Hellenbrand HRO 6 Series User manual

HRO 6 07/26/12
Reverse Osmosis
User’s Manual
Model
HRO 6-1800, HRO 6-4000, HRO 6-5000
HRO 6-7000, HRO 6-9000, HRO 6-10,000

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TABLE OF CONTENTS
INTRODUCTION ................................................................................................................................... 5
SAFETY ................................................................................................................................................ 5
FEED WATER AND OPERATION SPECIFICATIONS .................................................................................. 6
REJECTION, RECOVERY AND FLOW RATES ............................................................................................ 6
SYSTEM REQUIREMENTS AND OPERATION GUIDELINES....................................................................... 7
MEMBRANE ELEMENTS ....................................................................................................................... 9
HRO 6-1800, HRO 6-4000, HRO 6-5000, HRO 6-7000, HRO 6-9000, HRO 6-10,000. Error! Bookmark not
defined.
SYSTEM IDENTIFICATION ................................................................................................................... 17
SYSTEM PURGING.............................................................................................................................. 22
INITIAL START-UP .............................................................................................................................. 23
OPERATING DO’s AND DON’Ts........................................................................................................... 25
OPERATION AND MAINTENANCE....................................................................................................... 25
MEMBRANE REMOVAL AND REPLACEMENT ...................................................................................... 27
FLUSHING THE SYSTEM...................................................................................................................... 29
PREPARING UNIT FOR STORAGE OR SHIPMENT ................................................................................. 29
REVERSE OSMOSIS TROUBLESHOOTING ............................................................................................ 30
TEMPERATURE CORRECTION FACTORS FOR MEMBRANE................................................................... 32
OPERATION ....................................................................................................................................... 34
DRAWINGS ........................................................................................................................................ 35

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INTRODUCTION
Your HRO 6-Series system is a durable piece of equipment which, with proper care, will last for many
years. This User’s Manual outlines installation, operation, maintenance, and troubleshooting details vital
to the sustained performance of your system.
The test results which are included with this User’s Manual indicate your system’s permeate (product) and
concentrate (waste) test results.
If your system is altered at the site of operation or if the feed water conditions change, please contact
your local dealer or distributor to determine the proper recovery for your application.
NOTE: IN ORDER TO MAINTAIN THE MANUFACTURER’S WARRANTY, AN OPERATING LOG
MUST BE MAINTAINED AND COPIES WILL NEED TO BE SENT TO YOUR LOCAL DEALER OR
DISTRIBUTOR FOR REVIEW.
NOTE: PRIOR TO OPERATING OR SERVICING THE REVERSE OSMOSIS SYSTEM, THIS USER’S
MANUAL MUST BE READ AND FULLY UNDERSTOOD. KEEP THIS AND OTHER ASSOCIATED
INFORMATION FOR FUTURE REFERENCE AND FOR NEW OPERATORS OR QUALIFIED
PERSONNEL NEAR THE SYSTEM.
SAFETY
The Safety section of this User’s Manual outlines the various safety headings used throughout this
manual’s text and are enhanced and defined below:
NOTE: INDICATES STATEMENTS THAT PROVIDE FURTHER INFORMATION AND CLARIFICATION.
CAUTION: INDICATES STATEMENTS THAT ARE USED TO IDENTIFY CONDITIONS OR
PRACTICES THAT COULD RESULT IN EQUIPMENT OR OTHER PROPERTY DAMAGE.
WARNING: INDICATES STATEMENTS THAT ARE USED TO IDENTIFY CONDITIONS OR
PRACTICES THAT COULD RESULT IN INJURY OR LOSS OF LIFE. FAILURE TO FOLLOW
WARNINGS COULD RESULT IN SERIOUS INJURY OR EVEN DEATH.
DO NOT UNDER ANY CIRCUMSTANCE; REMOVE ANY CAUTION, WARNING, OR OTHER
DESCRIPTIVE LABELS FROM THE SYSTEM.

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FEED WATER & OPERATION SPECIFICATIONS
Nothing has a greater effect on a reverse osmosis system than the feed water quality.
NOTE: IT IS VERY IMPORTANT TO MEET THE MINIMUM FEED WATER REQUIREMENTS.
FAILURE TO DO SO WILL CAUSE THE MEMBRANES TO FOUL AND VOID THE
MANUFACTURER’S WARRANTY.
NOTE: HIGHER FEED TDS AND/OR LOWER TEMPERATURES WILL REDUCE THE SYSTEM’S
PRODUCTION.
REJECTION, RECOVERY AND FLOW RATES
HRO 6-Series reverse osmosis systems are designed to produce permeate water at the capacities
indicated in the “design basis section” on page 21 of this manual. For example, the HRO 6-10,000
produces 6.25 gallons per minute of permeate water at the listed operating test conditions.
The amount of total dissolved solids (TDS) rejected by the membrane is expressed as a percentage. For
example, a 99% rejection rate means that 99% of total dissolved solids do not pass through the
membrane. To calculate the % rejection, use the following formula:
% Rejection = [(Feed TDS – Product TDS) / Feed TDS] x 100
Example:
99% = [(550-5.5)/550] x 100
NOTE: ALL TDS FIGURES MUST BE EXPRESSED IN THE SAME UNITS, TYPICALLY PARTS PER
MILLION (PPM) OR MILLIGRAMS PER LITER (MG/L).
HRO 6-Series reverse osmosis systems are designed to reject up to 99% NaCl, unless computer
projections have been provided or stated otherwise.

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The amount of permeate water recovered for use is expressed as a percentage. To calculate % recovery,
use the following formula:
% Recovery = (Product Water Flow Rate / Feed Water Flow Rate) x 100
Example:
26% = (1.04/4.00) x 100
% Rejection = [(Feed TDS – Product TDS) / Feed TDS] x 100
Example:
99% = [(550-5.5)/550] x 100
NOTE: ALL FLOW RATES MUST BE EXPRESSED IN THE SAME UNITS.
SYSTEM REQUIREMENTS AND OPERATION GUIDELINES
PLUMBING
The membranes and high pressure pumps used on HRO 6-Series systems require a continuous flow of
water with a minimum feed pressure of 45 psi, not to exceed 90°F.
FEED WATER CONNECTION
1. Locate the 1” FNPT Solenoid Valve feed water inlet.
(Figure 1A, Page 14)
2. Attach the inlet piping to the 1” FNPT Solenoid Valve feed water inlet.
3. Be certain that all of the dissolved solids within the feed water are soluble at the concentrations
attained in the system.
PERMEATE (PRODUCT WATER) CONNECTION
Locate the 1” or 3/4” connection (Depending on the unit) labeled permeate and attach to storage tank.
Ensure that the permeate water can flow freely with no backpressure. Backpressure can cause
irreversible damage to the membrane elements. The 1” or 3/4” (Depending on the unit) permeate line can
be run to the holding tank with PVC fittings, or other FDA approved materials. This is so the material
being used does not leach into the permeate water.
CAUTION THE pH OF THE REVERSE OSMOSIS PERMEATE WATER WILL TYPICALLY
BE 1-2 pH UNITS LOWER THAN THE FEED WATER PH. A LOW PH CAN BE VERY AGGRESSIVE
TO SOME PLUMBING MATERIALS SUCH AS COPPER PIPING.

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CONCENTRATE (WASTE WATER) CONNECTION
Locate the 1” or 3/4” connection (Depending on the unit) labeled concentrate and attach to a drain. Run
the concentrate line to an open drain in a free and unrestricted manner (no backpressure). It is advised
that an air-break be used on the concentrate line to prevent siphoning of water from the pressure vessels
when the system is in standby.
CAUTION: ANY RESTRICTIONS OR BLOCKAGE IN THE DRAIN LINE CAN CAUSE
BACKPRESSURE, WHICH WILL INCREASE THE SYSTEM’S OPERATING PRESSURE. THIS CAN
RESULT IN DAMAGE TO THE SYSTEM’S MEMBRANES AND COMPONENTS.
ELECTRICAL
The motor used on the HRO 6-Series systems are pump and motor combination. The motor is available
in 220/460 Volt, 50/60 Hertz, 1 Phase/3 phase. Each HRO 6-Series system is equipped with a 5 foot
electrical cord.
Ensure that the electrical circuit supplying the system is compatible with the requirements of the specific
HRO 6 model you are installing.
NOTE: IT’S RECOMMENDED THAT A LICENSED ELECTRICIAN WIRE YOUR SYSTEM IN
ACCORDANCE WITH LOCAL AND NATIONAL ELECTRICAL CODES (NEC).
WARNING: TO REDUCE THE RISK OF ELECTRICAL SHOCK, THE INCOMING POWER
SUPPLY MUST INCLUDE A PROTECTIVE EARTH GROUND.
HRO 6-Series systems are typically controlled with a liquid level switch in a storage tank. The liquid level
switch turns the system on when the water level in the tank drops, and off when the tank is full. Liquid
level switches can be obtained by your local dealer or distributor. If a liquid level switch is to be used,
install it at this time.
PRE-FILTRATION
HRO 6-Series systems are supplied with a 5 micron sediment filter. Change the cartridge once a month or
when a 10-15 psi differential exists between the two pre-filter gauges. Ask your local dealer or distributor
about Pre-Filtration systems, if required.
NOTE: THE SYSTEM MUST BE OPERATED USING FILTERED FEED WATER ONLY.
PUMP
The pump used on the HRO 6-Series systems is of the multi-stage centrifugal stainless steel type.
Follow these guidelines to ensure proper operation of the pump:
The pump must NEVER be run dry. Operating the pump without sufficient feed water will damage
the pump.

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ALWAYS feed the pump with filtered water. The pump is susceptible to damage from sediment
and debris.
If any damage occurs to your system’s pump a re-build kit may be available. Contact your local
dealer or distributor and inform them of your system’s model and pump size.
MOUNTING
The free standing system should be bolted down in compliance with local regulation standards or
securely fastened.
MEMBRANE ELEMENTS
HRO 6-Series reverse osmosis systems come pre-loaded with Thin Film Composite (TFC) HF4 High Flow
Extra Low Energy membranes, unless otherwise specified. General membrane element performance
characteristics are listed on the following pages:
HF4-STANDARD

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HF5-OPTIONAL

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NF3-OPTIONAL

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NF4-OPTIONAL

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LC LE-4040-OPTIONAL

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LC HR-4040-OPTIONAL

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HRO 6-1800, HRO 6-4000, HRO 6-5000, HRO 6-7000,
HRO 6-9000, HRO 6-10,000 SYSTEM IDENTIFICATION
FIGURE 1A

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NUMBER IDENTIFICATION
1. SOLENOID VALVE – TURNS ON/OFF FEED WATER
2. 5 MICRON SEDIMENT – REMOVES PARTICULATES
3. PRESSURE GAUGE – MEASURES FEED PRESSURE
4. PRESSURE GAUGE – MEASURES PRESSURE AFTER FILTERS
5. PRESSURE GAUGE – MEASURES PUMP PRESSURE
6. PRESSURE GAUGE – MEASURES CONCENTRATE PRESSURE
7. COMPUTER CONTROL – CONTROLS RO SYSTEM FUNCTIONS
8. RECYCLE VALVE – RECYCLES CONCENTRATE BACK TO FEED (IF APPLICABLE)
9. CONCENTRATE VALVE– CONTROLS FLOW OF CONCENTRATE (WASTE) WATER TO
THE DRAIN
10. RO PUMP AND MOTOR – PRESSURIZES RO SYSTEM
11. THROTTLE VALVE – CONTROLS FLOW OF PUMP
12. FLOW METER – MEASURES FLOW OF PERMEATE WATER
13. FLOW METER – MEASURES FLOW OF CONCENTRATE (WASTE) WATER
14. FLOW METER – MEASURES FLOW OF CONCENTRATE RECYCLE WATER
15. PRESSURE SWITCH – TURNS OFF RO PUMP WHEN FEED PRESSURE FALLS BELOW
15PSI
16. PERMEATE CHECK VALVE – PROTECTS MEMBRANE ELEMENTS FROM
BACKPRESSURE
17. PRESSURE VESSELS – HOUSES MEMBRANE ELEMENTS
18. PERMEATE SAMPLE VALVE- MEASURES THE QUALITY OF EACH MEMBRANE

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FIGURE 1B

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FIGURE 1C
FIGURE 1D