es100 direct space humidification system installation ... · es100 direct space humidification ....

Smart fog

ES100 DIRECT SPACE HUMIDIFICATION

SYSTEM

Installation & Operations Manual

NEED HELP? Call 1-800-921-5230 (+1-775-954-0070) or EMAIL: [email protected]

www.smartfog.com

CONTENTSES100 SYSTEM PARTS & FITTINGS INFORMATION.......................................................... 4RECOMMENDED INSTALLATION STEPS............................................................................. 5PLUMBING THE AIR, CONTROL AND WATER...................................................................... 6PUSH-TO-CONNECT FITTINGS CONNECTION .................................................................. 7INSTRUCTIONS (1/4 - 1/2” TYPE)........................................................................................... 7PUSH-TO-CONNECT FITTINGS (3/4” TYPE)........................................................................ 8ZEROTDS WATER FILTER SYSTEM INFORMATION.......................................................... 9SAMPLE INSTALLATION LAYOUT........................................................................................ 10SAMPLE INSTALLATION LAYOUT........................................................................................ 11SAMPLE INSTALLATION LAYOUT........................................................................................ 12PLACEMENT OF THE ES100 HUMIDIFIER......................................................................... 13MOUNTING THE ES100 HUMIDIFIER.................................................................................. 14PLACEMENT AND MOUNTING OF CPLC CONTROLLER................................................. 15AND ES100PB CONTROL CENTER..................................................................................... 15CPLC CONTROLLER WIRING INFORMATION................................................................... 16ES100PB CONTROL CENTER OPERATION....................................................................... 17WIRING THE AIR VALVE........................................................................................................ 17(IN CASE YOU NEED TO DISCONNECT AND EXTEND/DISCONNECT THE WIRE)..... 17WIRING AND MOUNTING OF THE RH SENSOR................................................................ 18CONNECTING THE COMPRESSED AIR............................................................................. 19CONNECTING THE WATER SOURCE................................................................................. 20CONNECTING THE ZEROTDS WATER FILTER (200-300 GPD)....................................... 21CONNECTING THE ZEROTDS WATER FILTER (500-2500 GPD)..................................... 22PLUMBING THE AIR, WATER AND CONTROL LINES....................................................... 23CONNECTING THE HEAT TRACE....................................................................................... 24FLUSHING THE PIPES.......................................................................................................... 25CONNECTING THE PIPES TO THE ES100 HUMIDIFIERS............................................... 26SYSTEM START-UP CHECK LIST........................................................................................ 27SETTING UP THE CPLC CONTROLLER............................................................................. 27TROUBLESHOOTING CHECKLIST...................................................................................... 28ZEROTDS WATER FILTER 200-300 GPD MAINTENANCE GUIDE................................... 30ZEROTDS WATER FILTER 200-2500 GPD -REPLACING SEDIMENT CARTIRIDGES... 30ZEROTDS WATER FILTER 200-300 GPD - REPLACING RO MEMBRANE...................... 31ZEROTDS WATER FILTER 500-2500 GPD MAINTENANCE GUIDE................................. 32ZEROTDS WATER FILTER 500-2500 GPD - RO MEMBRANE REPLACEMENT............. 33ZEROTDS WATER FILTER 500-2500 GPD FLUSHING PROCEDURE............................. 34ES100PB AIR FILTER SET & BLUE FILTER ....................................................................... 35

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Smart fog ES100 HUMIDIFICATION SYSTEM Installation & Operations Manual

3 © 2015 SMART FOG INC.

ATTENTION INSTALLERThe ES100 Humidification System is a durable piece of equipment which with proper care will last for many years. This manual outlines installation, operation, maintenance and troubleshooting details vital to the sustained performance of the system.

We recommend to keep this and other associated information about the system for future reference and for new operators or qualified personnel near the system.

Smart Fog provides all fittings and piping necessary for installation. Only use piping and fittings provided by Smart Fog after the air and water filteration.

If the system is altered at the site of operation, or if the operations conditions change, please consult Smart Fog technical staff for assistance.

SMART FOG TECHNICAL SUPPORT Tel: 1-800-921-5230 or +1-775-954-0070Email: [email protected]

RECEIVING & UNPACKING• Check packing list carefully to ensure all materials have been delivered.• All material shortages are to be reported to Smart Fog Inc. Within 48 hours from receipt of

goods. Smart Fog assumes no responsibility for any material shortages beyond this period.• Inspect shipping boxes for damage and note damages on shipping way-bill accordingly.• After unpacking, inspect equipment for damage and if damage is found, notify the shipper

promptly. • Some components are pre-wired at factory, when unpacking please handle with care.

PLEASE READ THE ENTIRE MANUAL BEFORE PROCEEDING WITH THE INSTALLATION AND START-UP. FAILURE TO FOLLOW THE INSTRUCTIONS OR OPERATING PARAMETERS MAY LEAD TO THE PRODUCT’S FAILURE, AND UNDER-PERFORMANCE.


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4© 2015 SMART FOG INC.

ES100 SYSTEM PARTS & FITTINGS INFORMATIONWHAT IS INCLUDED WITH THE SYSTEMThe system includes all pipes and fittings required to put the system together. It is recommended, unless prior approval from Smart Fog is obtained, to use the provided pipes and fittings for optimum system performance. Smart Fog is not responsible for system under performance if other materials are used.

ESSENTIAL TOOLS FOR INSTALLATIONPlease see below the tools required for system installation. We recommend to cut the pipes with a sharp pipe cutter to avoid leakage. Smart Fog Tool Kit shown below can be purchased from Smart Fog to aid in the installation process.

Wire Stripper

Monkey Wrench

Screw Driver

Drill

Pipe Cutter

Pipe Cutter

Small (-) Screw Driver

Smart Fog Tool Kit Includes:

Teflon TapeQuick Connect Release Tool (for 1/4” & 3/8”)

Pipe Sharpener

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RECOMMENDED INSTALLATION STEPSWe recommend to follow the steps below for successful installation process. This is a suggestion, for installation aid only.

STEP 1: Unpack and locate all components, pipes & fittings.

STEP 2: Mount the ES100 Humidifier Boxes DO NOT UNPLUG THE PLUGS ON TOP OF THE HUMIDIFIER AT THIS POINT.

STEP 3: Mount the CPLC Controller & ES100PB Control Center. Check all terminal block connections are in place. Sometimes wires can become loose during shipments.

STEP 4: Mount and wire the relative humidity sensor/s.

STEP 5: Connect the AIR Source.

STEP 6: Place the ZeroTDS Water Filter in place & connect the water source.

STEP 7: Plumb the AIR, WATER & CONTROL LINE to the ES100 Humidifiers. DO NOT CONNECT THE PIPES TO THE ES100 HUMIDIFIERS AT THIS STAGE.

STEP 8: FLUSHING PROCEDURE

STEP 9: Connect all pipes into the ES100 Humidifier.

STEP 10: Start up the ZeroTDS Water Filter.

STEP 11: Start up the CPLC Controller.

STEP 12: Check for leaks and make sure the system is operating correctly (follow the system start-up check list)

IMPORTANT NOTEDO NOT REMOVE THE PLUGS FROM THE ES100 HUMIDIFIERS BEFORE COMPLETING THE FLUSHING PROCEDURE ON PAGE.

1

AIR IN

2

CONTROLIN

3

WATERIN

4

READ PSI


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If the ES100PB Control Center has an “AIR OUT” and “WATER OUT” outlet, run the appropriate pipe from the ES100PB Control Center to the ES100 humidifiers. Otherwise, run the air line from the air filter and the water pipe from the ZeroTDS Water Filter unit or water source directly to the ES100 humidifiers. (Please refer to installation manual pages 19-20 for more information)

You can use a mounting clip to mount all pipes together to the wall or a zip tie to affix to existing piping. Please select the shortest distance possible from the ES100PB Control Center to the ES100 humidifier(s).

IMPORTANT INFORMATION ABOUT THE AIR PIPE LENGTHAs shown in the table below, to avoid air pressure drop to each ES100 humidifier unit(s). Please consider the relation of the pipe length and the number of units attached to each pipe. FOR EXAMPLE: If your air pipe is 1/2” and 50 ft long, you can only attach 3 units of ES100 humidifiers to it. If you have more units, you must run an additional pipe from the air filter or use a larger pipe size. To run another pipe from the ES100PB Control Center, please use a tee connector.

Please don’t hesitate to contact us if you have any questions regarding the air pipe length.

PLUMBING THE AIR, CONTROL AND WATER

Pipe Size Pipe Length ES100-1 ES100-2 ES100-1 ES100-23/4" 500' 14 73/4" 400' 16 83/4" 300' 20 103/4" 200' 20 103/4" 100' 30 153/4" 50' 30 151/2" 500'1/2" 400'1/2" 300' 11/2" 200' 2 11/2" 100' 4 21/2" 50' 6 33/8" 500' 10 53/8" 400' 10 53/8" 300' 20 103/8" 200' 30 153/8" 100' 50 253/8" 50' 50 25

Air Water

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PUSH-TO-CONNECT FITTINGS CONNECTION INSTRUCTIONS (1/4 - 1/2” TYPE)

MAKE A CLEAN TUBE CUTCut the tube using a sharp pipe cutter tool. It is important to ensure that the cut has not made the tube out of shape. Check that the tube has a smooth outside diameter without any burrs or score marks prior to inserting it into the fittings.

Pipe cutter toolTubing Collet

Collet Flange

O-rings

Tubing Collet

Collet Flange

O-rings

INSERT TUBE INTO FITTINGPush the tubing through the collect and dual o-rings until it bottoms out against the tube stop.The collet holds the tube in place and the dual o-rings provide a leak resistant seal.

TEST & INSPECTPush and pull the tubing toward and away from the fitting to ensure that it has been installed properly. Test and inspect the installation for any leaks.

TUBE REMOVALRelieve pressure from the tubing and fitting. Push uniformly around the collet flange against the fitting body while pulling the tubing away from the fitting to release it.

.The quick connect release tool can also be used to re-lease the fittings by using it to press on the collet.


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PUSH-TO-CONNECT FITTINGS (3/4” TYPE)

COMPRESSION FITTINGS CONNECTION INSTRUCTIONS (3/4 - 2” TYPE)

Cut the end of the pipe using a sharp pipe cutter. Angel the pipe end using the provided chafing tool.

Disassembly tool(provided by Smart Fog)

Pipe Chafing Tool Pipe Cutter

Mark the insertion depth on the pipe.

Push the pipe into the fit-tings, until it reaches the in-ternal edge stopper (beyond the internal ring).

The mark on the pipe should reach the nut. Pull on the pipe to make sure the pipe is in place.

FITTINGS DISASSEMBLY

To disassemble the pipe from the fitting, use the red disassembly tool provided to lightly unscrew the cap.

Mark the insertion depth on the pipe.

Release the coupling nut, almost to the end of the thread but do not remove all the way. Mark the insertion depth on the pipe.

Push the pipe into the fitting, until it reaches the internal edge stopper. The mark on the pipe should reach the nut. Tighten the nut manually.

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ZEROTDS WATER FILTER SYSTEM INFORMATION

60

60

60

60

60

60

60

60

Ports

The ZeroTDS Water Flow must be set to the Product (Permeate) and Drain (Concentrate) as specified below.

Port “A” Operating Electricity (A)

Model Dimensions (in) Weight (lb) A B C Min (psi) psi 110/1 phase 230V

200 7 x 17 x 22 45 3/8” 3/8” 1/4” 40 100 2A

300 7 x 25 x 32 50 3/8” 3/8” 1/4” 40 100 4A

500 14 x 20 x 27 65 1” 3/8” 3/8” 40 150 6

1000 14 x 20 x 27 70 1” 3/8” 3/8” 40 150 8.2

1500 19 x 23 x 46 105 1” 3/8” 3/8” 40 150 11

2000 19 x 23 x 46 115 1” 3/8” 3/8” 40 150 11

4000 30 x 38 x 47 235 1” 1” 1” 40 150 16 8.3

5000 30 x 38 x 47 250 1” 1” 1” 40 150 17 8.3

Model Min Max

ZeroTDS Feed Water (psi) Operating Water (psi)

Permiate Concentrate

Water Flow (GPM)

200

300

500

1000

1500

2500

4000

5000

Min/Max

40

40

40

40

40

40

40

40

Pump Pressure

90 100 Auto 0.14

90 100 Auto 0.21

140 150 0.35

140 150 0.7

140 150 1

140 150 1.4

140 150 2.8

140 150 3.5

Auto

Auto

1

1

1

1.7

3

3

0.5

0.5

0.7

1.4

2/6

3.5/6

6/14

7/14

The ZeroTDS Water Filter is a four stage water filter that filters out the water completely to 0 ppm of Total Dissolved Solids. In order for the filteration system to operate correctly, please follow the installation instructions carefully.

Please follow the connection guide carefully, especially connecting the CONCENTRATE port to a drain feed. If the filter system is not allowed to drain, it will result in system malfunction.

It is also important to check the TDS reading on the digital meters provided on-board all of our ZeroTDS Water Filters at least once a month. If there are any issues with the system you will be able to tell by the “OUT” or “IN-MODE” reading on the TDS meter.

For maintenance and cartridge replacement information, please refer to the MAINTENANCE section of the manual.

TABLE A:


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SAMPLE INSTALLATION LAYOUT

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HU 1

SMA

RT F

OG

Zer

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SW

ATE

R FI

LTRA

TION

SYS

TEM

AIR

FIL

TER

SMA

RT F

OG

PRE

SSUR

E TA

NK

AIR

CO

MPR

ESSO

R

WA

TER

SOUR

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120V

AC

1PH

60H

Z

N L12

0V /

5AM

P

120V

/ 24

VTR

ANSF

OR

MER

24V

AC

120V

/ 5

AMP

DR

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ON

TAC

T, T

YP 2

SMA

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OG

CO

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CEN

TER

(ES1

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3)N

O P

OW

ERWAT

ER F

ILTE

R/

STR

AIN

ER

24V

DC

- 4

CO

ND

UCTO

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HEIL

DED

WIR

E22

AW

G [1

8 A

WG

>20

0’]

rH%

24V

DC

- 4

CO

ND

UCTO

R S

HEIL

DED

WIR

E22

AW

G [1

8 A

WG

>20

0’]

rH%

24V

DC

- 4

CO

ND

UCTO

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HEIL

DED

WIR

E22

AW

G [1

8 A

WG

>20

0’]

rH%

rH S

ENSO

R

rH S

ENSO

R

rH S

ENSO

R

SMA

RT F

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CPL

C3

CO

NTR

OLL

ER (

120-

240V

AC

)SM

ART

FO

G E

2 RE

LATIV

E HU

MID

ITY S

ENSO

R

ZON

E 1

CO

NTR

OL

ZON

E 2

CO

NTR

OL

ZON

E 3

CO

NTR

OL REA

D P

SI

1/4"

[AIR

]

1/4"

[AIR

]

1/4"

[AIR

]

1/4"

[AIR

]

3/8"

[WA

TER]

24V

DC

- 10

CO

ND

UCTO

R S

HEIL

DED

WIR

E22

AW

G [1

8 A

WG

>20

0’]

ZOO

M V

IEW

END

1/2

”

END

3/8

”

ES10

0-2 1/4” [AIR]

1/2” [AIR]

3/8” [WATER]

1/4” [AIR]

TEE

3/8”

X 3

/8”

X 3/

8”

TEE

1/2”

X 1

/2”

X 1/

2”

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TEE

1/2”

X 1

/2”

X 1/

2” N

EXT

TO A

IR F

ILTE

R

System Installation Layout Using 1/2” Air Pipe 3 Zone System with 3 Relative Humidity Sensors

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qw

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qw

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HU 1

SMA

RT F

OG

Zer

oTD

SW

ATE

R FI

LTRA

TION

SYS

TEM

AIR

FIL

TER

SMA

RT F

OG

PRE

SSUR

E TA

NK

AIR

CO

MPR

ESSO

R

WA

TER

SOUR

CE

120V

AC

1PH

60H

Z

N L12

0V /

5AM

P

120V

/ 24

VTR

ANSF

OR

MER

24V

AC

120V

/ 5

AMP

DR

Y C

ON

TAC

T, T

YP 2

SMA

RT F

OG

CO

NTR

OL

CEN

TER

(ES1

00PB

3)N

O P

OW

ERWAT

ER F

ILTE

R/

STR

AIN

ER

24V

DC

- 4

CO

ND

UCTO

R S

HEIL

DED

WIR

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AW

G [1

8 A

WG

>20

0’]

rH%

24V

DC

- 4

CO

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WIR

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G [1

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ENSO

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CPL

C3

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120-

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CO

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ZON

E 2

CO

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OL

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CO

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OL REA

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1/4"

[AIR

]

1/4"

[AIR

]

1/4"

[AIR

]

1/4"

[AIR

]

3/8"

[WA

TER]

24V

DC

- 10

CO

ND

UCTO

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DED

WIR

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G [1

8 A

WG

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END

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END

3/8

”

ES10

0-2 1/4” [AIR]

1/2” [AIR]

3/8” [WATER]

1/4” [AIR]

TEE

3/8”

X 3

/8”

X 3/

8”

TEE

3/4”

X 1

/2”

X 3/

4”

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System Installation Layout Using 3/4” Air Pipe 3 Zone System with 3 Relative Humidity Sensors


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FlowRequirements:ES100-1: 3 cfmES100-2: 5 cfmES100-1H: 3 cfmES100-2H: 5 cfm

Please note:Each zone of thespecified units ofES100 is controlledby a output in theControl Center(ES100PB). TheControl Center(ES100PB) arecontrolled by theCPLC Controller.

CPLC3

Water Source

Air Compressor

ES100-1

ES100PB3

Water 3/8” or 1/2”

Air 1/2” or 1”

6 wire 18 gauge shielded

Air 1/4” (Control)Air 1/4” (Control)

Air 1/4” (Control)

ES100-1

ES100-2

Pressure Tank

RH S

enso

r

RH S

enso

r

RH S

enso

r

3 wire 22 gauge shielded100-130 psi

Zone 2 Zone 3

Zone 1

Air 1/4” (READ PSI)

100-240VAC 3A

ZeroTDS

Pleaseinquire for

best location

Pleaseinquire for

best location

Pleaseinquire for

best location


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PLACEMENT OF THE ES100 HUMIDIFIER

ES10

0

2-3’

3’

Roof

ChillerFans

Air Flow

OPTION 1View from side.

4’

ChillerFans

ES100

OPTION 2View from top.

Mount on adjacent wall

ES

100 4’

10’

3’

Ceiling

FIGURE 2: Enforcement Zone Side View

Enforcement Zone

4’

ES

100

10’

6’

Enforcement Zone

Enforcement Zone

ES

100

Enforcement Zone

Enforcement Zone

FIGURE 3: ES100 installed on chiller fan

ES100

For Example

In locating an appropriate position for the ES100 humidifier, please locate a position which the enforcement zone (refer to FIGURE 2 & 3) does not come in contact with any object.

If there are fans (chiller or other) in the room, the ES100 humidifier units must be installed in-front or parallel to the fans (or on the side wall like in Figure 2). Do not place the ES100 humidifiers unit behind the fans or on the opposite wall facing the fans. If there are no fans in the room the ES100 humidifier unit can be installed on any of the walls.

The ES100 unit does not require any fans to operate.

When two or more ES100 humidifier units are being installed in a room, the units will need to be distributed equally. Make sure the enforcement zone does not collide with each other. See FIGURE 4.

IMPORTANT NOTE: DO NOT PLACE THE ES100 HUMIDIFIERS AGAINST THE

AIR FLOW

FIGURE 4: Enforcement Zone Top View

ES1004’

10’

3’

Cei

ling

FIG

UR

E 2

: Enf

orce

men

t Z

one

Sid

e V

iew

En

forc

emen

t Z

on

e

4’

ES100

10’

6’

En

forc

emen

t Z

on

e

En

forc

emen

t Z

on

e

ES100

En

forc

emen

t Z

on

e

En

forc

emen

t Z

on

e

FIG

UR

E 3

: ES

100

inst

alle

d o

n ch

iller

fan

ES

100

For

Exa

mp

le

In case the roof is not horizontal, the ES100 humidifier should be placed slanted with the slope of roof or in the adjacent wall. See FIGURE 5 below.

FIGURE 5: For sloped roof installations with fan coils


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MOUNTING THE ES100 HUMIDIFIER

11/16”

7/32”

10-3/8”

16-5

/8”

The ES100 humidifier enclosure box can be mounted utilizing the four (4) mounting brackets. Please find the mounting brackets in the fittings kit bag.

Screw each bracket tightly into the enclosure’s four back corners.

IMPORTANT NOTETHE ES100 HUMIDIFIER UNITS ARE PRE-CALIBRATED AT FACTORY. OPENING THE BOX AND TAMPERING WITH THE NOZZLES AND NEEDLE VALVES INSIDE WITHOUT FACTORY AUTHORIZATION MAY RESULT IN WARRANTY VOID AND SYSTEM MALFUNCTION.


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PLACEMENT AND MOUNTING OF CPLC CONTROLLERAND ES100PB CONTROL CENTERThe CPLC Controller and the ES100PB Control Center, can be mounted utilizing the four (4) mounting brackets. Screw each bracket tightly to the box. The units can be mounted next to one another or in separate locations by extending the wiring connecting them. The CPLC Controller and ES100PB Control Centers are pre-wired at factory. Wiring can be extended if required. The 18 gauge wire can be disconnected and re-connected if longer distances are required.

IMPORTANT NOTEWHEN MOUNTING THE CPLC CONTROLLER AND ES100PB CONTROL CENTER, PLEASE SELECT A LOCATION WHICH IS ACCESSIBLE AND CONVENIENT FOR DAY TO DAY MONITORING AND CONTROL.

11/16”

7/32”10-3/8”

16-5

/8”

11/16”

7/32”

10-3/8”

16-5/8”

Back of CPLCCPLC 18

GaugeWire

Back of ES100PBES100PB

NOTE:Plug in the silencer.(provided in the fittings kit)

Placement Notes: The CPLC Controller contains the PLC Controller for the humidification system. Therefore, it should be installed in a location with easy access for users.

The ES100PB Control Center with enclosed air filter set should be placed at a location where the box can be opened for air filter cartridge replacement.


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ES100PB(24v DC)

Power(120v-240v AC)

Sensor(24v DC)

TerminalBlock

SD Card Slot

PLC Controller

Power Supply

Breaker (6A)

CPLC CONTROLLER WIRING INFORMATIONWIRING INSTRUCTIONSThe CPLC Controller is pre-wired at factory. In case you need to extend the wires for the ES100PB Control Center and the Relative Humidity sensors, please refer to the wiring guide provided on the internal door of the CPLC Controller.

TURNING ON/OFFThe CPLC Controller can be turned ON/OFF using the breaker. Push the button. The CPLC Controller maintains its setting memory even when turned off.

All of our CPLC Controllers are pre-wired at factory for testing purposes, the pre-wired system comes with 3-4’ of sensor and ES100PB Control Center wire. If you need to extend the wires, the following wire types can be used.

Connection with SENSOR : 4 Conductor 22 gauge shielded wireES100PB Control Center : 4 Conductor 22 gauge shielded wireIf wires are ran more than 100’, we recommend to use 18 gauge shielded wires rather than 22 gauge.

TERMINAL BLOCK USE INSTRUCTIONS

The CPLC Controller wiring diagram is mounted inside each controller internal door.

WIRE LENGTH INFORMATION

The type of terminal blocks we use are designed for fast conductor connection. There is no need to strip or implement splicing protection. The cables simply need to be cut to length for contact to be made in a matter of seconds.

IMPORTANT NOTEPLEASE CHECK THE TERMINAL BLOCK CONNECTIONS PRIOR TO STARTING UP THE SYSTEM. SOMETIMES CONNECTIONS CAN BECOME LOOSE DURING SHIPMENT.


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1.

4. 5. 6.

9.7.

2. 3.2 (-)

(+) (-)

1 (+)

1

8.

Insert the valve terminal back to the Air Valve

Connect the wires from the SF Controller (CPLC) to the Valve Terminal

2

WIRING THE AIR VALVE(IN CASE YOU NEED TO DISCONNECT AND EXTEND/DISCONNECT THE WIRE)

INSTALLATION NOTEValve Terminal 1 : (1V+ 24VDC) REDValve Terminal 2 : (2V- 24VDC) BLACK* Polarities do not change.

ES100PB CONTROL CENTER OPERATIONOnce the CPLC Controller is turned on, check that the lights on the air valves (see illustration below) are turning on. If you have multiple zone systems, with multiple air valves, make sure that the air valves are turning on when the corresponding zone is operating at the CPLC Controller.

AIR FILTERS

AIR VALVES

BLUE WATER FILTER

AIR FILTER SET DRAINThe air filters have an automatic drain feature. When full, they will drain automatically from the bottom (see arrows). We recommend to connect a 1/4” tube to a holding bucket to avoid spillage.


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WIRING AND MOUNTING OF THE RH SENSORPlease see below sensor mounting and wiring information. We have two types of sensors, and you can refer to the packing list to see which type of sensor is provided with your system.

INSTALLATION NOTE SENSORS CAN BE LOCATED NEAR THE CPLC CONTROLLER OR IN A SAFE SPOT IN THE ROOM. SELECT A LOCATION WHERE THE SENSOR IS NOT LO-CATED ON THE OPPOSITE SIDE OF THE ES100 HUMIDIFICATION UNITS.

RELATIVE HUMIDITY SENSOR E1 SERIES

RELATIVE HUMIDITY SENSOR E2 SERIESThe E2 Sensor comes with a mounting bracket as shown below. Carefully mount the sensor to the wall using the provided bracket. We recommend placing the relative humidity sensor 6 ft off the floor. Note: This type sensor has an address that is pre-programmed at factory. There is a zone number noted on the sensor, please make sure the correct zone sensor is placed in the correct zone.

When placing the relative humidity sensor, please locate a position which is 6 ft off the floor. 18 U+

RHT

23

76

5

Connect1 +V242 RH13 Temp1

1...+UB2...B-RS4853...A-RS4854...GND

E2 SENSOR COMPONENTS E2 SENSOR WIRING GUIDE1: BROWN +24VDC4: BLACK - 24VDC3: BLUE - A (+)2: WHITE - B (-)

Please attach the mounting clip onto the E2 sensor. Mount the sensor to the wall in a safe location, away from heavy traffic to avoid accidental damages.

Sensor ProbeMounting Clip

Mount the sensors with screws to the wall, in a safe location, away from heavy traffic to avoid accidental damages.


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CONNECTING THE COMPRESSED AIRSmart Fog Humidification System comes with air filters. Make sure only filtered compressed air supply feeds the humidification system. The provided air filters are typically enclosed inside the ES100PB Control Center. However, some systems are supplied with external air filters. Please follow the instructions below to ensure optimal system operation. After the ES100PB Control Center and supplied air filters, only Smart Fog supplied fittings and pipes should be used. Compressed air pressure should not exceed 120 PSI.

INSTALLATION NOTETHE PROVIDED 1/2” X 1/2” NPT MALE ADAPTER SHOULD BE USED TO CONNECT THE SYSTEM TO THE AIR SOURCE. APPLY TEFLON TAPE ON THE NPT THREAD. FOR APPLICATIONS WHERE 1” X 1” MALE ADAPTERS ARE PROVIDED, PLEASE REFER TO THE SETUP GUIDE BELOW (DIAGRAM A).

1/2” X 1/2” MALE ADAPTER CONNECTION GUIDE

PB

1/2”

ES100-2 ES100-1

CONNECTING THE AIR SOURCE WITH EXTERNAL AIR FILTERS

Compressed Air

Source AIR FILTER SET

ES100PB

1/2” x 1/2”

7AIR IN

ES100PB9

AIR OUT

ES1001AIR IN

Air 1/2”

WATER IN - Water 3/8”

Air Filter Drain 3/8”

AIR IN - Air Compressor 1/2”

Water 3/8”

Control 1/4” (up to 3 zones)

Read PSI 1/4”

ToES100 Units

Apply Teflon tape

Diagram A

Insert the 1” compressed air line directly into the provided air filter set. Any 1” Male Thread fitting can be used. Note, this fitting is not provided with the fittings kit.

Connect the supplied Male Adapter fitting (1/2” x 1/2”) to the compressed air source.

CONTINUED TO NEXT PAGE


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CONNECTING THE WATER SOURCE

INSTALLATION NOTETHE PROVIDED 1/2” X 3/8” NPT MALE ADAPTER SHOULD BE USED TO CONNECT THE SYSTEM TO THE WATER SOURCE. APPLY TEFLON TAPE ON THE NPT THREAD. PLEASE REFER TO “INSTALLING ZEROTDS WATER FILTER” FOR DETAILS ON ZERO TDS WATER FILTER WATER PRESSURE REQUIREMENTS.

Apply Teflon tape on the NPT thread.

WATERSOURCE OR

1/2” x 3/8”

ES100PB ES100

ZEROTDS8FEED ES100PB ES100PERMIATE

WATEROUT

WATERIN

WATERIN

WATERIN

WATEROUT

Connect the supplied Male Adapter fitting (1/2” x 3/8”) to the water source.Follow the diagram below for the water connection guide. If you have the ZeroTDS Water Filter, the water source should be connected to the water filter first, and then to the water in on the ES100PB Control Center. If you are using your own filtered water source, the water connection should be connected directly to the ES100PB Control Center - WATER IN port.Water pressure into the ES100PB Control Center should not exceed 50 PSI.

AirCompressor ES100

Water

Air 1/2”

Water

Control (up to 5 zones)

Read PSI

ES100PB

CONNECTING THE AIR SOURCE WITH EXTERNAL AIR FILTERS(CONTINUED FROM PREVIOUS PAGE)

See below the connection illustration on how to connect the ES100PB Control Center to the main air line with and external air filter.

3/4 x 1/2 x 3/4” TEE


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CONNECTING THE ZEROTDS WATER FILTER (200-300 GPD)The ZeroTDS Water Filter 200-300 GPD models are per-calibrated and will run as soon as it’s connected to electricity. On initial start-up, prior to connecting the ZeroTDS Water Filter 200-300 GPD models to the ES100PB Control Center, drain the PERMEATE water for about 20 minutes. Please follow the start-up procedure before to ensure optimum filter operation.

INSTALLATION NOTE• FEED WATER PRESSURE MUST NOT EXCEED 40 PSI. IF YOU HAVE WATER PRESSURE

FLUCTUATIONS, WE RECOMMEND TO ADD A WATER PRESSURE REGULATOR BEFORE THE ZEROTDS WATER FILTER.

• THE CONCENTRATE PORT MUST BE CONNECTED TO AN ACTIVE DRAIN. IT SHOULD NOT BE PLUGGED. PLUGGING THE CONCENTRATE PORT WILL MALFUNCTION THE FILTER SYSTEM.

1

Feed

Product“B” 3/8”

Drain“C” 1/4”

Water Source“A” 3/8”

Permeate Concentrate

Pressure TankZero TDS

ES100PB

Test Valve

Pressure Tank

IN OUT

0

2040

6080 100 120

140160

020

40 60

10080

020

40 60

10080

WATER FEED PRESSURE

SYSTEM PRESSURE

PERMEATEWATER PRESSURE

TDSMETER

START-UP PROCEDURE1. Turn the source water on, and close the pressure

tank valve going into the ES100PB Control Center. Open the test valve to allow water to flow out to a drain.

2. Plug the water filter to an electrical outlet. This will turn the ZeroTDS Water Filter ON.

3. Let the system drain through the test valve for approx. 20 min.

4. While the system is in operation, check the SYSTEM PRESSURE gauges, and make sure the reading is within recommended range (refer to page 8, TABLE A).

5. Check the TDS meter. Make sure the IN & OUT readings are within the recommended range. The recommended range is 0-5 ppm IN and 0-2ppm OUT. If the reading is too high, wait for a day and read again. ** TDS Meter reading should be taken only when the filter is in operation

6. Once you confirm the filter system is running correctly, and allow 20 min to pass - you can close the TEST VALVE, and open the valve and allow the PERMEATE water to flow into the ES100PB Control Center WATER IN port.

1

Feed


Drain“C” 1/4”




ES100PB

Test Valve

Pressure Tank

The ZeroTDS Water Filter should work for a few hours to fill the system. The system is full when the PREMEATE WATER pressure reaches 40 PSI.

If you have any issues with the start-up steps or with any of the recommended system pressures, please call us to speak with one of our support personnel. if you let the ZeroTDS Water Filter run without the optimum pressures, it may cause issues.

1

Feed


Drain“C” 1/4”




ES100PB

Test Valve

Pressure Tank

The pressure tank pressure is pre-set at factory. There is no need to adjust the pressure. Pressure is pre-set at 8 PSI.

On/Off

MonitorIN OUT

ABOUT THE TDS METERWe recommend to check the IN & OUT Readings on the on-board meter. Use the ON/OFF button to turn the meter on, and then press the IN & OUT buttons to show the readings. Reading must be read while the filter system is in operation.


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CONNECTING THE ZEROTDS WATER FILTER (500-2500 GPD)The ZeroTDS Water Filter 500-2500 GPD models are per-calibrated and will run as soon as it’s connected to electricity. On initial start-up, prior to connecting the ZeroTDS Water Filter 500-2500 GPD models to the ES100PB Control Center, drain the PERMEATE water for about 30 minutes. Please follow the start-up procedure before to ensure optimum filter operation. Refer to table in page 9 for optimum operation pressures.

INSTALLATION NOTE• FEED WATER PRESSURE MUST BE BETWEEN 40-80 PSI. IF YOU HAVE WATER PRESSURE

FLUCTUATIONS, WE RECOMMEND TO ADD A WATER PRESSURE REGULATOR BEFORE THE ZEROTDS WATER FILTER.

• THE CONCENTRATE PORT MUST BE CONNECTED TO AN ACTIVE DRAIN. IT SHOULD NOT BE PLUGGED. PLUGGING THE CONCENTRATE PORT WILL MALFUNCTION THE FILTER SYSTEM.

Inlet WaterPressure

ON/OFFSwitch

PumpPressure

ConcentrateWaterFlow

PermiateWater Flow

ConcentrateWater

Adjustment

Pressure AfterSediment Filter

START-UP PROCEDURE1. Turn the source water on, and close the pressure tank

valve going into the ES100PB Control Center. Open the test valve to allow water to flow out to a drain.

2. Plug the water filter to an electrical outlet. Turn the filter on by the ON/OFF Switch.

3. Let the system drain through the test valve for approx. 30 min.

4. While the system is in operation, check the FEED WATER PRESSURE and SYSTEM PRESSURE gauges, and make sure the reading is within recommended range (Refer to page 8, TABLE A).

5. Check the CONCENTRATE water flow. If the readings are not as per the table below, adjust the CONCENTRATE water pressure using the CONCENTRATE WATER ADJUSTMENT valve.

6. Check the pump pressure gauge to make sure the pressure is between 140-150 PSI. If the pressure gauge reading is not correct, adjust using the by-pass valve located on the side of the filter.

7. Check the PREMEATE pressure reading. It should be as per the table below. If the pressure is incorrect, please call our support team.

8. After the filter is working for 30 min, check the TDS meter. Make sure the IN & IN MODE readings are within the recommended range.

9. Once you confirm the filter system is running correctly, and allow 30 min to pass - you can close the TEST VALVE, and open the valve and allow the PERMEATE water to flow into the ES100PB Control Center WATER IN port.

The ZeroTDS Water Filter should work for a few hours to fill the system. The system is full when the PREMEATE WATER pressure reaches 40 PSI.

The pressure tank pressure is pre-set at factory. There is no need to adjust the pressure.

IN MODE = “OUT”

Cover

POWER

IN MODE

PPM

ALARM

ABOUT THE TDS METERWe recommend to check the IN & OUT Readings on the on-board meter. The reading Reading must be read while the filter system is in operation.


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PLUMBING THE AIR, WATER AND CONTROL LINESINTO THE ES100 HUMIDIFIERSIMPORTANT NOTEDO NOT REMOVE THE PLUGS FROM THE ES100 HUMIDIFIERS BEFORE COMPLETING THE FLUSHING PROCEDURE ON PAGE.

1

AIR IN

2

CONTROLIN

3

WATERIN

4

READ PSI

Please follow the procedures below to prepare the pipes to connect into the ES100 Humidifier: 1. Cut the pipe using a pipe cutter and plug-in the

appropriate size TEE fitting into the main pipe (see table below.

2. Cut the appropriate length of pipes to insert into the TEE fitting and into the ES100 Humidifier box. However, DO NOT INSERT THE PIPES INTO THE ES100 Humidifier unit yet. (Before removing the plugs, follow the flushing procedure on page )

INSTALLATION NOTEDO NOT CONNECT THE AIR, WATER AND CONTROL LINES DIRECTLY INTO THE ES100 HUMIDIFIERS. PLEASE USE A TEE FITTING, EVEN IF IT’S ONLY A SINGLE ES100 HUMIDIFIER UNIT. THE ONLY LINE THAT CAN BE CONNECTED DIRECTLY INTO THE ES100 HUMIDIFIER IS THE READ PSI LINE.

1/4”

1/2”

1

AIR IN(1/2” OD PIPE)

2

CONTROLIN

(1/2” OD PIPE)

3

WATERIN

(3/8” OD PIPE)

4

READPSI

(1/4” OD PIPE)

3/8”

ES100PB (AIR OUT)MIDDLE UNIT 1 9

ES100PB (WATER OUT)MIDDLE UNIT 2 10

ES100PB (ZONE # CONTROL)MIDDLE UNIT 3 13

1/4”

1/2”

1


2

CONTROLIN

(1/2” OD PIPE)

3

WATERIN

(3/8” OD PIPE)

4

READPSI

(1/4” OD PIPE)

3/8”




1/4” ES100PB (ZONE # READ PSI)14

PIPING OF THE MIDDLE ES100 Unit

PIPING OF THE END ES100 Unit


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CONNECTING THE HEAT TRACE (FOR THE ES100-1H & ES100-2H UNITS)

Prior to plugging the heat trace into an electrical outlet, the trace located outside of the ES100 Humidifier must be insulated together with all the pipes coming out of the unit. The insulation should be done for all the pipes that are located inside the cold temperature room (under 45F).

If not insulated properly, the ES100 Humidifier will not be able to work properly. Insulation is not provided with the Smart Fog System.

The Heat trace requires 120 VDC, 5W/ft.

Heat Trace

Cover with Insulation


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FLUSHING THE PIPES

INSTALLATION NOTE: THIS IS ONE OF THE MOST IMPORTANT STEPS IN THE INSTALLATION PROCESS. PLEASE READ THE INSTRUCTIONS CAREFULLY.

1. Please make sure that the end caps at the end of each air & water pipe are removed. 2. Make sure none of the pipes are plugged into the ES100 Unit. Leave the plugs in at this stage. 3. To flush the water lines, turn on the source water until you see the water coming out from the

3/8” pipe that will connect into the water in of the ES100 humidifiers for approx. 10-20 min. For systems with ZeroTDS Water Filter, please follow filter start-up process. For most filters, you will need to let the product water drain for 10-20 min prior to allowing for flushing process. Once water lines flushing is completed, remove the plug and connect the water line into the ES100 humidifier.

4. To flush the air, turn on the main air valve and flush it for 10 min. Once the air lines are flushed, you can remove the plugs and plug the air line directly to the ES100 humidifiers. Do not connect the READ PSI line to the ES100PB Control Center. After flushing all the air lines, connect the read PSI line to the ES100 Humidifier first, and turn the air on.

5. To flush the air control line, open the main air valve. Then, open the ES100PB Control Center Box. Locate the air valve. Press the manual operation button (see diagram 1A) for 30 seconds. When you confirm air is coming out, close the valve and let go of the manual operation button. Once flushing is completed, remove the plug and connect the air control line into the ES100 humidifier.

6. Now, flush the read psi line. After the air lines have been flushed, connect the line to the last ES100 humidifier.

7. Connect the end caps to the end of the pipe line. This completes the flushing procedure.

If any of the above steps are unclear, and you need assistance, please don’t hesitate to contact Smart Fog Tech Support.

Push pipe in

DIAGRAM 1A

Manual operation button of the Air control valve

End cap fitting The air control valve is located inside the ES100PB Control Center.


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CONNECTING THE PIPES TO THE ES100 HUMIDIFIERS

1/4”

1/2”

1


2

CONTROLIN

(1/4” OD PIPE)

3

WATERIN

(3/8” OD PIPE)

4

READPSI

(1/4” OD PIPE)

3/8”




1/4” ES100PB (ZONE # READ PSI)14

After all the pipes have been flushed, the next step is to remove the plugs from the ES100 unit and plus the pipes that have been prepared previously to the ES100 Humidifier.

1/4”

1/2”

1


2

CONTROLIN

(1/2” OD PIPE)

3

WATERIN

(3/8” OD PIPE)

4

PRESSUREOUT

(1/4” OD PIPE)

3/8”




PIPED MIDDLE ES100 HUMIDIFIER UNIT

PIPED END ES100 HUMIDIFIER UNIT

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SETTING UP THE CPLC CONTROLLERThe CPLC Controller has the following factory default settings when turned on. To change any of the settings, please refer to the CPLC manual provided with the system. The following are the default values set in the CPLC Controller. Relative Humidity Target : 75%Compressed Air Minimum Pressure : 90 PSION/OFF Time Setting: 10 SEC ON/ 20 SEC OFF

After setting the CPLC Controller with your desired relative humidity target level, we recommend you let the system run for a week to see how the environment reacts. If after one week, the relative humidity level target is not reached, please consult us for further settings.

• Check electricity – make sure CPLC and ZeroTDS Water Filter get power.• Compressed Air Pressure Check – at least 100-110 psi. • Check water pressure going into ZeroTDS Water Filter. See page 9 for recommended water pressures for

your ZeroTDS Water Filter. • Check all the compressed air lines, and make sure there are no leaks.• Turn on the CPLC and make sure it’s reading all the rH sensors.• Check the setting on the CPLC Controller o Press F2--> Factory Default--> F1• At this point, check that all the air solenoid valves located in the ES100PB Control Centers are operating. You

can check this by opening the ES100PB Control Centers, and checking when the CPLC Controller has an “X” next to a zone number, that the corresponding valve is opening/closing (you will hear a click and the valve when open will light up).

• Check that the source water is open, and drain is connected to drain and turn the ZeroTDS Water Filter ON (plug into electricity).

o For the first 10 min, drain all the water including PRODUCT (PERMEATE) water coming out of the filter. After 10 min, let the PRODUCT (PERMEATE) water go into the pressure tank and the humidification system. o Check that the filter pump is running. o Check the WATER FEED pressure is at least 40 psi. o Check SYSTEM PRESSURE o Once the system has started, make sure drain is coming out of the drain pipe. o Let the filter work at least 20-30 min or until the booster pump stops automatically (this may take a couple of hours when the filter is initially started). o Check that the pressure tank valve is open to let the PRODUCT water into the humidification system.• Once the humidification system gets feed water and the pressure is over 20 psi in the CPLC Controller (F1

screen), check to make sure there are no leaks on the water lines.• If all of the above is working, open the source compressed air, and let the system operate.• Look at the CPLC Controller screen, and check that the air pressure is showing 100 psi and water pressure

20 psi, when the system is in operation.• Set the CPLC Controller to the following: o Press F2-->Factory Default-->F1 o Press F2-->Air Sensor --> Set the air sensor to 90 psi o Set all ZONES to “MANUAL” operation. o Set all ZONES to 10 SEC ON, 20 SEC OFF o Follow the CPLC Manual and set the required RH for each zone.• Once the CPLC Controller has been set, check each zone to make sure the ES100 humidifiers are operating

correctly. Check for any obstacles in front of the “enforcement zone”.• If you have a system with multiple ZONES, please check that the sensors are connected correctly for each

allocated zone.

SYSTEM START-UP CHECK LIST


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TROUBLESHOOTING CHECKLISTWe strive to provide quick and hassle free customer service and technical support. The following section provides general guidelines for troubleshooting the ES100 humidification system.

Before contacting us for technical assistance, please collect the following information: PSI Compressed Air Pressure (Check at the CPLC Controller) PSI System Water Pressure (Check at the CPLC Controller) PSI Water Pressure at the ZeroTDS Water Filter System rh% Target Relative Humidity Set at CPLC Controller rh% Current Relative Humidity (Shown at the CPLC Controller)

ON and OFF Cycles (Refer to CPLC)

If you are contacting our team regarding issues with the ZeroTDS Water Filter System, please collect the following information: PSI PERMEATE Water Pressure at ZeroTDS Water Filter System PSI Product Water Pressure (Check at the CPLC Controller)

TDS Meter Reading (Both IN & IN MODE or OUT) PSI FEED Water Pressure at ZeroTDS Water Filter System PSI CONCENTRATE Water Pressure at ZeroTDS Water Filter System

NOTES:

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If there is no water/fog coming out of the ES100 Humidifier

• Check the water pressure at the CPLC Controller. Pressure must be above 40 PSI.

• Check the water source. Is the valve open?• Check Electricity• Make sure all connectors and wires inside the CPLC

are secure.• Check if controller is showing the relative humidity

level• To bypass sensor set relative humidity to 100%• Check water at the ZeroTDS Water Filter• If there is no water, check if the ZeroTDS Water Filter

is working• Check for air and water leakage • If a leak is found, push the pipe into the connectors to

secure the connection.• Is the room temperature below 45F? If so, please

contact us for recommendations.• Not enough compressed air pressure. Check that the

system is getting 100 PSI.If the ES100 is leaking water Check the water pressure coming into the ES100PB

Control Center. If the water pressure is above 60 PSI.

CPLC Controller is not working Check the breaker, since it might have been triggered due to fluctuations of electricity. Check if all the wires are secure and check if the red jumpers are in place.

ES100 unit is dripping at the nozzle If there is dripping at the nozzle, this may be due to mineral buildup on the outlet of the nozzle. If you have a ZeroTDS Water Filter, please check the TDS meter. You may have to replace the water filter elements. If the TDS level at the ZeroTDS Water Filter is showing correctly, check the supply compressed air pressure. It may have dropped below 100 PSI.

ZeroTDS Water Filter not producing enough water

If the ZeroTDS Water filter is not producing enough water, check the water pressure while the filter is in operation. For units above 500 GPD, the source water pressure should be above 40 psi. Check if the pump is working. Check what is the water pressure 200/300 GPD which should be 100 psi and on units 500 GPD and above 150 psi. Check if there is concentrate water coming out. If all the above is functioning as per spec, we suggest to replace the water filter cartridges. Water filter cartridges can be obtained by calling us. In general, we recommend to change the filter elements once in 2 years (or less depending on the TDS reading).

If rH value on the CPLC Controller shows 0% If the relative humidity shows 0, then the sensors are malfunctioning or wires are disconnected. Check the wires between the CPLC and the sensor. Check first if there is 24 VDC at the sensor.


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ZEROTDS WATER FILTER 200-300 GPD MAINTENANCE GUIDE

On/Off

MonitorIN OUT

We recommend to check the TDS meter on-board the ZeroTDS Water Filter at least once a month. TDS meter reading must be read while the water filter system is in operation. To turn the meter on, press the ON/OFF button.If the OUT reading shows a value above 1 PPM, the filter cartridges should be replaced.

The ZeroTDS 200-300 GPD water filters each have 4 cartridges. Here is the list of cartridges for each type of filter. ZeroTDS 200 GPD Water FilterZTDS2514-RM 2514 MembraneZTDS2520-DI 2520 DI CartridgeZTDS2520-SPCB 2520 CB CartridgeZTDS2520-5M 2520 5 Micron Cartridge

ZeroTDS 300 GPD Water FilterZTDS2521-RM 2521 MembraneZTDS2520-DI 2520 DI CartridgeZTDS2520-SPCB 2520 CB CartridgeZTDS2520-5M 2520 5 Micron Cartridge

TDS METER

Replacing the Sediment Cartridges1. Unscrew the housing from the filter body using the provided

wrench tool. 2. Remove the old cartridges from the housing.3. Remove the wrapping plastic from the new cartridges.4. Insert the new cartridge into housing. Make sure the cartridge

is inserted in the correct direction as shown on the previous page.

5. Screw in the housing back into place.

ZEROTDS WATER FILTER 200-2500 GPD REPLACING SEDIMENT CARTRIDGES

5 Micron Carbon DI

Black top

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MEMBRANE ELEMENT REMOVAL

FEED WATERIN

PRODUCT AND WASTEWATER OUT

Remove membrane element from the right (feedwater) side of the membrane housing.

L1-SERIES MEMBRANE ELEMENTREMOVAL

L1-SERIES SYSTEM FRONT VIEW

FEED WATERIN



SEAL SIDE

Note: Long nose pliers may be necessary to pull the oldmembrane element out of the membrane element housing.

MEMBRANE ELEMENT INSTALLATION

FEED WATERIN


SEAL SIDE


L1-SERIES MEMBRANE ELEMENTINSTALLATION

FEED WATERIN


SEAL SIDE

Install membrane through the right side (feed water)of the membrane housing with brine seal located onthe feed water side.

Note: Lubricate the brine seal and o-rings with a non-petroleumbased lubricant, such as Dow Corning® 111. Do not use apetroleum-based lubricant.

SEAL SIDE



RETAINING DISCS INSTALLATION INSTRUCTION RETAINING DISCS INSTALLATION INSTRUCTION

INSERT TWO HALF-MOON RETAINING DISCSINTO GROOVE ON VESSEL UNTIL THEY AREFULLY SEATED.

SUBSEQUENTLY FASTENUSING #5 ALLEN WRENCH.

1

2

INSERT TWO HALF-MOON RETAINING DISCSINTO GROOVE ON VESSEL UNTIL THEY AREFULLY SEATED.


1

2

FRP VESSEL WITH RETAINING DISCSINSTALLED.


2

ENG-141 REV. A


2

FRP VESSEL WITH RETAINING DISCSINSTALLED.

ENG-141 REV. A

Replacing the RO Membrane1. Close the water source.2. Remove the end cap from the right (feed water) side of the membrane housings. This is done by removing

the two half-moon retaining disks using a #5 allen wrench. The end plug should then freely slide out of the pressure vessel.

3. Remove the membrane bag containing the element from the shipping box. The membrane should be contained within a plastic oxygen barrier bag.

WEAR GLOVES FOR THE FOLLOWING STEPS IN ORDER NOT TO CONTAMINATE THE MEMBRANE!4. Cut the bag open as close as possible to the seal at one end of the bag, so the bag may be re-used if

necessary.5. Make sure all parts are clean and free from dirt. Examine the brine seal and permeate tube for nicks and

cuts. Replace the O-rings of the brine seal if damaged.6. Flow directions should be observed for installation of the membrane element into pressure vessels.WARNING: THE BRINE SEAL MUST BE IN THE SAME POSITION AS IT WAS FOR FACTORY PRE-INSTALLED MEMBRANE ELEMENT. THE BRINE SEAL IS A RUBBER SEAL THAT PROTRUDES ON ONE SIDE OF THE MEMBRANE AND IS ALWAYS ON THE FEED SIDE OF THE MEMBRANE ELEMENT. FOR THE 200-300 GPD RO SYSTEMS THE BRINE SEAL SHOULD BE ON THE RIGHT SIDE OF THE MEMBRANE HOUSING.

7. Remove membrane element from the right (feed water) side of the membrane housing. Long nose pliers may be necessary to pull the old membrane element out of the membrane element housing.

8. Lubricate the brine seal and o-rings with a non-petroleum based lubricant. Do not use petroleum-based lubricant.

9. Install membrane through the right side (feed water) of the membrane housing with brine seal located on the feed water side.

10. With a smooth and constant motion, push the membrane element into the housing so the brine seal enters the housing without coming out of the brine seal groove.

11. Re-install the end plug on the right side by gently twisting the end cap, while pushing it onto the housing. Ensure that you do not pinch or fatigue any o-rings while re-installing the end plug. Push the end plug on until the outer diameter of the plug is flush with the outer diameter of the pressure vessel.

12. Insert the two half-moon retaining disks until they are fully seated. Subsequently fasten using a #5 Allen wrench.

13. Reconnect any fittings that may have been disconnected when the membrane pressure vessels were disassembled.

14. To start the system, please refer to the start-up section of the manual.

ZEROTDS WATER FILTER 200-300 GPD REPLACING THE RO MEMBRANE

MEMBRANE ELEMENT REMOVAL

FEED WATERIN



L1-SERIES MEMBRANE ELEMENTREMOVAL

L1-SERIES SYSTEM FRONT VIEW

FEED WATERIN



SEAL SIDE


MEMBRANE ELEMENT INSTALLATION

FEED WATERIN


SEAL SIDE


L1-SERIES MEMBRANE ELEMENTINSTALLATION

FEED WATERIN


SEAL SIDE



SEAL SIDE




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ZEROTDS WATER FILTER 500-2500 GPD MAINTENANCE GUIDEWe recommend to check the TDS meter on-board the ZeroTDS Water Filter at least once a month. TDS meter reading must be read while the water filter system is in operation. To turn the meter on, press the ON/OFF button.If the IN-MODE reading shows a value above 1 PPM, the filter cartridges should be replaced.

We also recommend to flush the water filter once a week for 30 min. For flushing procedures, please refer to page 34 of this manual.

The ZeroTDS 500-2500 GPD water filters all have different number of cartridges. Please see below the number of cartridges and part numbers for each filter size. Here is the list of cartridges for each type of filter.

ZeroTDS 500 GPD Water Filter2 x ZTDS2521-RM 2521 MembraneZTDS2520-DI 2520 DI CartridgeZTDS2520-SPCB 2520 CB CartridgeZTDS2520-5M 2520 5 Micron Cartridge




IN MODE = “OUT”

Cover

POWER

IN MODE

PPM

ALARM

TDS METER

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Replacing the RO Membrane1. Close the water source.WARNING: All pressure gauges must read ZERO before proceeding. Before attempting, disconnect the power from the system and bleed all water pressure from the system. 2. Remove the end caps from the top of the membrane housings. This is done by removing the white snap ring of the

membrane housing. 3. Remove the membrane bag containing the membrane element from the shipping box. WEAR GLOVES FOR THE FOLLOWING STEPS IN ORDER NOT TO CONTAMINATE THE MEMBRANE!4. Cut the bag open as close as possible to the seal at the end of the bag, so the bag may be re-used if necessary.5. Make sure that all parts are clean and free from dirt. Examine the brine seal and permeate tube for nicks or cuts.

Replace the O-rings or brine seal if damaged.6. Flow directions should be observed for installation of each element into each housing.

ZEROTDS WATER FILTER 500-2500 GPD RO MEMBRANE REPLACEMENT

27AT – Series User’s Manual

21/60502-FTKM

FIGURE 4

View from the back of AT-500, AT-1000 reverse osmosis system.

WARNING: THE BRINE SEAL MUST BE IN THE SAME POSITION FOR EACH MEMBRANE ELEMENT HOUSING, SO MARK EACH HOUSING PRIOR TO REMOVING THE MEMBRANE ELEMENTS. THE BRINE SEAL IS A RUBBER SEAL THAT PROTRUDES ON ONE SIDE OF THE MEMBRANE AND IS ALWAYS ON THE FEED SIDE OF THE MEMBRANE ELEMENT. 7. Remove one membrane element at a time from the membrane element housings, from the top of the housing. Long nose pliers may be necessary to pull the old membrane element out of the housing. 8. Lubricate the brine seal with non petroleum based lubricant, Silicone DC 111.9. Install the brine seal side of the membrane element first. When the housings have a direction of flow from bottom to top, the brine seal should be located at the bottom of the housing. 10. At a slight angle, insert the membrane while slightly rotating the element being careful not to tear or flip the brine seal. A slow twisting motion should be used to insert the membrane element, to ensure the brine seal stays in place. 11. With a smooth and constant motion, push the membrane element into the housing so the brine seal enters the housing without coming out of the brine seal groove. 12. Re-install the end caps by gently twisting the end cap while pushing it onto the housing. Ensure that you do not pinch or fatigue any O-rings while re-installing the end plug. Push the end plug on until the outer diameter of the plug is flush with the outer diameter of the membrane housing. 13. Insert the snap ring until it is fully seated. Install the locking clip if available.14. Reconnect any fittings that may have been disconnected when the membrane element housings were disassembled. 15. To start-up the system, please refer to the initial start- up section of this manual.

ZeroTDS 500 GPD ZeroTDS 1000 GPD


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ZEROTDS WATER FILTER 500-2500 GPD FLUSHING PROCEDUREWe recommend to flush the system once a week for approx 20 min. This helps to extend the life of the filter membranes on-board.

1. Please follow the following steps to start and stop the flushing cycle for the filter: Open the TEST VALVE located next to the pressure tank (see illustration below). Close the valve going into the pressure tank. Make sure the test valve is plumbed into an active drain.

2. To start the flushing cycle, please turn the CONCENTRATE WATER ADJUSTMENT KNOB anti-clockwise all the way.

3. Please allow flushing to commence for approx. 20 min. 4. To end flushing cycle, turn the knob clockwise until the CONCENTRATE WATER FLOW is

reading according to the recommended value in TABLE A on page 8.

Inlet WaterPressure

ON/OFFSwitch

PumpPressure

ConcentrateWaterFlow

PermiateWater Flow

ConcentrateWater

Adjustment

Pressure AfterSediment Filter

1

Feed


Drain“C” 3/8“”

Water Source500-2500 3/8”



ES100PB

Test Valve

Pressure Tank

Pressure Tank needs to be at 35psi (for ZeroTDS 500 and up)

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Note: after the flushing is complete, make sure the system pressure shows 150 PSI. If system pressure is not 150 PSI, adjust the by-pass valve located on the pressure pump until the system pressure indicate 150 PSI. Use a flat screw driver to increase or decrease the pressure to the bypass valve. To increase the pressure turn the screw clockwise. To decrease the pressure, turn the screw counter clockwise.

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BY-PASS VALVEThe by-pass valve must remain CLOSED at all times. Please make sure it is never OPEN. See diagrams on the right.

OPEN POSITION

CLOSEDPOSITION

SHOULD NOT BE LIKE THIS

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ES100PB AIR FILTER SET & BLUE FILTER

Blue Filter

Air Filters

The ES100PB Control Center contains the air filter set and a screen blue water filter.

BLUE FILTER MAINTENANCEWe recommend once a year to wash the blue filter, if you are not using the Smart Fog ZeroTDS Water Filter System. There is no cartridges to replace.

To wash the filter, disconnect it from the fittings using the provided quick-connect tool. Wash it in a sink, and place it back inside the ES100PB Control Center.

AIR FILTER SET MAINTENANCEWith all air filter sets, either inside or outside the ES100PB Control Center, we recommend to replace the air filter cartridges once in two years.

To replace the air filter cartridges, follow the steps below: 1. Turn off the source air.2. Remove the air filter set from

the ES100PB Control Center by disconnecting them from the quick-connect fittings. You can use the provided tool for ease of disconnection.

3. Unscrew the housing from the filter body by pushing down on A (see above diagram).

4. Slide down the filter cover to reveal the element.

5. Unscrew the filter element and replace.

Filter elements can be purchased from Smart Fog.

A

Smart fogNEED HELP? Call 1-800-921-5230 (+1-775-954-0070) or

EMAIL: [email protected]

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