Service Manual for USRO5-100-QC-38
Contents
1. HA __ SS Ee Tera a mee T ME Threaded Shank Faucet Connector 2 Mounting the Faucet Disassemble hardware from the treaded shank Chrome base plates and rubber washers slide up the shank to the faucet body Feed threaded shank through the sink hole and orient the faucet From below sink slide lock washer and hex nut over threaded shank and tighten with a wrench Note It is best to have someone hold the faucet from above the sink to keep it from moving out of place If this is not possible then tighten the hex nut until it is just slightly less than completely tight Then turn the faucet base from above the sink tightening it while orienting the faucet in the desired location 3 John Guest Angle Stop Valve See Figure 2 The John Guest Angle Stop Valve provides a simple easy connection between the angle stop cold water shut off and the bottom of the riser tube The Angle Stop Valve has built in shut off and provides the feed supply connection for the reverse osmosis system To Existing Figure 2 Faucet To Reverse E Angle Stop Osmosis y gt l Valve System Cold Water Shut Off Valve Procedures 1 Shut off the cold water supply using the angle stop shut off located under your sink 2 After shutting off the valve relieve the pressure by opening the handle on your faucet on the cold water side 3 Using an adjustable wrench disconnect the ri2. For convenience on under sink installations it may be advisable to complete under sink tubing connections at this time 6 RO Component Installation Install RO membrane O ring end first carbon prefilter s and sediment pre filter in vertical mounted housings Be sure RO Membrane is pushed into Membrane housing as far as it will go It is recommended that filters and membranes be handled with clean or gloved hands 7 RO Unit Installation The RO unit is normally mounted to the right or left sink cabinet sidewall depending on where supply tank is to be located Generally the unit is installed at the front of the cabinet and the tank at the rear To mount the unit elevate it at least 2 off the floor level it and mark the location of mounting holes needed Drill hole for mounting screws and install screws allowing the mounting bracket slots to slip over them Note If the cabinet sidewalls are not solid unit may sit on the floor with screws used just to keep it against the cabinet in a vertical position 8 Pre fill amp Supply Tank Placement Pre filling the storage tank is recommended so there is sufficient pressure to check for leaks and water to flush the carbon post filter To do this connect the feed line that will serve the RO unit directly to the bladder tank A 3 8 x 1 4 reducer is provided for this purpose Allow the water to fill the bladder until it stops Close the tank valve shut off the feed pressu
3. on the icemaker after the RO system has been drained several times and the tank has a full supply of water Icemaker lines are often run in the rafters of unfinished basements or finished basements with drop ceilings and then up to the fridge If the basement has a hard ceiling this won t be an option and the line would have to be run through cabinets In cases where a basement or cabinets connecting sink and fridge are not available icemaker connections cannot be made Note Before any service is performed on the RO system turn off icemaker valve and icemaker unit Turn back on only after RO system has been sanitized and flushed out System Start up Prior to start up 1 Check all fitting connections 2 Open ball valve shut off allow system to pressurize and check for leaks 3 Open valve on bladder tank and open faucet until water flows 4 Close faucet wait five minutes and check for leaks 5 Allow system to produce a full tank of RO water 2 3 hours Flushing System and Checking Operation 1 Flip the faucet lever up and this will keep faucet on Do this and allow tank to completely drain of all water Do not use this water 2 Close faucet and re inspect system for leaks 3 Allow system to produce water for 4 hours at this point the bladder tank will be full 4 Open faucet again and allow tank to empty for a second time Do not use this water 5 Close faucet and allow unit to produce a
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7. Installation and Service Guide Reverse Osmosis System with Quick Connect Fittings Nem ie USRO4 50 QC 38 USA USRO4 60 QC 38 USA USRO4 100 QC 38 USA a USRO5 50 06 38 USA USRO5 60 QC 38 USA USRO5 100 QC 38 USA Please read this manual carefully before attempting installation SYSTEM AND FAUCET DIAGRAM __ Long Reach Drinking Faucet 7s Tubing Angle Stop Valve to Faucet sup Pls bsp ft water to RO uni Y4 tubing Seg Fig 2 7 E connects to CJ Drain Clamp Flow Restrictor Cold Water Line rs h always on right UY See Fig 3 and Drain 3 5 Tibi o Ya tubing 7s Tubing to Tank Stage 5 NOIR toad Sy Carbon Post Filter UL o A A Stage 4 f A a Bladder TFC Membrane pa Tank Sn Stage 1 Stage 3 ___ sediment Prefilter Carbon Block Stage 2 Ja QUI Carbon Block Only present on 5 stage systems insert tube How to make a Quick Connect Connection da A 1 Fitting grips before it seals Ensure tube is pushed into the tube stop 2 Push the tube into the fitting to the tube stop The collet gripper has Push up to tube stop stainless steel teeth which hold the tube firmly in position while the O ring provides a permanent leak proof seal 3 Pull on the tube to check that it is secure It is a good practice to test the system prior to leaving site and or before use Pull to check secure 4 To disconnect ensure th
8. SE OSMOSIS SYSTEM System Components 1 Cold Water Line 2 Angle Stop Valve 3 Cold Water Shut off Valve 4 Melt Blown Sediment Pre Filter 5 Carbon Block Pre Filter 6 Nipple 7 Mounting Bracket 8 Single Clip 9 Automatic Shut Off Valve 10 RO Membrane Housing 11 Check Valve 12 Tank Valve 13 Bladder Tank 14 Double Clip 15 Inline Granular Carbon Post Filter 16 Drain Flow Restrictor 17 Quick Connect Faucet Connector 18 Reverse Osmosis Water Faucet 19 1 Drain Pi io cae Units come with plugs in the inlet outlet and open end of T on the post filter to create an air tight seal Remove these plugs to perform the installation Locking clips are used on fittings where the tubing has a bend near the fitting
9. asy ability to shut off the water supply when servicing the unit These are shown in Figure 2 A Drain Saddle is used to make a waste water connection with your drain under the sink This is designed to fit around a standard 1 1 2 OD drainpipe The drain saddle valve should always be installed before above the p trap and on the vertical or horizontal tailpiece Do not install the drain saddle near a garbage disposal to avoid clogging the drain line with debris Unit preparation Open shipping carton remove components and check that all parts are present Installation Steps All plumbing must be completed in accordance with state and local plumbing codes Some municipalities may require installation by a liscensed plumber Check your local plumbing codes for more information 1 Faucet Installation See Figure 1 If the sink has a sprayer it may be disconnected for faucet installation A pipe cap or plug will be necessary to seal the sprayer connection or sprayer can be left connected under the sink When making the faucet hole if a sprayer or other existing hole in not being used check below the sink to make sure the drill will not interfere with anything under the sink A 2 flat surface on the sink is required for mounting the faucet The faucet should be positioned so it flows into the sink and the spout should be allowed to swivel freely for convenience If an existing hole is being used to mount the fauce
10. e system is depressurized before removing the lo tube Push in collet squarely against face of fitting With the collet held in this position the tube can be removed The fitting can then be re used O Disconnecting Note See exploded diagram on last page of this A manual regarding locking clips and plugs a Your Reverse Osmosis RO System has been tested to ensure it will operate correctly The following periodic maintenance is recommended so your system will provide years of trouble free service e Prefilters sediment Once per year e Prefilter carbon block s Once per year e RO Membrane Usually Every 2 years e Postfilter carbon Once per year System Components The following components make up your reverse osmosis system Prefilter 1 sediment Melt Blown Polypropylene filter removes larger particles such as dirt rust amp sediment Prefilter 2 amp 3 if applicable 10 Micron Carbon Block removes chlorine and chemical contaminants in the feed water and protects the RO membrane Reverse Osmosis Membrane Thin Film Composite Membranes reduces dissolved minerals metals and salts In this process harmful compounds are separated by the membrane from the water and the contaminants are flushed to the drain A coconut shell activated carbon postfilter is provided for a final polish and to remove tastes odors and to provide great tasting water The RO module is the main component and h
11. ilters are replaced it is recommended that the system be sanitized Sanitizing the System After all filters are removed from the system housings have been cleaned tank is empty and faucet is open Add 1 gallon of water to a clean bucket Add 1 teaspoon of unscented household bleach Add 1 cup of this solution to each filter housing Tighten filter housings with solution on RO assembly Connect membrane housing and feed tube Open tank valve and feed pressure valve Allow water to fill the RO housing assembly until water comes out of faucet 8 Close the faucet 9 Allow water to run for 5 minutes 10 Shut off feed pressure 11 Allow solution to stand for 30 minutes 12 Open faucet and allow system to drain 13 Remove water from housings before installing new filters and membrane 14 Install new filters tighten housings and reconnect all tubing connections 15 Open feed pressure valve and check for leaks 16 Allow the system to make a full tank of water 17 Run 2 cycles to drain to rinse out sanitizing solution before using water Troubleshooting A Na RO Systems are highly sensitive to pressure and temperature RO Membranes always perform better under higher pressures They produce more water faster and of better quality with high pressure The vast majority of problems with RO Systems are a result of low pressure The effects of low pressure include water constantly running to the drain slow
12. ive connection to draw the water supply to the reverse osmosis system Alternatives include self piercing valves T fittings and faucet adaptors that connect between the faucet and the top of the riser tube Please consult your distributor or an installation professional for additional assistance 4 Drain Saddle Valve Installation See Figure 3 A Drain Saddle is used to make a wastewater connection with the drain under the sink which is designed to fit around a standard 1 1 2 OD drainpipe The drain saddle valve should always be installed before above the p trap and on a vertical or horizontal drain Do not install the drain saddle near a garbage disposal to avoid clogging the drain line with debris Figure 3 Drain Pipe Foam Gasket 14 Drain Line 14 Nut Ya Screw Drain Clamp Back Plate Procedures 1 Position the drain saddle valve at selected location and mark for the opening 2 Drill 1 4 hole at mark through one side of pipe 3 Remove backing from gasket and place adhesive side to the fitting half of drain clamp around hole 4 Position both halves of drain saddle on drain pipe so the opening aligns with drilled hole Use a small drill bit to verify that drain clamp is properly aligned 5 Secure drain saddle clamp on valve with bolts and nuts provided Do not over tighten and make sure there is equal space between saddle halves on each side 5 Initial tubing connections
13. nother tank of water 6 At this point supply line to ice maker connection optional may be opened and RO water is ready to be consumed Replacing Filters amp Sanitizing The System Each year the filters in the system should be replaced Usually the membrane can be replaced every other year but the prefilters and post filter should be changed annually and in some cases more often Filter Replacement 1 Turn off valve on RO bladder tank Turn off feed water pressure Open RO faucet to relief pressure Using the supplied housing wrench remove the filter housing Discard old filters Clean filter housings with a cleaning brush Follow sanitizing steps in Sanitizing the System section 8 Install new filters in system 9 Remove and replace GAC Post filter Remove fittings from old post filter re apply Teflon tape and install fittings in new post filter 10 Turn on feed pressure 11 Open tank valve 12 Allow water in tank to flush out post filter and run to drain until empty Run 2 more complete batches to drain before using water ey AD p Membrane Replacement 1 Remove the supply tube from the end of the membrane housing that has only 1 tube 2 Unthread the cap from the membrane housing 3 Remove membrane using a pair of pliers 4 Clean membrane housing with a brush Note When installing a new membrane be sure to push the membrane into the housing as far as it will go Each time the f
14. olds the prefilters and membrane and posifilter A bracket is provided so they can be mounted under the sink or ina basement Bladder tank holds RO purified water ready to use Automatic shut off valve closes when the storage tank is full and shuts off the water supply to conserve water The valve activates when the tank pressure is 2 3 of the feed pressure The RO Faucet is used to dispense purified water when you want it Feed water saddle valve connects to the cold water line to supply water to the RO system Wastewater saddle valve connects to the drain to remove reject water from the RO system Tubing connects all RO components Quick Connect fittings are used for necessary tubing connections These fittings connect by pushing the tube into the fitting past a slight resistance until the tube bottoms out in the fitting Simply make a clean cut in your tubing and gently push in the tubing until it will not go any further To ensure that your tubing has made a snug fit pull back gently on the tubing it should catch Always check for leaks to ensure a watertight connection see Figure 1 Tools The following tools may be necessary depending on each particular installation Y variable speed electric drill 2 500 RPM is best for stainless steel Ys Ya amp Y metal cutting bits Ve Ya amp Y Concrete drill bits for porcelain sinks Phillips head screw driver 6 adjustable wrench Teflon tape am
15. p Plastic tubing cutter Hammer amp Center punch System Location Your RO system may be installed under a sink or in a basement Do not install unit where it would be exposed to freezing temperatures Connecting to an icemaker or other remote location can also be considered if a connection can be made without using more than 12 of tubing otherwise a delivery pump may be needed Farther runs can be attempted and a pump can be added later only if needed Guidelines for component placement are as follows Faucet should be placed on or near the sink where drinking cooking water is normally required A 2 flat surface is required to mount faucet if an existing hole is not available The thickness of the mounting surface should not exceed 1 or a faucet extension not supplied will be needed Bladder Tank maybe placed where it is convenient within ten feet of the faucet Under the sink or in a nearby cabinet or in basement rafters are excellent choices Full tanks can weigh more than thirty pounds so make sure any shelving used is secure Bladder tank can be placed on its side or upright RO Unit may be mounted on either side of the sink in the back of a cabinet or in the basement Mounting the unit on the left or the right side of the cabinet under the sink provides for easier access to the unit for future maintenance A Faucet Adaptor and Ball Valve Shut Off are used to supply feed water to the RO unit and provide an e
16. re release the tube from the reducer and remove the reducer from the tank valve The supply tank should be placed under the counter or within 10 feet of the RO unit Note Tanks are pre pressurized with air at 7 psi 9 Final Tubing Connections With all components in place complete final tubing connections with these guidelines 1 Tubing should follow contour of the cabinets 2 Cut tubing to correct length using square cuts and a proper cutting tool 3 Make sure there are no crimps in the tubing 4 Keep tubing from the RO unit to the tank and faucet as short as possible for good flow 5 The Drain line is a short 1 2 tube connected to the membrane housing On this tube is a 3 cylindrical drain flow restrictor This is where the drain line connects to the RO unit Do not remove the drain flow restrictor as this will cause a failure in the system Icemaker hookup optional and requires a T fitting and additional shut off valve not supplied with RO unit The RO unit can be connected to any standard refrigerator icemaker or ice maker water dispenser Do not connect to a commercial type bar icemaker To complete this operation connect a T with a shut off valve into the faucet tubing and route tubing to the refrigerator Hooking up to existing copper tubing is not recommended due to possible corrosion Turn off icemaker inside freezer prior to turning off the existing tap water supply line to the refrigerator Turn
17. ser tube from the existing cold water shut off 4 Move the tubing away from the valve to make room for the John Guest Angle Stop Valve 5 Connect the swivel end of the John Guest Angle Stop Valve to the threads on the cold water shut off This connection should only be hand tight 6 Connect the riser tube to the male end of the John Guest Angle Stop Valve and tighten with a wrench 7 Connect a length of 1 4 tubing between the John Guest Fitting on the Angle Stop Valve and the inlet of the RO unit Flexible Riser Tubes Most riser tubes that are used today are made of flexible material either braided stainless steel braided plastic or gray 3 8 plastic tubing These flexible tubes are the easiest to use with the John Guest Angle Stop Valve because the 2 of additional space needed for the Faucet Adaptor can be easily accommodated by flexing this kind of riser A shorter riser tube will not be needed Copper Riser Tubes If your riser tube is made of copper you will need to either make a bend in the copper to allow for the 2 of space needed for the John Guest Angle Stop Valve If the copper tube is 3 8 bending it can be done easily by hand The John Guest Angle Stop Valve works with 3 8 shut off valves and riser tubes In some cases older plumbing may use a larger size shut off and riser tube In this case it would be necessary to either replace the old valve and riser tube with new 3 8 parts or use an alternat
18. t proceed to Step 2 Installation procedures for Porcelain Enamel Ceramic on Metal or Cast Iron Precautions must be taken to penetrate the porcelain through to the metal base and prevent chipping or scratching Procedures 1 Mark the center with center punch for the 1 4 pilot hole 2 Carefully drill pilot hole with masonry pit through porcelain and stop when metal shows Use light pressure and slow speed 3 Switch the bit to a standard metal cutting bit to continue to cut through the metal below the porcelain surface 4 Continue to enlarge the pilot hole with larger masonry amp metal cutting bits until the hole is 1 2 Installation procedures for Stainless Steel Sinks Procedures 1 Mark the center with center punch for the 1 4 pilot hole 2 Drill the pilot hole 3 Continue to enlarge hole with larger size drill bit until it is 1 2 4 Clean up sharp edges Note Air Gap Faucets are required by some municipalities These faucets require a 1 Y hole in the sink rather than the Y hole required by the standard faucet included with the RO system To make a 1 hole to accommodate an air gap faucet requires special tools such as a chassis punch stainless steel or a Relton cutter porcelain if a large enough hole is not already available Ask your local dealer for more information Figure 1 Chrome Based Plate Rubber Washer Lock PATA Metal Washer Hex Nut
19. water production and low water volume available in storage tank In these cases where low pressure exists a booster pump will be required It is highly recommended that your system be sanitized each year On the following page is a table showing RO Membrane performance over a range of temperatures and pressures Membranes are tested at 65 psi of pressure and temperature of 77 degrees For each incremental change in either variable membrane performance changes accordingly Higher pressures increase production and vice versa To troubleshoot a poor performing RO System an accurate measure of the pressure and temperature of water will be required This will require a pressure gauge to determine exactly what the water pressure is that is feeding the membrane Descriptions of water pressure such as good high or strong unfortunately are no help in diagnosing an RO System Pressure Gauge Not Supplied Female Connector Ya FPT x 14 Quick Connect S Not Supplied Disconnect tube feeding into membrane housing and connect to pressure gauge with fitting U PRESSURE TEMPERATURE CHART Te ex ex ex rx rx rx a rx a ro ro ro ro rot rot ot F PSI PSI PSI PSI as 02521 02650 02005 05516 05068 03979 0430 04663 04074 05505 05008 05099 05501 05002 05956 07205 as o2e17 02782 02108 02453 03708 04144 04480 04034 05170 05525 osama 00
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