2200 RO Manual

2200 RO Manual
Mar Cor Purification Biolab Equipment Ltd.
2200M – PORTABLE
WATER PURIFICATION SYSTEM
Installation, Operation, and Maintenance Manual
Rev. 0.3
2200M-Portable Water Purification System
INTENDED USE:
This system is intended to remove organic and inorganic substances and
microbial contaminants from water that is used to dilute dialysis concentrate to
form dialysate and to produce purified water for dialyzer reprocessing and
equipment rinse and disinfection.
SOFTWARE VERSION: V6.7e.132
BIOLAB REFERENCE #:
PART #:
PANEL SERIAL #:
DATE MANUFACTURED:
Rev. 0.3
Page 2 of 76
2200M-Portable Water Purification System
MANUAL REVISION HISTORY
Revision
0.2
0.3
Author
Richard Marmen
Richard Marmen
Date
Oct. 3, 2006
June 2008
Changes
Formatting
MANUAL PREPARATION
RICHARD MARMEN - Engineering Manager
June 2008
Mar Cor Purification - Biolab Equipment Ltd.
Rev. 0.3
Page 3 of 76
2200M-Portable Water Purification System
ABOUT THIS MANUAL…
This Manual contains information that is CONFIDENTIAL to Mar Cor Purification – Biolab
Equipment Ltd. and should not be disclosed to third parties or duplicated for any purposes, in
whole or in part.
This Manual describes procedures necessary to install, operate and maintain the 2200M –
Portable Water Purification system. It will make reference to different manufacturer’s component
manuals for detailed instructions. Please read this Manual carefully before installing and
operating your system.
Your warrant may be voided if installation or operation instructions are not followed exactly.
If you need further assistance, please call our Technical Support Department
Toll Free: 1-800-268-5035
In Canada: 905-639-7025
Website: www.mcpur.com
Rev. 0.3
Page 4 of 76
2200M-Portable Water Purification System
TABLE OF CONTENTS
Safety and General Precautions………………………….……………………………………………………...8
1.0 What Is The 2200M Portable RO System?....................................................................................... 10
1.1
How Does A Portable RO System Work?................................................................................. 10
2.0 Description And Function Of System Components....................................................................... 13
2.1
Pre-Filter Cartridge ..................................................................................................................... 13
2.2
Pressure Gauges ........................................................................................................................ 13
2.3
Solenoid Valve ............................................................................................................................ 13
2.4
Feed Water Low Pressure Switch ............................................................................................. 14
2.5
Booster Pump ............................................................................................................................. 14
2.6
Conductivity/Temperature Sensors.......................................................................................... 14
2.7
Manual Flow Control Needle Valves ......................................................................................... 15
2.8
Flow Rota-meters........................................................................................................................ 15
2.9
Check valve ................................................................................................................................. 16
2.10 Sonalert Alarm ............................................................................................................................ 16
2.11 Product Divert Solenoid............................................................................................................. 16
2.12 Product Pressure Relief Valve ..................................................................................................16
2.13 System Materials Of Construction............................................................................................ 17
3.0 Installation Requirements ................................................................................................................. 18
3.1
Unpacking The System .............................................................................................................. 18
3.2
Space/Room Requirements....................................................................................................... 18
3.3
Drain Connections...................................................................................................................... 18
3.4
Electrical Hook-Up...................................................................................................................... 19
3.5
Pre-treatment Requirements .....................................................................................................19
3.5.1
Installation Options................................................................................................................ 20
3.6
Feed Water Parameters.............................................................................................................. 21
3.7
Panel Electrical Control Interlocks ........................................................................................... 21
3.8
D0841.4 Microprocessor………………………………………………………………………………22
3.9
D0903 Display Electrical Installation Termination Table ........................................................ 23
3.10 D0949 Remote Electrical Installation Termination Table........................................................ 23
3.11 10 Pins Female Chassis Mounted Receptacle (for 26M15A-2RO model) ............................. 23
3.12 Panel Electrical Field Termination Description ....................................................................... 24
3.12.1 Alarm Group .......................................................................................................................... 24
3.12.2 Audible Alarm (Option) .......................................................................................................... 24
3.12.3 Remote Start/Stop Timer (Option)......................................................................................... 24
3.12.4 Tank High Level, Start/Stop (HL) .......................................................................................... 24
3.12.5 Tank Intermediate Level (INT)............................................................................................... 25
3.12.6 Remote Standby (RS-B)........................................................................................................ 25
3.12.7 Drain Valve Switch Contact................................................................................................... 25
3.12.8 Drain Valve Contact .............................................................................................................. 26
4.0 RO Digital Controller ......................................................................................................................... 27
4.1
Process Operation AND Controls ............................................................................................. 27
4.2
Automatic Control Systems ...................................................................................................... 27
4.3
Control Panel Components .......................................................................................................27
4.4
RO Microprocessor Controller Overview ................................................................................. 28
Rev. 0.3
Page 5 of 76
2200M-Portable Water Purification System
4.4.1
Water Quality Monitoring....................................................................................................... 28
4.4.2
System Indication .................................................................................................................. 28
4.4.3
Alarm/Warning Monitoring..................................................................................................... 28
4.4.4
Programmable Set-points...................................................................................................... 29
4.4.5
Operation Modes................................................................................................................... 29
4.4.6
Controller Options ................................................................................................................. 30
4.4.7
Monitoring Information on the Display................................................................................... 30
4.4.8
Setup Parameters ................................................................................................................. 31
4.4.9
Customize Menu.................................................................................................................... 34
4.4.10 Alarms ................................................................................................................................... 38
4.5
Set-Up Reference Table ........................................................................................................... 43
5.0 Start-Up ............................................................................................................................................... 45
5.1
Pre-Start-Up Verification............................................................................................................ 45
5.2
Control Panel/Microprocessor Start-Up Procedure ................................................................ 45
5.3
TANK Feed Reverse Osmosis System Start-up Procedure ................................................... 46
5.4
Direct Feed Reverse Osmosis System Start-up Procedure ................................................... 47
6.0 Operation ............................................................................................................................................ 49
6.1
Membrane Operating Parameters ............................................................................................. 49
6.2
Effects Of Pressure On Performance ....................................................................................... 50
6.3
EFFECTS OF RECOVERY ON PERFORMANCE ...................................................................... 50
6.4
Adjusting Flows, Pressure AND Recovery .............................................................................. 52
6.5
Effects Of Temperature On Performance................................................................................. 53
7.0 MAINTENANCE .................................................................................................................................. 54
7.1
MAINTENANCE REQUIREMENTS ............................................................................................. 54
SAMPLE LOG SHEET............................................................................................................................ 55
7.2
Reverse Osmosis Sanitization Cleaning Overview................................................................. 56
7.3
Dealing With A Hardness/Metal Oxide Fouling Problem ........................................................ 57
7.3.1 What are Hardness and Metal Oxides? .................................................................................... 57
7.3.2
The Problem .......................................................................................................................... 57
7.3.3
Recognizing Hardness Scaling and Metal Oxide Fouling ..................................................... 57
7.3.4
What to do if Hardness/Metal Oxide Fouling is Suspected?................................................. 57
7.4
Dealing with Colloidal/Silica Fouling Problems ...................................................................... 58
7.4.3
What Are Colloids? What Is Silica?....................................................................................... 58
7.4.3
The Problem .......................................................................................................................... 58
7.4.3
Recognizing Mixed Colloidal/Silica Fouling........................................................................... 58
7.4.3
What to do if Colloidal/Silica Fouling is Suspected? ............................................................. 58
7.5
Dealing with an Alum and/or Polymer Fouling Problem ........................................................ 59
7.5.1
What Are Alum And Polymers?............................................................................................. 59
7.5.2
The Problem .......................................................................................................................... 59
7.5.3
Recognizing Alum/Polymer Fouling ...................................................................................... 59
7.5.4
What to do if Alum/Polymer Fouling is Suspected ................................................................ 60
7.6
Manufacturer’s Recommended Cleaning and Sanitization Chemicals................................. 60
7.7
CLEANING AND SANITIZATION CHEMICAL SOLUTION CONCENTRATION
REQUIREMENTS.................................................................................................................................... 61
7.7.1
Foulants and Chemicals:....................................................................................................... 61
7.7.2
Chemical Concentrations: ..................................................................................................... 61
7.8
Minnclean® AC Cleaner Chemical Overview............................................................................ 62
7.8.1
Specifications ........................................................................................................................ 62
7.9
Minnclean® TF Cleaner Chemical Overview ............................................................................ 63
7.9.1
Specifications ........................................................................................................................ 63
7.10 Minncare® DISINFECTANT Chemical Overview ...................................................................... 64
7.11 MINNCARE® TEST STRIPS OVERVIEW.................................................................................... 67
7.11.1 Specification: ......................................................................................................................... 67
Rev. 0.3
Page 6 of 76
2200M-Portable Water Purification System
7.12 TEST STRIPS USER INSTRUCTIONS ....................................................................................... 68
7.12.1 Minncare® P/N 78338 Residual Test Strips .......................................................................... 68
7.12.2 Minncare® P/N 78339 1% Test Strips ................................................................................... 68
7.13 SANITIZATION/CLEANING PROCEDURE USING A TANK ONLY .......................................... 68
7.14 NEUTRALIZING CLEANING AND SANITIZATION SOLUTIONS.............................................. 70
7.15 TANK DECOMMISSIONING AND STORAGE............................................................................ 70
7.16 REVERSE OSMOSIS SYSTEM RE-START PROCEDURE ....................................................... 70
7.17 RO SYSTEM SHUT-DOWN PROCEDURE................................................................................. 71
7.18 PRE-FILTER REPLACEMENT PROCEDURE............................................................................ 72
Troubleshooting........................................................................................................................................ 73
Warranty..................................................................................................................................................... 74
Contact Information .................................................................................................................................. 75
Customer System Notes........................................................................................................................... 76
Rev. 0.3
Page 7 of 76
2200M-Portable Water Purification System
SAFETY
This Manual describes procedures necessary to install, operate, and maintain the 2200M –
Portable Water Purification System. It makes references to the component manuals of other
manufacturers.
Please read this entire Manual carefully before installing and operating your system. Pay
particular attention to all danger and caution statements to avoid serious injury to the operator
and damage to the system.
This equipment is a medical device and changes to the design and substitution of
components are performed only under design controls and are documented. Any
changes without design controls are not allowed and are in contravention to
regulation(s).
Operation of this system outside of its intended use and without adequate
pretreatment/post-treatment that meets AAMI RD62:2006 and CSA Z364.2.2-03 standard
guidelines is not allowed and is in contravention to regulation(s).
DEFINITIONS
WARNING:
Indicates a potentially hazardous situation which, if not avoided, could result in death
or serious personal injury.
CAUTION:
Indicates a potentially hazardous situation which, if not avoided, could result in
minor or moderate personal injury or possible damage to the system.
NOTE:
Information that requires special emphasis.
LABELS
This symbol, if noted on the equipment,
indicates
high
voltage
Disconnect the main power supply to the equipment before opening panels.
Rev. 0.3
output.
Page 8 of 76
2200M-Portable Water Purification System
GENERAL PRECAUTIONS
The following are general precautions that must be taken with the 2200M – Portable RO Water
Purification System. Please read these precautions before installing or operating the system.
•
WARNING: Use this device only with the specified feed water and pretreatment
chemicals determined by a Mar Cor water analysis. Use all sanitizing and cleaning
agents according to the instructions in this Manual. Failure to comply with the above
could result in personal injury.
•
WARNING: Ensure that the system is connected to a power source in compliance
with local and national electrical codes. Failure to comply may create a shock or fire
hazard.
•
WARNING: To prevent electrical shock, disconnect the electrical power to the
system before servicing.
•
WARNING: Ensure that all piping connections are tight to avoid leakage.
•
WARNING: Always relieve the pressure in chemical lines before disassembly to
protect yourself against possible chemical spray.
•
WARNING: Ensure that there is adequate ventilation around the system to avoid the
build up of chemical fumes.
•
WARNING: Follow carefully the manufacturer's safety instructions in their individual
manuals and labels on chemical containers.
Rev. 0.3
Page 9 of 76
2200M-Portable Water Purification System
1.0
WHAT IS THE 2200M PORTABLE RO SYSTEM?
1.1
HOW DOES A PORTABLE RO SYSTEM WORK?
Reverse Osmosis, invented in 1959, is the newest major method of water purification
and one of the types of cross flow membrane filtration. It is a process, which removes
both dissolved organics and salts using a mechanism different from ion exchange or
activated carbon. The pressurized feed water flows across a membrane, with a portion
of the feed permeating the membrane. The balance of the feed sweeps parallel to the
surface of the membrane to exit the system without being filtered. The filtered stream is
the “permeate” because it has permeated the membrane. The second stream is the
“concentrate” because it carries off the concentrated contaminants rejected by the
membrane (FIGURE 1). Because the feed and concentrate flow parallel to the
membrane instead of perpendicular to it, the process is called “cross-flow filtration” (or,
erroneously, “tangential flow”). Depending on the size of the pores engineered into the
membrane, cross- flow filters are effective in the classes of separation known as reverse
osmosis, nano-filtration, ultra-filtration and the more recent micro-filtration.
FIGURE 1 - CROSS FLOW FILTRATION
Cross-flow membrane filtration allows continuous removal of contaminants, which in
“normal flow” filtration would “blind” (cover up) or plug the membrane pores very rapidly.
Thus the cross-flow mode of operation is essential to these processes.
Rev 0.3
Page 10 of 76
2200M-Portable Water Purification System
Reverse Osmosis (RO) was the first cross-flow membrane separation process to be
widely commercialized. RO removes most organic compounds and up to 99% of all ions
(FIGURE 2). A selection of RO membranes is available to address varying water
conditions and requirements.
RO can meet most water standards with a single-pass system and the highest standards
with a double-pass system. This process achieves rejections of 99.9+% of viruses,
bacteria and pyrogens. Pressure in the range of 50 to 1000 psig (3.4 to 69 bars) is the
driving force of the RO purification process. It is much more energy-efficient compared to
phase change processes (distillation) and more efficient than the strong chemicals
required for ion exchange regeneration.
FIGURE 2 - REVERSE OSMOSIS
Rev. 0.3
Page 11 of 76
2200M-Portable Water Purification System
Sepralators (Spiral-Wound Membrane Elements) have gained the greatest
acceptance in the market. They are the most rugged, leak-free and pressure-resistant
configuration. The spiral design allows for optimum membrane surface area and fluid
dynamics to produce a high permeate flow for the size of equipment required.
Sepralators are available with RO, NF, UF, and MF membranes. Sepralators (FIGURE
3) are quite easy to maintain with a routine cleaning program. A major advantage is
enhanced “self-cleaning” due to turbulent flow at the membrane surface. This feature
dramatically reduces fouling, thereby enhancing performance and membrane life. Spiralwound designs also offer the greatest selection of membrane material, allowing users to
“tailor” a system design to suit their purification requirements.
FIGURE 3 - SPIRAL WOUND MEMBRANE ELEMENT (SEPRALATOR)
Rev. 0.3
Page 12 of 76
2200M-Portable Water Purification System
2.0
DESCRIPTION AND FUNCTION OF SYSTEM COMPONENTS
This section describes briefly the function of the major components of the standard 2200M Portable Water Purification System. Refer to the manufacturer of the individual components for
a more detailed description.
NOTE: Due to the custom nature of the Reverse Osmosis system (i.e. pumps, ultraviolet
sterilizers, filters, valves, gauges, etc.) some components are not described.
2.1
PRE-FILTER CARTRIDGE
A pre-filter housing is installed on the inlet (feed) of the system and is located on the
right side of the system. The housing contains a 1.0 micron filter cartridge. As the feed
(raw) water flows through the filter the suspended particles that are greater than the
micron rating of the filter are trapped. The filter used is a graded density type, meaning
the outer core of the filter has a larger pore size and progressively gets smaller towards
the middle of the filter. The rating (micron size) is measured at the core of the filter. This
type of filter will help prevent premature plugging.
2.2
PRESSURE GAUGES
Four pressure gauges are installed at various points in the Reverse Osmosis system.
They are as follows:
•
•
•
Two 0-100 psig gauges are installed on the inlet and outlet of the pre-filter housing.
They provide indication of the feed water pressure and also provide indication of the
pre-filter(s) delta pressure. This delta pressure allows the operator to determine
when the filter is required to be changed.
One 0-600 psig gauge is surface mounted on the front of the cabinet. The gauge will
provide an indication of the pump discharge pressure before entering the first
membrane housing.
The final gauge 0-600 psig is surface mounted on the front of the cabinet. It provides
an indication of pressure after the water has passed through all the membrane
housings. With this gauge and the pump discharge gauge the delta pressure can be
calculated. This reading will provide an indication as to whether or not the
membranes have become fouled.
2.3
SOLENOID VALVE
One inlet solenoid valve is installed on the system. The solenoid (½”) is located on the
outlet of the pre-filter housing. It is a normally closed valve that isolates the feed (raw)
water and opens when the system is in operation or in FLUSH mode.
Rev 0.3
Page 13 of 76
2200M-Portable Water Purification System
2.4
FEED WATER LOW PRESSURE SWITCH
The feed (raw) water normally closed low pressure switch, preset to 12.5 psig, is located
on the bottom left side of the panel. It is connected (1/4” tube) to the inlet water block
just after the feed solenoid valve and senses the feed water pressure. When the system
is in operation and the feed pressure drops below 12.5 psig it will shut down (alarm) after
a 10 second delay. This will prevent damage occurring to the booster pump.
CAUTION: Feed water pressure must be between 30-60 psig when the system is
operating. Continuous operation of the system below 12.5 psig can result in
premature pump and motor failure.
2.5
BOOSTER PUMP
A rotary vane pump increases the feed water pressure to 100-220 psi (6.9-15.2 bars),
the pressure that is required for purification by reverse osmosis. The pump is located in
the cabinet, mounted in the horizontal position.
2.6
CONDUCTIVITY/TEMPERATURE SENSORS
Two conductivity/temperature sensors are installed on the system. They provide an
indication of the feed and product conductivity/temperature. Their location and purpose
are as follows:
•
•
The feed conductivity/temperature sensor is installed in the feed block. It measures
the combined feed and reject recycle conductivity/temperature before the booster
pump. The measured conductivity will be higher than the raw source. The feed water
temperature is also measured at this point. An adjustable alarm set-point of 30-50°C
(86-122°F) will shut the system down after a 10 second delay to prevent damage to
the membrane cartridges.
The product conductivity/temperature sensor is installed in the product block. It
measures the product conductivity/temperature of the final product. The controller
calculates the system percent rejection using the feed and product conductivity
readings. The percent rejection indicates the amount of impurities that the system is
removing from the feed. It is calculated as follows:
% Rejection =
Feed - Product
X 100
Feed
A poor quality adjustable set-point of 1-100 μS (1-100 x 10K Ω) can be programmed. If
the product water quality is greater than the set-point a poor quality alarm will display on
the screen.
Rev. 0.3
Page 14 of 76
2200M-Portable Water Purification System
2.7
MANUAL FLOW CONTROL NEEDLE VALVES
Two manual needle control valves are installed on the system to provide pressure and
flow adjustment of the various streams. Their location and purpose are as follows:
•
•
The reject valve is mounted on the front of the cabinet. This valve is used to control
the reject flow to drain and pressure.
The reject recycle valve is mounted on the front of the cabinet. This valve is used to
control the recycle flow and pressure.
CAUTION: Never fully close the reject and reject recycle valves when the system
is in operation. Damage to equipment can occur.
CAUTION: Proper flows, pressures and recoveries must be maintained at all
times. Failure to operate the system within the design parameters will result in
permanent damage to the membrane cartridges.
2.8
FLOW ROTA-METERS
Three flow Rota-meters are installed on the system. Their location and purpose are as
follows:
•
•
•
The reject Rota-meter is surface mounted on the front of the cabinet. This Rotameter shows how much reject water the system is sending to drain.
The reject recycle Rota-meter is surface mounted on the front of the cabinet. It
provides indication of the amount of reject water that is being recycled back into the
feed of the system.
The product Rota-meter is located to the right of the recycle Rota-meter. It indicates
the amount of product water the system is producing.
From these flow readings the following system performance data can be calculated:
% Array Recovery =
Product
X 100
Product + Reject + Reject Recycle
% System Recovery =
Product
X 100
Product + Reject
Rev. 0.3
Page 15 of 76
2200M-Portable Water Purification System
2.9
CHECK VALVE
A check valve is installed on the system. Its location and purpose is as follows:
•
The recycle check valve is mounted inside the cabinet after the recycle needle valve.
This check valve will prevent the back-flow of feed water from the pump suction into
the reject line.
2.10 SONALERT ALARM
An audible alarm is mounted on the side of the cabinet and will sound if an alarm has
occurred. The alarm must be silenced by pressing SILENCE or STOP on the keypad
interface.
2.11 PRODUCT DIVERT SOLENOID
A normally closed product divert solenoid valve is installed on the product block of the
system. When the RO is stopped, or in ‘Flush’, ‘Standby’, ‘Tank Full’ or any other alarm
condition, the product solenoid is closed preventing any product water from exiting the
system.
2.12 PRODUCT PRESSURE RELIEF VALVE
An adjustable (0-60 psig) pressure relief valve is installed on the product block. The
relief port is connected to the drain line. When the system is running and product water
is closed off the product water will divert through the relief valve and into the reject
(drain). If there is an alarm (ex. Poor Quality) the product divert solenoid will close and
the product water will divert to drain. One of the other relief ports is capped with quick
connect; a gauge can be installed to set the pressure (maximum 60 psig) on the relief
valve. The relief valve will also prevent any reject water from entering the product line.
Rev. 0.3
Page 16 of 76
2200M-Portable Water Purification System
2.13 SYSTEM MATERIALS OF CONSTRUCTION
Component
Feed Manifold Block
High Pressure Piping
Low Pressure Piping
Housings
Membrane
• Permeate Carrier
• Feed Spacer
• Central Tube
• Glue
• Brine Seal
• O-ring
• External Wrap
• ATD
Pressure Gauge
Conductivity Sensors
Pump
Inlet Solenoid
Flow Meter
Needle Valve
Filter Housing
Cabinet
Rev. 0.3
Std. Material
PVC
Polypropylene Flexible Tubing
Polypropylene Flexible Tubing or PVC
304 SS
Polyester
PP
ABS
Urethane
Buna N
Buna N
FRP
Noryl
316 Stainless Steel and Brass
Noryl/SS
316L SS
Brass
Acrylic Body, 316 Stainless Steel Float
316L Stainless Steel
PP
Steel Powder Coated
Page 17 of 76
2200M-Portable Water Purification System
3.0
INSTALLATION REQUIREMENTS
Once the system is unpacked and in place, the following items are to be completed before startup:
•
•
•
•
Interconnect piping including drains
Electrical interconnect wiring
Feed Water Supply
Electrical Source (G.F.I. Receptacle Required)
Refer to the P&ID and Electrical Drawing to assist in the installation.
NOTE: Due to site conditions some of the Installation procedures might have to be
altered.
3.1
UNPACKING THE SYSTEM
Unpack the system carefully and inspect all components for any possible signs of
damage. Do not install the 2200M - Portable Water Purification System if damage is
apparent. Notify your representative and the carrier. Retain all literature for future
reference.
3.2
SPACE/ROOM REQUIREMENTS
The system must be floor mounted in a space that includes unobstructed access to the
feed, drain and electrical controls for ease of operation and service. Position the unit in
its approximate final location with all of the pre- and post-treatment accessories. Provide
enough room to remove the membrane(s). The room must have adequate lighting and
safety equipment (safety shower, face shield, gloves, chemical suits, spill equipment
etc.)
WARNING: A room with good ventilation is required to help remove heat and any
chemical fumes.
3.3
DRAIN CONNECTIONS
Facility drains are to be sized for the maximum flow of the system. Drain connections are
to be plumbed such that siphoning of the system will not occur. Provide adequate air
gaps for each drain connection.
Rev 0.3
Page 18 of 76
2200M-Portable Water Purification System
3.4
ELECTRICAL HOOK-UP
Before starting the system it is very important that electrical services have been checked
for the following
1. Ensure that the fused (G.F.I. Receptacle) power supply to panel is connected.
2. Ensure proper voltage is connected and verified.
3. Ensure that all input or output devices in the panel are hooked up properly and
verified.
4. Ensure all electrical work meets or exceeds local electrical codes.
WARNING: Use proper safety procedures when working in the electrical panel.
Disconnect and/or lock out power supply to the system and tag it out. The
system must be properly grounded to prevent personal injury or damage to the
system.
WARNING: All electrical connections are to be made by a qualified electrician.
All local codes and regulations are to be observed. Refer to the electrical
drawing for connection points, voltage, phase and current load.
WARNING: The system must be properly grounded to prevent personal injury or
damage to the system.
3.5
PRE-TREATMENT REQUIREMENTS
To assure peak operating performance the pretreatment to the system must be chosen
carefully. Water must meet or exceed the feed water parameters. The following
pretreatment is for a typical surface potable drinking water.
•
•
•
•
•
•
•
Temperature blending valve. To maintain 25°C feed water.
Pressure regulating valve – to maintain a constant feed pressure between 30-60 psig.
Safety pressure relief valve set to 60 psig – to prevent over pressurization of the
pretreatment components.
Second pressure regulating valve installed just before the RO in direct feed
application. Set between 25 and 35 psig.
Back-washable carbon for removal of chlorine.
Automatic water softener for removal of hardness.
Vacuum breaker to prevent pretreatment (carbon, softener) from imploding.
CAUTION: The above information is just a typical pretreatment. Feed water
sources can vary significantly and can require more or less pretreatment
components. Please consult your local water treatment representative if you are
unsure.
Rev. 0.3
Page 19 of 76
2200M-Portable Water Purification System
3.5.1
Installation Options
Sample
Valve
Distribution Loop
Pressure
Gauge
0-100
PSIG
Check Valve
Check Valve
Pretreated
Potable Water
Potable Feed
Water
Pressure
Regulating
Valve
(25 to 60 psig)
2200M Portable
Pressure
Regulating
Valve
(25 to 35 psig)
Check Valve
Drain
Direct Feed Applications
Minimum Installation Requirements
Pretreated Potable
Water
Potable Feed
Water
2200M Portable
To Storage Tank
Pressure
Regulating
Valve
(25 to 60 psig)
Drain
Tank Feed Applications
Minimum Installation Requirements
Rev. 0.3
Page 20 of 76
2200M-Portable Water Purification System
3.6
FEED WATER PARAMETERS
Feed water must meet the following specifications for successful operation of the 2200M Portable Water Purification System and warranty validation:
CAUTION: Feed water must meet or exceed the National Drinking Water
Regulations for potable water including the following listed in the table below.
Variable
Temperature
Chlorine
Optimum pH
Operating pH
Cleaning pH
Free Chlorine
Iron, Manganese
Feed NTU
LSI
Feed SDI
Service
Feed Inlet
Feed Inlet
Feed Inlet
Feed Inlet
Feed Inlet
Feed Inlet
Feed Inlet
Feed Inlet
Reject
Feed Inlet
Units
°C
ppm
ppm
ppm
Min.
2
0.0
7.0
4.0
2.0
0.0
0.0
<1.0
<-1.0
<3.0
Max.
35
0.0
7.5
11.0
11.5
<0.1
<0.1
CAUTION: System design is based on a computer projection analysis. Refer
to the analysis provided for detailed information on system parameters and
performance.
NOTE: The computer project analysis provided does not represent a
guarantee of performance and is solely provided as a service.
3.7
PANEL ELECTRICAL CONTROL INTERLOCKS
Listed in the table below are the electrical termination points to the microprocessor
controller and the individual components on the system. Also included is brief description
and function of customer terminations. The terminal numbers listed are connection made
directly at the microprocessor control. Refer to the electrical drawing for additional
component terminations (Booster/Distribution Pumps, Ultraviolet Sterilizers, Solenoids,
Tank Low Level Switches ext.)
Rev. 0.3
Page 21 of 76
2200M-Portable Water Purification System
3.8
D0841.4 MICROPROCESSOR
(C/W V6.7e.132 Software) Electrical Installation Termination Table
Description
Feed Probe
Term
5,6,7,8
I/O
I
Voltage
Sensor
Product Probe
13,14,15,
16
15,16
I
Sensor
I
Sensor
17,18,19
23,24
I
O
12,CT,12
24VAC
Pre-wired
Pre-wired
25,26
O
24VAC
Pre-wired
27,28
O
24VAC
Not Used
29,30
31,32
O
O
24VAC
24VAC
Customer Connection
Customer Connection
33,34
I
12VDC
Pre-wired
35,36
I
12VDC
Not Used
36,37
I
12VDC
Customer Connection
37,38
I
12VDC
Customer Connection
39,40
I
12VDC
Customer Connection
40,41
42,43
45,46
I
I
O
12VDC
12VDC
24VAC
Customer Connection
Pre-wired (Jumper)
Pre-wired
Optional 0.1 Cell
Constant Product
Probe (EPROM
Req.)
AC Voltage Supply
RO Pump Starter
(ROP)
Water Inlet Solenoid
(WIS)
Reject Solenoid
(RS)
Alarm Group
Audible Alarm
(Option)
Low Pressure
Switch (LP)
RO Pump Overload
(O/L1)
Remote Start Timer
(Option)
Intermediate Level
(INT)
Remote Standby
(RS-B)
High Level (HL)
Drain Valve Switch
Drain Valve
Rev. 0.3
Comments
Pre-wired (grn, wht, red,
blk)
Pre-wired (grn, wht, red,
blk)
Connect Thornton Sensor
Leads 1 and 2 to 15, 6 to
16
Page 22 of 76
2200M-Portable Water Purification System
3.9
D0903 DISPLAY ELECTRICAL INSTALLATION TERMINATION TABLE
Description
Interface Cable,
When Remote
D0949 Card Not
Used
Interface Cable,
When Remote
D0949 Card Used
3.10
Voltage
I
Comments
Pre-wired Option
Connection Cable Direct To
D0841.4 Controller
Pre-wired Option
Connection Cable To D0949
Controller DB9 (P2)
Term
I/O
DB9 (P1)
O
2,3,4,5,6
O
DB9 (P3)
O
Voltage
12VDC
Comments:
Pre-wired Option Connect
Cable To D0841.4
Customer Connection (5
Wire Cable) To Alarm
Monitor D0871
Customer Connection
(1000’ Max.) To Remote
PC. Software For PC
Required.
10 PINS FEMALE CHASSIS MOUNTED RECEPTACLE (FOR 26M15A2RO MODEL)
Description
Product Divert
High Level
Common
Common
Remote Standby
Alarm Group
Alarm Group
(Common)
Control Power
CR4 By-Pass Relay
Rev. 0.3
DB9 (P2)
I/O
I
D0949 REMOTE ELECTRICAL INSTALLATION TERMINATION TABLE
D0949 Remote
Card (Option)
Interface Cable To
D0841.4 Controller
Interface Cable To
Alarm Monitor
D0871
Interface Cable to
Remote PC Monitor
3.11
Term
DB9
Term
1
2
3
4
5
6
7
I/O
O
I
O
O
O
O
O
Voltage
12VAC
12VDC
8
9
10
O
O
12VAC
12VAC
12VDC
12VAC
12VAC
Comments:
Customer Connection
Customer Connection
Customer Connection
Customer Connection
Customer Connection
Customer Connection
Customer Connection
Customer Connection
Customer Connection
Not Used
Page 23 of 76
2200M-Portable Water Purification System
3.12 PANEL ELECTRICAL FIELD TERMINATION DESCRIPTION
3.12.1
Alarm Group
This 24VAC contact can be used to provide a signal to a building control system,
nurse’s station, etc. When an alarm condition occurs the contact will be active.
CAUTION: It is recommended that a 24VAC relay be installed between the
contact and the monitoring device to prevent damage to the controller. The
contact is rated for a maximum load of 1.0 Amps @ 24VAC when the standard
150VAC step-down transformer is used. If a higher current is required (maximum
5.0 Amps @ 24VAC) the step-down transformer will have to be increased.
3.12.2 Audible Alarm (Option)
This 24VAC contact can be used to activate an audible alarm. When an alarm
condition occurs the contact will activate an audible alarm. If the audible alarm is
silenced and the alarm condition is still present the audible alarm will re-activate
within two minutes.
CAUTION: It is recommended that a 24VAC relay be installed between the
contact and the monitoring device to prevent damage to the controller. The
contact is rated for a maximum load of 1.0 Amps @ 24VAC when the standard
150VAC step-down transformer is used. If a higher current is required (Maximum
5.0 Amps @ 24VAC) the step-down transformer will have to be increased.
3.12.3 Remote Start/Stop Timer (Option)
This contact is designed to interface with an optional 7-day timer. This allows the
user to program a start and stop time when the system is in operation. The
contact used to activate this input must be a normally open TYPE-C DRY
CONTACT.
NOTE: Customize menu configuration is required to use this function.
CAUTION: Contacts must be a TYPE-C DRY CONTACT. Damage to controller
will occur if powered contacts are used.
3.12.4 Tank High Level, Start/Stop (HL)
This contact is used to start and stop the system via an optional tank level
controller. The contact used to activate this input must be a normally open TYPEC DRY CONTACT. When the contact is open the system will operate and when
the contact closes the system will be placed in standby (Tank High Level). To
reduce the On/Off cycling of the system a dead band must be incorporated in the
level controller or a second level contact can be installed and tied in the
intermediate level terminal.
Rev. 0.3
Page 24 of 76
2200M-Portable Water Purification System
CAUTION: Contacts must be a TYPE-C DRY CONTACT. Damage to controller
will occur if powered contacts are used.
3.12.5 Tank Intermediate Level (INT)
This contact is used in conjunction with the tank high level contact. A two point
level controller can be used. The level controller contacts must be a normally
open TYPE-C DRY CONTACTS. As the tank is filling the intermediate level
contact will close and then the high level contact will close placing the system in
standby (Tank High Level). As the water is being consumed, the water level will
drop. The tank high level contact will open and then the intermediate level
contact will open. The system will restart at this point. This configuration will
provide a dead band reducing the On/Off cycling of the system.
CAUTION: Contacts must be a TYPE-C DRY CONTACT. Damage to controller
will occur if powered contacts are used.
3.12.6 Remote Standby (RS-B)
This contact is used to interlock pretreatment / post treatment equipment with the
system. The contact must be a normally open TYPE-C DRY CONTACT. When a
pretreatment / post treatment device such as a softener goes into regeneration
the contact closes placing the system in STOP mode. When the regeneration
cycle is complete and the contact opens the system will restart in whatever mode
it was in before. When multiple pretreatment / post treatment devices are used
the electrical connections are to be terminated in parallel.
CAUTION: Contacts must be a TYPE-C DRY CONTACT. Damage to controller
will occur if powered contacts are used.
3.12.7 Drain Valve Switch Contact
The valve switch contact can be used to install a drain/auto switch (or jumper).
What this switch does is allows the operator to either divert the product water to
drain manually (Drain Position) or set it to auto so the valves (option) will
automatically divert to drain on poor quality (programmable set-point), during
manual or auto flush or when the system is stopped or standby including tank
full. The switch contact must be a normally open TYPE-C DRY CONTACT.
CAUTION: Contacts must be a TYPE-C DRY CONTACT. Damage to controller
will occur if powered contacts are used.
Rev. 0.3
Page 25 of 76
2200M-Portable Water Purification System
3.12.8 Drain Valve Contact
The valve contacts are used to connect a solenoid divert valve(s). The valve can
be air solenoid to activate pneumatic valves or two solenoid valves, one normally
open and one normally closed. The normally closed valve should be plumbed to
the tank (loop) and the normally open to drain. The valve will only activate when
the product water quality is below the programmable set-point (fail-safe
operation).
CAUTION: The contact is rated for a maximum load of 1.0 Amps @ 24VAC when
the standard 150VAC step-down transformer is used. If a higher current is
required (Maximum 5.0 Amps @ 24VAC) the step-down transformer will have to
be increased.
NOTE: Each individual panel can be custom designed or modified to suit
customer needs. Please contact your local representative for options.
Rev. 0.3
Page 26 of 76
2200M-Portable Water Purification System
4.0
RO DIGITAL CONTROLLER
4.1
PROCESS OPERATION AND CONTROLS
This section provides an overview of the operation of the control panel and
microprocessor controller. Included here are the basic functions of the control panel
components and explanations of panel control functions.
NOTE: The purpose of this section is only to familiarize operators with the control
panels and its basic functions. Operators must refer to the Vendor's Literature for
detailed information on individual components.
4.2
AUTOMATIC CONTROL SYSTEMS
Many water treatment units and systems are controlled automatically by mechanical or
microprocessor controllers. The programming of the controller, whether done with
mechanical devices or with computer "software", provides preset step times and
termination set points for most of the unit or system process steps.
The programmable controller uses "Inputs" and "Outputs" to monitor and control the
system. "Inputs" come from such devices as conductivity sensors, pressure switches,
valve limit switches and control panel switches. "Outputs" consist of signals to open or
close the various control valves, signals to sound alarms at appropriate times and
signals to start pumps and motors.
In simplest terms, a programmable controller uses the information from "Input" devices
and the logic of its programming to make "decisions" about process step advancement
and individual "Output" signals.
4.3
CONTROL PANEL COMPONENTS
The control panel is constructed from the following main components:
•
•
•
•
•
•
•
Rev 0.3
Electrical enclosure
Power cord
Step down transformers
Microprocessor controller
Keypad interface
Pump motor protection devices
Fuses, Terminals
Page 27 of 76
2200M-Portable Water Purification System
4.4
RO MICROPROCESSOR CONTROLLER OVERVIEW
The user-friendly DO841.4 monitoring controller with V6.7e.132 software is designed for
operating a reverse osmosis system. The controller uses a touch pad interface keypad
and display to provide useful information on the system. Parameters can be easily
changed to suit the user’s needs. Optional output cards can provide information via a
remote display or with a Personal Computer (PC). The PC will provide the information in
a Windows format. The system has many unique features including programmable
automatic restart for low pressure conditions, programmable alarm set-points for product
quality, feed temperature, programmable poor quality shutdown delay and
programmable flush times and durations. The controller has non-volatile memory backup
for power failure conditions. If a power failure should occur once the power has been
restored the system will re-start in the same mode as it was in before the failure
occurred.
The rest of this section will provide the user with the many features available and
programming steps to operate the reverse osmosis system.
4.4.1 Water Quality Monitoring
•
•
•
•
•
•
Feed water conductivity (resistivity)
Feed water temperature
Product water conductivity (resistivity)
Product water temperature
Product water non-temperature compensated conductivity (resistivity) using
the 0.1 cell constant optional probe. This probe is factory set.
% Rejection of water impurities between input and output conductivities.
4.4.2 System Indication
•
•
•
•
•
•
Product tank levels (Low, Intermediary, High)
Active modes (RUN/ FLUSH/STANDBY/CLEAN)
Operation mode status (RUNNING, FLUSHING, STOPPED, TANK FULL,
TANK FILLING)
Pump running time in hours (ROP), up to 32000 hours.
Time remaining before next flush cycle in minutes and seconds.
Time remaining when in auto flush condition.
4.4.3 Alarm/Warning Monitoring
•
•
•
•
Rev. 0.3
Poor quality of purification
Feed water low pressure <12.5 psi (Fixed digital input)
Pump input current overload (digital input)
Feed water high temperature of water
Page 28 of 76
2200M-Portable Water Purification System
•
•
Remote standby
Optional audible alarm (Re-alarm <2 minutes if alarm still present)
4.4.4 Programmable Set-points
•
•
•
•
•
Product water poor quality (1-100 μS/cm)
Poor quality shutdown delay (4-240 Seconds)
Feed high temperature shutdown (2-50°C (36-122°F))
Flush period (10-600 seconds)
Flush cycle (30-120 minutes)
4.4.5 Operation Modes
The following will provide the user with information on the controller modes of
operation (‘RUN’/ ‘STANDBY’/‘FLUSH’).
To alter the setup data or change the system mode of operation it is necessary to
be in the STOP mode. The message “SYSTEM STOPPED” will be on the
display in this menu. If the system is not in this mode you will have to press the
“STOP” or “OK” key to reach it. These steps are required to prevent the user
from altering certain parameters or operation modes during service.
4.4.5.1
STOP Mode
When the “STOP” key is pressed the system will stop and remain in this
state until another mode key is pressed.
4.4.5.2
RUN Mode
This is the main mode of operation for the controller. When the “RUN”
key is pressed the water purification cycle will begin. Refer to the SETUP
menu for different RUNNING options available.
4.4.5.3
FLUSH Mode
When the “FLUSH” key is pressed the system will continually flush. This
will help reduce membrane fouling by allowing more water to pass over
the membrane surface.
4.4.5.4
STANDBY Mode
When the “STANDBY” key is pressed the system will stop. In this state
the system will automatically FLUSH (programmable set-point) to prevent
stagnant water and reduce membrane fouling.
Rev. 0.3
Page 29 of 76
2200M-Portable Water Purification System
4.4.6 Controller Options
4.4.6.1
Product Divert (Option)
When this optional controller input is activated via a manual or timer
external switch the product divert valves (optional) will be activated to
allow the product water to flow to drain. When the external switch is in the
auto position the product divert valves (optional) will automatically divert
to drain on the following conditions:
•
•
•
In “STANDBY”/“FLUSH” and “STOP” mode.
In “RUN” mode only if product quality is greater then the
programmable set point.
In all alarm conditions.
4.4.6.2
Remote Alarm Panel (Option)
A Remote Alarm Panel can be mounted in a different location (control
room/ nurses station) to provide the operator with a LED indication of the
system operation. The display indicates the following:
•
•
•
•
•
Power (Green Light)
Power Quality (Red Light)
Low Pressure (Red Light)
Pump Overload/High Temperature (Red Light)
Alarm Silence (Black Push Button) (Re-alarm <2 min. if alarm still
present)
4.4.6.3
RS-232 Remote PC Interface & Software (Option)
A RS-232 output card and software can be installed to communicate to a
PC (Maximum 1,000’). The PC will display graphically real time
information on the system operation. The PC monitor will indicate the
following:
•
•
•
•
Operation Mode
Quality Reading
Tank State
Alarms
4.4.7 Monitoring Information on the Display
In all three modes of operation, it is possible to monitor pertinent information in
real time on the screen. The different topics are displayed on the keypad.
Depending on what mode the system is running, all topics or only a few will be
enabled. Only pertinent information is available in each mode. For instance, it
will be impossible to monitor the % rejection in FLUSH mode.
Rev. 0.3
Page 30 of 76
2200M-Portable Water Purification System
Some keys have two topics on the same button. If both of them are available in
the active mode, it is possible to switch between them just by pushing on the
button. If you push once, the first topic appears on screen, pushing once again
gives you the second topic, and if pushed again, a blank space appears and no
information is displayed.
The following shows the different monitoring parameters accessible by pressing
corresponding keys:
4.4.7.1
Tank Level
When the system feeds a tank the display will indicate the level (LOW,
INTERMEDIATE and HIGH).
4.4.7.2
Temperature
Feed and Product water temperature can be displayed. By pressing the
key the second time, the temperature reading will switch between the
feed and product water.
4.4.7.3
% Rejection
The product % rejection will be displayed. This will tell the user the
condition of the membranes.
4.4.7.4
Pump Time
This will display the pump operational timer (Max. 32000 hrs). It gives the
user an indication of the pump operation and if any maintenance is
required.
4.4.7.5
Conductivity/Resistivity
This will display the feed and product water conductivity or resistivity.
4.4.7.6
Flush Time
This will display the status of the flush process. “FLUSH IN” indicates the
time remaining before the next flush and “REMAINING” indicates the
amount of time remaining when flushing.
4.4.8 Setup Parameters
To alter the setup data it is necessary to be in “STOP” mode. The screen
message “SYSTEM STOPPED” will be on the display. If the system is not in this
mode you will have to press the “STOP” or “OK” key to reach it.
Rev. 0.3
Page 31 of 76
2200M-Portable Water Purification System
NOTE: It is recommended that all the set-up data that the user enters
is recorded for reference and troubleshooting. Refer to page 39 for a
reference table that can be copied and filled in.
4.4.8.1
SETUP Menu
Screen Description: SET-UP MAIN MENU
Access:
Item
Options
1>
Clean Mode
2>
Customize
3>
Alarms
Selection
NOTE: The system must be in the STOP mode
to modify the set-up parameters. The screen
message “SYSTEM STOPPED” is displayed
when the STOP mode is activated.
<OK>
CLEAN MODE
Use this mode when the system requires a cleaning,
sanitization or preservative for the membranes during a
shutdown.
When this function is activated the inlet valve remains
closed and the cleaning/disinfectant solution is fed (drawn)
into the pump (ROP). It is recirculated through the
membranes and back to the cleaning tank. The reject
solenoid (RS) remains open. The remote standby signal
(RS-B) and low pressure alarms are disabled in this
function. To exit this function, press the “STOP” key.
CAUTION: This function should only be used
when the RO pump(s) is less than 5 horse
power (hp). Damage to the system and pump
can occur. System with greater than 5.0 hp,
should use a separate cleaning pump (Clean-InPlace System) when a cleaning or sanitization is
required.
CUSTOMIZE
Select this option to enter the sub menu for setting system
parameters for flush operation, units of display and feeding
of product water.
ALARMS
Select this option to enter the sub menu for setting the
system alarm set-points.
Rev. 0.3
Page 32 of 76
2200M-Portable Water Purification System
4.4.8.2
CLEAN Mode
This mode is only to be used when the system requires a cleaning, sanitization or
to preserve the membranes during a shutdown.
When this function is entered the inlet valve remains closed and the solution is
fed (drawn) into the pump (ROP). It is re-circulated through the membranes and
back to the cleaning tank (The reject solenoid (RS) is also open). The remote
standby signal (RS-B) and low pressure alarms are disabled in this function. To
exit this function, press the “STOP” key.
4.4.8.2.1 CLEAN Mode Initialization
The following will provide you with the necessary instruction to place
the controller in CLEAN Mode. Refer to the MAINTENANCE section
of this manual for more detailed information on using the clean
function..
1. Press the “STOP” key. The display should read “SYSTEM
STOPPED”.
2. Follow the cleaning setup procedure in the MAINTENANCE
section of this manual
3. Press the “SETUP” key and then the # “2” key. The following
screen will appear.
4.4.8.3
Clean Menu
Screen Description: CLEAN MENU
Access from Main Menu:
READ INSTRUCTION MANUAL
BEFORE DOING THIS
COMMAND
<OK>
<CANCEL>
First, follow the cleaning/sanitization procedure in
SECTION 4.4.4 and 4.4.5 for set-up. Press the OK
key to start the cleaning/sanitization process or the
CANCEL key to return to the set-up main menu.
After the cleaning/sanitization process is completed,
press the STOP key to end.
4. Press the “OK” key to start the cleaning process or “CANCEL” to
return to Setup Menu #1.
5. After the cleaning process is complete press the “STOP” key to
end.
Rev. 0.3
Page 33 of 76
2200M-Portable Water Purification System
4.4.9 Customize Menu
In this menu the user has the option of changing certain settings to suit their
needs. Three different setup menus are available. To change between them
press the “SETUP” key as indicated in the bottom left corner of the screen.
Described below is the function of each menu option that can be accessed.
4.4.9.1
Customize menu #1
Screen Description: CUSTOMIZE MENU #1
Access from Main Menu:
Item
Option
Selection
1>
Direct Feed:
NO (Default)
2>
Flush-> Run Mode:
YES (Default)
3>
Flush w/o Pump
NO (Default)
<SETUP=next>
<OK>
DIRECT FEED:
This option is provided to feed product water to a
storage tank or directly to the point of use. When this
option is changed to YES the system is set to operate
in direct feed mode. A jumper (switch or 7 day timer)
must be installed between terminals 36 & 37 directly
on the circuit board terminals. When the contact
closes the system will operate and never flush. When
the contact is open the system will go into the
STANDBY mode and perform its programmed flush
cycle. In the default NO selection is made, the system
will run until the water in the holding tank reaches
high level. At this point the system will stop and wait
until the water in the tank drops to the intermediate
level and then restart. The system will automatically
flush at a programmable cycle weather it is in tank full
or standby mode.
FLUSH
RUN MODE:
When this option is changed to NO, the system will
not flush at any time while in the RUN mode. In the
default YES selection the system will flush at a
programmed cycle.
FLUSH w/o PUMP:
When this option is changed to YES, the system will
flush without the pump. In the default selection NO,
the system will flush with the pump running.
4.4.9.2
Direct Feed
When this option is changed to YES the system is set to operate in direct
feed. A jumper (switch or 7 day timer) must be installed between
terminals 36 and 37 directly on the circuit board terminals. When the
contact closes the system will operate and never flush. When the contact
is open the system will go into STANDBY mode and perform its
programmed flush cycle. In the default position NO the system will run
Rev. 0.3
Page 34 of 76
2200M-Portable Water Purification System
until the water in the holding tank reaches high level. At this point the
system will stop and wait until the water in the tank drops to the
intermediate level, then restarts. The system will automatically flush
(programmable cycle) whether it is in tank full or standby.
4.4.9.3
FLUSH-> RUN Mode
When this option is changed to NO, the system will not flush at any time
while in RUN mode. In the default position the system will flush at the
programmed cycle.
4.4.9.4
Flush w/o Pump
When this option is changed to YES, the system will flush without the
pump. In the default position NO the system will flush with the pump
running.
4.4.9.5
Customize menu #2
Screen Description: CUSTOMIZE MENU #2
Access from Main Menu:
Item
Option
Selection
1>
Ω (Default)
2>
Ω Resistivity or S
Conductivity
Temp. comp
NO (Default)
3>
Flush At Start
YES (Default)
<SETUP=next>
<OK>
RESISTIVITY / CONDUCTIVITY:
Provides an option to select the display for water quality in
terms of electrical resistivity or conductivity.
When this option is changed to S the feed and product
water quality is measured in conductivity and the unit
display is shown in μS beside the value. In the default
selection, the feed and product water is measured in
resistivity and the unit display is shown in Ω beside the
value.
TEMPERATURE COMPENSATE:
When the option is changed to YES, the feed and product
water will be displayed with a temperature compensated
value. In the default position NO, the feed and product
water will be displayed without temperature compensation.
NOTE:
The
optional
sanitary
product
conductivity has a 0.1 cell constant. The reading
displayed is a non-temperature compensated
and cannot be changed. The jumper settings on
the product are factory preset and cannot be
changed.
FLUSH AT START:
When this option is changed to NO, the system will not
flush at system start-up. In the default selection YES, the
system will flush every time it will start.
Rev. 0.3
Page 35 of 76
2200M-Portable Water Purification System
4.4.9.5.1 Ω Resistivity or S Conductivity
When this option is changed to S the feed and product water is
measured as conductivity and the screen will have a μS beside
the value. In the default position the feed and product water is
measured as resistivity and the screen will have a Ω beside the
value.
4.4.9.6
Temp. Comp
When the option is changed to YES the feed and product water will be
displayed as a temperature compensated value. In the default position
NO the feed and product water will be displayed as a non-temperature
compensated value.
NOTE: The optional sanitary product conductivity has a 0.1 cell constant. The
reading displayed is non-temperature compensated and cannot be changed. The
jumper settings on the product are factory preset and cannot be changed.
4.4.9.7
Flush at Start
When this option is changed to NO, the system will not start with a flush.
In the default position YES the system will go into a flush every time it
starts.
4.4.9.8
Customize menu #3
Screen Description: CUSTOMIZE MENU #3
Access from Main Menu:
Item
Option
Selection
1>
Temperature in °C or °F
°C (Default)
2>
Clear ROP Timer
NO (Default)
3>
Flush Delays
Sub-Menu’s
<SETUP=First>
<OK>
TEMPERATURE IN oC or oF:
Displays water temperature in select unit.
CLEAR RO PUMP TIMER:
When the option is changed to YES, the pump timer will be
reset to 00000. The option will automatically default back to
NO.
FLUSH DELAYS:
Choose this option to enter a sub menu for setting flush
duration time and flush frequency, time between each flush
cycle.
Rev. 0.3
Page 36 of 76
2200M-Portable Water Purification System
4.4.9.9
Temperature in °C or °F
When this option is changed to °F the feed and product temperature will
be displayed in the selected temperature units. In the default position the
feed and product temperature will be displayed in °C. The adjustable feed
water high temperature set-point menu will also change temperature
units.
4.4.9.10 Clear pump timer
When the option is changed to YES the pump timer will be reset to
00000. The option will automatically default back to NO.
4.4.9.11 Flush Delays
When this option is selected the following screen will appear:
Screen Description: CUSTOMIZE MENU #3 – Item #3 Sub-Menu
Access from Main Menu:
FLUSH PERIOD:
Enter the flush duration time in seconds. The processor will
multiply the number entered by 10. This means if the number 9 is
entered, the system will flush for 90 seconds.
Flush Period
9? (1, 60) X 10s
<CANCEL>
<OK>
Flush Cycle
FLUSH CYCLE:
Enter the time between the flush cycles in minutes.
60? (30,120)nm
(period included)
<CANCEL>
Press OK to go to next to the Flush Cycle screen.
<OK>
NOTE: The flush cycle time is calculated according
to the current flush period.
The processor will multiply the number entered by 10. This means if the
number 9 is entered the system will Flush for 90 seconds.
The number that is entered indicates the time in minutes between Flush
cycles.
NOTE: The flush cycle is calculated according to the current flush period.
Rev. 0.3
Page 37 of 76
2200M-Portable Water Purification System
4.4.9.12 Changing the Customize Setting
The following will provide the steps required to change the
customize menu settings as described in the previous pages.
1. Press the “STOP” key. The display will read, “SYSTEM
STOPPED”.
2. Press the “SETUP” key and then the desired menu.
3. Press the desired number key to change the setting. If
<Cancel> appears in the bottom left corner it can be pressed
to escape that menu.
4. Press the <SETUP=next> to go to next menu or press “OK”
to return to main display.
5. If <SETUP=first> appears in the bottom left corner it can be
pressed to return you to the first menu.
6. Once your selections are made press “OK” until the
“SYSTEM STOPPED” screen appears. At this point the
system can be started.
4.4.10 Alarms
In this menu the user has the following options available to change.
4.4.10.1 Alarm menu #1
Screen Description: ALARM MENU #1
Access from Main Menu:
Item
Option
Selection
1>
Alarm->Stop:
YES (Default)
Alarm->Stop->Restart
retry every 010m
(Default)
Sub Menu
1 retry (Default)
2>
3>
<SETUP=next>
Poor Quality Delay
<OK>
ALARM
STOP:
Select the option to shut-down the system when an alarm
occurs. When NO selection is made, the system will not
stop when an alarm condition is detected.
ALARM
STOP
RESTART:
Select this option to set the number of retries and the time
between each retries. (See ALARM MENU #1 – Item #2
Sub-Menu screens)
POOR QUALITY DELAY
Select this option to enter desired time delay before the
system shut-down when a poor quality alarm occurs. (See
ALARM MENU #1 – Item #3 Sub-Menu screens)
Rev. 0.3
Page 38 of 76
2200M-Portable Water Purification System
4.4.10.2 Alarm->Stop
When this option is changed to NO the system will not stop when an
alarm condition occurs. The alarm will only be displayed on the screen. In
the default position YES the system will shut down if an alarm occurs.
4.4.10.3 Alarm->Stop->Restart
When this option is selected the following screen will appear:
Screen Description: ALARM MENU #1 – Item #2 (Alarm
Stop
Restart) Sub-Menu
Access from Main Menu:
NUMBER OF RETRIES:
Enter the number of retries (0-6) the system will perform before
shut-down using the arrow key.
SELECT <<-> NUMBER OF RETRIES:
(0..6): 1
Press the OK key to go to the next set-up screen.
<OK>
◄─
SELECT <<-> NUMBER BETWEEN RETRIES:
NOTE: This function is only available on a low
(10m..150m): 010m
◄─
NUMBER BETWEEN RETRIES:
Enter the desire amount of time (10, 20, 40, 90 or 150 minutes)
between retries using the arrow key and press the OK key to
return to the Alarm Menu #1 screen.
<OK>
pressure alarm. The system considers a
successful restart when no alarm condition has
occurred in 11 minutes from an automatic
restart.
The user will enter the desired number of retries (0-6) the system
will perform using the arrow key. After the selection is made the
user is to press “OK” and the next screen will appear.
The user will now enter the desired amount of time (10,20,40,90
or 150 minutes) between retries using the arrow key and then
press “OK” to return to the alarm menu.
NOTE: This function is only available on a low pressure alarm. The system
considers a successful restart, when no alarm conditions have occurred in 11
minutes since an automatic restart.
Rev. 0.3
Page 39 of 76
2200M-Portable Water Purification System
4.4.10.4 Poor Quality Delay
When this option is selected the following screen will appear:
Screen Description: ALARM MENU #1 – Item #3 (Poor Quality Delay) Sub-Menu
Access from Main Menu:
Poor Quality Delay
120? (4,240) s
<CANCEL>
<OK>
POOR QUALITY DELAY:
Enter the desired time delay in seconds before the system
shut-down when a poor water quality alarm occurs. Press the
CANCEL key if this menu has been mistakenly accessed or
press the OK key to return to the Alarm Menu #1 screen.
NOTE: When the system starts or restarts with
ROP pump ON, an 8 minute and 30 second delay
is activated. This allows the system to flush and
bring up the quality after long shutdown
periods. The system will still indicate a poor
quality alarm and the product will be diverted to
drain if it is installed. Once the delay has
elapsed, the poor quality shutdown delay will
become the default.
The user can enter the desired time delay before the system will shut
down (Stop) when a poor quality alarm has occurred. Press the
“CANCEL” key if this menu has inadvertently been accessed or press
“OK” to return to the alarm menu.
NOTE: When the system starts or restarts (RO Pump ON) an 8 minute and 30
second delay will activate. This allows the system to flush up to quality during
long shutdown periods. The system will still indicate a poor quality alarm and
the product will divert to drain if they are installed. Once the delay has elapsed
the poor quality shutdown delay will become the default.
Rev. 0.3
Page 40 of 76
2200M-Portable Water Purification System
4.4.10.5 Alarm menu #2
Screen Description: ALARM MENU #2
Access from Main Menu:
Item
Option
Selection
1>
Feed Temp. SetPt
Sub Menu
2>
Poor Quality SetPt
Sub Menu
<SETUP=first>
<OK>
FEED TEMPERATURE SET-POINT:
Select the option to shut-down the system when an alarm
occurs. When NO selection is made, the system will not
stop when an alarm condition is detected.
ALARM
STOP
RESTART:
Select this option to set the number of retries and the time
between each retries. (See ALARM MENU #1 – Item #2
Sub-Menu screens)
POOR QUALITY DELAY
Select this option to enter desired time delay before the
system shut-down when a poor quality alarm occurs. (See
ALARM MENU #1 – Item #3 Sub-Menu screens)
Screen Description: ALARM MENU #2 – Item #1 (Feed Temp. SetPt) Sub-Menu
Access from Main Menu:
Feed Temp. SetPt
35? (30, 50) °C Or 95? (86,122) °F
<CANCEL>
<OK>
FEED TEMPERATURE SET-POINT:
Enter the desired set-point for feed water alarm temperature.
When the system reaches this set-point, it will alarm and shutdown (stop). Press the CANCEL key if this menu has been
mistakenly accessed or press the OK key to return to the
Alarm Menu #2 screen.
NOTE: The processor uses temperature in oC to calculate
the conductivity and resistivity measurements. When
temperature unit is set in oF, rounding error may occur.
The user can enter the desired feed water alarm temperature that will
shut down (Stop) and alarm when that temperature is reached. The
“CANCEL” key can be pressed if this menu has inadvertently been
accessed or press “OK” to return to the alarm menu.
Rev. 0.3
Page 41 of 76
2200M-Portable Water Purification System
4.4.10.6 Conductivity or Resistivity Set-Point
When this option is selected the following screen will appear:
Screen Description: ALARM MENU #2 – Item #2 (Poor Quality SetPt) Sub-Menu
Access from Main Menu:
Conductivity or Resistivity. SetPt
2? (1,100) μS Or 50? (1,100) x 10 K Ω
<CANCEL>
<OK>
CONDUCTIVITY or RESISTIVITY SET-POINT:
Enter the desired set-point for product water quality alarm. This
will trigger a poor quality alarm, divert the product water to
drain, if installed, and shut-down the system after programmed
time delay. Press the CANCEL key if this menu has been
mistakenly accessed or press the OK key to return to the
Alarm Menu #2 screen.
The user can enter the desired product water alarm set-point that will
trigger a poor quality alarm, divert the product to drain (if installed) and
shut-down the system after the programmable time delay. The
“CANCEL” key can be pressed if this menu has inadvertently been
accessed or press “OK” to return to the alarm menu.
4.4.10.7 Changing Alarm Settings
The following will provide the steps required to change the settings as
described in the previous page.
1. Press the “STOP” key. The display will read, “SYSTEM
STOPPED”.
2. Press the “SETUP” key and then the desired menu.
3. Press the desired number key to change the setting. If <Cancel>
appears in the bottom left corner it can be pressed to escape that
menu.
4. Press the <SETUP=next> to go to the next menu or press “OK”
to return to main display.
5. If <SETUP=first> appears in the bottom left corner it can be
pressed to return to the first menu.
6. Once your selections are made press “OK” until the “SYSTEM
STOPPED” screen appears. At this point the system can be
started.
Rev. 0.3
Page 42 of 76
2200M-Portable Water Purification System
4.5
Set-Up Reference Table
The following table lists the factory settings for the set-up parameters. Record all the set-up data at the system start-up and
every time a value is modified. Keep these log sheets for future reference.
Screen Name
Parameter Name
Factory Default
Customer Setting
Customize
Menu #1
Direct Feed
Menu #1
Flush → Run Mode
Yes
Menu #1
Flush w/o Pump
No
Menu #2
Ω or S
Ω
Menu #2
Temp. Comp.
Yes
Menu #2
Flush At Start
Yes
Menu #3
Temperature
°C
Rev 0.3
Page 43 of 76
2200M-Portable Water Purification System
Screen Name
Parameter Name
Menu #3
ROP Timer
Menu #3
Flush Delay
Factory Default
Customer Setting
0
Menu #3 – Item #3 Sub-Menu
•
Flush Period
90 s
Menu #3 – Item #3 Sub-Menu
•
Flush Cycle
60 min.
Alarm
Menu #1
Alarm → Stop
Menu #1
Alarm → Stop → Restart
Menu #1
Poor Quality Shutdown Delay
120 s
Menu #2
Feed Temperature Set-Point
35°C or 95°F
Menu #2
Poor Quality Set-point
Menu #2 – Item #2 Sub-Menu
•
Conductivity
Menu #2 – Item #2 Sub-Menu
•
Resistivity
Rev 0.3
Yes
1,10 min.
2 μS
500K Ω
Page 44 of 76
2200M-Portable Water Purification System
5.0
START-UP
5.1
PRE-START-UP VERIFICATION
After the system has been installed the following items are to be checked before
commissioning of the system is to begin:
•
•
•
•
•
•
•
•
•
•
Feed water supply is connected and verified
Electrical supply is connected and verified
Interconnect piping including drains are complete and verified
All water piping lines pressure are tested and flushed to remove debris
Pretreatment devices are installed and a functional test performed
Post treatment devices are installed and a functional test performed
Pre-filter cartridges are installed
All appropriate valves are open on system
Feed water tests are performed
All tank accessories are installed and ready to receive water
Refer to the individual manufacturers component manuals for additional start-up
procedures.
WARNING: Use proper safety procedures when working in the electrical panel.
Disconnect and/or lock out power supply to system and tag it out. The system
must be properly grounded to prevent personal injury or damage to the system.
NOTE: A pressure test of the piping, connections and tanks must be performed
before starting the system.
WARNING: A complete sanitization is required on the reverse osmosis system
prior to use. This will assure that the system is operating and producing product
water that meets and exceeds the standards. Refer to the MAINTENANCE
section in this manual for sanitization instructions.
5.2
CONTROL PANEL/MICROPROCESSOR START-UP
PROCEDURE
The follow procedure will assist the user in the commissioning of the main control panel
and microprocessor.
NOTE: Due to site conditions some of the procedures might have to be altered.
1. Check that the Ground Fault Interrupt (G.F.I.) receptacle is wired and installed
correctly.
2. Check that the proper voltage is connected and verified.
3. Check that all input and output devices in panel are hooked up properly and verified.
4. Plug the electrical cord into the receptacle.
5. Allow the panel view to initialize.
6. Enter the desired set-up parameters in the microprocessor controller.
Rev 0.3
Page 45 of 76
2200M-Portable Water Purification System
WARNING: Use proper safety procedures when working in the electrical panel.
Disconnect and/or lock out power supply to system and tag it out. The system
must be properly grounded to prevent personal injury or damage to the system.
5.3
TANK FEED REVERSE OSMOSIS SYSTEM START-UP
PROCEDURE
1. Divert the product line to drain.
NOTE: The flexible hose that is to be used must be the same size or larger than
the line (valve) that it is being hooked up to.
2. Fully open the reject and recycle needle valve.
3. Verify and adjust if necessary if the feed water pressure is between 25 and 60 psi.
Water must be flowing to drain to perform this adjustment.
4. Set the water tempering device output to 25ºC (if applicable). Water must be flowing
to drain to perform this adjustment.
5. Slowly allow feed water in to the system pre-filter.
6. Place the controller in RUN mode. The inlet valve will open and after a five second
delay the pump will start. The system will enter FLUSH mode for 90 seconds. Allow
the flush cycle to finish.
NOTE: The RO will not flush if it has been disabled in the controller set-up menu.
7. Adjust the reject flow control needle valve to the flow in SECTIONS 6.4. Flow rates
are based on the feed water temperature on the system.
8. Adjust the reject recycle flow control needle valve to the flow in SECTIONS 6.4. Flow
rates are based on the feed water temperature on the system.
NOTE: Flow adjustment should be made slowly.
NOTE: System not using a water softener must be set to operate at 50%
recovery.
CAUTION: Never fully close the reject and reject recycle flow control needle
valves when the system is in operation. Damage to the system can occur.
NOTE: The flow rates in steps 7-8 are to be verified and adjustment will be
required until the system has stabilized. A +25 / - 15% in product flow can occur
during the first 1-3 months of operation. Refer to SECTIONS 6.1 - 6.5 for the
membrane operating parameters and performance notes.
9.
Allow the system to operate to drain for 2 hours (4 hours for dialysis application) and
record and verify the system parameters are within the desired limits.
10. Once the time has elapsed and the system parameters are met turn the controller to
OFF mode. Connect the product line to the process tank.
11. Place the system back to RUN mode.
CAUTION: Once the system is in operation a daily (per shift) log sheet is required
to be filled out to validate the warranty. Flow and pressure adjustment will also be
required during this time. Refer to the MAINTENANCE section of this manual for
Rev 0.3
Page 46 of 76
2200M-Portable Water Purification System
more details.
5.4
DIRECT FEED REVERSE OSMOSIS SYSTEM START-UP
PROCEDURE
1. Divert the product line to drain.
NOTE: The flexible hose that is to be used must be the same size or larger than
the line (valve) that it is being hooked up to.
2. Fully open the reject and recycle needle valve.
3. Verify and adjust if necessary if the feed water pressure is between 25 and 60 psi.
Water must be flowing to drain to perform this adjustment.
4. Set the water tempering device output to 25ºC (if applicable). Water must be flowing
to drain to perform this adjustment.
5. Slowly allow feed water in to the system pre-filter.
6. Set the controller for Direct Feed: Yes and the Flush → Run Mode: No. Refer to
section 4.4.9 for instructions.
7. Place the controller in RUN mode. The inlet valve will open and after a five second
delay the pump will start. The system will enter FLUSH mode for 90 seconds. Allow
the flush cycle to finish.
NOTE: The RO will not flush if it has been disabled in the controller set-up menu.
8. Adjust the reject flow control needle valve to the flow in SECTIONS 6.4. Flow rates are
based on the feed water temperature on the system.
9. Adjust the reject recycle flow control needle valve to the flow in SECTIONS 6.4. Flow rates
are based on the feed water temperature on the system.
NOTE: Flow adjustment should be made slowly.
NOTE: System not using a water softener must be set to operate at 50%
recovery.
CAUTION: Never fully close the reject and reject recycle flow control needle valves
when the system is in operation. Damage to the system can occur.
NOTE: The flow rates in steps 7-8 are to be verified and adjustment will be
required until the system has stabilized. A +25 / - 15% in product flow can occur
during the first 1-3 months of operation. Refer to SECTIONS 6.1 - 6.5 for the
membrane operating parameters and performance notes.
10. Set the second pressure regulator between 25 and 35 psi. Water must be flowing to drain to
perform adjustments.
11. Allow the system to operate to drain for 2 hours (4 hours for dialysis application) and
record and verify the system parameters are within the desired limits.
12. Once the time has elapsed and the system parameters are met turn the controller to
OFF mode. Connect the product line to the loop feed.
Rev 0.3
Page 47 of 76
2200M-Portable Water Purification System
13. Place the system back to RUN mode.
CAUTION: Once the system is in operation a daily (per shift) log sheet is required
to be filled out to validate the warranty. Flow and pressure adjustment will also be
required during this time. Refer to the MAINTENANCE section of this manual for
more details.
NOTE: When the system is operating in direct feed and there and no or little water is
being drawn off from the loop you will notice a decrease in product flow due to back
pressure in the loop. As water is being drawn off the loop, the system will produce
more product water as the loop pressure decreases.
CAUTION: Do not make flow adjust to increase the product flow when in direct feed.
Flow adjustments are to be made when product water is diverted to drain.
Rev 0.3
Page 48 of 76
2200M-Portable RO Water Purification System
6.0
OPERATION
6.1
MEMBRANE OPERATING PARAMETERS
Variables
Service
Units Min.
Max
Temperature
Feed Inlet
2
35(1)
°C
Chlorine
Feed Inlet
ppm
0.0
0.0
Optimum pH
Feed Inlet
7.0
7.5
Operating pH
Feed Inlet
4.0
11.0
Cleaning pH
Feed Inlet
2.0
11.5
Free Chlorine
Feed Inlet
ppm
0.0
<0.1
Iron, Manganese
Feed Inlet
ppm
0.0
<0.1
Feed NTU
Feed Inlet
<1.0
LSI
Reject
<-1.0
Feed SDI
Feed Inlet
<3.0
Typical Operating
Pump Outlet
psig
100
200 (2)
Pressure
Membrane Pressure Pump Outlet To
psig
5
13(3)
Drop
Reject
Design Product (Flux) Product Outlet
gpd
1050 per membrane
Flow Rate
Product (Flux) Flow Product Outlet
%
-15
+25
Rate Variation
Rejection
Inlet To Product
%
Avg. 99.0 / Min. 98.0
Notes:
(1) Actual membrane maximum temperature is 50°C. System alarm set-point
35°C.
(2) Actual membrane maximum pressure 400psig. System components maximum
pressure 220 psig.
(3) Maximum pressure drop includes piping and is shown per membrane.
Rev 0.3
Page 49 of 76
2200M-Portable Water Purification System
6.2
EFFECTS OF PRESSURE ON PERFORMANCE
The operating pressure of the system also affects the product flow rate. The amount of
permeate produced is directly proportional to the pressure difference between the feed
and product sides of the RO membrane. This pressure difference is known as the TransMembrane Pressure (TMP) and can be calculated as:
TMP = Feed Pressure - Product Pressure
If the product from the RO system feeds directly to a loop or downstream equipment
such as Electrical Deionization or ion exchange polishing, there may be significant
product pressure that decreases the TMP. The product flow rate given for each system
is based on the TMP. It may be necessary to increase the feed pressure to get sufficient
TMP if the product pressure exceeds 15 psi (1 bar).
CAUTION: Never exceed a trans-membrane pressure of 220 psi (15 bars) for
Thin Film Composite (TFC) cartridges.
CAUTION: Trans-membrane pressure should be reduced if the feed water
temperature is greater than 25oC, to avoid exceeding the design flow rate.
6.3 EFFECTS OF RECOVERY ON PERFORMANCE
The recovery of RO systems is defined as the percent of the feed water (including reject
recycle) that becomes purified product water. The recovery is calculated by:
% Array Recovery =
Product
X 100
Product + Reject + Reject Recycle
% System Recovery =
Product
X 100
Product + Reject
The design recoveries of the RO systems are given in the chart on the following page.
The percent salt rejection and rate of membrane fouling can be affected by the array
recovery and system recovery. At higher recoveries, the reject flow rate through the
system is reduced. This results in an increase in the concentration of dissolved solids at
the membrane surface, and a decrease in the ability of the reject stream to flush
suspended materials from the system.
Recycle Flow =
Product
-Product-Reject
% Array Recovery
Rev 0.3
Page 50 of 76
2200M-Portable Water Purification System
# of Membranes In
Series
Delta P. - psig
(kPa)
Maximum
Recovery
Percentage
1
2
3
4
10 (69)
20 (138)
30 (207)
38 (262)
15%
25%
35%
45%
CAUTION: Recoveries are listed above without recirculation, with the optional
recirculation valve closed. Exceeding these recoveries will result in short
membrane life. This will invalidate the normal 1-year warranty.
NOTE: After setting the proper recovery (above) you can then open the
recirculation valve to increase the "system" recovery up to 75% provided the
feed water is still within specification (sample at reject).
Rev 0.3
Page 51 of 76
2200M-Portable Water Purification System
6.4 ADJUSTING FLOWS, PRESSURE AND RECOVERY
The reject and reject recycle flow control valves are used to adjust the flow rates and
recovery on the system.
Periodic flow adjustment will be required as the membrane cartridges age and as the
feed water changes (ex. temperature).
CAUTION: Do not exceed the design recovery as this can result in decreased
salt rejection and membrane fouling or scaling.
CAUTION: Never completely close the reject and reject recycle valves.
2200M
75% System Recovery / 30% Array
Recovery
°C
°F
Pro FL Rej FL Rec FL
25.0 77.0
1.5
0.5
3.0
gpm
24.0 75.2
1.5
0.5
2.9
gpm
23.0 73.4
1.4
0.5
2.8
gpm
22.0 71.6
1.4
0.5
2.7
gpm
21.0 69.8
1.3
0.4
2.6
gpm
20.0 68.0
1.3
0.4
2.6
gpm
19.0 66.2
1.2
0.4
2.5
gpm
18.0 64.4
1.2
0.4
2.4
gpm
17.0 62.6
1.1
0.4
2.3
gpm
16.0 60.8
1.1
0.4
2.2
gpm
15.0 59.0
1.1
0.4
2.1
gpm
14.0 57.2
1.0
0.3
2.0
gpm
13.0 55.4
1.0
0.3
1.9
gpm
12.0 53.6
0.9
0.3
1.8
gpm
11.0 51.8
0.9
0.3
1.7
gpm
10.0 50.0
0.8
0.3
1.7
gpm
9.0 48.2
0.8
0.3
1.6
gpm
8.0 46.4
0.7
0.2
1.5
gpm
7.0 44.6
0.7
0.2
1.4
gpm
6.0 42.8
0.6
0.2
1.3
gpm
5.0 41.0
0.6
0.2
1.2
gpm
4.0 39.2
0.6
0.2
1.1
gpm
3.0 37.4
0.5
0.2
1.0
gpm
2.0 35.6
0.5
0.2
0.9
gpm
1.0 33.8
0.4
0.1
0.8
gpm
Pro FL: Product Flow
Rev 0.3
2200M
50% System Recovery / 30% Array
Recovery
°C
°F
Pro FL Rej FL Rec FL
25.0 77.0
1.5
1.5
2.0
gpm
24.0 75.2
1.5
1.5
1.9
gpm
23.0 73.4
1.4
1.4
1.9
gpm
22.0 71.6
1.4
1.4
1.8
gpm
21.0 69.8
1.3
1.3
1.8
gpm
20.0 68.0
1.3
1.3
1.7
gpm
19.0 66.2
1.2
1.2
1.6
gpm
18.0 64.4
1.2
1.2
1.6
gpm
17.0 62.6
1.1
1.1
1.5
gpm
16.0 60.8
1.1
1.1
1.5
gpm
15.0 59.0
1.1
1.1
1.4
gpm
14.0 57.2
1.0
1.0
1.3
gpm
13.0 55.4
1.0
1.0
1.3
gpm
12.0 53.6
0.9
0.9
1.2
gpm
11.0 51.8
0.9
0.9
1.2
gpm
10.0 50.0
0.8
0.8
1.1
gpm
9.0 48.2
0.8
0.8
1.0
gpm
8.0 46.4
0.7
0.7
1.0
gpm
7.0 44.6
0.7
0.7
0.9
gpm
6.0 42.8
0.6
0.6
0.9
gpm
5.0 41.0
0.6
0.6
0.8
gpm
4.0 39.2
0.6
0.6
0.7
gpm
3.0 37.4
0.5
0.5
0.7
gpm
2.0 35.6
0.5
0.5
0.6
gpm
1.0 33.8
0.4
0.4
0.6
gpm
Rej FL: Reject Flow
Rec FL: Recycle Flow
Page 52 of 76
2200M-Portable Water Purification System
6.5 EFFECTS OF TEMPERATURE ON PERFORMANCE
The product flow rate for the RO system given is based on a feed water temperature of
25oC. The product flow rate will be reduced at temperatures below 25oC as the viscosity
of the water increases, making it more difficult to force water through the reverse
osmosis membrane.
CAUTION: At temperatures higher than 25oC, the operating pressure should be
reduced to maintain the design flow rate. Operating at a higher product flow will
invalidate the RO membrane warranty.
If the temperature is not 25oC, a correction factor must be used to calculate the expected
product flow rate from the system. The table below gives temperature correction factors
to be applied for feed temperatures other than 25oC.
Temperature correction factors are listed for all Reverse Osmosis elements. The
reference temperature is 77°F (25°C).
Temperature
RO
F ° (C °)
40 (4)
0.48
50 (10)
0.60
60 (16)
0.73
70 (21)
0.88
77 (25)
1.00
80 (27)
1.06
90 (32)
1.26
Rev 0.3
Page 53 of 76
2200M-Portable RO Water Purification System
7.0
MAINTENANCE
7.1
MAINTENANCE REQUIREMENTS
After the system has been commissioned, it will require scheduled maintenance on a
daily, weekly, and monthly basis. Regular maintenance is necessary:
•
•
•
to ensure operating efficiency
to ensure maximum membrane life
to ensure warranty protection
The prescribed maintenance program ensures that the feed water meets the system
specifications despite seasonal and unexpected changes in the feed water quality.
The system requires maintenance such as cartridge replacement, cleaning, and
sanitization of the system and accessory storage tanks. Feed water quality must be
monitored and recorded on a daily basis to ensure that it remains within the specified
parameters. When replacing cartridges, inspect the O-rings for signs of deterioration or
cracking; replace as required.
The performance of the system and the quality of feed and permeate water must be
monitored and recorded in a log book. Refer to next page for a sample log sheet.
WARNING: Each component on the system has its own maintenance
requirements. Refer to the individual component manuals for instructions.
NOTE: The sample log sheet provided is only a guide and may not contain all
the monitoring points that are required for warranty of some of the
manufactured components. Please refer to the individual component
manufacturer’s manual for details on other monitoring requirements. The limits
are based on computer projections and calculations. They may not reflect actual
readings when the system is in operation.
Sample Log Sheets Notes:
1) A +25 / -15% in product flow can occur during the first 1-3 months of operation. The
array and total system recovery must be maintained to prevent premature fouling of
the membrane elements.
2) Refer to the computer performance projection provided for limits.
NOTE: It is recommended that the system should be disinfected using
Minnclean® and Minncare® products at least monthly and more often as
required.
Rev 0.3
Page 54 of 76
2200M-Portable Water Purification System
SAMPLE LOG SHEET
All readings and test are to be performed when system is in operation.
Feed water must meet or exceed the National Drinking Water Regulations for potable water including the
following listed in this table to validate the warranty:
Parameter
Test
Units
Sun
Mon
Tue
Wed
Thu
Fri
Sat
D/W
Date
D/M/Y
Time
HH/MM
Feed Temperature
D
°C
Feed pH
W
Feed Total Chlorine
D
ppm
Feed Iron
W
ppm
Feed Total Hardness
W
ppm
Feed Iron, Manganese
W
ppm
LSI of Reject
W
Feed SDI
W
Feed NTU
W
Pre-Filter Inlet Press
W
psig
Pre-Filter Outlet Press
D
psig
Pre-Filter Δ Press
D
psig
Pump Press
D
psig
Reject Press
D
psig
Membrane Δ Press
D
psig
Product Flow
D
lpm
Reject Flow
D
lpm
Recycle Flow
D
lpm
Feed Recycle Quality
D
uS/cm
Product Quality
D
uS/cm
Rejection
D
%
Array Recovery
D
%
System Recovery
D
%
% Array Recovery =
Product
X 100
Product + Reject + Reject Recycle
% System Recovery =
Product
X 100
Product + Reject
% Rejection =
Feed – Product
X 100
Feed
NTU (Nephelometric Turbidity Units)
SDI (Silt Density Index)
Press (Pressure)
ΔP (Pressure Differential)
Rev 0.3
Page 55 of 76
2200M-Portable Water Purification System
7.2
REVERSE OSMOSIS SANITIZATION CLEANING OVERVIEW
The following procedures will assist in the sanitization and cleaning of the reverse
osmosis system.
NOTE: Due to site conditions some of the procedures might have to be
altered.
There is no specific frequency for cleaning the Reverse Osmosis system. A cleaning
should only be performed when the RO system requires it. A specific cleaning schedule
can do more harm than good. Cleaning should only be performed if flow rates and/or
quality begin to drop below allowable limits. Cleanings are performed to remove
particulate, inorganic scale and organic fouling. Routine sanitization treatment is
recommended on the Reverse Osmosis system to control bacteria and remove
biological film.
In order to understand the concept of RO membrane cleaning, it is important to know
something about membrane fouling. The purpose of this guide is to present basic
information about the different types of foulants and how to identify them when they
affect RO membrane performance. Also discussed is how to choose the right cleaner
and the correct use of available cleaning agents.
There are three major groups of RO membrane foulants: hardness/metal oxides,
colloidal/silica, and alum/polymers. These potential problems can exist independently,
but can also occur together resulting in a "mixed" fouling. These major groups have
been selected for discussion because they represent the most common problems that
have been encountered by the operators of industrial RO systems.
The symptoms of RO membrane fouling can range from gradual declines in flux
(product) over several months, to severe losses overnight. The ultimate results of
membrane fouling can also vary widely, from complete recovery after cleaning, to
permanent damage.
The correct cleaning method is essential to a successful cleaning. The cleaning
instructions on the following pages will allow selection of the appropriate cleaner based
on the types of RO pretreatment being employed and feed water characteristics. While
the occasional need for cleaning may arise due to pretreatment equipment failure or a
temporary change in feed water composition, persistent or severe fouling should be a
cause for re-evaluation of the RO pretreatment.
The following basic discussions are of RO foulants, how to identify them, and what to do
once they have affected membrane performance.
Rev 0.3
Page 56 of 76
2200M-Portable Water Purification System
7.3
DEALING WITH A HARDNESS/METAL OXIDE FOULING
PROBLEM
7.3.1 What are Hardness and Metal Oxides?
Hardness most commonly encountered is in the form of calcium carbonate
(CaCO3) and/or calcium sulfate (CaSO4). These compounds are found widely
throughout the United States and Canada and occur naturally in groundwater.
Metal oxides are the result of soluble substances naturally occurring in
groundwater being oxidized prior to, or at the membrane surface. Iron and
manganese are examples of commonly found metals that can pose significant
fouling problems to an RO element.
7.3.2 The Problem
Membranes become scaled (a term used in cases of hardness fouling) when the
hardness minerals become supersaturated and they precipitate out of solution
onto the membrane surface. This is caused by pure water being removed from
the feed solution at the membrane surface resulting in an increase of the
concentration of mineral salts left behind. When the solubility limits are
exceeded, precipitation occurs. The severity of the problem is related to
hardness levels, pH, water temperature, and recovery efficiency of the RO
system. The same type of fouling problem can occur with several types of soluble
metals that are forced out of the solution and become deposited on the
membrane surface.
7.3.3 Recognizing Hardness Scaling and Metal Oxide Fouling
In general, simple hardness scaling results in a slow decline of flux and the
attendant decrease in salt rejection. The decline can take from weeks to months
to become apparent. If a combination of scaling and metal oxide fouling occurs,
there will be a rapid decrease in flux and salt rejection.
7.3.4 What to do if Hardness/Metal Oxide Fouling is Suspected?
•
•
•
•
Rev 0.3
Check to see if the softener is working properly.
Find out the levels of hardness and metals in the feed water.
Clean the RO system before there is a 15-20% decline in flux from normal.
Failure to reverse this type of scaling will result in permanent damage to the
membranes.
Generally, the use of solution is recommended. Refer to cleaning instructions.
Page 57 of 76
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7.4 DEALING WITH COLLOIDAL/SILICA FOULING PROBLEMS
7.4.3 What Are Colloids? What Is Silica?
Colloids are very fine, suspended solids that can coagulate and become
entrapped on the RO membrane surface. Colloids found in feed water usually are
of the aluminum silicate group. Colloidal materials including aluminum hydroxide
can also be found. Silica that is dissolved (SiO2) is naturally present in most feed
waters. It is usually found in concentrations ranging from 1-100 mg/L.
7.4.3 The Problem
During the process of Reverse Osmosis, colloids are destabilized and as the
concentration of salts increase, they coagulate and foul the element. The rate of
fouling is directly related to the concentration of colloidal material present, and
their stability. A test called the SDI (Silt Density Index) is usually used as a
measure of colloidal concentration. The stability of colloids in solution is a
function of their electrical charge. This stability is often expressed as a
measurement of zeta potential. Silica poses a problem when, due to the removal
of pure water in the RO process, it becomes more concentrated and can then
polymerize to form colloidal silica, or precipitate as a silicate.
7.4.3 Recognizing Mixed Colloidal/Silica Fouling
Fouling due to colloidal/silica material is usually quite slow, with a gradual decline
in flux and no real change in salt rejection as the symptoms. In the presence of
metal oxides, however, the decline can be more dramatic. If fouling continues
untreated, an eventual decrease in salt rejection is common.
7.4.3 What to do if Colloidal/Silica Fouling is Suspected?
•
•
•
•
Rev 0.3
Find out from your water department if the presence of colloidal/silica
material is temporary or a standard constituent of your feed water.
Pretreatment may be required for these foulants. Check to see if the prefilter is of the right type and working properly. An "absolute" rated filter
may be required.
Consider the addition of an appropriate chemical feed system.
Reference the cleaning instructions.
Page 58 of 76
2200M-Portable Water Purification System
7.5 DEALING WITH AN ALUM AND/OR POLYMER FOULING PROBLEM
7.5.1 What Are Alum And Polymers?
Alum and/or polymers are frequently used by municipal water treatment facilities
as flocculants to settle out dirt and other suspended matter in water sources.
Ideally, all of the added alum/polymer is supposed to be removed in the process,
but in actual practice, a small amount of alum/polymer often remains in the water
supply. One of the properties of these flocculants that make them effective is that
they easily coagulate and come out of solution. Unfortunately, this property can
present troublesome conditions for high efficiency RO systems (i.e.-over
33%recovery) or if feed water residual of these substances is high after municipal
treatment.
7.5.2 The Problem
When residual alum/polymers are present in the feed water supply to an RO
system, a membrane fouling problem may exist. Alum/polymers can coagulate
on the membrane surface and slowly clog it, especially in the presence of other
constituents such as silica and iron. Unfortunately, water softeners and filters are
not effective at removing alum/polymers. The extent of the fouling problem is
also related to the pH of the feed water and the recovery efficiency of the RO
system. The lower the pH and the lower the recovery, the less alum/polymer
complexes will tend to foul the membrane.
7.5.3 Recognizing Alum/Polymer Fouling
The first sign of alum/polymer fouling is a loss of product water flow rate. Unlike
most other types of fouling which take a long time to developed, alum/polymer
fouling can cause a reduction in product water flow rate in a matter of days.
There may be little or no decrease in % rejection performance. The sooner the
signs of alum/polymer fouling are recognized, the easier it will be to reverse its
effects. Therefore, it is important to check the product water flow rate on a
frequent basis.
NOTE: There are other causes for lowered product flow rate such as colder feed
water temperature. This should be ruled out as a possible cause before
alum/polymer fouling is suspected.
Rev 0.3
Page 59 of 76
2200M-Portable Water Purification System
7.5.4 What to do if Alum/Polymer Fouling is Suspected
•
•
•
•
•
If you haven't already, call the water department and ask if alum and/or
polymers are used in their treatment.
Find out the levels of silica and iron (even that imparted by galvanized piping)
present in the feed water.
If the product flow rate decreases from its expected level, refer to the
cleaning instructions.
If the water conditions are such that alum/polymer fouling continues to occur,
then periodic cleaning may have to become part of regular maintenance.
Consider additional methods (e.g. adding a Chem. Feed system, or lowering
the recovery) to deal with the fouling.
7.6 MANUFACTURER’S RECOMMENDED CLEANING AND
SANITIZATION CHEMICALS
The following cleaners and sanitizers have been evaluated and found to be compatible
with the elements. In addition to the generic cleaners listed below, there are many
chemical companies that market membrane cleaners. For best results, use factory
approved brand anti-scalants, cleaners and sanitizers for your specific elements.
Type of Foulant:
Mineral scale and metal precipitates:
Organics, silt, bacterial slime:
Organics, silt, bacterial slime:
Bacteria (Sanitizers):
Cleaner/Sanitizer:
HCl, or citric acid, pH 2
Sodium hydroxide, 0.5%
Sodium dodecyl sulfate, 0.1%
Adjust to pH 11.5 with HCl if necessary
Trisodium phosphate, 1%
Sodium tripolyphosphate, 1%
Sodium dodecyl sulfate, 0.1%
Tetrasodium EDTA, 1%
Adjust to pH 11.5 with HCl if necessary
Sodium bisulfite, 0.1%
Chlorine dioxide, 30 ppm
NOTE: It is recommended that the system should be disinfected using
Minnclean® and Minncare® products at least monthly and more often as
required.
Rev 0.3
Page 60 of 76
2200M-Portable Water Purification System
7.7
CLEANING AND SANITIZATION CHEMICAL SOLUTION
CONCENTRATION REQUIREMENTS
Listed in the table below are the cleaning and sanitization chemical solution
concentration requirements to be used with the Clean In Place (CIP) skid
provided.
NOTE: Due to site conditions some of the procedures might have to be altered.
Chemical quantities to be used are to be diluted with 100 litres of RO quality
water (10-30°C) or better.
CAUTION: RO quality water or better must be used when rinsing and preparing
the cleaning and sanitization solutions. Failure to do so will result in damage to
the membrane elements.
CAUTION: An RO quality water flush (with CIP system) is required between
each cleaning or sanitization step. If not performed, a thermal reaction can occur
resulting in damage to the membrane elements.
CAUTION: When performing a cleaning or sanitization you must first do an acid
cleaning. This will remove any metal build up on the membrane and prevent the
membranes from oxidization. When cleaning the system make sure that you are
operating at high flow rates and low pressure. If high pressure is used,
contaminants can be further pushed inside the membranes
7.7.1 Foulants and Chemicals:
Type of Foulant:
Mineral scale and metal precipitates:
Organics, silt, bacterial slime:
Bacteria (Sanitizers):
Chemical Type:
Minnclean® AC Cleaner
Minnclean® TF Cleaner
Minncare® Cold Sterilant
7.7.2 Chemical Concentrations:
Chemical Used:
Quantity when diluted in 100 litres of RO quality
water or better:
1.76 lbs (0.798 kg), pH 2.0 to 2.4
Minnclean® AC
Cleaner
Minnclean® TF Cleaner 1.76 lbs (0.798 pH 11.4 to 11.2
Minncare® Cold
0.361 US Gallons (1.40 liters), pH 3.0 to 3.5
Sterilant
Rev 0.3
Page 61 of 76
2200M-Portable Water Purification System
7.8
MINNCLEAN® AC CLEANER CHEMICAL OVERVIEW
For use on thin film composite (polyamide) reverse osmosis membrane systems, it is
especially formulated to remove mineral scale (calcium carbonate) and metal hydroxides
from the membrane surface. Minnclean® AC is an acidic (low pH) membrane cleaner.
7.8.1 Specifications
Compound:
Normal
Cleaning:
pH of Solution:
Foam Level:
Cloud Point:
Rinse-ability:
Storage:
Acidic Powder
1 pound cleaner per 15 gallons RO water
2.0-2.4
Moderate
None
Good
Store sealed container in a cool dry place. Indefinite cleaner
stability under good storage conditions.
CAUTION: When performing a cleaning or sanitization you must first do an acid
cleaning. This will remove any metal build up on the membrane and will prevent
the membranes from oxidization. When cleaning the system make sure that you
are operating at high flow rates and low pressure. If high pressure is used you
might push the contaminants further inside the membranes
WARNING: When performing a cleaning or sanitization it is very important to use
the proper safety apparatus. Refer to the Material Safety Data Sheet (MSDS)
provided with the sanitant or cleaner before using them.
WARNING: CAUSES EYE AND SKIN IRRITATION, HARMFUL IF
SWALLOWED, CONTAINS SULFAMIC ACID. Prevent contact with skin, eyes
and avoid contamination of clothing. Do not take internally. Prevent breathing
dust. Use approved goggles and rubber gloves when handling. For industrial use
only.
In case of contact, flush eyes and skin with plenty of water for at least 15
minutes; for eyes, get medical attention. Contaminated clothing should be
removed immediately and washed before reuse. If taken internally and
person can swallow, give one glass of water or milk. Do not induce
vomiting. Get immediate medical attention. DO NOT MIX WITH
CHLORINATED SOLUTIONS OR COMPOUNDS.
Rev 0.3
Page 62 of 76
2200M-Portable Water Purification System
7.9 MINNCLEAN® TF CLEANER CHEMICAL OVERVIEW
For use on thin film composite (polyamide) reverse osmosis membrane systems, it is
especially formulated to remove organic foulants such as grease, grime and biological
matter from the membrane surface. Minnclean® TF is an alkaline (high pH) membrane
cleaner.
7.9.1 Specifications
Compound:
Normal
Cleaning:
pH of Solution:
Foam Level:
Cloud Point:
Rinse-ability:
Storage:
Acidic Powder
1 pound cleaner per 15 gallons RO water
11.4 to 11.2
Moderate
None
Good
Store sealed container in a cool dry place. Indefinite cleaner
stability under good storage conditions.
CAUTION: When performing a cleaning or sanitization you must first do an acid
cleaning. This will remove any metal build up on the membrane and will prevent
the membranes from oxidization. When cleaning the system make sure that you
are operating at high flow rates and low pressure. If high pressure is used you
might push the contaminants further inside the membranes.
WARNING: When performing a cleaning or sanitization it is very important to use
the proper safety apparatus. Refer to the Material Safety Data Sheet (MSDS)
provided with the sanitant or cleaner before using them.
WARNING: MAY CAUSE BURNS, HARMFUL IF SWALLOWED, CONTAINS
SODIUM METASILICATE. Prevent contact with skin, eyes and avoid
contamination of clothing. Do not take internally. Prevent breathing dust. Use
approved goggles and rubber gloves when handling. For industrial use only.
In case of contact with eyes, flush thoroughly with water. Get medical
attention. If taken internally and person can swallow, give one glass of
water or milk. Do not induce vomiting. Get immediate medical attention. For
external contact, thoroughly wash affected areas after handling.
Rev 0.3
Page 63 of 76
2200M-Portable Water Purification System
7.10 MINNCARE® DISINFECTANT CHEMICAL OVERVIEW
DIN (Canada):
Compound:
Normal
Cleaning:
pH of Solution:
Foam Level:
Cloud Point:
Rinsability:
Storage:
02277484
Hydrogen Peroxide 22.0% / Peroxyacetic Acid 4.5% / Inert
Ingredients 73.5%
1% Concentration
1.3
Moderate
None
Good
Store sealed container in a cool (<24°C) dry place. 1 year
shelf life
PRECAUTIONARY STATEMENTS
CAUTION: Hazard to humans and domestic animals. Corrosive. Causes
irreversible eye damage. Harmful if absorbed through skin. Do not get in eyes,
on skin, or on clothing. Avoid contact with skin. Prolonged or frequent repeated
skin contact may cause an allergic reaction in certain individuals. Wash hands
before eating, drinking, chewing gum, using tobacco or using the toilet.
Remove contaminated clothing and wash hands before reuse. Caution should
be used when applying indoors because pets may be at risk. KEEP OUT OF
REACH OF CHILDREN.
CAUTION: First Aid - If inhaled, move person to fresh air. If person is not
breathing, call 911 or an ambulance, then give artificial respiration, preferably
mouth-to-mouth, if possible. Call a poison control center or doctor for further
treatment advice. If on skin or clothing, take of contaminated clothing, rinse
skin immediately with plenty of water for 15-20 minutes. Remove contact
lenses, if present, after first 5 minutes, then continue rinsing.
Call a poison control center or doctor for treatment advice. If swallowed, call a
poison control center or doctor immediately for treatment advice. Have a
person sip a glass of water if able to swallow. Do not induce vomiting unless
told to by a poison control center or doctor. Do not give anything by mouth to
an unconscious person.
NOTE: Hot Line Number – For chemical emergency, spill, leak, fire,
exposure and accident, call Chemtrec, day or night (800) 424-9300, (703)
527-3887. Have the product container or label with you when calling a poison
control center or doctor, or going for treatment. You may also contact
Chemtrec at 1-800-424-9300 for emergency medical treatment information.
Note to Physician – Probable mucosal damage may contraindicate the use of
gastric lavage.
NOTE: Personal Protective Equipment (PPE) – Handlers must wear:
goggles or face shields, and protective rubber gloves.
Rev 0.3
Page 64 of 76
2200M-Portable Water Purification System
WARNING: Environmental Hazards – This product is toxic to birds, fish and
aquatic invertebrates. For guidance, contact your regional or local regulatory
authority. Physical and Chemical Hazards – This product contains an
oxidizing agent.
NOTE: Storage and Disposal – Do not contaminate water, food or feed by
storage or disposal. Storage: Store upright in shipping carton. Do not expose
to direct sunlight. Maintain temperature below 24oC (75oF). Avoid contact with
combustible materials. Avoid contamination from any source, including metals,
dust, etc. Such contamination may cause rapid decomposition, generation of
large quantities of oxygen gas and high pressures. Store in original closed
container – NEVER TAMPER WITH VENT. Disposal: Waste resulting from
the use of this product may be disposed of on-site by dilution in a sanitary
sewer or at an approved waste disposal facility. Container Disposal: Triple
rinse empty container with water, then offer for recycling or reconditioning or
puncture and dispose of in a sanitary landfill, incinerate, or, if allowed by state
and local authorities, by burning. If burned, stay clear of the smoke.
PRODUCT EFFICACY
ƒ
ƒ
ƒ
ƒ
Sporicidal
Bactericidal
Fungicidal
Cleaner/Sanitizer
100X dilution, 11 hours
100X dilution, 11 hours
100X dilution, 11 hours
(Non-food contact surfaces) 32X dilution, 10 minutes
(Food contact surfaces Staphylococcus aureus and Escherichia coli)
320X dilution, 1 minute
ƒ
ƒ
ƒ
ƒ
Hospital Disinfectant 100X dilution, 10 minutes
Pseudomonacidal
Broad Spectrum Disinfectant 100X dilution, 10 minutes
Germicidal Spray Disinfectant 100X dilution, 10 minutes
RO Membrane Sanitizer 100X dilution, 36 minutes
20oC
20oC
20oC
20oC
25oC
20oC
20oC
20oC
20oC
GENERAL DIRECTIONS FOR USE
DO NOT USE AFTER EXPIRATION DATE.
Do not allow MINNCARE Liquid Disinfectant to mix with alkaline substances
such as bleach (sodium hypochlorite).
If spilled, flush away with large quantities of water.
Use purified water when diluting MINNCARE Liquid Disinfectant.
MINNCARE Liquid Disinfectant is a single-use product not intended for reuse.
Fresh sanitizing solution should be prepared daily or more often if the solution
becomes diluted or soiled.
DIRECTIONS FOR SANITIZING OF REVERSE OSMOSIS MEMBRANES
MINNCARE Liquid Disinfectant is recommended for sanitizing reverse osmosis
membranes and their associated distribution systems. This product has been
shown to be an effective disinfectant when tested by AOAC methods.
MINNCARE Liquid Disinfectant may not totally eliminate all vegetative
Rev 0.3
Page 65 of 76
2200M-Portable Water Purification System
microorganisms in reverse osmosis membranes and their associated piping
systems due to their construction and//or assembly, but can be relied upon to
reduce the number of microorganisms to acceptable levels when used as
directed. The possibility of recontamination by the incoming water supply may
exist. MINNCARE Liquid Disinfectant should be used in a sanitation program
which includes bacteriological monitoring of the entire RO water system.
MINNCARE Liquid Disinfectant may be used for reverse osmosis (RO)
systems, which are compatible with diluted hydrogen peroxide solutions. The
MINNCARE Liquid Disinfectant has a shelf life of one year. MINNCARE Liquid
Disinfectant should not be stored at its 1% use dilution since this may
compromise its effective concentration. This product is not registered for use
on kidney dialyzers and dialysis machines.
The RO manufacturer should be consulted prior to use of MINNCARE Liquid
Disinfectant to determine the temperature and pH range acceptable for the
particular membranes. At a 100X dilution (1% concentration), the pH range for
MINNCARE Liquid Disinfectant is 3.0-3.5. RO water systems vary in design
according to the particular needs of the user. Because of the variations in
materials of construction at different facilities, some systems may have
components of pumps, gasket, etc. that are not compatible with long term
exposure to copper, brass, iron and certain other metals. MINNCARE Liquid
Disinfectant has also exhibited a decreased resistance to latex and Buna-N
with extended exposure. MINNCARE Liquid Disinfectant solution has been
found compatible with typical system materials such as stainless steel. It is
also compatible with polypropylene, high-density polyethylene, polysulfone,
Teflon, polycarbonate, neoprene, ABS, nylon, acrylic silicone, Plexiglas,
ethylene propylene, VITON, FLUOREL, PVC and CPVC.
Because of the individuality of the RO water system in design and construction
as well as the quality of raw feed water, all OR water does not contain the
same components. Dependent upon your particular system, all or portions of
the following procedure may be for sanitizing.
Biological or organic fouling of the membrane or other parts of the system
should be removed with appropriate cleaner. It is important to follow the
membrane manufacturer’s recommended cleaning procedure. After cleaning,
flush the system with RO permeate. Mineral deposits should be removed with
an acidic cleaner prior to sanitizing of the membrane. Again, follow the
membrane manufacturer’s recommended cleaning procedure. Then flush the
unit with RO permeate. The presence of iron or other transition metals, in
conjunction with the hydrogen peroxide in MINNCARE Liquid Disinfectant,
could cause membrane degradation. Prepare a 1% solution (1 part
MINNCARE Liquid Disinfectant to 99 parts water) by adding the MINNCARE
Liquid Disinfection solution to permeate water. Fill the entire water circuit to be
sanitized with a 1% solution and allow the diluted solution to reach a minimum
temperature of 20oC (68oF). Do not exceed the membrane manufacturer’s
recommended temperature. Recirculate the 1% MINNCARE Liquid
Disinfectant until the entire system is filled. Allow the elements to soak in the
1% MINNCARE Liquid Disinfection solution for a minimum of 36 minutes at
20oC (68oF).
Rev 0.3
Page 66 of 76
2200M-Portable Water Purification System
Rinse the RO system and check for residuals by following the directions on the
MINNCARE Residual Test Strips label. The residual test strip should indicate
less than 2ppm. Rinse times will vary depending on the size of the RO system.
Residual sanitizer that may enter the system because of chemical rebound can
be eliminated by diverting product water to drain for a short period of time.
7.11
MINNCARE® TEST STRIPS OVERVIEW
Minncare® test strips provide quick results with easy-to-read indicators. Use the
Minncare® 1% TS test strips as a pass/fail measurement for adequate concentration of
sterilant after dilution. Then, verify residual levels after rinse-out using Minncare®
Residual Test Strips.
They verify adequate concentration of a 1% Minncare® solution during sanitization of
your high purity water system. These convenient dip-and-read strips can be used at any
test port in your system to provide an accurate pass/fail measurement of Minncare®
solution. The Test Strips are easy-to-use and are conveniently packaged in 100 test
strips per container. Each strip has a “reaction zone” pad located at one end of the strip.
When stored and used properly, the test strip pad can indicate residual Minncare® levels
as low as 1 part per million (ppm). The reaction zones are set to provide six different
reading levels at 100, 30, 10, 3, 1 and 0 (zero) parts per million.
7.11.1 Specification:
Storage
Rev 0.3
1. Containers that have not been opened must be stored in a
refrigerator (5-15°C Do not freeze). When a container has
been opened do not put it back into the refrigerator. Repeated
opening of a continuously refrigerated container will cause
enough condensation to exceed the capacity of the container
drying agent (located in stopper cap). The test strips are
damaged by excessive moisture.
2. Store containers that have been opened in a cool and dry
place without refrigerating.
3. Failure to store test strips properly will result in inaccurate
readings.
4. To check the color reaction, strips should be tested against a
known 3 ppm concentration of hydrogen peroxide (0.1 ml of
3% hydrogen peroxide in 1000 ml of purified water). If the
result is not greater than 1 ppm and less than 10 ppm per the
color chart, the strips must be discarded.
5. Each container has an expiry date. Do not use after date
printed on the container.
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7.12
TEST STRIPS USER INSTRUCTIONS
7.12.1 Minncare® P/N 78338 Residual Test Strips
1. Collect a sample of the rinse solution.
2. Remove a test strip from the tube and immediately replace the lid.
3. Dip the test strip into the solution to be tested for one second, such that the
reaction zone is properly wetted.
4. Remove the test strip, gently shake off excess liquid, and compare the
reaction zone with the color scale between 5 and 10 seconds after exposure.
NOTE: If test strip indicates dark blue to brown or green to brown, the
concentrations are too high for the color scale. Read Minncare® Cold Sterilant
package insert instruction for additional information
7.12.2 Minncare® P/N 78339 1% Test Strips
1. Collect a 1 ml or greater sample of the Minncare® sample.
2. Remove a test strip from the tube and immediately replace the lid.
3. Dip the test strip into the solution into the solution to be tested, such that the
reaction zone is properly wetted.
4. Remove the test strip and gently shake off excess liquid.
5. Within 10 seconds, note the entire reaction pad color development.
•
•
•
1%= Blue-gray or blue-black color over the entire reaction pad within
2-5 seconds, and which does not fade, indicates Minncare® levels of
1% or greater.
No color development, or immediate fading of blue-grey or blue-black,
indicates Minncare® levels of less than 1%.
1% Minncare® = 400 ppm Peracetic Acid, test strips is accurate +/- 50
ppm.
NOTE: The reaction pad may slowly change/develop color after the initial
reaction. This is normal and should be ignored for the purpose of test
interpretation.
7.13
SANITIZATION/CLEANING PROCEDURE USING A TANK ONLY
The procedure below will assist the operator in sanitizing/cleaning the
membrane cartridges using a small tank only.
NOTE: Due to site conditions some of the procedures might have to be altered
1. Pre-record the flow rates, pressures and product quality to determine if the cleaning /
sanitization will improved the RO overall performance.
2. Place the RO system in STOP mode.
3. Remove the system side panel and disconnect the carbon tank inlet and outlet lines.
4. Using the 3/8” coupling supplied with the system connect the two lines together.
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5. Connect a 3/8” poly tube line from the tank (bottom) to the cleaning inlet (CIP). Divert
the product and reject lines to the top of the cleaning and secure the line.
6. Fill the tank with RO quality water (20-30°C) or better.
7. Fully open the RO C.I.P. inlet valve
8. Press the “SETUP” key and then the # “2” key. The following screen will appear.
READ INSTRUCTION MANUAL
BEFORE DOING THIS
COMMAND
<OK>
<CANCEL>
9. Press the “OK” key to start the cleaning process.
10. Verify that water is flowing from the tank into the RO and back to the tank. Check for
leaks and fix if any are found.
WARNING: Secure all hoses and check for leaks before adding chemicals. This will
prevent possible chemical spray. Failure to comply with the above could result in
personal injury.
11. Press the “STOP” key on the keypad.
12. Add the predetermined amount of sanitization/cleaning chemical to the tank. Mix the
chemical until total dissolved.
CAUTION: When performing a sanitization/cleaning you must first do an acid
cleaning. This will remove any metal build up on the membrane and prevent the
membranes from oxidization.
13. Press the “SETUP” key and then the # “2” key.
14. Press the “OK” key to start the cleaning process.
15. Allow the solution to re-circulate for 5 minutes and check the solution concentration
(pH) is within limits.
NOTE: If the concentration (pH) is too low add some more chemical to bring the
concentration (pH) up. If the concentration is too high add some caustic (NaOH) or
acid (HCl) to bring the concentration (pH) down.
NOTE: If the pH dramatically decreases/increases or become dirty the solution
should be disposed of and a new batch made. Check your local municipality waste
discharge limits before dumping the solution. See SECTION 9.17 for details.
16. Allow the solution to re-circulate for 30 minutes and check the solution concentration
periodically. Monitor the temperature of the solution to make sure it does not reach
>50°C.
17. After the time has elapsed press the “STOP” key on the keypad.
18. Neutralize the cleaning solution. Refer to SECTION 9.15.
19. Once the solution is neutralized dispose of the solution.
20. Fill the tank with RO quality (or softened and de-chlorinated) water or better.
21. Press the “SETUP” key and then the # “2” key.
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2200M-Portable Water Purification System
22. Press the “OK” key to start the cleaning process.
23. Allow the water to re-circulate for 5 minutes. Check the concentration (pH) is within
the discharge limits. If it is not the tank will have to be dumped and refilled until the
limits are met.
24. Press the “STOP” key on the keypad.
25. Proceed to SECTION 9.16.
7.14
NEUTRALIZING CLEANING AND SANITIZATION SOLUTIONS
After each batch of solution is used it will be required to be neutralized. Each batch will
have a different concentration after each use. Therefore it will have to be calculated at
each time. The calculated volumes are a start point and additional chemicals may have
to be added.
WARNING: When using chemicals it is very important to use the proper safety
apparatus. Refer to the Material Safety Data Sheet (MSDS) provided with the
chemicals before using them.
NOTE: Check your local municipality for waste discharge regulations.
Sodium Hydroxide (Caustic, NaOH) will neutralize low pH (2-6) solutions.
Hydrochloric Acid (HCl) will neutralize high pH (8-14) solutions.
7.15
TANK DECOMMISSIONING AND STORAGE
After each cleaning/sanitization of the system the following should be performed:
1.
2.
3.
4.
5.
Ensure that all CIP hoses are disconnected and drained of any water.
Ensure that the cleaning tank and pump are drained of any water.
Ensure all chemical containers are closed and stored away.
Ensure all valves are in the proper position (Open or Closed) to restart the system.
Proceed to the RO restart procedure SECTION 8.17.
7.16
REVERSE OSMOSIS SYSTEM RE-START PROCEDURE
The following procedure will assist the operator in restarting the RO system.
1. Disconnect the product line connected to the process (ex. Tank).
2. Divert the product and reject line to drain.
NOTE: The flexible hose that is to be used must be the same size or larger than
the line (valve) that it is being hooked up to.
3. Re-install the carbon filter.
4. Fully open the reject and recycle needle valve.
5. Install a pre-filter cartridge if required. See SECTION 9.19.
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2200M-Portable Water Purification System
6. Slowly open feed water valve to the system pre-filter.
7. Place the controller in RUN mode. Allow the flush cycle to complete before making
any adjustments.
NOTE: The RO will not flush if it has been disabled in the controller set-up
menu.
8. Adjust the reject flow control needle valve to the flow calculated.
9. Adjust the reject recycle flow control needle valve to the flow calculated.
NOTE: Flow adjustment should be made slowly.
CAUTION: Never fully close the reject and reject recycle flow control needle
valves when the system is in operation. Damage to the system can occur.
10. Allow the system to operate to drain for 2 hours (4 hours for dialysis application) and
record and verify the system parameters are within the desired limits.
11. Once the time has elapsed and the system parameters are met, turn the controller
to OFF mode. Divert the product to the process (ex. Tank).
12. Turn the controller to RUN mode.
13. Record the system performance and compare it to the data collected before the
cleaning/sanitization to determine if the cleaning/sanitization has improved system
performance.
7.17
RO SYSTEM SHUT-DOWN PROCEDURE
NOTE: Due to site conditions some of the procedures might have to be altered.
1. At shutdown, flush the system with permeate or pretreated DI water, if available. The
flush water must be free of any chemical additives.
2. Relieve system pressure and shut down feed pumps.
3. When the system is secured, ensure that water does not drain from the elements.
Also ensure that there is no back pressure on the elements from the permeate side.
CAUTION: If there is greater than atmospheric pressure on the permeate line
during operation, check valves should be included in the permeate line to prevent
even momentary back pressure on the membrane elements during a shutdown.
4. For extended shutdowns (greater than one week), a preservative solution should be
added to the system to eliminate biological growth.
5. If the system is not being used for less than one week, it is usually sufficient to
merely flush the system with fresh, pretreated feed once per day to minimize
biological growth.
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2200M-Portable Water Purification System
7.18
PRE-FILTER REPLACEMENT PROCEDURE
NOTE: Due to site conditions some of the procedures might have to be altered.
1. Turn the system off and close the inlet valve to the inlet of the pre-filter housing.
2. Turn the system back to RUN and then OFF to relieve the pressure.
3. Remove the filter bowl by turning it counter clockwise.
NOTE: Hold bowl securely as it is being removed. It is full of water.
4. Dump excess water and discard old filter cartridge.
5. Inspect and replace o-ring if signs of cracking and/or wear are found.
6. Using clean gloves sprayed with 70% isopropyl alcohol install the new filter cartridge.
NOTE: If gloves are not available open the top of the filter cartridge bag and
insert the filter in the bowl as you remove the bag. Avoid touching the filter.
7. With the filter in the bowl, align with the center of the head and hand tighten the bowl
clockwise.
8. Slowly open the inlet valve to the pre-filter housing. Check for leaks and repair if any
are found.
NOTE: The bowl should only be tightened by hand. If it requires more torque
this indicates that the o-ring requires replacement.
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2200M-Portable RO Water Purification System
TROUBLESHOOTING
The following tables refer to troubleshooting of a standard 2200M - Portable Water Purification
System. The “possible causes” and “corrective actions” may differ for custom systems.
Problem
Possible Cause
Corrective Action
Pre-filter High
Pressure Drop
Dirty Filter
Replace filter.
Membrane High
Pressure Drop
Fouled Membrane
Identify the foulant. Follow the appropriate
cleaning procedure.
Low Product Flow
Fouled Membrane
Identify the foulant. Follow the appropriate
cleaning procedure.
Feed Temperature
Low
Poor Quality
Check Feed Temperature.
Check Recoveries
Re-adjust Flows.
Fouled Membrane
Identify the foulant. Follow the appropriate
cleaning procedure.
Feed Water out of
Specification
Check Feed Water.
Up Stream Valve
Closed
Identify and open valve.
Build Water Supply
Verify and/or install Booster System.
Inlet Solenoid Valve
Malfunction
Call Mar Cor Technical Support.
Faulty Sensor
Call Mar Cor Technical Support.
Pump Overload
Motor and/or Pump
Damaged
Verify and/or Replace.
System Will Not Start.
Tank Full
Check tank level, drain tank to intermediate
level.
No Power to System
Check that power is available to system.
Tripped Motor Thermal
Overload
Check pump thermal overload.
Pretreatment in
Regeneration
Check pretreatment.
System Stopped
Press RUN.
Feed Water
Temperature too High
Correct the Feed Water temperature. Add
blending valve or adjust setting on Feed Line.
Low feed water
pressure
High Temperature
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2200M-Portable RO Water Purification System
WARRANTY
General Limited Warranty
Mar Cor Purification and Biolab Equipment Ltd. (“Mar Cor”) warrants all products
manufactured by Mar Cor to be free from defects in material and workmanship under
normal use for a period of one year from date of shipment. Warranty is only provided
when the equipment is properly maintained in accordance with Mar Cor instructions.
Our obligation shall be limited to the repair or replacement at our option of any parts we
deem defective. Consequential damages due to the failure of any part or system are not
provided. Mar Cor provides no other warranty, expressed or implied. There is no
warranty of merchantability or fitness for a particular purpose. Other manufacturer’s
equipment offered, as part of any proposal shall carry the manufacturer’s warranty. On
site, labour is covered for the first 90 days. Travel time and expenses are not covered.
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2200M-Portable RO Water Purification System
CONTACT INFORMATION
For further information regarding the operation or maintenance of the 2200M – Portable Water
Purification System and for ordering, please contact your local Mar Cor Purification office. When
ordering replacement parts, please provide the Biolab Reference Number found on the cover
page of this Manual.
UNITED STATES OF AMERICA
Mar Cor Purification, Inc.
4450 Township Line Rd
Skippack, PA 19474-1429
Tel: (484) 991-0220
Toll Free: (800) 346-0365
Fax: (484) 991-0230
[email protected]
-------------------------------------------------------------------------------------------------------------------------------
CANADA
Mar Cor Purification - Biolab Equipment Ltd.
3250 Harvester Rd - Unit 6
Burlington, ON L7N 3W9
Tel: (905) 639-7025
Toll Free: (800) 268-5035
Fax: (905) 639-0425
WORLD WIDE WEB
www.mcpur.com
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2200M-Portable RO Water Purification System
CUSTOMER SYSTEM NOTES
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