure reducing valve in the water supply
pipe to the RO system. A booster pump should be used for low
pressure applications.
Do not install the reverse osmosis system in extreme hot or cold
temperatures. Temperature of the water supply to the reverse osmosis
system must be between 40°F (°C) and 100°F (38°C). Do not install on
hot water lines.
The reverse osmosis membranes contain a foodgrade preservative for
storage and shipment. New membranes should be flushed for one
hour prior to use. This flush removes the preservative. The
preservative is not harmful but makes the product water taste
objectionable.

4 THE BASIC REVERSE OSMOSIS SYSTEM
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THE BASIC REVERSE OSMOSIS SYSTEM
Your Merlin™ Reverse Osmosis (RO) Drinking Water System is a
water treatment unit. It uses water pressure to reverse a natural
physical process called osmosis. Water, under pressure, is forced
through a semi-permeable membrane to filter out minerals and
impurities. Clean drinking water goes to the faucet. Minerals and
impurities are sent to the drain with RO waste water.
The system includes replaceable filters and membrane elements. The
prefilter removes sand, silt, dirt, rust particles, other sediments, and
chlorine from the water supply before they enter the RO membrane
elements. The postfilter removes any tastes and/or odors that may
remain in the water after passing through the RO membrane elements.
BEFORE INSTALLING THE RO SYSTEM
• Best performance of the system will be achieved when the
incoming water has been treated (softened).
• The water coming into the system must be within certain limits for
sediments, pressure, etc. Refer to the specifications to determine if
your installation is within the limits.
• A water quality analysis can be performed to determine if incoming
water requires any treatment. Contact your dealer/installer.
• The filters and membrane elements in the RO system need to be
replaced ona regularbasis. Follow the instructionsfor replacement
that are in this manual.
• The faucet options for the Merlin RO have not been tested or
certified by the Water Quality Association. It is recommended that
faucets meeting National Codes be used.
NOTE: For optimal system performance, use the system for at least
2 minutes continuously each day.
WARNING: The Merlin RO system is designed to work without the
aid of a storage tank. Installation of a pressurized storage tank will
negatively affect system performance.

THE BASIC REVERSE OSMOSIS SYSTEM 5
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REVERSE OSMOSIS PACKAGE
The reverse osmosis system is purchased as an installation kit. Two kit
options are available: Merlin I, P/N 1255052 includes a faucet and air
gap. Merlin II, P/N 1263870 does not include a faucet or air gap.
Before starting installation check that the following components are
available:
Quantity Item Part Number
1 Manifold 1244617
1 Support Leg 1239708
1 Locking Bar 1239731
1 Disconnect Elbow and O-ring—Flush Mechanism 1240119
1 1/4-inch Collet Lock Clip 1240626
1 1/4-inch Plug 1240624
1 Disconnect Elbow and O-ring— Feed Water 1240117
2 1/2-inch Collet Lock Clip 1240628
1 Disconnect Elbow and O-ring—Concentrate Stream 1264462
1 Disconnect Elbow and O-ring—Permeate Stream 1240118
5 3/8-inch Collet Lock Clip 1240627
3 White Sumps 1239705
3 Sump O-ring 1240326
2 Lubricant, Silicone 1013501
1 3/8-inch Tube-To-Threaded Tubing Connection 1240625
Tubing
4 feet 1/2-inch Natural Color Inlet 1240622
4 feet 3/8-inch Blue Color Product 1240621
4 feet 3/8-inch Black Color Concentrate 1240620
3 feet 1/2-inch Red Color Drain 1240623
Faucet Kit
1* Faucet and Air Gap 1254894
* Faucet and air gap not included with Merlin II
Drain Connection
1 Packaged Drain Boa Kit 1240564
Filters
2 Membrane Elements 1238342
1 White Carbon Prefilter 1237460
1 In-Line 3/8-inch Carbon Post Filter 1244746
NOTE: The system inlet (feed water) connection/valve is not
included in the standard package. Contact your system supplier.

6 THE BASIC REVERSE OSMOSIS SYSTEM
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LOCATION OF SYSTEM The reverse osmosis system is designed for installation under a sink,
usuallyin the kitchen or bathroom. The RO assembly can be placed on
the cabinet floor in any position that does not apply pressure on the
disconnect elbows. The RO product water faucet installs on the sink or
on the countertop next to the sink.
The RO system can also be located in a location away from the faucet.
A nearby water source and drain point are required.
Water Supply: To provide supply water to the RO system inlet, a feed
supply fitting is required or install pipe fittings as needed.
Drain Point: A suitable drain point is needed for reject water from the
RO system. A floor drain, laundry tub, standpipe, sump, etc. are all
acceptable. A sink p-trap drain adapter is included to install as an
optional drain point where codes permit.
All components and tubing should be located in an area which is not
exposed to freezing temperatures. Do not expose unit or tubing to
direct sunlight.
Dispensing Faucet: The faucet should be placed near the sink where
drinking water is normally obtained. Convenience of use (filling of
water pitchers and glasses) and an open area beneath the faucet
under the sink for attaching product and drain tubing are
considerations. A 2-inch diameter flat surface is required above and
below the installation site. The thickness of mounting surface should
not exceed 1-1/4 inches. Avoid any strengthening webbing on the
underside of the sink.
RO Manifold Assembly: The manifold can be installed on either the
right or left side of the under-sink area or cabinet. Installation in the
basement is also an option. One possible location is near the
laundry/utility sink where cold potable water and drain access are
close. The location chosen should allow adequate clearance and
accessibility for membrane element changes.
Feed Water Connection: The feed water valve should be located as
close to the manifold assembly as possible. USE A POTABLE COLD
WATER SUPPLY ONLY. Softened water is preferred as it will extend
the life of the RO membrane element.
NOTE: Keep the lengths of tubing short. Longer lengths of tubing
will decrease system performance. A booster pump can be used on
the supply line.
NOTE: The feed water connection is not included in the package.

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Drain Connection - Depending on plumbing codes, the waste water
may need to go to drain through an anti-siphon air gap. A detachable
faucet air gap is included with the system. If discharging into the utility
sink or standpipe, an air gap of greater than 1.5 inches above the flood
rim must be provided.
Do not connect the system drain line to the dishwasher drain or near
the garbage disposal. Back pressure from these units may cause the
air gap to overflow.
In restricted under-sink areas, it may be easier toinstall the faucet first.
Allow adequate tubing lengths for final system placement.
Figure 1 Typical Under-Sink Installation
NOTE: All plumbing should be done in accordance with state and
local plumbing codes.
Some codes may require installation by a licensed plumber; check
with the local plumbing authority prior to installation.
Dispensing Faucet
with Air Gap
Inlet-1/2" Natural
Feed Water Valve
Cold Water Line Only Carbon Postfilter
Waste Concentrate
3/8" Black
Drain - 1/2" Red
Product - 3/8" Blue
Drain Coupling
Install above P trap
Plugged Top Connector
Locking Bar
Keep to Minimum
Prefilter
RO Membranes
Su
pp
ort Le
g
(
sum
p
wrench
)
Manifold
Elbow
Connectors
Note: If a flush tank is not
installed the manifold
connection must remain
plugged. Removal of
plug will cause a system
leak.

8 THE BASIC REVERSE OSMOSIS SYSTEM
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Figure 2 Typical Basement Installation
Floor
Flush Tank
(Optional)
Dispensing Faucet
without Air Gap
1.5" Air Gap Required
Inlet-1/2" Natural
Drain - 3/8" Black
Feed Water Valve
Cold Water Line Only
1/4" Blue
Carbon Postfilter
Product - 3/8" Blue
RO Assembly
Note: If a flush tank is not
installed the manifold
connection must remain
plugged. Removal of
plug will cause a system
leak.

THE BASIC REVERSE OSMOSIS SYSTEM 9
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REQUIRED TOOLS AND MATERIALS
• Adjustable wrench, and larger adjustable jaw pliers or pipe wrench
to fit sink drain
• Saw for cutting drain pipe
• Slotted and Phillips head screwdrivers
• Tubing cutters
• Electric drill and bits for cutting the faucet mounting hole
Note that some sinks will have a pre-drilled hole with a plug for the
faucet.
INSTALLATION STEP 1: Install cold water supply valve
STEP 2: Install drain adapter
STEP 3: Install faucet
STEP 4: Make tubing connections
STEP 5: Install RO assembly
STEP 6: Put system into operation
STEP 1: INSTALL COLD WATER SUPPLY VALVE
Comply with local plumbing codes. A typical connection using a water
supply valve is shown. The feed water valve is not included with
system. Contact supplier for this item.
Water Supply Valve
Cold water pipes vary in size and style. The installer will determine
type of valve that will be used. Install a valve on the cold water supply
pipe to adapt 1/2-inch OD tubing. If threaded fittings are used, be sure
to use pipe joint compound or Teflon tape on outside threads.
Turn the valve off.
NOTE: Consult a licensed plumber if you are not familiar with
plumbing procedures.
NOTE: Be sure to turn off the water supply and open a low faucet to
drain the pipe.

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STEP 2: INSTALL DRAIN ADAPTER
Follow the instructions in the Appendix for installation of the Drain
Boa™, if used.
The drain adapter is designed to fit 1-1/2-inch (3.8 cm) sink drain pipe.
The adapter installs directly to the sink tailpiece.
STEP 3: INSTALL FAUCET
A. Prepare Mounting Hole
1. Select a location for the faucet. Be sure it will fit flat against the sink
or counter and that there is space underneath for tubing.
2. If drilling is needed, make a 1-1/8-inch to 1-1/4-inch diameter hole.
Figure 3
WARNING: To avoid damaging a sink, consult a qualified plumber
or installer for the proper method of drilling holes in porcelain or
stainless steel.
Gasket Air Gap Module
Trim Ring
Standoff
Washer
Nut
Water In Connection
Horseshoe
Clip

THE BASIC REVERSE OSMOSIS SYSTEM 11
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B. Assemble Faucet
The tubing and fasteners are assembled to the faucet before the
faucet is placed in position. If not using the air gap module, skip to
step #3.
1. If the air gap feature is used, place the gasket in position on the
faucet.
2. Add the air gap module.
3. Slide the decorative ring over the tubing connections and up to the
bottom of the faucet.
4. Slide the standoff onto the threaded tube, followed by the standard
washer and nut.
5. Screw the threaded hose connector on the end of the threaded
tube.
6. Connect the blue 3/8-inch product tubing by firmly pushing it into
the connector.
7. If using the air gap module, push the black 3/8-inch tubing onto the
small hose barb from the collar. The red 1/2-inch tubing is pushed
onto the large hose barb.
8. Put the faucet into position.
9. The horseshoe clip is positioned around the threaded pipe under
the sink and above the standoff.
10. Tighten the nut against the clip to hold the faucet in position.
STEP 4: MAKE TUBING CONNECTIONS
The connections to the faucet should be complete, the remaining
connections are:
• Feed connection—clear tubing from feed valve to white elbow
connector
• Drain connection—either red tubing from the air gap or black
tubing from grey elbow connector will attach to the drain adapter
• Permeate connection—blue tubing from faucet to blue elbow
connection
• To the flush tank (if used)
• Attach the fittings to the manifold
A typical connection is shown in Figure 4.

12 THE BASIC REVERSE OSMOSIS SYSTEM
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Figure 4 Side View and Cutaway of Tubing Fitting
Postfilter
Install the postfilter inline with the blue permeate tubing. Secure tubing
with collet lock clips.
Drain Adapter
The drain adapter has a rubber inlet that accepts the 3/8-inch black
drain tube or the 1/2-inch red tube. The 3/8-inch black tubing will
connect here if the faucet is not using the air gap module.
When the tubing is in position, use the supplied hose clamps to secure
the connection.
NOTE: Make sure the tubing
is pushed past the O-rings
for a secure fit.Also, when
replacing any tubing, cut
tubing back ~1/4 inch prior
to re-inserting to prevent
leaks.
Tubing Collet O-Ring
O-Ring
Collet Lock Clip
NOTE: For optimal system performance, we recommend using
tubing lengths that are as short as possible.
NOTE: When sliding tubing into the drain adapter inlet, wet the
tubing. Water will help the tubing slide into the rubber inlet.

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Feed Water Valve (Not Supplied)
The feed water valve attaches to a nearby cold water supply line. The
installer will determine the type and size of valve that will be installed.
This valve connects to the 1/2-inch natural tubing.
Flush Tank (Optional)
If the flush tank is used, the 1/4-inch blue tubing will be used to
connect to the top fitting of the RO assembly manifold. Remove the
plug and push the tubing into the fitting until it stops.
STEP 5: INSTALL RO ASSSEMBLY
The RO Assembly includes the following components: sumps (3),
support leg, prefilter, RO membrane elements (2), and postfilter. The
tubing is attached to the manifold by the elbow connectors. When
choosing a location for the system, allow enough tubing for it to be
moved for periodic servicing of the filters and membrane elements.
Figure 5 Merlin RO Assembly
CAUTION: If the flush tank is not used, the 1/4-inch fitting on the
manifold must be plugged or water will leak out.
RO Membranes
Prefilter
Sumps
Support Leg
Manifold
Elbow
Connectors
WARNING: Do not attempt to mount/hang the Merlin. Do not try to
drill mounting holes anywhere on the system. If putting above
ground/cabinet level, a sturdy, permanent shelf is recommended.

14 THE BASIC REVERSE OSMOSIS SYSTEM
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Recommended Placement Positions
The Merlin assembly should be positioned in one of two ways.
The first position is with the unit standing upright using the support leg
with the sumps horizontal. The tubing is directed to provide the best fit.
The second position, sets the unit on end so the manifold is horizontal
and the sumps are pointing up. The tubing is directed upward and the
locking bar is down to lock the tubing connections.
See illustrations at left.
The table below shows the coding system for the fitting connections.
Each fitting has a unique “keyed” socket on the manifold. Each fitting
also has a graphic symbol molded into the elbow with a corresponding
symbol on the manifold.
Connector Symbol Connection Tubing Color
OFlushing (optional) Blue
!Feed-Inlet Natural
"Concentrate Black
!Product Blue
First Position
Second Position
Locking Bar
WARNING: Be sure to lubricate the O-rings on the fitting elbows
with silicone lubricant, prior to inserting into manifold.
WARNING: Do not turn the incoming water valve on until the
locking bar is in place.
NOTE: If the installation is not using the optional flush tank, the top
connection will not have tubing. Instead a plug will be inserted into
the fitting. Do not remove plug unless you are attaching the tubing
and the flush tank.

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When all of the connections have been made, use the locking bar to
hold the fittings in position. Match the symbols on the locking bar to the
corresponding symbols on the manifold.
Figure 6 Locking Bar
STEP 6 SYSTEM STARTUP
1. Inspect all connections.
2. If the flush tank is not installed, the 1/4-inch port on the manifold
must be plugged.
3. Position manifold horizontal with openings facing up.
4. Remove new membrane elements from packaging.
5. Lubricate element O-rings, brine seals, and sump O-rings with
silicone lubricant.
6. Securely insert O-ring end of membrane elements into manifold.
7. Remove carbon/sediment prefilter from packaging. Check that
gaskets are in place.
8. Place carbon filter in manifold.
9. Replace sumps and tighten until it bottoms out.
Pressure Test System
To check for leaks, the system must be filled with water and brought up
to operating pressure.
1. Open cold water feed valve slowly. Run at 1/2 open for a minute,
then open fully.
2. Open faucet until water runs.
Symbols
CAUTION: Elements contain a foodgrade preservative. The use of
sterile/latex gloves is recommended.

16 TO CARE FOR THE RO SYSTEM
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3. Check for leaks.
4. Purge the system. Open the faucet and run the water through the
RO system for one hour.
The RO system is now ready for use.
TO CARE FOR THE RO SYSTEM
The components of the RO system are designed to function with
minimal maintenance. However, the membrane elements and filters
will need to be replaced on a regular schedule.
Run the system for at least two minutes each day for optimal
performance.
REPLACEMENT OF PREFILTER AND POSTFILTER
The carbon/sediment prefilter removes sediment and certain
chemicals, such as chlorine, from the water. Depending on water use
and the amount of impurities, this filter should be replaced every six to
twelve months.
Whenever the prefilter is replaced, the postfilter should also be
replaced.
REPLACEMENT OF RO MEMBRANE ELEMENTS
The functional life of the RO membrane elements will vary based on
feed water quality. Product water should be tested periodically to verify
the membrane elements are performing properly. For most residential
applications, the RO membrane elements should be replaced every
two to four years.
NOTE: When the faucet is initially turned on, water may temporarily
sputter from the air gap until the air is purged. Allow 1 to 3 hours for
any trapped air noise in the system to subside.
NOTE: The one hour flush removes a food grade preservative from
the membrane elements. It is not harmful but may affect the taste of
the water.
NOTE: Softened water is recommended for optimal system
performance and RO membrane element life.

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REPLACEMENT OF THE PREFILTER, POSTFILTER, AND RO MEMBRANE
ELEMENTS
1. Turn off the water supply to the RO System.
2. Reduce system water pressure by opening the faucet.
3. Disconnect locking bar and place the fittings (with tubing still
connected) into a tub or bucket.
4. Move system into a contained area, such as a sink or tub.
5. Remove the support leg from the three sumps and unscrew the top
sump as shown to access the prefilter element. The support leg
functions as a wrench to loosen the sump, Figure 7.
Figure 7
CAUTION: Even with the water supply turned off the membrane
and prefilter sumps will contain a considerable amount of water. By
positioning the RO assembly in a sink or tub, most of the water will
be contained.
NOTE: There is no need to disconnect tubing from fittings on the
manifold. Remove locking bar and pull fittings out. Lubricate O-rings
with silicone prior to re-assembly.
NOTE: If changing only the prefilter and postfilter, the other sumps
do not need to be removed.
If changing the membrane elements, the prefilter and postfilter
should also be changed.

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6. Remove exhausted prefilter and discard.
7. If Changing Membrane Elements:
A. Remove membrane sumps. Remove and discard used
elements.
B. Remove new elements from packaging.
C. Lubricate element O-rings, brine seals, and sump O-rings
with silicone lubricant.
D. Securely insert O-ring end of elements into manifold. See
Figure 8.
E. Replace sumps and tighten until it bottoms out.
8. Sanitize the system.
A. The manifold should be positioned flat with the sump
connections facing up.
Figure 8
CAUTION: The person handling the filters and membrane elements
must have clean hands to keep the system sanitized. The use of
sterile/latex gloves is recommended.
CAUTION: Elements contain a foodgrade preservative. The use of
sterile/latex gloves is highly recommended.
NOTE: The system should be sanitized whenever a membrane
element or filter is replaced.
Prefilter Center Opening Membrane Element Locations

REPLACEMENT OF THE PREFILTER, POSTFILTER, AND RO MEMBRANE ELEMENTS 19
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B. Pour a tablespoon (15 milliliters) of chlorine bleach into the
center opening of the prefilter sump connection. See
Figure 8.
9. Install prefilter.
A. Remove new prefilter from packaging. Ensure gaskets are
secure. Insert prefilter into proper opening on manifold.
B. Lubricate sump O-ring with silicone lubricant.
C. With the prefilter element in place, screw the sump into the
connection. Tighten until it bottoms out.
10. Replace the postfilter.
A. To unlock the fittingsfrom the tubing,push down on the collet
sleeves and pull the tubing out.
B. Discard the exhausted postfilter.
C. To prevent leaks, cut the tubing back approximately
1/4 inch prior to connecting the new postfilter. Make sure flow
direction arrow aligns with water path. Reinsert tubing and
collect locks.
11. Re-connect the fittings to the manifold and lock in position with
locking bar.
12. Re-position the assembly and turn the water supply on. Check the
system for any leaks.
13. Open the faucet and run water for two minutes.
14. Shut off the faucet and allow the system to stand idle for 20 to 30
minutes.
15. Open the faucet and run water for two minutes or until chlorine
odor is gone.
NOTE: The sumps are sealed using an O-Ring. Tighten by hand. If
any leaks are detected when water pressure is applied, the sumps
can be tightened further.
CAUTION: When the faucet is opened, water may sputter from the
air gap until the trapped air is purged.
NOTE: Carbon fines may be present until the postfilter element is
flushed out.

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16. Check for any system leaks.
The RO system is now ready for use.
NOTE: If the two RO membrane elements were replaced the
system should be flushed for one hour. This flush removes the food
grade preservative from the elements. The preservative is not
harmful but may affect the taste of the water.