4400M RO Manual

4400M RO Manual
Biolab Equipment Ltd. o/a Mar Cor Purification
4400M – Digital Reverse Osmosis System
Installation, Operation and Maintenance Manual
Unit may not appear exactly as shown
MAN-4400MCOLD (rev.J)
4400M Digital RO System
FOR PERSONAL AND SYSTEM SAFETY, AND FOR OPTIMUM PRODUCT
PERFORMANCE, MAKE SURE YOU THOROUGHLY READ AND UNDERSTAND
THE CONTENTS OF THIS MANUAL BEFORE INSTALLING, USING OR
MAINTAINING THIS PRODUCT.
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 PRODUCT PURIFIED WATER FOR DIALYZER REPROCESSING AND
EQUIPMENT RINSE AND DISINFECTION.
SOFTWARE VERSION: V6.7e.132
BIOLAB SERIAL #:
DEVICE IDENTIFIER:
DATE MANUFACTURED:
MAN-4400MCOLD (rev.J)
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4400M Digital RO System
MANUAL REVISION HISTORY
Revision
Author
Date
Changes
G
J Parkin
March, 2014
3.5 Warning added 4.3 Caution note added / 4.4 Acidic
and Alkaline cleaners added / A5 Duplicate lines removed
and materials updated / A9 Log Sheet identified as
Sample, footnotes expanded. / A11 Sample P&ID Added /
Minor verbiage corrections / clarifications
H
J Parkin
October, 2014
Logo/Format Update /Spelling Standardization/ Biolab
Reference Number renamed to S/N / Moved Specification
before Warnings / 4.4.9 Remove test strip storage info
and replace with Caution
J
J Parkin
August, 2015
Replace A11 P&ID with Clearer Image, Update A13 Spare
Parts List,
MANUAL PREPARATION
Richard Marmen – Engineering Manager
7-Aug-2015
Biolab Equipment Ltd o/a Mar Cor Purification
Date
MAN-4400MCOLD (rev.J)
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4400M Digital RO System
TABLE OF CONTENTS
INTENDED USE ....................................................................................................................................................... 2
SAFETY ................................................................................................................................................................... 7
DEFINITIONS .......................................................................................................................................................... 7
LABELS ................................................................................................................................................................... 7
SPECIFICATIONS ..................................................................................................................................................... 8
GENERAL PRECAUTIONS ........................................................................................................................................ 9
1.0
GENERAL INFORMATION ............................................................................................................................ 11
1.1
1.2
2.0
HOW DOES THE RO PROCESS WORK? ............................................................................................................11
RO TECHNOLOGY USED IN MEDICAL APPLICATIONS .....................................................................................12
INSTALLATION AND START-UP .................................................................................................................... 14
2.1 UNPACKING THE SYSTEM ..............................................................................................................................14
2.2 SPACE/ROOM REQUIREMENTS .....................................................................................................................14
2.3 SETTING UP THE SYSTEM ...............................................................................................................................15
2.4 INSTALLATION OF EXTERNAL CONNECTIONS TO THE 4400M SYSTEM ..........................................................15
2.5 START-UP .......................................................................................................................................................16
2.5.1
Electrical Hook-up Verification.............................................................................................................16
2.5.2
Pre-Start-up Verification ......................................................................................................................16
2.5.3
Control Panel/Microprocessor Start-up ...............................................................................................17
2.5.4
4400M System Start-up .......................................................................................................................18
2.5.5
Checking the RO Pump Rotation ..........................................................................................................19
2.5.6
Purging Air from the RO Pump .............................................................................................................20
3.0
OPERATIONS AND MONITORING ................................................................................................................ 21
3.1 SYSTEM OPERATIONS ....................................................................................................................................21
3.2 SYSTEM OPERATION CONTROLS ....................................................................................................................22
3.2.1
The Display Navigation ........................................................................................................................22
3.2.2
Set-Up Screen Descriptions ..................................................................................................................25
3.2.3
Set-Up Data Reference Table ...............................................................................................................32
3.2.4
Controller Options ................................................................................................................................32
3.3 OPERATING PROCEDURES .............................................................................................................................33
3.3.1
System Start-up....................................................................................................................................34
3.3.2
Normal Operations ..............................................................................................................................34
3.3.3
System Shut-down ...............................................................................................................................34
3.4 MONITORING SYSTEM PERFORMANCE .........................................................................................................35
3.5 MONITORING RO MEMBRANE PERFORMANCE ............................................................................................37
3.5.1
Effects of Pressure on Membrane Performance ..................................................................................37
3.5.2
Effects of Recovery on Membrane Performance..................................................................................38
3.5.3
Effects of Temperature on Membrane Performance ...........................................................................39
4.0
MAINTENANCE ........................................................................................................................................... 41
4.1 MAINTENANCE REQUIREMENTS ...................................................................................................................41
4.1.1
Scheduled Maintenance Log Sheet ......................................................................................................42
4.2 REPLACEMENT PROCEDURES ........................................................................................................................44
4.2.1
Pre-filter Replacement Procedure ........................................................................................................44
MAN-4400MCOLD (rev.J)
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4400M Digital RO System
4.2.2
Solenoid Valve Seal Replacement Procedure .......................................................................................44
4.3 OVERVIEW OF SYSTEM SANITIZATION & RO MEMBRANE CLEANING ............................................................45
4.3.1
Dealing with a Hardness/Metal Oxide Fouling Problem ......................................................................46
4.3.2
Dealing with a Colloids/Silica Fouling Problem ....................................................................................47
4.3.3
Dealing with an Aluminum/Polymer Fouling Problem .........................................................................47
4.4 CHEMICAL CLEANING AND SANITIZATION .....................................................................................................48
4.4.1
Clean-In-Place (CIP) Equipment Requirements ....................................................................................49
4.4.2
Cleaning/Sanitization Chemicals ..........................................................................................................52
4.4.3
Overview of Recommended Chemicals ................................................................................................53
4.4.4
Cleaning/Sanitization Procedure Using a CIP System Skid ...................................................................57
4.4.5
Cleaning/Sanitization Procedure Using a Tank and RO Pump .............................................................60
4.4.6
Tank Decommissioning and Chemical Storage ....................................................................................62
4.4.7
Neutralizing Cleaning/Sanitization Solutions .......................................................................................62
4.4.8
Restarting RO System after Chemical Cleaning/Sanitization Procedures ............................................63
®
4.4.9
MINNCARE Test Strips Overview ........................................................................................................64
4.5 RO MEMBRANE ELEMENT STORAGE .............................................................................................................65
5.0
TROUBLESHOOTING ................................................................................................................................... 67
5.1 TROUBLESHOOTING ALARMS/MESSAGES .....................................................................................................67
5.2 SYSTEM DIAGNOSIS .......................................................................................................................................68
5.2.1
System Test Matrix ..............................................................................................................................69
WARRANTY .......................................................................................................................................................... 70
CONTACT INFORMATION ..................................................................................................................................... 71
A1 4400M DIGITAL REVERSE OSMOSIS SYSTEM ................................................................................................... 72
DESCRIPTION & FUNCTION OF SYSTEM COMPONENTS ..........................................................................................73
A2 4400M CONTROL PANEL DISPLAY ................................................................................................................... 78
A3 SET-UP MENU DISPLAY NAVIGATIONAL FLOW CHART .................................................................................... 79
A4 ALARM LOG SHEET ......................................................................................................................................... 80
A5 DEVICE MATERIALS OF CONSTRUCTION.......................................................................................................... 81
A6 WATER SAMPLING PROCEDURE...................................................................................................................... 82
A7 REQUIREMENTS FOR INSTALLATION OF EXTERNAL CONNECTIONS TO THE 4400M SYSTEM ........................... 83
DRAIN CONNECTION REQUIREMENTS ....................................................................................................................83
PIPING REQUIREMENTS ..........................................................................................................................................83
PRE-TREATMENT REQUIREMENTS ..........................................................................................................................83
POST-TREATMENT REQUIREMENTS ........................................................................................................................84
PANEL ELECTRICAL TERMINATION REQUIREMENTS ...............................................................................................84
FEED WATER REQUIREMENTS .................................................................................................................................84
ELECTRICAL SUPPLY REQUIREMENTS ......................................................................................................................85
A8 4400M RO TYPICAL FLOW RATES .................................................................................................................... 86
A9 TABLE OF SYSTEM MONITORING PARAMETERS .............................................................................................. 88
A10 SITE ACCEPTANCE TEST (SAT) PROCEDURES .................................................................................................. 90
INSTALLATION VERIFICATION CHECKLIST................................................................................................................91
DISPLAY SCREEN SETTINGS & DEFAULT SETPOINTS ................................................................................................92
MAN-4400MCOLD (rev.J)
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4400M Digital RO System
SYSTEM TEST MATRIX .............................................................................................................................................93
RO PERFORMANCE VERIFICATION LOG ...................................................................................................................94
DISCREPANCY LOG ..................................................................................................................................................95
A11 SAMPLE PROCESS & INSTRUMENT DRAWING ............................................................................................... 96
A12 ELECTRICAL CONTROL INTERLOCKS FOR THE CONTROL PANEL ..................................................................... 97
PANEL ELECTRICAL FIELD TERMINATION DESCRIPTIONS FOR THE OPTIONAL FEATURES .......................................98
A13 SPARE PARTS LIST ....................................................................................................................................... 101
CUSTOMER SYSTEM NOTES ............................................................................................................................... 103
MAN-4400MCOLD (rev.J)
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4400M Digital RO System
SAFETY
This Manual describes procedures necessary to install, operate, and maintain the 4400M Digital Reverse Osmosis 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 ISO 13959, ISO 11663 and ISO 26722 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
Read all labels and tags attached to the equipment. Personal injury or damage to the
equipment could occur if not observed.
This symbol, if noted on the equipment, indicates a hot surface. Avoid any direct
contact with the surface.
This symbol, if noted on the equipment, indicates high voltage output. Disconnect
the main power supply to the equipment before opening panels.
MAN-4400MCOLD (rev.J)
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4400M Digital RO System
SPECIFICATIONS
MACHINE NOMENCLATURE *
X
X
M
1
X
Number of RO
Elements
Membrane
Type
Medical
Application
304 SS
Housing
Source Voltage
(Volt/ Phase/ Hz)
2, 3, 4, 5, 6, 8, 9,
10, 12
2 - Sanitary
5 - Low Fouling
B-
2
X
316 SS Pump
Digital
Control
Feed Design
2 – 230 / 1 / 60
3 – 380 / 3 / 50
4 – 420 / 3 / 50
5 – 115 / 1 / 60
6 – 208 / 3 / 60
7 – 230 / 3 / 60
8 – 460 / 3 / 60
9 – 575 / 3 / 60
E – Direct Feed
F - Tank Feed
X Represents options available
* Option XXM16B-2X (208 Volt, 3 Phase, 60Hz) has an ETL mark and has been tested to ANSI/UL 61010rd
1/CAN/CSA-C22.2 No.61010-1-12 (3 Edition) and FFC 47CFR 15B clB.
FLOW RATES @ 75% RECOVERY
RO Element
Quantity
Capacity (GPD)
@ 77°F (25°C)
Product
Flow Rate
GPM (LPM)
Concentrate
Flow Rate
GPM (LPM)
Motor
Horse Power
(hp)
Weight
(lbs.)
2
4,000
2.8 (10.5)
0.8 (3.0)
2.0
438
3
6,000
4.2 (15.9)
1.3 (4.9)
3.0
481
4
8,000
5.6 (21.2)
1.8 (6.8)
3.0
506
5
10,000
6.9 (26.1)
2.3 (8.7)
5.0
593
6
12,000
8.3 (31.4)
2.8 (10.6)
5.0
627
8
16,000
11.0 (41.6)
3.7 (14.0)
5.0
721
9
18,000
12.5 (47.3)
4.2 (15.9)
7.5
764
10
20,000
14.0 (53.0)
4.7 (17.8)
7.5
783
12
24,000
17.0 (64.4)
5.7 (21.6)
7.5
832
OPERATING PARAMETERS
Operating Pump Pressure
< 250 psi
Operating Temperature
2 – 35 C (35 – 95 F)
Standard Electrical Requirement
208 VAC , 3-phase, 60 Hz
Feed Water Quality
Refer to Appendix A7
o
o
DIMENSIONS – Inch (mm)
4400M - Digital RO Skid
MAN-4400MCOLD (rev.J)
38 (965) Width
29 (737) Depth
80.5 (2045) Height
page 8 of 103
4400M Digital RO System
GENERAL PRECAUTIONS
The following are general precautions that must be taken with the 4400M System. Please read
these precautions before installing or operating the system.
WARNING This system is a registered medical device. Operation of this system outside of
its intended use and without adequate pre-treatment/post-treatment that
meets ISO 13959-11 standards will void the system’s medical device license.
WARNING Changes to the design, substitution of components or other changes will void
the system’s medical device license.
WARNING The input water quality to the RO must meet the National Primary Drinking
Water, Standards of the United States Environmental Protection Agency (EPA)
or Canadian Federal and Provincial guidelines governing drinking water in
Canada.
WARNING Only chemicals listed in the manual may be used with the 4400M system.
Other chemicals may not be compatible with the material of construction.
When using chemical cleaners or sanitizers, ensure the system is properly
rinsed prior to use for dialysis.
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 After installation and subsequent use, when any component of the RO system
is changed or replaced, the user should conduct appropriate tests to ensure
that the revised system meets the initial design criteria and water quality
requirements.
WARNING A suitable carbon filter should always be present as pre-treatment for the RO
unit in order to prevent chlorine/chloramine damage to the Composite
Polyamide RO membrane and harm to the patient. Mar Cor strongly
recommends the use of two carbon tanks, used in a series configuration with
a minimum empty bed contact time of 10 minutes.
WARNING Some settings are user adjustable via the HMI (Human-Machine-Interface).
Only personnel that understand the operation of the 4400M should change.
WARNING Do not attempt to tamper with or perform any unauthorized modifications to
the device including programming changes. Any unauthorized work on the
device could cause damage to the equipment or harm to personnel and
patients.
MAN-4400MCOLD (rev.J)
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4400M Digital RO System
WARNING While a water treatment system may produce water of sufficient quality to
meet the requirements of ISO 13959-11, distribution of the water may
degrade its quality to the point where it no longer meets the requirements of
the above mentioned standards if the distribution system is not designed,
installed and/or maintained appropriately. Construction and materials of the
distribution loop must be compatible with the RO system and avoid dead legs
in the pipe routing.
WARNING Connect this device to a proper ground connection in accordance with the
National Electrical Code if applicable. The system skid, panel and piping shall
be properly grounded and bonded for safety.
WARNING Surge suppression shall be used on the incoming main power feed to the panel
if frequent voltage spikes (e.g. lightening, utility variations) are common in
the geological area.
WARNING Do not, under any circumstances, remove any Caution, Warning or any other
descriptive labels from the devices until the conditions warranting the label
are eliminated.
WARNING To avoid fire or explosion, do not operate this device in an explosive
environment or near flammable materials or anesthetics.
WARNING To prevent electrical shock, disconnect the electrical power to the system
before servicing.
WARNING Use a clean soft cloth with a mild soap or detergent to clean the HMI display.
Dry the display with a chamois or moist cellulose sponge to avoid water spots.
Remove fresh paint splashes and grease before drying by rubbing lightly with
isopropyl alcohol (70% concentration). Afterward, wash using a mild soap or
detergent. Rinse with clean water.
MAN-4400MCOLD (rev.J)
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4400M Digital RO System
1.0
GENERAL INFORMATION
The 4400M - Digital Reverse Osmosis (RO) system produces up to 16.7 US gallons per minute
(64.4 litres per minute) of product water suitable for applications requiring biological and
inorganic purity. The product water quality meets ISO 13959, ISO 11663 and ISO 26722
Standard requirements. More than 99% of all microorganisms, pyrogens, particulates, organics
with a molecular weight greater than 300, and up to 95% of all dissolved inorganic
contaminants from the feed water are removed.
The 4400M RO system is supplied on a skid consisting of a pump, RO element housings,
manifolds, valves, pressure gauges, flow rotameters, a control panel and tubing. The system
skid and manifolds are shipped fully assembled, pre-piped and pre-wired. See APPENDIX A1 for
detailed description of the system components. The standard RO system is available in 208VAC
(60 Hz) 3-phase but it is also customized to 230, 380, 420, 460, 575 VAC 3-phase or 115/230
VAC single phase power supply. The system is offered with a choice of 2, 3, 4, 5, 6, 8, 9, 10 or 12
RO membrane elements to suit specific product flow requirements.
A NEMA 4-12 control panel consists of a digital controller, an electronic digital interface and
display for setting and monitoring process control parameters. Optional control interfaces are
provided with the RO system for:





Feeding product water to a Storage Tank or a Direct Feed line.
Diverting product water to the drain.
A Remote Alarm Panel.
A Remote PC Interface.
A Product 0.1 Cell Constant Conductivity/Temperature Sensor.
NOTE
1.1
The 4400M system does not include external pre-treatment and posttreatment devices, piping and fittings to the point of use.
HOW DOES THE RO PROCESS WORK?
Reverse Osmosis (RO) is a cross flow membrane filtration process used for water purification. It
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 called the
“permeate”. The second stream is called the “concentrate” because it carries off the
concentrated contaminants rejected by the membrane. Because the feed and concentrate flow
parallel to the membrane instead of perpendicular to it, the process is called “cross flow
filtration”. 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, ultrafiltration and the more recent micro filtration.
MAN-4400MCOLD (rev.J)
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4400M Digital RO System
The cross flow membrane filtration allows continuous removal of contaminants, which in the
normal flow filtration would “blind” and plug the membrane pores very rapidly. Thus the cross
flow mode of operation is essential to the RO process.
The RO was the first cross flow membrane separation process to be widely used. The RO
removes most organic compounds and up to 99% of all ions. A selection of RO membranes is
available to address varying water conditions and requirements.
The 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 is the driving force of the RO purification
process. It is much more energy-efficient compared to phase change processes such as
distillation and more efficient than the strong chemicals required for ion exchange
regeneration.
1.2
RO TECHNOLOGY USED IN MEDICAL APPLICATIONS
The performance requirements of the RO system used by medical and pharmaceutical
businesses are different from many market segments because, in addition to conductivity and
total organic carbon (TOC), viable microbial organisms and endotoxin are also measured in the
RO product water. Specific microbial limits are defined in the ISO 13959, ISO 11663 and ISO
26722 standards. From a regulatory perspective, the end-user’s obligation is to ensure these
limits are satisfied at the point of distribution. Advancements in membrane technology
combined with pressure from regulatory agencies have increased RO system performance
expectations, particularly regarding microbial organisms and endotoxin measurements. Today,
it is common for end-user protocols to stipulate very low, viable microbial organisms and
endotoxin levels in RO product water.
The RO membranes have a relatively large surface area, ambient operating temperatures, and
the absence of chlorine or other disinfectants that combine to create a microbial organisms
breeding environment on the product side of RO membranes. To exhibit better system control
over microbial levels, routine chemical sanitizing processes are employed based on the
bacterial level measured in the product water.
Chemicals used in the RO membrane cleaning procedures include low and high pH-based
cleaners for the primary purpose of removing hardness scale and organic deposits that may
build up on the membrane surface as foulants.
Bacteria counts taken from water streams are typically representative of the planktonic
organisms in the stream and not necessarily of microbial organisms that exist in a biofilm within
the water system. Biofilms are a complex organization of microbial organisms formed by one of
many common species, which adhere to a surface and cover themselves from the fluid stream
in a somewhat protective polysaccharide boundary layer.
MAN-4400MCOLD (rev.J)
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4400M Digital RO System
Biofilms form naturally, but the growth may be mitigated with appropriate fluid velocity,
smooth sanitary pipe designs and periodic and appropriate sanitization processes. However,
biofilms have proven to be quite resilient to many chemical sanitization processes due to their
protective boundary layer. Studies demonstrate biofilms may survive even after 60 minutes of
exposure to chlorine-based sanitizing chemicals. Therefore, preventing the formation of
biofilms is a primary goal with respect to regular and periodic sanitization processes.
MAN-4400MCOLD (rev.J)
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4400M Digital RO System
2.0
INSTALLATION AND START-UP
2.1
UNPACKING THE SYSTEM
Unpack the 4400M - Digital RO system carefully and inspect all components for any possible
signs of damage. Do not install the system if damage is apparent. Notify your representative
and the carrier immediately. Retain all literature for future reference.
2.2
SPACE/ROOM REQUIREMENTS
The RO 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. The floor must be
capable of supporting the operating weight of the system. Provide enough room to remove
piping. The room must have adequate lighting and safety equipment (safety shower, face
shield, gloves, chemical suits, spill equipment etc.)
Operating Weight Range: 438 to 832 lbs (199 to 377 kg)
The Room Shall Meet The Following Requirements:
1. Floor shall be slopped to drain in case of water leaks. It is also recommend that a dike and leak
detector be installed.
2. The water system should not be installed above critical areas or equipment (e.g. computer
rooms, electrical equipment). If required, every precaution shall be made to prevent water
leaks.
3. The room containing the installed system shall be climate controlled to protect the system from
freezing at all times. Ambient temperature shall not exceed 30°C (86°F) and relative humidity
shall be held between 5% and 95% (non-condensing) when the equipment is in operation.
4. The system shall be located where noise levels will not disturb patients.
5. The system shall be installed in a room with adequate lighting and ventilation to remove
chemical fumes during system maintenance.
6. Serviceable space requirement for removing RO membranes from their SS housings is 48” in the
vertical direction or no space requirement if removing with its SS housings all together.
7. Minimum 18” serviceable space required on the left, right and back of system is required.
8. Based on safety regulations, from the front of the control panel to the opposite wall shall be 42”
if the wall is insulated or 48” if the wall is non-insulated.
CAUTION
This equipment must not be allowed to freeze. Irreparable harm to various
components, including RO membranes may result.
NOTE
The user/operator should recognize that moisture can be caused by
condensation and is not necessarily an equipment leak. This equipment will
function in the presence of condensation.
WARNING A room with good ventilation is required to help remove heat and any
chemical fumes.
MAN-4400MCOLD (rev.J)
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4400M Digital RO System
2.3
SETTING UP THE SYSTEM
The system shall be transported by lifting the base of the frame. Use proper mobile lifting
equipment capable of moving the entire weight of the system.
Empty Weight by Model:
Model
Weight, lbs (kg)
Model
Weight, lbs (kg)
4400M-4K
438 (199)
4400M-16K
721 (327)
4400M-6K
481 (218)
4400M-18K
764 (347)
4400M-8K
506 (230)
4400M-20K
783 (355)
4400M-10K
593 (269)
4400M-24K
832 (377)
4400M-12K
627 (284)
Mount the system on a floor taking into account the following considerations:



Unobstructed access to the feed, drain and electrical controls for ease of operation and
service. Always follow all applicable local codes.
Position the unit in its approximate final location to accommodate pre-treatment and
post-treatment accessories.
Position the unit in its approximate final location, leaving enough room to remove
piping and filter.
WARNING Do not install the 4400M - RO System near equipment that requires electrical
service. Maintenance of the 4400M - RO System may involve water spillage
that could create an electrical shock hazard.
NOTE
A room with good ventilation is required to help remove heat and any
chemical fumes.
NOTE
The room must have adequate lighting and safety equipment (safety shower,
face shield, gloves, chemical suits, spill equipment, etc.)
WARNING Do not off load or place equipment without using proper equipment. If not
capable contact a local millwright to off load or place the equipment.
2.4
INSTALLATION OF EXTERNAL CONNECTIONS TO THE 4400M SYSTEM
Installation of external connections to the 4400M system such as drain connections, the pretreatment device(s), and post-treatment device(s) must be done in such a way that the product
water quality is not degraded in reaching the point of use. The specific requirements listed in
Appendix A7 must be met to achieve best product water quality that meets ISO 13959, ISO
11663 and ISO 26722 Standard requirements.
MAN-4400MCOLD (rev.J)
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4400M Digital RO System
Refer to the Process and Instrument Diagram (P&ID), the General Arrangement (GA) drawing,
the Electrical Drawing (ED) and Individual Component Manufacturer’s Manuals to assist in the
installation. The information on the electrical termination points to the microprocessor and the
individual components in the system is provided in APPENDIX A11.
NOTE
2.5
It is the responsibility of the contractor or the installer who incorporates any
external device(s) to the 4400M medical system to ensure that the
incorporation of the device does not compromise the ability of the overall
system to deliver product water quality at the point of use. It must meet the
ISO 13959, ISO 11663 and ISO 26722 Standards. (Reference: ISO 26722
Element 4.2.1.1).
START-UP
2.5.1
Electrical Hook-up Verification
Before starting the 4400M system it is very important that electrical services have been
checked for the following:




Fused (main disconnect) power supply to panel(s) is connected.
Proper voltage is connected and verified.
All input or output devices in the panel are hooked up properly and verified.
All electrical work meets local electrical codes
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. Refer to the electrical drawing for connection points, voltage,
phase and current load.
WARNING To prevent electrical shock, disconnect the electrical power to the system
before servicing.
WARNING Use proper safety procedures when working in an electrical panel. Disconnect
and/or lock out the power supply to the system and tag it out. The system
must be properly grounded to prevent personal injury or damage to the
system.
2.5.2
Pre-Start-up Verification
The 4400M system is pre-tested at the factory and the panel view is set to the default values.
After the overall water system has been installed, the following items should be checked before
commissioning of the RO system is to begin:
MAN-4400MCOLD (rev.J)
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4400M Digital RO System












Plant clean dry air supply is connected and verified if required.
Plant feed water supply is connected and verified.
Plant electrical supply is connected and verified.
Interconnect including drains are completed and verified.
All water piping lines are pressure tested and flushed to remove debris.
Pre-treatment devices are installed and a functional test is performed.
Post treatment devices are installed and a functional test is performed.
Pre-filter cartridges are installed as per instructions in section 4.2.1.
All appropriate valves are open in the overall water treatment system.
Feed water tests are performed.
The 4400HX – Hot Water Sanitization system is ready, if connected.
All tank accessories are installed and ready to receive water.
NOTE
2.5.3
A pressure test of the piping, connections and tanks must be performed before
starting the system to avoid leakage of water and cleaning chemicals.
Control Panel/Microprocessor Start-up
The following procedure will assist the technician in the commissioning of the main control
panel and programmable logic controller of the 4400M system.
WARNING Use proper safety procedures when working in an electrical panel. Disconnect
and/or lock out the power supply to the system and tag it out. The system
must be properly grounded to prevent personal injury or damage to the
system.
NOTE
Due to site conditions some of the procedures might have to be altered.
1. Open the panel and check the main voltage feed before the main disconnect with a multi-meter
to verify it is within +10 /-10%.
2. Set the pump overload switch to the START position.
3. Close the panel.
4. Turn all panel switches to the OFF position.
5. Turn the main disconnect to the ON position.
6. Allow the panel view to initialize.
7. Enter the desired set-up parameters in the microprocessor controller. Refer to section 3.2.
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4400M Digital RO System
2.5.4
4400M System Start-up
Perform the system start-up in step-by-step sequence below. Refer to SECTION 3.2 of the
Manual to navigate through the digital controller display on the control panel.
If the system is connected to a 4400HX system, ensure that it is ready for RO system operation.
Please refer to the 4400HX system manual for details.
1. Fully open the reject to drain valve and fully close the reject CIP (Clean-In-Place) valve.
2. Connect a flexible hose to the product CIP valve and fully open the valve. Fully close the product
valve connected to the process (example, tank).
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. Open the reject and recycle needle valve.
NOTE
When either opening or closing any needle valve, DO NOT over-extend or
over-tighten the valve as galling damage may occur. When fully opening the
valve, do so till resistance is felt and then close the valve ¼ turn. When fully
closing the valve, DO NOT use wrenches or other tightening tools. Close valve
till snug.
4. Verify the feed water pressure is between 30 to 60 psig and adjust if necessary. Water must be
flowing to drain to perform this adjustment.
5. Set the water tempering device output to 25ºC, if applicable. Water must be flowing to drain to
perform this adjustment.
6. Slowly open the feed water valve to the system pre-filter.
7. Purge air from the RO pump. Refer to section 2.5.6 for instructions.
8. Check the RO pump rotation is correct. Refer to section 2.5.5 for instructions.
9. Place the controller in the RUN mode. The inlet valve and the reject valve will open and after a
five second delay the pump will start. The system will perform a start-up flush first for 90
seconds. Allow the flush cycle to finish.
NOTE
The RO will not flush if it has been disabled from the controller set-up menu.
10. Adjust the reject flow control needle valve to the flow rates shown in APPENDIX A8.
11. Adjust the reject recycle flow control needle valve to the flow rates shown in APPENDIX A8.
NOTE
When either opening or closing any needle valve, DO NOT over-extend or
over-tighten the valve as galling damage may occur. When fully opening the
valve, do so till resistance is felt and then close the valve ¼ turn. When fully
closing the valve, DO NOT use wrenches or other tightening tools. Close valve
till snug.
12. Adjust the pump recycle (chase) flow control needle valve to reduce or increase the pump
discharge pressure if required.
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.
MAN-4400MCOLD (rev.J)
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4400M Digital RO System
NOTE
Flow adjustment should be made slowly.
NOTE
The flow rates in steps 10-12 must be verified and adjusted until the system
has stabilized. A +25/ -15% variation in product flow rate can occur within the
first three months of operation.
13. Allow the system to drain for two hours (four hours for dialysis application). Record and verify
that the system parameters are within the desired limits.
14. Once the time has elapsed and the system parameters are met set the controller to the STOP
mode. Close the product CIP valve and disconnect the flexible line. Fully open the product valve
connected to the process (for example, tank).
15. Place the system back into the RUN mode.
NOTE
Once the system is in operation, daily checks, in each shift, must be logged in
the Table of System Monitoring parameters in APPENDIX A9. Flow and
pressure adjustments must be made to operate the system within parameters
specified in Section 3.5. Failure to operate the system within limits will void
the product warranty.
16. A complete sanitization using MINNCARE® disinfectant (refer to section 4.4) must be performed
to assure the water meets or exceeds the ISO13959, ISO 11663 and ISO 26722 requirements.
17. After the sanitization is performed, take the necessary water samples and have them analyzed
by an accredited lab. Refer to APPENDIX A6 for Water Sampling Procedures.
NOTE
The water cannot be used for dialysis until the water quality is verified and
signed off by the physician.
NOTE
Upon successful start-up, the Site Acceptance Test (SAT) must be executed and
approved by the customer. Refer to the SAT document in APPENDIX A10 for
details of the quality requirements.
NOTE
After initial installation and subsequent use, if any component of the water
treatment system is changed or replaced, the user should conduct appropriate
tests to ensure that the revised system meets the initial design criteria.
(Reference: ISO 26722. Element 6.3, Item # aa)
2.5.5
Checking the RO Pump Rotation
The procedure below provides the necessary steps to check the circulation pump rotation. The
procedure is used on pumps that have been supplied with 3-phase feed voltage input
requirements.
1. Make sure the controller is in the STOP mode.
2. Viewed from the top of the motor, the pump must be rotating counter-clockwise.
3. Cycle the controller from the STOP to the RUN mode and allow the pump to start. Verify the
rotation. Cycle the pump a few times to make sure the rotation is correct.
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4400M Digital RO System
4. If the pump is rotating in the wrong direction, turn the main disconnect to the OFF position and
open the panel.
WARNING Use proper safety procedures when working in the electrical panel.
Disconnect and/or lock out the power supply to the system and tag it out. The
system must be properly grounded to prevent personal injury or damage to
the system.
5. Switch any two lead wires on the load side of the pump starter and secure the panel door.
6. Turn main disconnect ON and recheck the pump rotation.
2.5.6
Purging Air from the RO Pump
1. Using a wrench, loosen the priming plug located on the top of the pump.
2. Cycle the controller from the STOP to the RUN mode to allow water to enter the pump until a
steady stream of water is flowing from the priming plug. This may take some time depending on
the size of the pump.
3. Once a steady stream is flowing, tighten the priming plug and make sure the pump controller is
OFF.
Refer to the GRUNDFOS C-SERIES PUMP MANUAL for additional instructions.
CAUTION
Never run the pump dry. Damage to internal components can occur resulting
in poor system performance and premature pump failure.
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4400M Digital RO System
3.0
OPERATIONS AND MONITORING
3.1
SYSTEM OPERATIONS
The main operations performed by the 4400M - Digital RO system are as follows (See FIGURE
3.1 - Operations Flow Chart):
Normal RO - There are four modes of normal RO operations:




Stop – In this mode, the RO system will stop operating.
Standby – In this mode, the RO system remains on but does not perform any operation
except system flush at auto scheduled frequency for the set duration. Refer to section
3.2.2 for changing the flush duration time and frequency.
Run – In this mode, the system will perform normal RO operations. Refer to the SETUP
menu in section 3.2.2 for different options.
Flush – In this mode, the system continuously flushes the product water to drain. This
will help reduce membrane fouling by allowing more water to pass over the membrane
surface.
Sanitization - The 4400M – Digital RO system can be sanitized using a chemical disinfectant.

Chemical Sanitization/Cleaning – This operation is performed in the MANUAL mode
using a Clean-In-Place (CIP) system or a tank. For sanitization/cleaning with the tank, an
option of using the RO pump is provided.
NOTE
The RO system controller is locked-out by the 4400HX Hot Water Sanitization
System controller during part of the hot water sanitization of the distribution
loop.
Figure 3.1 – Operations Flow Chart
Normal RO
Operations
System Sanitization
Chemical
Sanitization /
Cleaning
(Using a CIP system or
tank)
MAN-4400MCOLD (rev.J)
Stop
Standby
Run
Flush
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4400M Digital RO System
3.2
SYSTEM OPERATION CONTROLS
The 4400M – Digital RO system is equipped with the user-friendly DO841.4 monitoring
controller with V6.7e.132 software. The controller uses a keypad interface 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 setpoints for product quality, feed temperature, programmable poor
quality shutdown delay and programmable flush times and durations. The controller has nonvolatile memory backup for power failure conditions. If a power failure should occur once the
power has been restored the system would re-start in the same mode it was in before the
failure occurred.
In this section, an overview of the operation of the digital controller is provided to help the user
gain familiarity and program basic system parameters. Refer to APPENDIX A1 for a description
of system components, APPENDIX A2 for a pictorial view of the System Control Panel and
APPENDIX A3 for the Screen Navigation flow chart.
3.2.1
The Display Navigation
The Electronic Digital Interface and Display allows the user to set the operations described in
section 3.1.
FIGURE 3.2 – ELECTRONIC DIGITAL INTERFACE & DISPLAY SCREEN
Display Screen
Key Pad
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4400M Digital RO System
NOTE
To change the system mode of operation or to enter set-up menu, the system
MUST BE placed in the STOP mode first. The message “SYSTEM STOPPED”
appears on the display when the STOP key is pressed.
Key
Function
STOP
Stops the RO system until another mode of operation is selected. This key must be
pressed before changing the operation mode of the system and before entering the setup menu.
RUN
This is the main mode of operation. The water purification cycle will begin when this key is
pressed. Refer to the SETUP menu for setting different options.
FLUSH
When this key is pressed, the system will continuously flush the water to drain. This will
help reduce membrane fouling.
STANDBY
When this key is pressed, the system will stop and automatically flush for programmable
setpoint to prevent stagnant water in the system and reduce membrane fouling.
SETUP
Press this key to change set-up data. The system must be in the STOP mode to enter the
set-up menu. Refer to the screen description tables in section 3.2.2 for detail.
OK
Press this key to confirm selection.
CANCEL
Press this key to cancel selection and return to previous menu.
In each mode of operation described above, the user can monitor the pertinent real-time
system parameters on the display screen shown in FIGURE 3.2. The user can view a specific
system parameter by directly pressing the parameter key on the keypad. If there are two
parameters displayed on a key, press the key once to display the first parameter and twice to
display the second parameter. If the key is pressed again, a blank screen will appear. The
description of each function is listed in the screen description tables in section 3.2.2.
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4400M Digital RO System
The following table shows the different monitoring parameters accessible by pressing
corresponding keys:
Key
Parameter Description
Tank Level
Displays water level in a tank if the RO product water is fed to the tank.
(LOW / INTERMEDIATE / HIGH)
Temperature
Displays the feed and the product water temperatures. Press the key again to toggle
between two temperatures.
% Rejection
Displays the amount of contaminants being rejected from the membranes. This reading is
dependent on the feed water supply. It should be used in relation to the feed water
quality to evaluate the condition of the membranes.
Pump Time
The reading shows the time the RO pump has been in operation. The maximum limit of
the timer is 32000 hrs. It is used to determine maintenance requirement for the pump.
Conductivity / Resistivity
Displays the feed and the product water quality in electrical conductivity (µS/cm) or
resistivity (Ωcm). Press the key again to toggle between the feed and the product
readings.
Flush Time
Displays the status of the Flush operation. “FLUSH IN” indicates the time remaining before
the next flush and “REMAINING” indicates the amount of flush time remaining for current
flush operation.
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4400M Digital RO System
3.2.2
Set-Up Screen Descriptions
The following tables describe the content of each set-up screen. Refer to APPENDIX A3 for the
Screen Navigation flow chart.
Screen Description: SET-UP MAIN MENU
Access:
Item
Options
1>
Clean Mode
2>
Customize
3>
Alarms
Selection
<OK>
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.
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-In-Place
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 setpoints.
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4400M Digital RO System
Screen Description: CLEAN MENU
Access from Main Menu:
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.
READ INSTRUCTION MANUAL
BEFORE DOING THIS
COMMAND
<OK>
<CANCEL>
After the cleaning/sanitization process
completed, press the STOP key to end.
is
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.
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4400M Digital RO System
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 pre-set 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.
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4400M Digital RO System
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>
o
o
TEMPERATURE IN C or F:
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.
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>
Press OK to go to next to the Flush Cycle screen.
Flush Cycle
60? (30,120)nm
FLUSH CYCLE:
Enter the time between the flush cycles in
minutes.
(period included)
<CANCEL>
<OK>
NOTE: The flush cycle time is calculated
according to the current flush period.
MAN-4400MCOLD (rev.J)
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4400M Digital RO System
Screen Description: ALARM MENU #1
Access from Main Menu:
Item
Option
1>
Alarm->Stop:
2>
Selection
YES (Default)
1 retry (Default)
Alarm->Stop->Restart
3>
Poor Quality Delay
retry every 010m
(Default)
Sub Menu
<SETUP=next>
<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)
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
◄─
<OK>
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.
SELECT <<-> NUMBER BETWEEN RETRIES:
(10m..150m): 010m
◄─
MAN-4400MCOLD (rev.J)
Press the OK key to go to the next set-up screen.
<OK>
NOTE: This function is only available on a low
pressure alarm. The system considers a
successful restart when no alarm
condition has occurred in 11 minutes
from an automatic restart.
page 29 of 103
4400M Digital RO System
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.
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>
FEED TEMPERATURE SETPOINT:
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.
<OK>
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)
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4400M Digital RO System
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 SETPOINT:
Enter the desired setpoint for feed water alarm
temperature. When the system reaches this
setpoint, it will alarm and shut-down (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.
o
NOTE: The processor uses temperature in C to
calculate the conductivity and resistivity
measurements. When temperature unit
o
is set in F, rounding error may occur.
Screen Description: ALARM MENU #2 – Item #2 (Poor Quality SetPt) Sub-Menu
Access from Main Menu:
CONDUCTIVITY or RESISTIVITY SETPOINT:
Conductivity or Resistivity. SetPt
2? (1,100) μS Or 50? (1,100) x 10 K Ω
<CANCEL>
MAN-4400MCOLD (rev.J)
<OK>
Enter the desired setpoint 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.
page 31 of 103
4400M Digital RO System
3.2.3
Set-Up Data 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
No
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
Menu #3
ROP Timer
0
Menu #3
Flush Delay
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
1,10 min.
Menu #1
Poor Quality Shutdown
Delay
120 s
Menu #2
Feed Temperature
Setpoint
Menu #2
Poor Quality Setpoint
Menu #2 – Item #2 Sub-Menu

Conductivity
Menu #2 – Item #2 Sub-Menu

Resistivity
3.2.4
Yes
35°C or 95°F
2 μS
500KΩ
Controller Options
The digital controller provides several options for external connections to enhance the RO
system performance and the monitoring function.
Product Divert
When this optional controller input is activated via a manual or an external timer switch, the
optional product divert valves are activated to allow the product water to flow to drain. When
the external switch is in the auto position the product divert valves will automatically divert to
drain in the following conditions:
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4400M Digital RO System



In “STANDBY”, “FLUSH” & “STOP” mode
In “RUN” mode, only if product quality is greater than the programmable setpoint.
In all alarm conditions.
Remote Alarm Panel
A remote alarm panel can be mounted in a different location (control room / nurses’ station) to
provide the operator with a LED indication of system operations. 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). The system will re-alarm for less than 2 minutes if
alarm is still present.
RS-232 Remote Personal Computer (PC) Interface and Software
A RS-232 output card and software can be installed to communicate to a PC hooked to a
maximum wire length of 1,000 ft. 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
Product 0.1 Cell Constant Conductivity / Temperature Sensor
In critical applications, a 0.1 cell constant conductivity sensor can be installed on the product. A
software (EPROM) upgrade is required with this option. This sensor can be a standard MNPT
thread or optional 316L stainless steel tri-clamp connection.
3.3
OPERATING PROCEDURES
The procedures below describe how to operate the 4400M - Digital RO system. Refer to the
information provided in section 3.2.2 on Set-Up Screen Descriptions to provide inputs to the
system controller.
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4400M Digital RO System
3.3.1
System Start-up
For Initial start-up or to restart from a complete system shut-down, refer to the start-up
procedures in section 2.5.
3.3.2
Normal Operations
See section 3.2 to perform RO operations and set-up system parameters.
3.3.3
System Shut-down
For temporary stoppage, the RO system can be shut-down in following ways:


By pressing the STOP key on the display keypad located on the control panel.
By turning the Main Disconnect lever to the OFF position when access to the control
panel is required for repair.
For extended shut-down period, follow the procedures below:
NOTE
Due to site conditions some of the procedures might have to be altered.
1. At shut down, flush the system with product water. The flush water must be free of any
chemical additives.
2. Relieve the system pressure and shut down the feed pump.
3. When the system is secured, ensure that the water does not drain from the elements. Also
ensure that there is no back pressure on the elements from the permeate side.
NOTE
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 shut-down, greater than one week, a preservative solution must be added to the
system to eliminate biological growth. Refer to section 4.4.6
5. If the plant is to be secured for less than one week, it is usually sufficient to flush the system
with fresh, pretreated feed water once per day to minimize biological growth.
CAUTION
In an event of complete system stoppage, restart the system as per Start-up
instructions provided in section 2.5 to avoid possible damage to the system.
MAN-4400MCOLD (rev.J)
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4400M Digital RO System
3.4
MONITORING SYSTEM PERFORMANCE
The 4400M system is designed to monitor the system performance. The following parameters
are monitored and displayed by the system:





Active 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
Product tank level: Low, Intermediate, High
Water Quality and Temperature Monitoring:






Feed water conductivity or resistivity
Feed water temperature
Product water conductivity or resistivity
Product water temperature
% Rejection of water impurities between input and output conductivities
Product water non-temperature compensated conductivity or resistivity using the 0.1
cell constant optional probe. This probe is factory set.
Any issues encountered by the system relating to water quality, pressure and temperature are
flagged by the system controls and alarms are displayed.
Alarm/Warning Monitoring:






Poor product water quality
Low feed water pressure (for less than 12.5 psi, fixed digital input)
Pump input current overload (digital input)
High feed water temperature
Remote standby
Optional audible alarm (Re-alarm every 2 minutes if alarm is still present)
Log all the alarms in the Sample Log Sheet provided in APPENDIX A4. This will help the
technician in troubleshooting.
NOTE
The troubleshooting of the system shall be performed by trained personnel or
a Mar Cor Technician.
The common problems encountered by a RO system are due to either mechanical failure of the
pressurization system or failure of the RO membrane. The breakdown of the pressurization
system can result from:
MAN-4400MCOLD (rev.J)
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4400M Digital RO System



Electrical problems
Mechanical interruption of the water flow
Mechanical destruction of the pump
The other common problems are related to the failure of RO membranes. They are caused by:



Inadequate RO pre-treatment that causes the membrane to foul, scale or become
chemically altered
The introduction of chemicals that are incompatible with the RO membrane
Breakdown of the membrane or mechanical seals (O-rings) between the different
elements
Therefore, in addition to monitoring the RO system parameters, the RO membrane
performance must also be monitored. Percent Rejection is used by the 4400M system to test
the performance of the RO membranes. Percent Rejection measures the product TDS (Total
Dissolved Solid) against the feed TDS. This percentage gives a general idea of the efficiency of
the RO membrane to remove ions. Because the ion exclusion rate of a membrane is a function
of the feed water ion concentration, it is very important to monitor changes within the feed
water to better control its impact on the final product water.
NOTE
The product water quality is proportionally related to feed
water quality. The user is responsible for monitoring the feed water quality.
Significant deterioration in feed water quality may change the product water
quality beyond acceptable limit. (Reference: ISO 26722. Element 6.3, Item j).
A table in APPENDIX A9 lists critical system parameters that must be checked at specified
frequency to ensure that any seasonal or temporary change in the feed water quality meets the
system specifications.
MAN-4400MCOLD (rev.J)
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4400M Digital RO System
3.5
MONITORING RO MEMBRANE PERFORMANCE
The table below describes variables that affect the performance of the RO membranes used in
the 4400M system. Any variable with out-of-range condition should be corrected to achieve the
maximum life of the membrane.
OPERATING PARAMETERS FOR RO MEMBRANES
Variables
Service Point
Unit
Min.
Max.
(1)
Temperature
Feed Inlet
C
2
Total Chlorine
Feed Inlet
ppm
0.0
<0.1
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 Pressure
Pump Outlet
psig
180
Membrane Pressure Drop
Pump Outlet To Reject
psig
5
Design Product (Flux) Flow Rate
Product Outlet
gpd
Product (Flux) Flow Rate
Product Outlet
%
Rejection*
Inlet To Product
%
35
300
(2)
13
2,000 per membrane
-15
+25
>90 %
WARNING:
 Percent Rejection target is based on ISO 13959 Water for Hemodialysis and Related Therapies. Other
options exist, and it is the ultimate responsibility of the customer to ensure the final water quatilty meets
required standards for use in dialysis.
NOTES:
o
o
(1) The Actual membrane maximum temperature is 45C (113 F). The System alarm setpoint is 35C (95 F).
(2) The Maximum pressure drop includes piping and is shown per membrane.
3.5.1
Effects of Pressure on Membrane Performance
The operating pressure of a system also affects the product flow rate. The amount of product
water 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 Trans-Membrane
Pressure (TMP) and can be calculated as:
TMP = Feed Pressure - Product Pressure
MAN-4400MCOLD (rev.J)
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4400M Digital RO System
If the product from the RO system feeds directly to a distribution 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).
NOTE
Never exceed a Trans-Membrane Pressure of 220 psi (15 bar) for TFC
cartridges.
NOTE
Trans-Membrane Pressure should be reduced if the feed water temperature is
greater than 25oC (77o F) to avoid exceeding the design flow rate.
3.5.2
Effects of Recovery on Membrane Performance
The recovery of RO systems is defined as the percent of feed water (including reject recycle
water) that becomes purified product water. The recovery is calculated by:
% Array Recovery =
% System Recovery =
Product
Product + Reject + Reject Recycle
Product
Product + Reject
X 100
X 100
The design recoveries of the RO systems are given in the table below. 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 =
MAN-4400MCOLD (rev.J)
Product
% Array Recovery
- Product - Reject
page 38 of 103
4400M Digital RO System
# of Membranes In Series
Delta P. - psig (kPa)
Maximum Recovery Percentage
1
2
3
4
5
10 (69)
20 (138)
30 (207)
38 (262)
45 (310)
15%
25%
35%
45%
53%
NOTE
Recoveries are listed above without recirculation. With the optional
recirculation valve closed, exceeding these recoveries will result in short
membrane life. This will void the RO membrane warranty.
NOTE
After setting the proper recovery, as suggested above, the recirculation valve
can be opened to increase the system recovery up to 75% provided the feed
water, sampled at reject, is still within specification.
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 condition changes.
NOTE
Do not exceed the design recovery as this can result in decreased salt rejection
and membrane fouling or scaling.
NOTE
Never completely close the reject and reject recycle valve.
NOTE
When either opening or closing any needle valve, DO NOT over-extend or
over-tighten the valve as galling damage may occur. When fully opening the
valve, do so till resistance is felt and then close the valve ¼ turn. When fully
closing the valve, DO NOT use wrenches or other tightening tools. Close valve
till snug
3.5.3
Effects of Temperature on Membrane Performance
The product flow rate for the RO system given is based on a feed water temperature of 25°C
(77oF). The product flow rate will be reduced at temperatures below 25°C as the viscosity of
the water increases, making it more difficult to force water through the membrane.
NOTE
At temperatures higher than 25°C, the operating pressure should be reduced
to maintain the design flow rate. Operating at a higher product flow will void
the RO membrane warranty.
If the temperature is not 25° C, a correction factor must be used to calculate the expected
product flow rate from the system. The table below provides temperature correction factors to
apply for feed temperatures other than 25°C.
MAN-4400MCOLD (rev.J)
page 39 of 103
4400M Digital RO System
NOTE: Temperature correction factors are listed for all RO elements. The reference temperature is
77°F (25°C).
Temperature °F (°C)
Correction Factor
MAN-4400MCOLD (rev.J)
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
page 40 of 103
4400M Digital RO System
4.0
MAINTENANCE
4.1
MAINTENANCE REQUIREMENTS
After the system has been commissioned, the 4400M system will require scheduled
maintenance at defined frequency. Regular maintenance is necessary in order to:




Ensure the product water quality meets or exceeds the ISO 13959, ISO 11663 and ISO
26722 standard requirements for dialysis water.
Ensure operating efficiency.
Ensure maximum membrane life.
Ensure warranty protection.
A Maintenance Log Sheet with reference pictorials is provided. It lists the items that need to be
monitored at specific frequency.
NOTE
Maintenance of the 4400M system following its installation is the
responsibility of the dialysis physicians and it is their responsibility to ensure
that product water is tested periodically (Reference: ISO 26722 Element 6.3.
Item a). Appropriate chemical cleaning/ sanitization must be performed to
maintain acceptable product water quality.
NOTE
This section does not cover maintenance of the pre-treatment devices. Refer to
their manufacturers’ manual for maintenance requirements.
NOTE
Use this system only with the specified feed water and pre-treatment
chemicals determined by a Mar Cor water analysis. Use all sanitizing and
cleaning agents according to the instructions in this Manual.
MAN-4400MCOLD (rev.J)
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4400M Digital RO System
4.1.1
Scheduled Maintenance Log Sheet
NOTE: All readings should be taken when the system is in operation. Failure to perform these normal checks at specified frequency
will void the product warranty.
LOG
FREQ.
D/M/Y
UNITS
Date
d
d/m/y
Time
d
h/m
Pre-filter Inlet Pressure (Fig. 4.1)
d
psig
<60
Pre-filter Outlet Pressure (Fig. 4.1)
d
psig
<60
Pre-filter Delta Pressure
d
psig
<10 psi clean or Once
a Month
Solenoid Valve Seals (Fig. 4.1)
y
d/m/y
PARAMETER
EXPECTED RESULTS
SUN
MON
TUES
WED
THU
FRI
Change Once Every
Two Years
ADDITIONAL NOTES:
In addition to checks above, perform daily checks for the system performance parameters listed in APPENDIX A9.
MAN-4400MCOLD (rev.J)
page 42 of 103
SAT
4400M Digital RO System
Figure 4.1 – LOCATIONS FOR MAINTENANCE CHECKS
Pre-filter Inlet
Pressure Gauge
Reject Solenoid Valve
Pre-filter outlet
Pressure Gauge
Feed Inlet Solenoid
Valve
Image shown may not reflect actual system
MAN-4400MCOLD (rev.J)
page 43 of 103
4400M Digital RO System
4.2
REPLACEMENT PROCEDURES
4.2.1
NOTE
Pre-filter Replacement Procedure
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 on to the RUN mode and then turn it OFF again to relieve the pressure.
3. Remove the filter bowl by turning it counter-clockwise.
NOTE
Hold the bowl firmly as it is being removed. It is full of water.
4. Dump excess water and discard the old filter cartridge.
5. Inspect and replace the o-ring if signs of cracking 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 them 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
4.2.2
The bowl should only be hand tightened. If it requires more torque this
indicates that the o-ring requires replacement.
Solenoid Valve Seal Replacement Procedure
The 4400M system uses two Burkert solenoid valves. The location of each solenoid valve in the
system is shown in FIGURE 4.1. It is recommended that the seals for the inlet solenoid valve
(YV2.00) be replaced every two years. Please refer to the Burkert’s Manufacturer’s Manual for
the procedure on the installation and removal of seals. There is no seal kit for the reject
solenoid valve
WARNING To prevent electrical shock, disconnect the electrical power to the system
before servicing.
WARNING Use proper safety procedures when working in an electrical panel. Disconnect
and/or lock out the 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 Drain all the water out in the system and relieve pressure before servicing.
MAN-4400MCOLD (rev.J)
page 44 of 103
4400M Digital RO System
CAUTION
4.3
Do not energize a solenoid coil with the coil removed from the valve stem.
Damage to the coil may occur.
OVERVIEW OF SYSTEM SANITIZATION & RO MEMBRANE CLEANING
The disinfection of the 4400M – Digital RO system must be done to control bacterial growth
and to remove biological film. Based on the feed water source, system operating conditions and
the user’s preventative maintenance practices, a routine sanitization treatment is
recommended on the RO system.
Chemical cleanings are performed to remove particulate, inorganic scale and organic fouling
from the RO membranes. There is no specific frequency for cleaning of the RO system. A
cleaning should be performed when the flow rates or water quality begin to drop below
allowable limits (refer to tables in section 3.5 and Appendix A8).
CAUTION
When performing a sanitization using the MINNCARE® disinfectant (or any
approved chemical disinfectant containing hydrogen-peroxide), an acid
cleaning must be performed on the RO system first to remove any metal
build-up on the membranes, preventing oxidization. When cleaning a RO
system follow membrane manufacturer’s recommendations and/or customer
approved cleaning/sanitization procedures.
It is recommended that the RO system is disinfected using MINNCARE® monthly or as required.
In order to understand the concept of RO membrane cleaning, it is important to know
something about membrane fouling. The next sub-sections present basic information about the
different types of foulants and how to identify them when they affect RO membrane
performance.
There are three major groups of RO membrane foulants: hardness/metal oxides, colloids/silica,
and aluminum/polymers. These potential foulants can exist independently, but can also occur
together resulting in a "mixed" fouling.
The symptoms of RO membrane fouling can range from gradual decline in product water flux
over several months, to severe loss overnight. The ultimate results of membrane fouling can
vary 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
pre-treatment being employed and feed water characteristics. While the occasional need for
cleaning may arise due to pre-treatment equipment failure or a temporary change in feed
MAN-4400MCOLD (rev.J)
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4400M Digital RO System
water composition, persistent or severe fouling should be a cause for re-evaluation of the RO
pre-treatments.
The following basic discussions are of RO foulants, how to identify them, and what to do once
they have affected membrane performance:
4.3.1
Dealing with a Hardness/Metal Oxide Fouling Problem
What are Hardness and Metal Oxides?
Hardness most commonly encountered is in the form of calcium carbonate (CaCO3) 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.
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.
Recognizing Hardness Scaling/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.
What to do if Hardness/Metal Oxide Fouling is suspected?




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 readings.
Failure to reverse this type of scaling will result in permanent damage to the
membranes.
Generally, the use of chemical solution is recommended. Refer to the manufacturer’s
recommended chemicals in section 4.4.2.
MAN-4400MCOLD (rev.J)
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4400M Digital RO System
4.3.2
Dealing with a Colloids/Silica Fouling Problem
What are Colloids? What is Silica?
Colloids are very fine, suspended solids that can clot and become entrapped on the RO
membrane surface. Colloids found in feed water are usually 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.
The Problem
During the RO process, colloids are destabilized and as the concentration of salts increases,
they clot and foul the element. The rate of fouling is directly related to the concentration of
colloidal material present, and its 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 polymerized to form colloidal silica, or precipitate as a silicate.
Recognizing Mixed Colloids/Silica Fouling
Fouling due to colloids/silica material is usually quite slow. Its symptoms are a gradual decline
in flux and no real change in salt rejection. In the presence of metal oxides, however, the
decline can be more dramatic. If fouling is not treated, an eventual decrease in salt rejection
will be observed.
What to do if Colloidal/Silica Fouling is suspected?




Find out from your water department if the presence of colloids/silica material is
temporary or a standard constituent of your feed water.
Pre-treatment may be required for these foulants. Check to see if the pre-filter is of the
right type and working properly. An "absolute" rated filter may be required.
Consider the addition of an appropriate chemical feed sanitization system.
Refer to the cleaning instructions in section 4.4.4 or 4.4.5.
4.3.3
Dealing with an Aluminum/Polymer Fouling Problem
What are Aluminum and Polymers?
Aluminum and polymers are frequently used by municipal water treatment facilities as
flocculent to settle out dirt and other suspended matter in water sources. Ideally, all of the
added aluminum/polymer is supposed to be removed in the process, but in actual practice, a
small amount of aluminum/polymer often remains in the water supply. One of the properties of
these flocculent that makes them effective is that they easily knot and come out of solution.
MAN-4400MCOLD (rev.J)
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4400M Digital RO System
Unfortunately, this property can present troublesome conditions for high efficiency RO
systems, with over 33% recovery.
The Problem
When residual aluminum/polymers are present in the feed water supply to a RO system, a
membrane fouling problem may exist. Aluminum/polymers can clot 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 aluminum/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
aluminum/polymer complexes will tend to foul the membrane.
Recognizing Aluminum/Polymer Fouling
The first sign of aluminum/polymer fouling is a loss of product water flow rate. Unlike most
other types of fouling which takes a long time to develop, aluminum/polymer fouling can cause
a reduction in product water flow rate in a matter of days. There may be little or no decrease in
percent rejection performance. The sooner the signs of aluminum/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 rates such as colder feed
water temperature. This should be ruled out as a possible cause before
aluminum/polymer fouling is suspected.
What to do if Aluminum/Polymer Fouling is suspected?





4.4
Inquire with the municipal water department and find out if aluminum/polymers are
used in their treatment.
Find out the levels of silica and iron, including those imparted by galvanized piping, are
present in the feed water.
If the product flow rate decreases from its expected level, clean the membranes as per
instructions in section 4.4.4 or 4.4.5.
If the water conditions are such that aluminum/polymer fouling continues to occur,
then periodic cleaning may have to become part of regular maintenance.
Consider additional methods such as adding a chemical feed sanitization system or
lowering the recovery to deal with the fouling.
CHEMICAL CLEANING AND SANITIZATION
This section describes requirements and procedures for the cleaning of the RO membranes and
chemical sanitization of the 4400M – Digital RO system. Information on the selection of the
right chemicals and their correct use is provided.
MAN-4400MCOLD (rev.J)
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4400M Digital RO System
4.4.1
Clean-In-Place (CIP) Equipment Requirements
The Clean-In-Place (CIP) system configuration can be used for the RO system sanitization or
membrane cleaning. It must be designed to support the flow and pressure requirements of
each individual system. The general guidelines for construction of a CIP system are provided
below.
Maximum Cleaning Feed Flow Rate and Pressure
Element Nominal Diameter:
Maximum Flow Rate:
Maximum Pressure:
4”
10.0 gpm per housing
60 psig
NOTE
Clean pressure vessels only in parallel. Where a series array of pressure vessels
is used for higher recoveries, each pass must be cleaned separately.
Cleaning Tank
The cleaning tank should be sized 2-3 times the estimated holding volume of the RO system
including membranes, CIP interconnect hoses and piping. It must be large enough to prevent
cavitation of the pump. The tank material must be biocompatible with the chemicals used in
the sanitization process. Refer to the tables below in order to determine the estimated holding
volume of hoses and membranes.
Hose Volume
Hose Diameter (inches)
Hose Volume (gallons /foot)
¾”
0.02
1”
0.04
2”
0.16
Membrane Element Volume
Element Diameter (inches)
Element Length (inches)
Volume Per Element (gallons)
4”
40”
2
Cleaning Pump
The cleaning pump must be sized to provide the maximum flow required per element. For
example a system with 4” membranes and a configuration of 3 banks of 4 elements will require
a pump to deliver 30 gpm. The pump’s wetted components should be constructed from 304 or
316 stainless steel.
MAN-4400MCOLD (rev.J)
page 49 of 103
4400M Digital RO System
NOTE
The pump must be flushed with clean water after a sanitization is completed
to prevent corrosion and damage to the pump.
Filter Housing (Optional)
The filter should be sized for the maximum flow rate. It should be constructed from 316
Stainless Steel, Polyethylene or Polypropylene.
Filter Cartridges (Optional)
An optional 5.0 micron nominally rated filter cartridge should be installed in the filter housing
to trap any particulate that is removed during the cleaning/sanitization process.
Controls
Controls should include the following:





NEMA 4-12 enclosure
Panel disconnect
Pump motor starter
Pump hand/off/auto switch
Low tank level switch
Piping and Valve Configuration
The piping and valves should be sized for the maximum flow rate. The material must be able to
withstand cleaning/sanitization solutions. Refer to the sample flow drawing in FIGURE 4.2 for a
typical CIP system set-up.
MAN-4400MCOLD (rev.J)
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4400M Digital RO System
FIGURE 4.2 – TYPICAL CLEAN-IN-PLACE (CIP) SETUP
SERVICE-BIOPUREHX2 (rev. J)
page 51 of 103
4400M Digital RO System
4.4.2
Cleaning/Sanitization Chemicals
The following cleaners have been evaluated and found to be compatible with the membrane
elements. In addition to the generic cleaners listed below, there are many chemical companies
that market membrane cleaners. For best results, use Mar Cor’s recommended brand for antiscalants and cleaners for your specific elements.
TYPE OF FOULANT
CHEMICAL
Mineral scale and metal precipitates
HCl or citric acid, pH 2
Organics, silt, bacterial slime
Sodium hydroxide, 0.5%
Sodium dodecyl sulfate, 0.1%
Adjust to pH 11.5 with HCl if necessary
Organics, silt, bacterial slime
Trisodium phosphate, 1%
Sodium tripolyphosphate, 1%
Sodium dodecyl sulfate, 0.1%
Tetrasodium EDTA, 1%
Adjust to pH 11.5 with HCl if necessary
Bacteria
Sodium bisulfite, 0.1%
Chlorine dioxide, 30 ppm
The tables below list the recommended chemicals and their concentration requirements for use
with the CIP system. Dilute the chemical quantities with 100 litres of RO quality water or better
at 10-30°C (50-86°F).
Recommended Chemicals
TYPE OF FOULANT
CHEMICAL
®
Mineral scale and metal precipitates
MINNCLEAN AC Cleaner
Organics, silt, bacterial slime
MINNCLEAN TF Cleaner
Bacteria
MINNCARE Disinfectant
®
®
Chemical Concentrations
CHEMICAL USED
QUANTITIES RECOMMENDED TO CREATE 100 LITRES
OF CLEANING/SANITIZATION SOLUTION.
®
1.76 lbs. (0.798 kg), pH 2.0 to 2.4
®
1.76 lbs. (0.798 kg), pH 11.4 to 11.2
MINNCLEAN AC Cleaner
MINNCLEAN TF Cleaner
®
MINNCARE Disinfectant
CAUTION
0.26 US Gallons (1.00 litres), pH 3.0 to 3.5
RO quality water or better must be used when rinsing and preparing the
cleaning/ sanitization solutions. Failure to do so will result in damage to the
membrane elements.
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CAUTION
A flush with RO quality water, using the CIP system, is required between each
cleaning/sanitization step. If not performed, a thermal reaction can occur
resulting in damage to the membrane elements.
CAUTION
When performing a sanitization using the MINNCARE® disinfectant (or any
approved chemical disinfectant containing hydrogen-peroxide), an acid
cleaning must be performed on the RO system first to remove any metal
build-up on the membranes, preventing oxidization. When cleaning a RO
system follow membrane manufacturer’s recommendations and/or customer
approved cleaning/sanitization procedures.
4.4.3
Overview of Recommended Chemicals
ACIDIC CLEANER
Acidic Cleaners (i.e. MINNCLEAN® AC cleaner) designed for use on thin film composite
(polyamide) RO membrane systems. It is especially formulated to remove mineral scale such as
calcium carbonate and metal hydroxides from the membrane surface. MINNCLEAN ® AC is an
acidic, low pH, membrane cleaner.
Specifications:
Compound
Low pH Powder (Acidic)
Normal Cleaning
1 pound (0.454 kg) cleaner per 15 gallons (57 litres) RO water
pH of Solution
2.0-2.4
Foam Level
Moderate
Cloud Point
None
Rinsability
Good
Storage
Store sealed container in a cool dry place. Indefinite cleaner stability under good storage
conditions.
ALKALINE CLEANERS
Alkaline cleaners (i.e. MINNCLEAN® TF cleaner) designed for use on thin film composite
(polyamide) RO 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.
Specifications:
Compound
High pH Powder (Alkaline)
Normal Cleaning
1 pound (0.454 kg) cleaner per 15 gallons (57 litres) RO water
pH of Solution
11.4 to 11.2
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Foam Level
Moderate
Cloud Point
None
Rinsability
Good
Storage
Store sealed container in a cool dry place. Indefinite cleaner stability under good storage
conditions.
MINNCARE® Disinfectant
Specifications:
DIN (Canada)
02277484
Compound
Hydrogen Peroxide 22.0% / Peroxyacetic Acid 4.5% / Inert Ingredients 73.5%
Normal Cleaning
1% Concentration
pH of Solution
1.3
Foam Level
Moderate
Cloud Point
None
Rinsability
Good
Storage
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-tomouth, if possible. Call a poison control center or doctor for further treatment
advice. If on skin or clothing, take off 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.
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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 1-800424-9300 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.
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
o
Sporicidal
100X dilution, 11 hours
20 C
Bactericidal
100X dilution, 11 hours
20 C
Fungicidal
100X dilution, 11 hours
20 C
(Non-food contact surfaces)
32X dilution, 10 minutes
20 C
(Food contact surfaces Staphylococcus aureus
and Escherichia coli)
320X dilution, 1 minute
20 C
Hospital Disinfectant Pseudomonacidal
100X dilution, 10 minutes
25 C
Broad Spectrum Disinfectant
100X dilution, 10 minutes
20 C
Germicidal Spray Disinfectant
100X dilution, 10 minutes
20 C
RO Membrane Sanitizer
100X dilution, 36 minutes
20 C
o
o
Cleaner/Sanitizer
MAN-4400MCOLD (rev.J)
o
o
o
o
o
o
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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 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, PTFE,
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 RO water does not contain the same components. Dependent
upon your particular system, all or portions of the following procedure may be for sanitizing.
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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).
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.
4.4.4
Cleaning/Sanitization Procedure Using a CIP System Skid
The procedure below will assist an operator in cleaning the RO membranes or sanitizing the RO
system using a Clean-In-Place (CIP) system. This procedure is written for the CIP configuration
shown in Figure 4.2.
CAUTION
When performing a cleaning/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 it. Carefully follow the
manufacturer’s safety instructions on the labels affixed to the chemical
containers.
CAUTION
When performing a sanitization, an acid cleaning must be performed first. This
will remove any metal build-up on the membranes and prevent the
membranes from oxidization. When cleaning the system, ensure it is
operating at high flow rates and low pressure. If high pressure is used,
contaminants can be pushed further inside the membranes.
NOTE
Due to varying site conditions, some of these procedures might have to be
altered.
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1. Record the flow rates, pressures and product quality before cleaning/sanitization. This data will
be compared with data collected after cleaning/sanitization to determine if the
cleaning/sanitization improved the RO performance.
2. Place the RO system in the STOP mode.
3. Place the cleaning skid pump switch in the OFF position.
4. Close all valves on the cleaning skid.
5. Install a 5 micron filter cartridge in the cleaning skid optional filter housing.
6. Close the inlet valve to the RO pre-filter housing.
7. Relieve the system pressure.
8. Connect a flexible hose (1” or 1½”) from the cleaning skid discharge to the RO skid CIP inlet
valve. Secure the line. See schematic in APPENDIX A1 for valve location.
9. Connect a flexible hose (½”, ¾”, or 1”) from the RO reject CIP outlet valve to the return
connection on the cleaning skid. Secure the line.
10. Connect a flexible hose (½”, ¾”, or 1”) from the RO product CIP outlet valve to the return
connection on the cleaning skid. Secure the line.
11. Close the RO product to process and the RO reject to drain valves.
12. Fully open the RO product CIP and the RO reject CIP valves.
13. Fully open the reject and the reject recycle valves.
NOTE
When either opening or closing any needle valve, DO NOT over-extend or
over-tighten the valve as galling damage may occur. When fully opening the
valve, do so till resistance is felt and then close the valve ¼ turn. When fully
closing the valve, DO NOT use wrenches or other tightening tools. Close valve
till snug.
14. Fill the cleaning tank with RO quality water or better at 20-30°C (68-86°F).
15. Fully open the cleaning skid pump inlet and the tank recycle valve.
16. Connect the cleaning skid electrical cord to the power source.
NOTE
17.
18.
19.
20.
21.
22.
If the skid is being used for the first time, verify pump rotation (see section
2.5.5) and adjust the optional low-level switch.
Prime the cleaning pump.
Place the cleaning skid selector switch in the ON position.
Adjust the tank recycle diaphragm valve until the pressure indicates approximately 50-60 psig.
Fully open the RO CIP inlet valve.
Fully open the cleaning skid inlet and the outlet filter housing valves.
Bleed the air from the cleaning skid filter housing using the sample valve. Verify that water is
flowing from the cleaning skid into the RO and back to the cleaning skid. Check for leaks and
repair if any are found.
CAUTION
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.
23. Turn the cleaning skid selector switch to the OFF position.
24. Fully open the tank recycle valve.
25. Close the cleaning skid filter housing inlet valve.
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26. Add the predetermined amount of cleaning/sanitization chemical to the cleaning tank.
CAUTION
When performing a sanitization, an acid cleaning must be performed first. This
will remove any metal build-up on the membranes and prevent the
membranes from oxidization. When cleaning the system, ensure it is
operating at high flow rates and low pressure. If high pressure is used,
contaminants can be pushed further inside the membranes.
27. Turn the cleaning skid selector switch to the ON position and allow the solution to recirculate
until the added chemical is fully mixed.
28. Fully open the cleaning skid filter housing inlet valve and adjust the tank recycle valve until the
pressure is between 50-60 psig.
29. Allow the solution to recirculate for five minutes and check to ensure that the solution
concentration (pH) is within limits from the sample valve located on the cleaning skid filter
housing.
NOTE
If the solution concentration (pH) is too high, add some acid (HCl) or if the
concentration (pH) is too low, add caustic (NaOH).
NOTE
If the pH dramatically decreases/increases or becomes dirty, the solution
should be disposed of and a new batch made. Check your local municipality
waste discharge limits before dumping the solution.
NOTE
For sanitization process, use the MINNCARE® residual test strips to check for
residual level. Refer to 4.4.9 for instructions.
30. Allow the solution to recirculate for thirty minutes and check the solution concentration
periodically. Monitor the temperature of the solution to make sure it does not reach above
45°C (113°F).
31. After the time has elapsed, turn the cleaning skid selector switch to the OFF position.
32. Neutralize the cleaning solution. Refer to section 4.4.7
33. Once the solution is neutralized, turn the cleaning skid pump OFF and dispose the solution using
the tank drain valve.
34. Close the tank drain valve and fill the tank with RO quality water or better.
35. Turn the cleaning skid selector switch to the ON position.
36. Allow the water to recirculate for five minutes. Check to ensure that 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.
37. Turn the cleaning skid selector to the OFF position and drain the tank.
38. Restart this procedure if a different chemical is to be used.
39. Proceed to section 4.4.6 for decommissioning of the tank.
40. Restart the RO system as per instructions in section 4.4.8.
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4.4.5
Cleaning/Sanitization Procedure Using a Tank and RO Pump
This procedure will assist an operator in cleaning the RO membranes or sanitizing the RO
system using a small tank and the RO pump only.
CAUTION
When performing a cleaning/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 it. Carefully follow the
manufacturer’s safety instructions on the labels affixed to the chemical
containers.
CAUTION
When performing a sanitization, an acid cleaning must be performed first. This
will remove any metal build-up on the membranes and prevent the
membranes from oxidization. When cleaning the system, ensure it is
operating at high flow rates and low pressure. If high pressure is used,
contaminants can be pushed further inside the membranes.
CAUTION
This procedure should only be used when the RO pump is less than 5.0 horse
power (hp). Damage to system and pump can occur. System with greater than
5.0 hp RO pump should use only a separate cleaning pump (Clean-In-Place
System) when a cleaning or sanitization is required.
NOTE
Due to different site conditions, some of these procedures might have to be
altered.
1. Record the flow rates, pressures and product quality before cleaning/sanitization. This data will
be compared with data collected after cleaning/sanitization to determine if the
cleaning/sanitization improved the RO performance.
2. Place the RO system in the STOP mode.
3. Close the inlet valve to the RO pre-filter housing.
4. Relieve the system pressure.
5. Connect a flexible hose (1” or 1 ½”) from the bottom of the tank to the RO skid CIP inlet valve.
Secure the line. See schematic in APPENDIX A1 for valve location.
6. Connect a flexible hose (½”, ¾”, or 1”) from the RO reject CIP outlet valve to the return
connection on the top of the tank. Secure the line.
7. Connect a flexible hose (½”, ¾”, or 1”) from the RO product CIP outlet valve to the return
connection on the top of the tank. Secure the line.
8. Close the RO product to process and RO reject to drain valves.
9. Fully open the RO product CIP and the RO reject CIP valves.
10. Fully open the reject and the reject recycle needle valves.
NOTE
When either opening or closing any needle valve, DO NOT over-extend or
over-tighten the valve as galling damage may occur. When fully opening the
valve, do so till resistance is felt and then close the valve ¼ turn. When fully
closing the valve, DO NOT use wrenches or other tightening tools. Close valve
till snug.
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11. Fill the tank with RO quality water or better at 20-30°C (68-86°F).
12. Fully open the RO CIP inlet valve.
13. Press the SETUP key on the controller’s keypad and then press the #1 key. The following screen
will appear.
READ INSTRUCTION MANUAL
BEFORE DOING THIS
COMMAND
<OK>
<CANCEL>
14. Press the OK key to start the cleaning/sanitization process.
15. Verify that water is flowing from the tank into the RO and back to the tank. Check for leaks and
repair if any are found.
CAUTION
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.
16. Press the STOP key on the keypad.
17. Add the predetermined amount of cleaning chemical to the tank. Mix the chemical until totally
dissolved.
CAUTION
When performing a sanitization, an acid cleaning must be done first. This will
remove any metal build-up on the membranes and prevent the membranes
from oxidization. When cleaning the system, ensure it is operating at high
flow rates and low pressure. If high pressure is used, contaminants can be
pushed further inside the membranes.
18. Press the SETUP key and the #1 key again.
19. Press the OK key to start the cleaning process.
20. Allow the solution to recirculate for five minutes, and check to ensure that the solution
concentration (pH) is within limits.
NOTE
If the solution concentration (pH) is too high, add some acid (HCl) or if the
concentration (pH) is too low, add caustic (NaOH).
NOTE
If the pH dramatically decreases/increases or becomes dirty, the solution
should be disposed of and a new batch made. Check your local municipality
waste discharge limits before dumping the solution.
NOTE
For sanitization process, use the MINNCARE® residual test strips to check for
residual level. Refer to section 4.4.9 for instructions.
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21. Allow the solution to recirculate for thirty minutes and check the solution concentration
periodically. Monitor the temperature of the solution to make sure it does not reach above
45°C (113°F).
22. After the time has elapsed, press the STOP key on the keypad.
23. Neutralize the cleaning solution. Refer to section 4.4.7.
24. Once the solution is neutralized, dispose the solution.
25. Fill the tank with RO quality water or better.
26. Press the SETUP key and the #1 key.
27. Press the OK key to start the cleaning process.
28. Allow the water to recirculate for five minutes. Check to ensure that 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.
29. Press the STOP key on the keypad.
30. Proceed to section 4.4.6 for decommissioning of the tank.
31. Restart the RO system as per instructions in section 4.4.8.
4.4.6
Tank Decommissioning and Chemical Storage
After each cleaning/sanitization, the following should be performed:
CAUTION
Always relieve the pressure in chemical lines before disassembly to protect
you and others against possible chemical spray.
1. All CIP hoses are disconnected and drained of any water.
2. The cleaning tank and pump are drained of any water.
3. All chemical containers are closed and stored away as per instructions provided in section 4.4.3
(for MINNCLEAN® and MINNCARE® products) or accompanying product brochures for other
chemicals.
4. Ensure the panel disconnect is turned OFF.
5. All valves are in the proper position (Open or Closed) to restart the system.
6. Restart the RO system as per instructions in section 4.4.8.
4.4.7
Neutralizing Cleaning/Sanitization Solutions
After each batch of solution is used, the local municipality may require it to be neutralized for
discharging. Each batch of solution will have a different concentration after each use. Therefore it will
have to be calculated at each time. Refer to the accompanying product brochure of the chemical used
for instructions on neutralizing the solution.
NOTE
Check with your local municipality for waste discharge regulations.
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4.4.8
Restarting RO System after Chemical Cleaning/Sanitization Procedures
The following procedure will assist the operator in restarting the RO system after performing chemical
membrane cleaning and/or sanitization.
1. Fully open the reject to drain valve and fully close the reject CIP (Clean-In-Place) valve.
2. Connect a flexible hose to the product CIP valve and fully open the valve. Fully close the product
valve connected to the external process such as tank.
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. Fully open the reject and recycle needle valves.
NOTE
When either opening or closing any needle valve, DO NOT over-extend or
over-tighten the valve as galling damage may occur. Open the valve until
resistance is felt then close the valve ¼ turn. When fully closing the valve, DO
NOT use wrenches or other tightening tools. Close valve till snug.
4. Install a pre-filter cartridge if required see section 4.2.1.
5. Slowly open the feed water valve to the system pre-filter.
6. Start the machine by pressing RUN. Allow the flush cycle to complete before making any
adjustments.
NOTE
The RO will not flush if the flush cycle has been disabled in the controller setup menu.
7. Adjust the reject flow control needle valve to the flow shown in APPENDIX A8.
8. Adjust the reject recycle flow control needle valve to the flow shown in APPENDIX A8.
9. Adjust the pump recycle (chase) flow control needle valve to reduce or increase the pump
discharge pressure if required.
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
When either opening or closing any needle valve, DO NOT over-extend or
over-tighten the valve as galling damage may occur. When fully opening the
valve, do so till resistance is felt and then close the valve ¼ turn. When fully
closing the valve, DO NOT use wrenches or other tightening tools. Close valve
till snug.
NOTE
Flow adjustment should be made slowly.
10. Operate system to drain, until all residual chemicals are removed and verify that the system
parameters listed in APPENDIX A9 are within the required limits.
CAUTION:
The length of the rinse time can vary and is dependent on feed water
conditions and temperature. This process could take several hours and it is
the responsibility of the end user to ensure that the water meets or exceeds
the required operating parameters (i.e. conductivity, pH, and temperature)
before returning the system to service.
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NOTE:
It is recommended that when doing any of the tests to ensure that all residual
chemicals are removed that that all processes/equipment are validated.
NOTE:
When sanitizing with Minncare® refer to section 4.4.9 Minncare® Test Strips
Overview
11. Allow the system to operate and drain for two hours (four hours for dialysis application) and
record and verify that the system parameters listed in APPENDIX A9 are within the desired limits
12. Once the time has elapsed and the system parameters are met, turn the controller to the OFF
mode by pressing the STOP key. Close the product CIP valve and disconnect the flexible line.
Fully open the product valve connected to the external process.
13. Turn the controller to the RUN mode.
14. Record the system performance and compare it to the data collected before cleaning to
determine if the chemical cleaning has improved the system performance.
4.4.9
MINNCARE® Test Strips Overview
The 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 the 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.
CAUTION:
Store sealed vials in a cool dry environment. It is not necessary to refrigerate.
Once open store at room temperature. DO NOT REFRIGERATE. Failure to store
tests property will result in inaccurate readings. Close vial tightly when not in
use.
NOTE:
Each container has an expiry date. Do not use after date printed on the
container.
Test Strip Instructions:
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.
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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
colour scale between five and ten seconds after exposure.
NOTE
If the test strip indicates dark blue to brown or green to brown, the
concentrations are too high for the colour scale. Read the MINNCARE®
disinfectant package insert instructions for additional information.
MINNCARE® P/N 78339 1% TEST STRIPS
1.
2.
3.
4.
5.
Collect 1ml or greater of the MINNCARE® sample.
Remove a test strip from the tube and immediately replace the lid.
Dip the test strip into the solution to be tested, such that the reaction zone is properly wetted.
Remove the test strip and gently shake off excess liquid.
Within ten seconds, note the entire reaction pad colour development.



NOTE
4.5
1% = Blue-gray or blue-black colour over the entire reaction pad within two to five
seconds, and which does not fade, indicates MINNCARE levels of 1% or greater.
No colour 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.
The reaction pad may slowly change and develop colour after the initial
reaction. This is normal and should be ignored for the purpose of test
interpretation.
RO MEMBRANE ELEMENT STORAGE
The general storage procedures are described below for short-term and long-term storage.
CAUTION
Under no circumstances shall the system be exposed to a temperature less
than 0°C (32°F). Irreversible damage to the membranes, system components
and piping can occur.
NOTE
The composite polyamide type of RO membrane elements must not be
exposed to chlorinated water under any circumstances. Any such exposure
will cause irreparable damage to the membrane. Absolute care must be taken
following any disinfection of piping or equipment or the preparation of
cleaning or storage solutions to ensure that no trace of chlorine is present in
feed water to the RO membrane elements. If there is any doubt about the
presence of chlorine, perform a chemical testing to confirm. Neutralize any
chlorine residual with a sodium bisulfite solution, and ensure adequate
contact time to accomplish complete dechlorination.
MAN-4400MCOLD (rev.J)
page 65 of 103
4400M Digital RO System
Short Term Storage
Short-term storage is for periods of more than five days and fewer than thirty days when a RO
system must remain out of operation with the RO elements in place. For short-term storage of
the membrane element, prepare each RO train as follows:



Flush the RO section with feed water while simultaneously venting any gas from the
system.
When the pressure tubes are filled, close the appropriate valves to prevent air from
entering the system.
Reflush at five-day intervals.
Long Term Storage
Long-term storage is for a period of more than thirty days when a RO system must remain out
of operation with the RO elements in place. For long-term storage, prepare each RO train as
follows:




Clean the RO membrane elements in place.
Flush the RO section with an approved biocide or an approved available product
prepared from product water.
When the RO section is filled with this solution, ensure it is completely filled and close
the valves to retain the solution in the RO section.
Repeat the last two steps with fresh solution every thirty days if the temperature is
below 27°C (80°F) or every fifteen days if the temperature is above 27°C (80°F).
When the RO system is ready to be returned to service, flush the system for approximately one
hour using low-pressure feed water with the product to drain valve open and then flush it again
at high pressure for 5 to 10 minutes with the product to drain valve open. Before returning the
RO system to service, check for any residual biocide in the product.
Replacement Membrane Storage
When RO elements are stored prior to installation, they should be protected from direct
sunlight and stored in a cool, dry place with an ambient temperature range of 20°C to 35°C
(68°F to 95°F). During the period of transit between the factory and the plant site, the elements
should not be exposed to temperatures below freezing, 0°C (32°F) or above 45°C (113°F). New
Elements are enclosed in a sealed polyethylene bag containing a storage solution, and then
packaged in a cardboard box.
MAN-4400MCOLD (rev.J)
page 66 of 103
4400M Digital RO System
5.0
TROUBLESHOOTING
5.1
TROUBLESHOOTING ALARMS/MESSAGES
The following table lists common problems with the 4400M system and their cause(s) and
troubleshooting tips.
NOTE
The troubleshooting of the system must be performed by a Mar Cor
Technician. Failure to do so may void the product warranty. Refer to other
Manufacturers’ Manuals for component specific troubleshooting tips.
Please refer to the Screen Setting Ranges and Defaults table (see section 3.2.3) to ensure the
range and default pre-set values of each alarm parameter are correct. Record any modified
values in the table for future reference.
NO.
1
2
3
4
5
PROBLEM
POOR PRODUCT QUALITY
HIGH PRESSURE DROP
ACROSS PRE-FILTER OR
MEMBRANE
LOW PRODUCT FLOW
SYSTEM WILL NOT START
LOW FEED PRESSURE
MAN-4400MCOLD (rev.J)
PROBABLE CAUSE
CORRECTIVE ACTION
High recovery
Re-adjust flow rates
Fouled membrane
Identify foulant. Follow appropriate
cleaning/sanitization procedure.
Feed water out-ofspecification
Check feed water quality
Dirty Filter
Replace filter
Fouled membrane
Identify the foulant. Follow appropriate
cleaning procedure.
Fouled membrane
Identify the foulant. Follow appropriate
cleaning procedure.
Low feed water
temperature
Check feed temperature.
Tank full
Check tank level. Drain to intermediate level.
Pre-treatment in
regeneration
Check pre-treatment. Wait for regeneration
process to end.
System stopped
Press the RUN key. Ensure the main disconnect
is not turned OFF.
Flow restriction;
upstream valve is closed.
Identify and open closed valve. Perform a
complete diagnosis for valve position.
Low pressure; Building
water supply
Verify and/or install booster system
Inlet solenoid valve
malfunction
Perform a complete diagnosis for valve
position.
page 67 of 103
4400M Digital RO System
Plugged pre-filter
Change filter
6
RO PUMP OVERLOAD
Damaged motor or
pump
Verify and replace
7
FEED TEMPERATURE HIGH
Feed water temperature
is too high
Correct feed water temperature. Add blending
valve or adjust setting on feed line.
8
INCORRECT FEED
TEMPERATURE READING
Faulty feed temperature
sensor; probe error
Replace the sensor
9
INCORRECT PRODUCT
TEMPERATURE READING
Faulty product temp.
sensor; probe error
Replace the sensor
5.2
SYSTEM DIAGNOSIS
The test matrix in section 5.2.1 lists the state of each critical component during each mode of
RO operations. Perform a step-by-step diagnosis and record all the results in the test matrix.
See FIGURE 4.1 to locate components on the system. If a discrepancy is noticed between the
state of the expected condition and the actual condition, contact Mar Cor Technical Services for
help.
NOTE
The system diagnosis must be performed by a Mar Cor Technician. Failure to
do so may void the product warranty.
MAN-4400MCOLD (rev.J)
page 68 of 103
4400M Digital RO System
5.2.1
System Test Matrix
Pumps
P2.00
RO Pump
OFF
OFF
OFF/ON
OFF
ON
ON
OFF
ON
OFF
ON/OFF
ON/OFF
ON/OFF
ON
OFF/ON
OFF
OFF
OFF
OFF
RO Pretreatment Lockout (Amber Light)
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
OFF
ON
ON
ON
ON
OFF
RO Panel
YS-RO
Solenoids
YV2.00
RO Feed Inlet Valve
CL
CL
CL/OP
CL/OP
OP
OP
OP
OP
OP
OP/CL
OP/CL
OP/CL
OP
CL
CL
CL
CL
CL
YV2.01
RO Reject Valve
CL
CL
CL/OP
CL/OP
CL
OP
OP
CL/OP
CL/OP
CL
CL
CL
CL
CL/OP
CL/OP
OP/CL
CL/OP
OP/CL
YV2.03
RO Product To Drain Valve (OPTIONAL)
OP
OP
OP
OP
O/C-Q
OP
OP
CL/OP
CL/OP
CL/OP
CL/OP
CL/OP
CL/OP
OP/CL
OP
OP
OP
OP
Legend:
OFF
The device is OFF
ON
The device is ON
Com m ents:
ON/OFF The device status changes from ON to OFF
OFF/ON The device status changes from OFF to ON
OP
The Valve is OPen
Perform ed By:
CL
The Valve is CLose
OP/CL
The Valve status changes from OPen to Close
Date:
CL/OP
*- Q
The Valve status changes from CLose to OPen
The Valve status changes based on Quality feedback
Verified By:
MAN-4400MCOLD (rev.J)
page 69 of 103
(Pass / Fail)
RO Clean Cancel
without RO Pump
(Pass / Fail)
RO Clean Re-start
without RO Pump
(Pass / Fail)
RO Clean Hold
without RO Pump
(Pass / Fail)
RO Clean Start without RO Pump
(Pass / Fail)
RO Clean with RO Pump
(Pass / Fail)
RO Run (OPTIONAL)
(Product Divert to Drain)
(Pass / Fail)
RO Run (To Lock-out)
During Pre-treatment
(Pass / Fail)
RO Run
(To High Level)
(Pass / Fail)
RO Run
(Run Available)
(Pass / Fail)
RO Run
(Auto Flush witH Pump OFF)
(Pass / Fail)
RO Run
(Auto Flush with Pump ON)
(Pass / Fail)
RO Run
(Start-up Flush with Pump OFF)
(Pass / Fail)
RO Run
(Start-up Flush with Pump ON)
(Pass / Fail)
RO Run
(Pass / Fail)
Standby
(Auto Flush with Pump OFF)
(Pass / Fail)
Standby
(Auto Flush with Pump ON)
(Pass / Fail)
Standby
(Pass / Fail)
DESCRIPTION
System - OFF (STOP)
ALL ITEM (Tag Name)
Instructions: Place the RO system into each mode of operation and record the state of each component. Each solenoid valve has a LED indicator light that will turn on when the valve is open. Write “P” for Pass if
the observed state of the component is same as the indicated state. Write “F” if the observed state is different from the indicated state.
4400M Digital RO System
WARRANTY
GENERAL LIMITED WARRANTY
Biolab Equipment Ltd o/a Mar Cor Purification and Mar Cor Purification Inc. (“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.
MAN-4400MCOLD (rev.J)
page 70 of 103
4400M Digital RO System
CONTACT INFORMATION
For further information regarding the operation or maintenance of the 4400M – Digital RO
system and for ordering, please contact your local Mar Cor Office. When ordering replacement
parts, please provide the Biolab Serial # found on the cover page of this Manual.
CANADA
Manufactured by: Biolab Equipment Ltd o/a Mar Cor Purification
3250 Harvester Rd - Unit 6
Burlington, ON L7N 3W9
Tel: (905) 639-7025
Toll Free: (800) 268-5035
Fax: (905) 639-0425
UNITED STATES OF AMERICA
Distributed By: 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]
WORLD WIDE WEB
www.mcpur.com
MAN-4400MCOLD (rev.J)
page 71 of 103
4400M Digital RO System
A1 4400M DIGITAL REVERSE OSMOSIS SYSTEM
RO Product CIP Valve
RO Reject CIP Valve
RO Product Flow
Rotameter
RO Reject Flow
Rotameter
Electronic Digital
Interface & Display
Screen
RO Recycle Flow
Rotameter
Control Panel
Reject Pressure
Gauge
Membranes
RO Pump Pressure
Gauge
RO Pump
Feed Pressure
Gauges
Pre-filter/ Inlet
Filter
CIP Inlet Valve
Unit may not appear exactly as shown
MAN-4400MCOLD (rev.J)
page 72 of 103
4400M Digital RO System
DESCRIPTION & FUNCTION OF SYSTEM COMPONENTS
Pre-Filter Cartridge
A pre-filter housing is installed on the feed inlet of the system and is located on the front of the
system skid. The housing contains a 1.0 micron filter cartridge or 25/1 dual grade cartridge on
larger system (6-12 membranes). 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. The outer core of the filter has a larger pore size and they progressively
get smaller towards the middle of the filter. The rating, in micron size, is measured at the core
of the filter. This type of filter will help prevent premature plugging.
Pressure Gauges
Four pressure gauges are installed at various points in the RO 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 pressure
differential (delta) at the pre-filter. This delta pressure reading helps the operator to determine
when the filter is required to be changed.
One 0-400 psig gauge is installed on the pump discharge. The gauge provides a reading of the
pump discharge pressure before entering the first membrane housing.
The final 0-400 psig gauge is installed on the reject manifold. It provides a reading of pressure
after the water has gone through all the membrane housings. With this and the pump discharge
gauge the delta pressure can be calculated. This reading will provide an indication fouling
condition of the membranes.
Solenoid Valves
Two solenoid valves are installed on the system. The position and purpose of each valve is
described below:
Feed Inlet Valve
This 1” or 1½” valve is located on the outlet of the pre-filter housing. It is a normally closed valve
that isolates the pretreated feed water. It will open when the system is in normal operation.
Reject Valve
This ⅛”solenoid valve is located on the reject manifold. It is a normally closed valve. The valve
will automatically open when the system is in the flush or clean mode. It allows a higher amount
of water to be rejected down the drain and increases the cross flow across the membranes to
help reduce fouling.
MAN-4400MCOLD (rev.J)
page 73 of 103
4400M Digital RO System
Product to Drain Valve (Optional)
This optional ½”, ¾” or 1” valve is located just after the product outlet valve and is plumbed to
the drain. It is a normally open valve. The valve will remain open when the water quality is
greater than the setpoint and automatically close when the water quality is less than the
setpoint during the RUN mode. The valve will remain closed during the STANDBY, FLUSH and
STOP mode and in all alarm conditions.
Feed Water Low Pressure Switch
A normally closed feed water low pressure switch, pre-set to 12.5 psig, senses the feed water
pressure. It is located on the bottom left side of the panel. It is connected with a 1/4” tube to
the inlet water block just after the feed solenoid valve. When the system is in operation and the
feed pressure drops below 12.5 psig, it will shut down the system and alarm after a 10 second
delay. This will prevent damage to the booster pump.
CAUTION
Feed water pressure must be between 30-60 psig when the system is in
operation. Continuous operation of the system below 12.5 psig can result in
premature pump and motor failure.
RO Pump
A vertical multi-stage stainless steel centrifugal pump increases the feed water pressure to 150300 psig (10.3-20.7 bar) required for purification by the reverse osmosis process. The pump is
mounted on the base of the skid frame in the front.
Conductivity/Temperature Sensors
Two conductivity/temperature sensors are installed on the system. They provide readings for
the feed water and product water conductivity and temperature. Their location and purpose
are as follows:


The feed conductivity/temperature sensor is installed in the feed block. It measures the
conductivity/temperature of the feed water mixed with the recycled reject water before
the booster pump. The measured conductivity will be higher than the raw feed water
source. The feed water temperature is also measured at this point. A setpoint of 35°C
(95°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 water. The system
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 water. It is calculated as follows:
MAN-4400MCOLD (rev.J)
page 74 of 103
4400M Digital RO System
% Rejection =
NOTE
Feed - Product
Feed
X 100
The percent rejection is calculated based on the conductivity of the feed water
after mixing with the recycled reject water.
Manual Flow Control Needle Valves
Three 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 installed on the left branch of the reject manifold. This valve is used to
control the reject flow to drain and pressure.
The reject recycle valve is installed on the right branch of the reject manifold. This valve is used
to control the recycle flow and pressure.
The final valve is located on the pump discharge line just behind the pump. It controls the pump
discharge pressure.
CAUTION
Never fully close the reject and reject recycle valves when the system is in
operation. Damage to equipment can occur.
NOTE
When either opening or closing any needle valve, DO NOT over-extend or
over-tighten the valve as galling damage may occur. When fully opening the
valve, do so till resistance is felt and then close the valve ¼ turn. When fully
closing the valve, DO NOT use wrenches or other tightening tools. Close valve
till snug.
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.
Flow Rotameters
Three flow rotameters are installed on the system. Their location and purpose are as follows:


The reject rotameter is located just above the reject needle valve. This rotameter shows
how much reject water the system is sending to drain.
The reject recycle rotameter is located to the right of the reject rotameter. It provides
indication of the amount of reject water that is being recycled back into the feed of the
system.
MAN-4400MCOLD (rev.J)
page 75 of 103
4400M Digital RO System

The product rotameter is located to the right of the recycle rotameter. It indicates the
amount of product water the RO system is producing.
From these flow readings, % Array Recovery and % System Recovery can be calculated. Refer to
section 3.5.2 for the formula.
Manual Valves
Manual valves are used as isolation or sampling valves on the system and their location and
purpose are as follows:






A ¼” valve is located on the feed line block. It is used for performing the feed water
chemistry test.
A 1” or 1½” valves is located on the feed line to the right side of the skid just before the
pump. This is the Clean-In-Place (CIP) inlet connection used for introducing the
cleaning/sanitization solution into the system.
Two ½”, ¾” or 1” valves are located on the reject line just above the flow rotameter.
These valves are used to isolate the reject water to drain and divert to the CIP tank
when a cleaning/sanitization is required.
Two ½”, ¾” or 1” are located on the product line just above the flow rotameter. These
valves are used to isolate the product water to the process and divert to the CIP tank
when a cleaning/sanitization is required.
A ¼” valve is located on the product line before the flow rotameter. It is used to collect
samples for water analysis.
A ¼” valve is located under the reject pressure gauge. It is used to collect water samples
to calculate the LSI index.
CAUTION
Always leave one valve open on the product and reject stream. If both valves
on either one or both the streams are closed, damage to the system and/or
personal injury can occur.
Check valves
One or two check valves are installed on the system. Their location and purpose are as follows:


A ¾” valve is installed on the recycle line just before it ties into the feed water piping.
This check valve will prevent the back-flow of feed water from the pump suction into
the reject line.
The optional second check valve (½”, ¾” or 1”) is installed on the outlet of the product
to tank solenoid valve. This prevents the back-flow of product water in the RO system.
This valve must be installed in the direct feed application.
Pressure Relief Valve
MAN-4400MCOLD (rev.J)
page 76 of 103
4400M Digital RO System
A single or double (on systems with 6 to 12 membranes) pressure relief valve is installed on the
product line. It will open if both product and CIP valves are closed; or if the product divert
valves fail. This will prevent over pressurizing the product line or membranes.
Control Panel
The control panel is constructed from the following main components:







Electrical enclosure
Main power disconnect
Microprocessor controller
Step down transformers
Keypad interface and display
Pump motor protection devices
Fuses, Terminals
See APPENDIX A2 for a view of switches and indicators located on the 4400M control panel.
NOTE
Auxiliary components that interface with the system (i.e. softeners, pumps,
filters, valves, tanks, gauge, etc.) are not described.
* Refer to Individual Manufacturers’ Component Manuals for detailed descriptions.
MAN-4400MCOLD (rev.J)
page 77 of 103
4400M Digital RO System
A2 4400M CONTROL PANEL DISPLAY
DC Power
Pre-treatment
Lockout
Main Disconnect
Auto Run
OFF/AUTO Switch
(OPTIONAL)
Digital Interface
Keypad & Display
Screen
Alarm Mute Button
Local Audible Alarm
Distribution Pump “B”
Run Light (OPTIONAL)
Distribution Pump “A”
Run Light (OPTIONAL)
Distribution Pump “A”
MAN/OFF/AUTO Switch
(OPTIONAL)
Distribution Pump “B”
MAN/OFF/AUTO Switch
(OPTIONAL)
Unit may not appear exactly as shown
MAN-4400MCOLD (rev. J)
page 78 of 103
4400M Digital RO System
A3 SET-UP MENU DISPLAY NAVIGATIONAL FLOW CHART
Set-up Menu
Item
Options
1>
Clean Mode
2>
Customize
3>
Alarms
Selection
<OK>
1> Clean Mode Menu
2> Customize Menu
Item
3> Alarms Menu
Selection
Item
READ INSTRUCTION MANUAL
1>
Direct Feed:
NO (Default)
1>
BEFORE DOING THIS
2>
Flush-> Run Mode:
YES (Default)
2>
3>
Flush w /o Pump
NO (Default)
COMMAND
<OK>
Option
<CANCEL>
<SETUP=next>
<OK>
3>
Option
Selection
Alarm->Stop:
YES (Default)
Alarm->Stop->Restart
Poor Quality Delay
1 retry (Default)
retry every 010m
(Default)
Sub
Menu
<SETUP=next>
<OK>
Item
Option
Selection
1>
Ω Resistivity or S
Conductivity
Temp. comp
Ω (Default)
SELECT <<-> NUMBER OF RETRIES:
2>
NO (Default)
(0..6): 1
3>
Flush At Start
YES (Default)
<SETUP=next>
◄─
<OK>
Item
Option
1>
2>
3>
<OK>
Selection
SELECT <<-> NUMBER BETWEEN RETRIES:
Temperature in °C or °F
°C (Default)
(10m..150m): 010m
Clear ROP Timer
NO (Default)
Flush Delays
Sub-Menu’s
<SETUP=First>
◄─
<OK>
<OK>
Poor Quality Delay
Flush Period
120? (4,240) s
9? (1, 60) X 10s
<CANCEL>
<CANCEL>
Flush Cycle
<CANCEL>
<OK>
<OK>
Item
Option
Selection
60? (30,120)nm
1>
Feed Temp. SetPt
Sub Menu
(period included)
2>
Poor Quality SetPt
Sub Menu
<OK>
<SETUP=first>
<OK>
Feed Temp. SetPt
35? (30, 50) °C Or 95? (86,122) °F
<CANCEL>
<OK>
Conductivity or Resistivity. SetPt
2? (1,100) μS Or 50? (1,100) x 10 K Ω
<CANCEL>
MAN-4400MCOLD (rev. J)
<OK>
page 79 of 103
4400M Digital RO System
A4 ALARM LOG SHEET
TIME
MAN-4400MCOLD (rev. J)
ALARM DESCRIPTION
CORRECTIVE MEASURE
page 80 of 103
4400M Digital RO System
A5 DEVICE MATERIALS OF CONSTRUCTION
COMPONENT
STANDARD MATERIAL
OPTIONAL MATERIAL
Feed Piping
PVC
304/316L SS
Reject Piping
PVC
304/316L SS
Product Piping
PVC
PP, PVDF, 304/316L SS
High Pressure Piping
316L SS
-
High Pressure Housings
304 SS
FRP, 316L SS
Membrane

Permeate Carrier
Polyester
-

Feed Spacer
PP
-

Central Tube
ABS
-

Glue
Urethane
-

Brine Seal
Buna N
No Seal

O-ring
Buna N
EPDM

External Wrap
FRP
Durasan

ATD
Noryl
-
Conductivity Sensors
Noryl/SS
SS, 316L SS TC
Pump
316L SS
304 SS
Tubing
Polyethylene
PP, 304/316L
Filter Housing
PP
304/316L
Panel
NEMA 4/12 Steel Light Grey
304/316L
Frame
Steel Epoxy Light Grey
304/316L
Valves
PVC
PP,PVDF, 316SS
Solenoid Valves
BR
316 SS
Flow Rotameters
PVC
PP/Polysulfone/Polyamide
Temperature Sensor
Noryl/SS
316 SS
MAN-4400MCOLD (rev. J)
page 81 of 103
4400M Digital RO System
A6 WATER SAMPLING PROCEDURE
Procedures:
Collect sample kit (sample containers, labels, etc.)
Locate the ports where samples are to be taken (see Fig. 1 to the right).
Wipe sampling ports with alcohol prior to use.
Open sampling port and allow water source to run freely for approximately 5 minutes.
Open the bottle and take sample from midstream. Do not touch the inside of the
bottle or sample water. Repeat step with a new bottle if contact is made.
Fill the container completely and tighten cap.
Check container for leaks by squeezing tightly. Repeat steps 4-6 if leaks are found.
Label container as per sample in Fig. 2 (to the right).
Place sample in fridge immediately.
Submit sample to the lab in an iced cooler with accompanying paperwork within 24
hours.
SV2.02
Product
SV2.00 Feed
Water
Fig 1: Front View of RO Unit
RECORD OPERATION NAME & PORT NAME
KEEP COLD
S/N: ________________
Date: _______________
Time: _______________
NOTE: Wear clean gloves while taking samples. Prevent mixing of any foreign particles with
sample water.
MAN-4400MCOLD (rev. J)
Fig 2: Sample Label
page 82 of 103
4400M Digital RO System
A7 REQUIREMENTS FOR INSTALLATION OF EXTERNAL CONNECTIONS TO THE
4400M SYSTEM
DRAIN CONNECTION REQUIREMENTS
Facility must meet the following requirements:



Drains must be sized for the maximum flow of the system.
Drain connections must be plumbed such that siphoning of the system will not occur.
Provide adequate air gaps for each drain connection.
PIPING REQUIREMENTS
Installation piping that is exposed to hot water or is in contact with the product water must
meet the following requirements:





Compatible with RO product water.
Stainless steel must be passivated prior to use and/or if welding is used for joining.
Material must meet the current ISO 13959, ISO 11663 and ISO 26722 standards.
Piping must be routed in such a way as to minimize dead legs, at point of use, larger
than 3 times the inside diameter of the pipe.
The minimum flow velocity in the piping system is 3 ft/s, for indirect feed systems and
1.5 ft/s for direct feed systems.
PRE-TREATMENT REQUIREMENTS
The 4400 M Digital RO system will operate most efficiently on filtered water with a pH less than
negative concentration LSI (Langlier Saturation Index) and a Silt Density Index (SDI) of 3 or
below. If the machine is operated on water with higher pHs, other forms of pre-treatment may
be necessary. A water analysis prior to start-up of the machine is required. To minimize the
chances of calcium carbonate, calcium sulfate, or other mineral precipitation on the membrane,
your equipment supplier will evaluate each application and water condition and make specific
recommendations to ensure continuity of membrane element warranty. Data from the water
analysis is analyzed to determine if potential problems may exist. If the machine is to be run at
a different location than was originally intended, a new water analysis is required for warranty
consideration and should be sent to your equipment supplier for review and recommendations
for operation of the machine.
MAN-4400MCOLD (rev. J)
page 83 of 103
4400M Digital RO System
The following pre-treatments are recommended for a typical surface potable drinking water
source:



A temperature blending valve for maintaining feed water temperature at 25C (77F) for
optimum performance.
Two (2) back washable carbon filters for the removal of chloramines. The carbon filters
must be sized to meet the minimum empty bed contact time as per ISO 13959, ISO
11663 and ISO 26722 standards.
An automatic water softener for removal of hardness.
Note
Water for dialysis must meet the minimum requirements as per ISO 13959, ISO
11663 and ISO 26722 standards.
POST-TREATMENT REQUIREMENTS
To assure the maximum product quality to your process and to protect the system the following
recommendation are provided:


Product mechanical safety pressure relief valve (60 psig, 414 kPa setpoint) installed
before the product divert valves. This will prevent over pressurization of the product
line due to mechanical or operator error (this relief valve is included on all standard
4400M Digital RO Systems).
Automatic product divert valves are installed after the manual product isolation valve.
These valves can operate electrically or pneumatically with an auto/drain switch and
light installed in the panel. This will allow the product water to divert to drain when the
system is OFF/standby/tank full, flush mode or if the quality is less than 90% rejection.
This will assure the product water sent to the process is within the desired
specifications.
Note
The above information is for recommendations only. Depending on the
process requirement, these requirements might not be needed. Please consult
your local water treatment representative.
PANEL ELECTRICAL TERMINATION REQUIREMENTS
Refer to the electrical schematic provided with the system.
FEED WATER REQUIREMENTS
Feed water must meet the most current National Drinking Water Regulations in the USA and
Guidelines for Canadian Drinking Water Quality in Canada for potable water including the
following listed in the table below:
MAN-4400MCOLD (rev. J)
page 84 of 103
4400M Digital RO System
Variable
Service
Units
Min
Max
Temperature
Feed Inlet
C (F)
2 (36)
45 (113)
Total Chlorine
Feed Inlet
ppm
0.0
<0.1
Optimum pH
Feed Inlet
7.0
7.5
Operating pH
Feed Inlet
4.0
11.0
Cleaning pH
Feed Inlet
2.0
11.5
Iron, Manganese
Feed Inlet
0.0
<0.1
Feed NTU
Feed Inlet
<1.0
Reject
< -1.0
Feed Inlet
<3.0
LSI
1
Feed SDI
ppm
ELECTRICAL SUPPLY REQUIREMENTS
The equipment must be connected to a 3-phase 208VAC ± 5% Voltage fluctuation supply. The
power must be free from damaging spikes, surges or sags.
1
LSI is required only if a feed water softener is not used as part of the pre-treatment
MAN-4400MCOLD (rev. J)
page 85 of 103
4400M Digital RO System
A8 4400M RO TYPICAL FLOW RATES
NOTE
The flow rates listed below are based on pretreated (dechlorinated, softened)
potable water feed with a total dissolved solids (T.D.S.) measurement of 230
ppm. The flow rates are to be used as a guide only. The RO pump discharge
pressure must not exceed 300 psig.
Flow Rates at 25°C (77°F) & 75% Recovery
Number of
Membranes
Percent
Recovery
Product Flow
Reject Flow
Recycle Flow
12
75%
17.0 GPM
5.7 GPM
17.8 GPM
10
75%
14.0 GPM
4.7 GPM
12.4 GPM
9
75%
12.5 GPM
4.2 GPM
18.1 GPM
8
75%
11.0 GPM
3.7 GPM
11.5 GPM
6
75%
8.5 GPM
2.8 GPM
7.6 GPM
5
75%
7.0 GPM
2.3 GPM
8.2 GPM
4
75%
5.5 GPM
1.8 GPM
6.8 GPM
3
75%
4.0 GPM
1.3 GPM
6.1 GPM
2
75%
2.5 GPM
0.8 GPM
5.9 GPM
Flow Rates at 5°C (41°F) & 75% Recovery
Number of
Membranes
Percent
Recovery
Product Flow
Reject Flow
Recycle Flow
12
75%
10 GPM
3.3 GPM
11.7 GPM
10
75%
8.0 GPM
2.7 GPM
7.1 GPM
9
75%
7.0 GPM
2.3 GPM
11.3 GPM
8
75%
6.0 GPM
2.0 GPM
6.6 GPM
6
75%
4.5 GPM
1.5 GPM
4.0 GPM
5
75%
4.0 GPM
1.3 GPM
5.5 GPM
4
75%
3.0 GPM
1.0 GPM
3.9 GPM
3
75%
2.0 GPM
0.7 GPM
3.2 GPM
2
75%
1.5 GPM
0.5 GPM
3.8 GPM
MAN-4400MCOLD (rev. J)
page 86 of 103
4400M Digital RO System
Flow Rates at 25°C (77°F) & 50% Recovery
Number of
Membranes
Percent
Recovery
Product Flow
Reject Flow
Recycle Flow
12
50%
17.0 GPM
17.0 GPM
6.5 GPM
10
50%
14.0 GPM
14.0 GPM
3.1 GPM
9
50%
12.5 GPM
12.5 GPM
9.7 GPM
8
50%
11.0 GPM
11.0 GPM
4.2 GPM
6
50%
8.5 GPM
8.5 GPM
1.9 GPM
5
50%
7.0 GPM
7.0 GPM
3.5 GPM
4
50%
5.5 GPM
5.5 GPM
3.1 GPM
3
50%
4.0 GPM
4.0 GPM
3.4 GPM
2
50%
2.5 GPM
2.5 GPM
4.3 GPM
Flow Rates at 25°C (77°F) & 50% Recovery (Using Low Fouling Membranes)
Number of
Membranes
Percent
Recovery
Product Flow
Reject Flow
Recycle Flow
12
50%
17.0 GPM
17.0 GPM
2.0 GPM
10
50%
14.0 GPM
14.0 GPM
2.0 GPM
9
50%
12.5 GPM
12.5 GPM
5.0 GPM
8
50%
11.0 GPM
11.0 GPM
2.0 GPM
6
50%
8.5 GPM
8.5 GPM
4.0 GPM
5
50%
7.0 GPM
7.0 GPM
2.0 GPM
4
50%
5.5 GPM
5.5 GPM
3.0 GPM
3
50%
4.0 GPM
4.0 GPM
3.0 GPM
2
50%
2.5 GPM
2.5 GPM
3.0 GPM
NOTE
Minimum Feed Pressure required is 50 psig when using low fouling
membranes on high TDS feed waters.
To consider the effect of temperature on the flow rates, use the correction factor table shown
in section 3.5.3.
MAN-4400MCOLD (rev. J)
page 87 of 103
4400M Digital RO System
A9 TABLE OF SYSTEM MONITORING PARAMETERS
CAUTION
System monitoring is required for some component warranty. Monitoring
parameters are dependent on feed water conditions and it is the
responsibility of the user to ensure that all applicable tests are completed at
the minimum intervals outlined in ISO 23500 Appendix C (Guidance for the
Preparation & Quality Management of Fluids for Hemodialysis & Related
Therapies).
NOTE
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.
NOTE
System monitoring should be completed under normal operating conditions.
NOTE
Feed water must meet the most current National Drinking Water Regulations in
the USA and Guidelines for Canadian Drinking Water Quality in Canada for
potable water.
MAN-4400MCOLD (rev. J)
page 88 of 103
4400M Digital RO System
SAMPLE DAILY LOG SHEET
Test
Freq.
Parameter
Units
Date
D/M/Y
Time
HH/MM
Feed Temperature
D
Feed pH
W
Feed Total Chlorine
Feed Fe
2
Feed Total Hardness
LSI of Reject
Feed SDI
3
Mon
Tue
Wed
Thu
Fri
Sat
°C
S
ppm
M
ppm
D
ppm
M
2
Feed NTU
Sun
Y
2
Y
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
D
lpm
D
μS /cm
Product Quality
D
μS /cm
Rejection
D
%
Recycle Flow
Feed Recycle Quality
4
% Rejection =
Feed - Product
Feed
X 100
Legend
NTU- Nephelometric Turbidity Units
SDI - Silt Density Index
Press - Pressure
ΔP - Pressure Differential
2
3
4
S – At the beginning of each shift
D – Daily
W – Weekly
M – Monthly
Y – Yearly
Suggested frequency above but dependent on feed water source and/or customer approved procedure(s)
Suggested frequency above but dependent on feed water source and/or customer approved procedure(s). Not
required if softener is part of pre-treatment
Displayed on the 4400M RO controller, Record readings
MAN-4400MCOLD (rev. J)
page 89 of 103
4400M Digital RO System
A10 SITE ACCEPTANCE TEST (SAT) PROCEDURES
NOTE
This is a generic document for the Site Acceptable Test. It should be used to
verify the functionality and performance of the 4400M system only. Do not
use it for validation of the overall water system. This document must be
completed by the installer upon successful start-up of the overall water
system.
EXECUTION INFORMATION
Site Location:
Project/BM # or BIOLAB S/N:
Date Installed:
EXECUTION INFORMATION
Name:
Signature:
Date Executed:
Company & Title:
EXECUTION INFORMATION
Name:
Signature:
Date Approved:
Company & Title:
Instructions:
1. Verify system installation and complete the Installation Verification Checklist.
2. Record the setpoint values in the HMI Screen Settings and Default Setpoints Table.
3. Place the RO system in each mode of operations and record the state of each solenoid valve and
display on the control panel in the System Test Matrix Table.
4. RO Performance Verification
Complete the verification checks for the RO performance during normal RO run in the log table
provided.
At the end of the test, record all discrepancies in the log sheet provided. Submit ALL documents
(this sheet, item #1, #2, #3, #4) and the Discrepancy Log Sheet to the Mar Cor Quality
Department.
MAN-4400MCOLD (rev. J)
page 90 of 103
4400M Digital RO System
INSTALLATION VERIFICATION CHECKLIST
#
Item
Check (Yes / No)
1
Plant feed water supply is connected and verified.
2
Plant electrical supply is connected and verified.
3
Pre-treatment devices are installed and a functional test is performed.
4
Post treatment devices are installed and a functional test is performed.
5
Pre-filter cartridges are installed as per instructions in section 4.2.1.
6
All appropriate valves are open in the overall water treatment system.
7
Feed water tests are performed.
8
The 4400HX – hot water sanitization system is ready for operation (if
connected)
9
All tank accessories are installed and ready to receive water (if connected)
COMMENTS:
Verified By:
MAN-4400MCOLD (rev. J)
Initial:
Date:
page 91 of 103
4400M Digital RO System
DISPLAY SCREEN SETTINGS & DEFAULT SETPOINTS
Instructions: Record the actual values from the HMI screen in the “Customer Setting” Column
Screen Name
Parameter Name
Factory Default
Customer Setting
Customize
Menu #1
Direct Feed
No
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
Menu #3
ROP Timer
0
Menu #3
Flush Delay
Menu #3 – Item #3 SubMenu
Flush Period
90 s
Menu #3 – Item #3 SubMenu
Flush Cycle
60 min.
Alarm
Menu #1
Alarm → Stop
Menu #1
Alarm → Stop → Restart
1,10 min.
Menu #1
Poor Quality Shutdown
Delay
120 s
Menu #2
Feed Temperature
Setpoint
Menu #2
Poor Quality Setpoint
Menu #2 – Item #2 SubMenu
Conductivity
Menu #2 – Item #2 SubMenu
Resistivity
Verified By:
MAN-4400MCOLD (rev. J)
Initial:
Yes
35°C or 95°F
2 μS
500KΩ
Date:
page 92 of 103
4400M Digital RO System
SYSTEM TEST MATRIX
Pumps
P2.00
RO Pump
OFF
OFF
OFF/ON
OFF
ON
ON
OFF
ON
OFF
ON/OFF
ON/OFF
ON/OFF
ON
OFF/ON
OFF
OFF
OFF
OFF
RO Pretreatment Lockout (Amber Light)
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
OFF
ON
ON
ON
ON
OFF
RO Panel
YS-RO
Solenoids
YV2.00
RO Feed Inlet Valve
CL
CL
CL/OP
CL/OP
OP
OP
OP
OP
OP
OP/CL
OP/CL
OP/CL
OP
CL
CL
CL
CL
CL
YV2.01
RO Reject Valve
CL
CL
CL/OP
CL/OP
CL
OP
OP
CL/OP
CL/OP
CL
CL
CL
CL
CL/OP
CL/OP
OP/CL
CL/OP
OP/CL
YV2.03
RO Product To Drain Valve (OPTIONAL)
OP
OP
OP
OP
O/C-Q
OP
OP
CL/OP
CL/OP
CL/OP
CL/OP
CL/OP
CL/OP
OP/CL
OP
OP
OP
OP
Legend:
OFF
The device is OFF
ON
The device is ON
Comments:
ON/OFF The device status changes from ON to OFF
OFF/ON The device status changes from OFF to ON
OP
The Valve is OPen
CL
The Valve is CLose
OP/CL
The Valve status changes from OPen to Close
CL/OP
*- Q
The Valve status changes from CLose to OPen
The Valve status changes based on Quality feedback
MAN-4400MCOLD (rev.J)
Performed By:
Date:
Verified By:
page 93 of 103
(Pass / Fail)
RO Clean Cancel
without RO Pump
(Pass / Fail)
RO Clean Re-start
without RO Pump
(Pass / Fail)
RO Clean Hold
without RO Pump
(Pass / Fail)
RO Clean Start without RO Pump
(Pass / Fail)
RO Clean with RO Pump
(Pass / Fail)
RO Run (OPTIONAL)
(Product Divert to Drain)
(Pass / Fail)
RO Run (To Lock-out)
During Pre-treatment
(Pass / Fail)
RO Run
(To High Level)
(Pass / Fail)
RO Run
(Run Available)
(Pass / Fail)
RO Run
(Auto Flush witH Pump OFF)
(Pass / Fail)
RO Run
(Auto Flush with Pump ON)
(Pass / Fail)
RO Run
(Start-up Flush with Pump OFF)
(Pass / Fail)
RO Run
(Start-up Flush with Pump ON)
(Pass / Fail)
RO Run
(Pass / Fail)
Standby
(Auto Flush with Pump OFF)
(Pass / Fail)
Standby
(Auto Flush with Pump ON)
(Pass / Fail)
Standby
(Pass / Fail)
DESCRIPTION
System - OFF (STOP)
ALL ITEM (Tag Name)
Instructions: Place the RO system into each mode of operation and record the state of each component. Each solenoid valve has a LED indicator light that will turn on when the valve is open. Write “P” for Pass if the
observed state of the component is same as the indicated state. Write “F” if the observed state is different from the indicated state.
4400M Digital RO System
RO PERFORMANCE VERIFICATION LOG
Instructions:
Place the system into RUN mode and verify that all required performance parameters are met. Values can be taken from the instrument, itself, from
the displayed value on the display screen or from an external test. When “Actual Results” are similar to the “Expected Results”, circle “Pass”. If there is
a discrepancy between “Expected Results” and “Actual Results”, circle “Fail”. Log the discrepancy in the Discrepancy Log sheet provided.
Tag
Description
Expected Results
Actual Results
Eng. Units
AE2.00
RO Feed Conductivity
For Record
µS/cm
TE2.00
RO Feed Temperature
< 35°C (95° F)
Pass/Fail
°C
Pass / Fail
(1)
GPM
Pass / Fail
(1)
GPM
Pass / Fail
(1)
FI2.00
RO Reject Recycle Flow
SPEC
GPM @ 25°C (77° F)
FI2.01
RO Reject Flow
SPEC
GPM @ 25°C (77° F)
FI2.02
RO Product Flow
SPEC
GPM @ 25°C (77° F)
GPM
Pass / Fail
P2.00
RO Prefilter Inlet Pressure
<60 psig
PSIG
Pass / Fail
P2.01
RO Prefilter Outlet Pressure
<60 psig
PSIG
Pass / Fail
P2.02
RO Pump Pressure
<300 psig
PSIG
Pass / Fail
P2.03
RO Reject Pressure
<300 psig
PSIG
Pass / Fail
AE2.01
RO Product Conductivity
<30
µS/cm
Pass / Fail
TE2.01
RO Product Temperature
< 35°C (95° F)
°C
Pass / Fail
RO Percent Rejection
>90
%
Pass / Fail
NOTE: (1) See the Design Specification Label on the side of the RO control panel to obtain the specification value for your system
Conclusions / Comments:
Performance Verification: System Runs Correctly? YES / NO
Verified By
Initials
MAN-4400MCOLD (rev. J)
Date
page 94 of 103
4400M Digital RO System
DISCREPANCY LOG
Instructions
For every discrepancy that is found during this SAT, a discrepancy log entry shall be generated. Describe the discrepancy; keep the description
concise, other rows can be used if necessary. Describe the discrepancy resolution; keep the description concise, other rows can be used if necessary.
The person responsible for the correction initials and dates when the discrepancy is resolved.
Discrepancy Log
No.
Description of Discrepancy
MAN-4400MCOLD (rev. J)
Page ___ of ___
Discrepancy Resolution
Responsibility
Party(ies)
Date
page 95 of 103
Complete By
(Initial/Date)
4400M Digital RO System
A11 SAMPLE PROCESS & INSTRUMENT DRAWING
(P&ID may not be exactly as shown)
MAN-4400MCOLD (rev. J)
page 96 of 103
4400M Digital RO System
A12 ELECTRICAL CONTROL INTERLOCKS FOR THE CONTROL PANEL
Listed in the tables below are the electrical termination points to the microprocessor controller and the
individual components on the system. Also included is a brief description and function of optional
customer terminations. The terminal numbers listed are connection made directly at the microprocessor
control. Refer to the electrical drawing for additional component terminations (e.g. RO/Distribution
Pumps, Ultraviolet Sterilizers, Solenoids, and Tank Low Level Switches).
D0841.4 Microprocessor (c/w Version6.7e.132 Software) Electrical Installation Termination
Description
Term
I/O
Voltage
Comments
Feed Probe
5,6,7,8
I
Sensor
Pre-wired (grn, wht, red, blk)
Product Probe
13,14,15,16
I
Sensor
Pre-wired (grn, wht, red, blk)
Optional 0.1 Cell Constant Product
Probe (EPROM Req.)
15,16
I
Sensor
Connect Thornton Sensor
Leads 1& 2 to 15, 6 to 16
AC Voltage Supply
17,18,19
I
12,CT,12
Pre-wired
RO Pump Starter (ROP)
23,24
O
24VAC
Pre-wired
Water Inlet Solenoid (WIS)
25,26
O
24VAC
Pre-wired
Reject Solenoid (RS)
27,28
O
24VAC
Pre-wired
Alarm Group
29,30
O
24VAC
Customer Connection
Audible Alarm (Option)
31,32
O
24VAC
Customer Connection
Low Pressure Switch (LP)
33,34
I
12VDC
Pre-wired
RO Pump Overload (O/L1)
35,36
I
12VDC
Pre-wired
Remote Start Timer (Option)
36,37
I
12VDC
Customer Connection
Intermediate Level (INT)
37,38
I
12VDC
Customer Connection
Remote Standby (RS-B)
39,40
I
12VDC
Customer Connection
High Level (HL)
40,41
I
12VDC
Customer Connection
Drain Valve Switch (Option)
42,43
I
12VDC
Pre-wired / Field Option
Drain Valve (Option)
45,46
O
24VAC
Pre-wired / Field Option
D0903 Display Electrical Installation Termination Table
Description
Term
I/O
Voltage
Comments
Interface Cable (when Remote
D0949 Card is not used)
DB9
I
Pre-wired Option Connection
Cable Direct To D0841.4 Controller
Interface Cable (when Remote
D0949 Card is used)
DB9 (P2)
I
Pre-wired Option Connection
Cable To D0949 Controller DB9
(P2)
MAN-4400MCOLD (rev. J)
page 97 of 103
4400M Digital RO System
D0949 Remote Electrical Installation Termination Table (Canada Only)
D0949 Remote Card (Option
Term
I/O
Interface Cable To D0841.4
Controller
DB9 (P1)
O
Interface Cable To Alarm Monitor
D0871
2,3,4,5,6
O
Interface Cable to Remote PC
Monitor
DB9 (P3)
O
Voltage
Comments
Pre-wired Option Connect Cable
To D0841.4
12VDC
Customer Connection (5 Wire
Cable) To Alarm Monitor D0871
Customer Connection (1000’ Max.)
To Remote PC. Software For PC
Required.
PANEL ELECTRICAL FIELD TERMINATION DESCRIPTIONS FOR THE OPTIONAL FEATURES
Alarm Group:
This 24VAC contact can be used to provide a signal to a building control system or a nurse’s station.
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 Amp @ 24VAC when the standard 150VAC
step-down transformer is used. If a higher current is required (up to maximum
of 5.0 Amps @ 24VAC) the capacity of the step-down transformer should be
increased.
Audible Alarm:
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 Amp @ 24VAC when the standard 150VAC
step-down transformer is used. If a higher current is required (up to maximum
of 5.0 Amps @ 24VAC) the capacity of the step-down transformer should be
increased.
MAN-4400MCOLD (rev. J)
page 98 of 103
4400M Digital RO System
Remote Start/Stop Timer:
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.
CAUTION
Contacts must be a TYPE-C DRY CONTACT. Damage to the controller will occur
if powered contacts are used.
NOTE
Customized menu configuration is required to use this function.
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 TYPE-C DRY CONTACT. When the contact is open the
system will operate and when the contact closes the system will be placed in the STANDBY (Tank High
Level) mode. 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.
CAUTION
Contacts must be a TYPE-C DRY CONTACT. Damage to the controller will occur
if powered contacts are used.
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
the STANDBY (Tank High Level) mode. 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 the controller will occur
if powered contacts are used.
Remote Standby (RS-B):
This contact is used to interlock pre-treatment / post-treatment equipment with the system. The
contact must be a normally open TYPE-C DRY CONTACT. When a pre-treatment / post-treatment device
such as a softener goes into regeneration the contact closes placing the system in the STOP mode. When
the regeneration cycle is completed and the contact opens the system will restart in whatever mode it
was in before. When multiple pre-treatment / 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 the controller will occur
if powered contacts are used.
MAN-4400MCOLD (rev. J)
page 99 of 103
4400M Digital RO System
Drain Valve Switch Contact:
The valve switch contact can be used to install an auto switch or a jumper for drain function.
This switch allows the operator to either manually divert the product water to drain, when set
in the Drain Position, or automatically divert to drain on programmable poor quality setpoint
during manual or auto flush operation and when the system is in the STOP or STANDBY tank
full mode. For automatic diversion, the optional divert to drain solenoid valve must be installed.
The switch contact must be a normally open TYPE-C DRY CONTACT.
CAUTION
Contacts must be a TYPE-C DRY CONTACT. Damage to the controller will occur
if powered contacts are used.
Drain Valve Contact:
The valve contact is 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 or loop and the normally open to the
drain. The valve will only activate when the product water quality is below the programmable
setpoint (fail-safe operation).
CAUTION
The contact is rated for a maximum load of 1.0 Amp @ 24VAC when the
standard 150VAC step-down transformer is used. If a higher current is
required (up to maximum of 5.0 Amps @ 24VAC) the capacity of the stepdown transformer should be increased.
NOTE
Each individual panel can be custom designed or modified to suit the
customer’s needs. Please contact your local representative for options.
MAN-4400MCOLD (rev. J)
page 100 of 103
4400M Digital RO System
A13 SPARE PARTS LIST
When ordering parts for the system, please have the Biolab Serial # (located on side of main
panel).
TAG #
PART #
PART DESCRIPTION
F2.00
FM00120X
Filter Cartridge - 20" x 1.0 Micron Pre-filter (for 2,3,4 and 5
Membrane configuration)
F2.00
155360
Filter Cartridge - 20" x 25/1.0 Micron Double Grade DOE (for 6,8,9,
10 and 12 Membrane configuration)
FUA, FUB, FUC
AJT35
Fuse - 35A/600V RO Control Panel - Main Disconnect (2
Membranes)
F1A, F1B. F1C
ATDR12
Fuse - 12A/600V RO Control Panel - RO Pump (2 Membranes)
FUA, FUB, FUC
AJT40
Fuse - 40A/600V RO Control Panel - Main Disconnect (3 & 4
Membranes)
F1A, F1B, F1C
ATDR15
Fuse - 15A/600V RO Control Panel - RO Pump (3 & 4 Membranes)
FUA, FUB, FUC
AJT45
Fuse - 45A/600V RO Control Panel - Main Disconnect (5,6 and 8
Membranes)
F1A, F1B, F1C
ATDR30
Fuse - 30A/600V RO Control Panel - RO Pump (5,6 and 8
Membranes)
F2B, F2C
ATQR1
Fuse - 1A/600V RO Control Panel (2,3,4,5,6 & 8 Membranes)
F3A-B
ATDR3
Fuse - 3A/600V RO Control Panel (2,3,4,5,6 & 8 Membranes)
F4A-C, F5B-C, F6B-C
ATDR15
Fuse - 15A/600 RO Control Panel -VFD Dist'n Pumps (2,3,4,5,6,7 &
8 Membranes)
FA, FB
MDA-4
Fuse - 4A/250V RO Control Panel (2,3,4,5,6 & 8 Membranes)
FC
MDA-5
Fuse - 5A/250V RO Control Panel (2,3,4,5,6 & 8 Membranes)
FUA, FUB, FUC
AJT70
Fuse - 70A/600V RO Control Panel - Main Disconnect (9,10 and 12
Membranes)
F2A, F2B, F2C
ATDR35
Fuse - 35A/600V RO Control Panel - RO Pump (9,10 and 12
Membranes)
F5A, F5B
ATDR20
Fuse - 20A/600V RO Control Panel - Booster Pump (9,10 and 12
Membranes)
F6A, F6B, F6C
ATDR12
Fuse - 12A/600V RO Control Panel - Distribution Pump (9,10 and
12 Membranes)
F7A, F7B, F7C
ATDR12
Fuse - 12A/600V RO Control Panel - Distribution Pump (9,10 and
12 Membranes)
F8, F9, F3
ATDR5
Fuse - 5A/600V Optional UV Lamp, Auxiliary Equipment (9,10 and
12 Membranes)
F1A, F1B
ATQR1
Fuse - 1A/600V (9,10 and 12 Membranes)
F4
ATDR3
Fuse - 3A/600V (9,10 and 12 Membranes)
FA, FB
MDA-4
Fuse - 4A/250V RO Control Panel (9,10 and 12 Membranes)
FC
MDA-5
Fuse - 5A/250V RO Control Panel (9,10 and 12 Membranes)
MAN-4400MCOLD (rev. J)
page 101 of 103
4400M Digital RO System
TAG #
PART #
PART DESCRIPTION
P2.00
GP96455090
Gasket Kit for RO Pump, EPDM
ME2.00-2.11
Variable
Please contact your local Mar Cor Service Centre for assistance
HS2.00-2.11
VSH-40CAP34
Membrane Housing, End Caps
HS2.00-2.11
VSH-40-ORING
Membrane Housing, 0-Rings
HS2.00-2.11
VSH-40-GSKT
Membrane Housing, Gaskets
HS2.00-2.11
VSH-40-CLMPKIT
Membrane Housing, Clamp Kit
HS2.00-2.11
VSH-40-CHNLCLMP
Membrane Housing, Channel Clamps
P2.00
G96314449
CRN 1-17 SS Pump C/W 2.0 HP Motor (for 2 Membranes RO’s)
P2.00
G96314608
CRN 3-15 SS Pump C/W 3.0 HP Motor (for 3 Membranes RO’s)
P2.00
G96314451
CRN 3-17 SS Pump C/W 3.0 HP Motor (for 5 Membranes RO’s)
P2.00
G96314450
CRN 5-16 SS Pump C/W 5.0 HP Motor (for 6 & 8 Membrane RO’s)
P2.00
G96314610
CRN 5-18 SS Pump C/W 7.5 HP Motor (for 9 & 10 Membrane RO’s)
P2.00
G96314611
CRN 5-22 SS Pump C/W 7.5 HP Motor (for 12 Membrane RO’s)
PI2.02
50100602
Pressure Gauge - 0-400psi, SS, 2.5" L/F. 1/4" CBM
PS2.00
JB58A214C
Pressure Switch, 1/4" Brass, Inlet Low Pressure
SV2.00/ SV2.02
SS1-1/4
Sample Valve - 1/4" SS
AE/TE2.00/2.01
CTS110
Sensor - 3/4" MNPT Noryl Conductivity Sensor 10'
P2.00
GP96455086
Seal Kit for RO Pump (HQQE Seal)
YV2.00
457163X
Solenoid Valve, 1" RO Feed Valve, Brass, Burkert Type 6213 (for
2,3,4 and 5 Membrane configuration)
YV2.00
644223
Seal & Repair Kit for 1" Solenoid Valve Burkert Type 6213 P/N
457163X
YV2.00
457169D
Solenoid Valve, 1-1/2" RO Feed Valve, Brass, Burkert Type 6213
(for 6,7,8,9, 10 and 12 Membrane configuration)
YV2.00
644226
Seal & Repair Kit for 1-1/2" Solenoid Valve Burkert Type 6213 P/N
457169D
YV2.01
127299
Solenoid Valve, ⅛" RO Reject Valve, Brass, Burkert Type 6013
P2.00
GP96453520
Stack Kit for RO Pump
MAN-4400MCOLD (rev. J)
page 102 of 103
4400M Digital RO System
CUSTOMER SYSTEM NOTES
MAN-4400MCOLD (rev. J)
page 103 of 103
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