AqSep 2 WaterCube User Guide
The AqSep WaterCube 2 is designed to provide clean and safe drinking water from water with a high salt content, such as sea water or brackish water. It's an automatic unit that uses a three-step filtration process: pre-filtration, particle filtration, and membrane filtration. The unit is equipped with an automatic electronic monitoring system that provides information about the WaterCube's performance, such as filter condition, RO membrane condition, water quality, and water production.
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WaterCube2
User Guide
January 2015
AQSEP A/S
c/o Danfoss, Nordborgvej 81, E14-N26, DK-6430 Nordborg, Denmark
Tel.: (+45) 7488 4100 e-mail: [email protected]; website: www.aqsep.com
Table of Contents:
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1. Important safeguards
Basic safety precautions should always be followed, when electrical appliances are used. This also applies to the AqSep WaterCube2. These include the following:
1. Carefully read and follow the instructions in this manual.
2. Do not touch hot surfaces (e.g. electric motor).
3. To protect against fire, electric shock and injury to persons do not spray or immerse cord, plugs or machine in water or any other liquid.
4. Do not use the machine outdoors unless properly protected from sun and rain.
5. Do not place the machine near heat sources
6. Do not move the machine after installation
7. Prevent children from access to the machine
8. When filters need to be changed follow the instructions in this manual. Only use original parts for replacement, any other products will likely affect the performance of the machine
9. Do not touch any other part of the machine than the parts identified for user-replacement. The machine operates under high pressure and any unauthorised interference may cause shock or serious injury to persons. Contact your service agent if you have a problem with the machine
10. No modifications can safely be made to this machine. Consult your service agent if you want to discuss performance of the machine
11. Do not use the machine for anything other than its intended use.
2. Warrantees
2.1 What this warranty covers
AqSep warrants that each Machine is free from defects in materials and workmanship and conforms to its
Specifications. A Machine is here limited to a AqSep WaterCube with all its internal components.
During the warranty period, AqSep through authorised local service agents provides repair and exchange service for the Machine under the type of warranty service AqSep designates for the Machine. The warranty period for the Machine is a fixed period starting on its Date of Invoice. The warranty period is in accordance with local laws and regulations.
These warranties apply only in the country or region in which you purchased the Machine.
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2.2 What this warranty does not cover
This warranty does not cover the following:
1. failure or damage resulting from misuse (including, but not limited to use of any Machine capacity or capability, other than that for which the machine has been designed), accident, modification, unsuitable physical or operating environment (ref. specifications) or improper maintenance by you;
2. failure caused by a product for which AqSep is not responsible, including products, components or appliances in connection with the hydraulic and electrical system outside the Machine;
3. any product installed outside or onto a Machine
4. accessories, supply items and consumables (e.g. filters cartridges, RO membranes etc.).
5. any service or maintenance of a machine under Warranty, including the replacement of consumables.
For warranty on service and maintenance in connection with service contracts, please consult your local service agent.
The warranty is voided by removal or alteration of identification labels on the Machine or its parts.
AqSep does not warrant uninterrupted or error-free operation of a Machine, except for the high pressure pump.
The warranty on error free operation of this pump is subject to water quality compliance for the feed water.
Any technical or other support provided by a AqSep distributor, reseller or a AqSep service agent for a
Machine under warranty, such as assistance with “how-to” questions and those regarding Machine set-up and installation, is provided WITHOUT WARRANTIES OF ANY KIND. Warranties extended by your local reseller or service agent are not legally binding for AqSep or applicable to AqSep.
2.3 How to obtain warranty service
If the Machine does not function as warranted during the warranty period, contact the AqSep authorised service agent to obtain our warranty service. Typically, the service agent will be the dealer from whom you have purchased the Machine.
2.4 What AqSep will do to correct problems
AqSep is represented in your area by an authorised reseller or service agent who has undergone advanced training in the machine and its application. Therefore, all contact should go directly to your local reseller or service agent who will attempt to diagnose and resolve your problem over the telephone or by inspecting and repairing the machine on site. The reseller or service agent is backed up by a AqSep distributor or similar with technical expertise to guide your local service agent. Most problems can be diagnosed and rectified through this chain of expertise. However, the distributor has access to advanced technical back-up from AqSep’s’ Head
Office in Denmark.
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2.5 Your responsibilities as user
You are responsible for contacting your local service agent at the earliest possible time, i.e. as soon as possible after a fault has been suspected or identified.
When the warranty service involves the exchange of parts or an entire Machine, the item the AqSep appointed service agent replaces becomes the service agent’s property and the replacement becomes yours. You represent that all removed items are genuine and unaltered. The replacement may not be new, but will be in good working order and at least functionally equivalent to the item replaced. The replacement assumes the warranty service status of the replaced item. You agree further:
1. before AqSep or its authorised/appointed service agent exchanges a part or a Machine, to remove all features, parts, options, alterations, and attachments not under warranty service by AqSep and ensure that the Machine is free of any legal obligations or restrictions that prevent its exchange;
2. to obtain authorization from the owner , if the user is not the owner, to have AqSep’s local service agent service the Machine;
3. where applicable, before service is provided: a. follow the service request procedures that AqSep or its service agent provides; b. inform the AqSep service agent of the Machine's exact location;
4. to provide the AqSep authorised service agent with sufficient and safe access to your facilities to permit him to fulfil his obligations, including security, lighting and ventilation as well as any other safety equipment, if required by law;
5. when the type of warranty service requires that a machine is taken to workshop for repairs, the service agent will return the repaired Machine or provide a replacement Machine to you at his expense, unless the reasons for Machine fault comes under Section 2.2. above. The service agent is responsible for loss of, or damage to, your Machine only while it is 1) in the service agent’s possession or 2) in transit.
6. AqSep or its service agents cannot be held responsible for any loss to you or your estate for the failure of the Machine to function as intended.
2.6 Terms of warranty
The AqSep warranty period for the Machine is compliant with the laws of your country. However, the warranty is only valid if the quality, quantity and pressure of the feed water is within specified limits as given in the Specifications for the Machine. These are attached hereto.
2.7 Limitation of liability
UNDER NO CIRCUMSTANCES IS AQSEP OR ITS SUPPLIERS, DISTRIBUTORS, RESELLERS OR SERVICE AGENTS
LIABLE FOR ANY OF THE FOLLOWING, EVEN IF INFORMED OF THEIR POSSIBILITY: 1) THIRD PARTY CLAIMS
AGAINST YOU FOR DAMAGES (OTHER THAN THOSE UNDER THE FIRST ITEM LISTED ABOVE); 2) SPECIAL,
INCIDENTAL, OR INDIRECT DAMAGES OR FOR ANY ECONOMIC CONSEQUENTIAL DAMAGES; OR 3) LOST
PROFITS, BUSINESS REVENUE, GOODWILL OR ANTICIPATED SAVINGS.
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3. Introduction
Congratulations on your purchase of the AqSep WaterCube. The WaterCube will provide you with clean and safe drinking water for many years to come, if you follow the instructions in this manual.
The AqSep WaterCube produces completely pure and clean drinking water from water with a high salt content, such as e.g. sea water or brackish water.
The filtration process comprises three steps:
1. Pre-filtration/treatment: This step is critical for the continued functioning of the WaterCube.
2. Particle filtration inside the WaterCube: The unit comes with an integrated very fine filter cartridge that serves as the final protective barrier against particles in the water.
3. Membrane filtration and separation: The membranes are inside the machine and these separate water from all other elements and minerals. There are three ultra fine Reverse Osmosis (RO) membranes where the feed water is transformed into pure water without bacteria or virus
The unit requires water supplied at a certain pressure and at a certain quantity. If this does not take place the unit will shut down automatically to prevent damage to the machine. Similarly, the unit requires a small volume of clean fresh water for flushing the membranes at times. This also has to be fed to the unit at a certain minimum pressure. As such, the WaterCube will work as envisaged provided the external conditions are within the specified range. If the unit stops for some reason, always check that the external conditions are within specs.
4. Pre-treatment of feed water
For the WaterCube to function as intended, and for as long as envisaged, it is important that the feed water is free from sand and suspended particles such as silt, clay and organic matter. It is advisable to have a water treatment company design an appropriate pre-treatment system as water quality varies from place to place.
Irrespective of the source of water, an effective pre-filter of 3 micron size followed by a 10 micron ‘absolute’ sized filter must be installed before the WaterCube in order to ensure that the water quality is as given in the specifications. In order to reduce the number of filter replacements it is recommended to use 20 inch big blue filters.
Please ensure that the design of the hydraulic system suggested by your local dealer and/or agent takes this aspect into account. Your local dealer should also make every effort to avoid abstracting water with a high level of organic pollution as such pollution may affect the performance and lifetime of the RO membranes.
Similarly, the brine from the WaterCube should be discharged into a well, borehole or soakage pit located a safe distance away from the water intake. The required distance will depend on local conditions but as a guideline a minimum of 25 meters is recommended.
5. Operating the machine
The WaterCube functions automatically and it has a number of built-in safety features which will be explained in this manual. The user can operate and monitor the process on the panel and on the display.
5.1 Display
Once the WaterCube 2 has been connected to the electricity system and to the piped water system the Human
Machine Interface (HMI) will become active, displaying the status in the text screen, Figure 5.1
Figure 5.1: HMI panel
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Figure 5.2: Start/stop button
The WaterCube 2 is started by pressing the Start/stop button. And the text “Water production” appears.
5.2 The User Menu
The user can obtain all relevant information about the WaterCube’s performance through the HMI. The
WaterCube2 HMI menu provides information about the following:
Filter condition
RO membrane condition
Water quality
Water production measured in m
3
(1000 litres) or US Gallons from the initial start up
GSM signal strength, if applicable
The WaterCube 2 is equipped with an automatic electronic monitoring system that continuously provides information on all four parameters to the panel.
5.2.1 Filter Condition
Figure 5.2: Filter icon
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The WaterCube 2 is constantly measuring the pressure after the filters, and if the pressure reduces to a pressure inadequate for the high pressure pump, the Filter Icon will flash with a red light. The WaterCube 2 will automatically stop to prevent damage to the pump. A filter change is needed to make the system run again.
5.2.2 RO membrane Condition
Figure 5.3: Membrane icon
The WaterCube 2 is constantly measuring the system pressure before the RO membranes, which is the location where the highest pressure will occur. The WaterCube2 is programmed to flush the membranes at intervals in order to prevent clogging of the membranes. However, should the pressure rise to the maximum allowable pressure, the system will automatically shut down to prevent system damage, and the RO membrane icon will flash red. The RO membranes either need to be cleaned with a suitable membrane cleaning agent, or the membranes should be changed.
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5.2.3 Water Quality - Performance Levels
Figure 5.4: Status icon
In the Section below, details are provided on the meaning of the icon, Figure 5.4.
The rating of water quality, water production and filter and membrane conditions is provided at three levels:
Green water droplet: Excellent quality – no action required
Yellow water droplet: Good quality – no action required
Red water droplet: High salt contents in drinking water – action required
The panel indications for the different conditions are shown in Figure 5.5.
Figure 5.5: Water quality indicators
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Green water droplet - Excellent performance
With this indication no action is required. You can expect excellent performance by the WaterCube2 for 90 % of the operational time. However, differences in intake water quality or other factors may affect the performance. It is important for the continuous operation of the WaterCube2 that such factors are identified and corrected as soon as they are detected. Therefore, it is advisable to keep a daily log for the first month of operation after which the log should be kept weekly.
Yellow water droplet - Good performance
No action required. The yellow water droplet indicates a slightly reduced performance, a development that will inevitably occur with time. Filters will gradually become clogged and membranes will also slowly become affected by the continuous working process. However, at this level the machine will still provide water of fully acceptable and safe quality.
Red water droplet - Poor performance
The red water droplet indicates elevated high salt content in the water produced by the unit. It should be noted that although the salt content is elevated it is not at the same level as the intake water. The WaterCube 2 will at this stage automatically shut down to prevent the storage tank to be filled with salty water. The membranes need to be cleaned or changed. Please contact your service agent.
5.2.4 Water Production
Figure 5.6: Water production indicator
The system continuously calculates the amount of water produced by the WaterCube 2. The parameter is set to display either m
3
or US gallons.
5.3 Automatic Flushing System
Under normal circumstances the unit will produce water displaying the text “Water Production”. However, there is an automatic flushing system which at intervals suspends the water production and initiates the flushing cycle, indicated by the text “Flushing”. In this process the surface of the membranes are cleaned and the majority of the impurities that have settled on the surface of the membranes will be cleaned out.
This process helps to extend the periods between membrane cleaning and between replacements of the membranes. It is critically important that the water used for flushing purposes is free from chlorine or any other disinfectant. Such chemical compounds will destroy the membranes quickly and irreversibly and new membranes will be required.
The automatic flush takes place in the following cases:
The flush cycle starts automatically if the storage tank has become full. With a float switch installed a signal is transmitted to the unit, stopping the water production. A few seconds later the flush cycle
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starts and the membranes are flushed for a period of 60 seconds after which the machine goes into
Standby mode.
The water production process is also interrupted after approximately 8 hours of water production (in intervals or continuously) and the flushing cycle is started.
In stand-by mode the machine will automatically flush the membranes one time every 24 hours. This means that if the machine is not in use but still connected to the power system and ON, the machine will flush every 24 hours.
Please do NOT disconnect the fresh water flushing system when the machine is ON. Also please make certain that there is always water for flushing of the membranes. Each flush is using approx. 30 litres.
6.
6.1
Filter and Mineral Dispenser
Replacing Filter Cartridge
Photo 6.1: Filter (blue) and Calcite/mineral(white) Cartridges
The following section describes the procedure for changing the blue filters.
Please read the instruction carefully before changing the filters for the first time. For your safety, please follow each of the steps as advised.
Tools needed
Photo 6.2: Special Filter Wrench
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Process Description
Step 1 – Switch off the machine on the ON/OFF button on the HMI panel
Step 2 – Open the front and unscrew the two Allen screws on the bracket that hold the blue filter housing
Photo 6.3: Use a 6 mm Allen key to unscrew the bracket and take out both screws
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Step 3 – Push the push up fitting up and release the vertical black PE pipe
Photo 6.4-6.5: Remove the vertical PE pipes from the elbow fittings on both sides of the blue filter housing
Step 4 – Change the filter cartridge
Please note that the filter housings contain water and may be heavy. The water can be poured into nearest drain.
Photo 6.6 – 6.7: Unscrew the filter housing and take out the used filter
The filter cartridge is the white plastic item inside the filter housing. You can take it out with your hands and dispose of it together with your domestic waste. The filter does not contain any harmful substances but cannot be recycled or
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regenerated. The filter is a 10 micron absolute filter with an efficiency of 99.98 %. Any other filter used will make the warranty void. Please check the label on the filter housing.
Photo 6.8: Remove seal from the new filter cartridge before inserting it into the housing
After you have placed the new filter in the filter housing, remove the seal from the filter. The seal must face upwards.
Step 5 – Screw the new filter cartridge tightly into the bracket and fasten the housing
Photo 6.9-6.10: After changing the filter, fasten the housing and push the vertical PE pipes back into the elbow fittings
Step 6 – Screw the filter bracket back into place
Photo 6.11. Refit the filter bracket
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6.2 Replacing Mineral Dispenser Module
In the machine the mineral dispenser module, if supplied, is located above the blue filter cartridge. The colour of the mineral dispenser module is white, as shown in Photo 6.11.
Photo 6.12 and 6.13: Unscrewing the Mineral Dispenser Module
The mineral dispenser module is unscrewed using the same filter wrench as used for changing the filters. Once unscrewed the mineral container is lifted out from the container and disposed of. A new mineral container is inserted in the housing. Remove the plastic cover and insert the container into the white housing. The module is now operational.
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7. Service Messages
The number of service messages that may appear in the display are limited. However, in case any of these do appear it is important that the user understands the meaning and implications of the messages:
Message
Water
Production
Possible Reasons
Machine is running
Recommended Action
None
FWF loop Machine inactive due to fresh water flushing of membranes
Product water too salty
None. Wait for flush to end and the water production to start automatically
Call service agent Water
Quality
High
Pressure
Low Feed
Pressure
High Feed pressure
The machine pressure has increased to a high level.
Membranes may need attention
The pressure on the feed side is too low, i.e. less than 0.5 bar.
The pressure on the feed side is too high, i.e. more than 9 bar.
Call service agent. Do not attempt to handle this problem yourself.
Most likely the membranes will need cleaning and this can only be done by a service agent.
Check and if necessary clean pre-filters or replace pre-filter cartridges. Check and if necessary replace the built-in filter in the front of the machine. If the high pressure message continues to show after cleaning or changing all pre-filters, contact your service agent
Reduce feed pressure if possible. If not possible, contact service agent
Contact service agent Low System
Pressure
Replace filters
Filter getting clogged Replace the filter inside the front of the machine in accordance with this manual
Call service agent to replace and clean membranes Replace membrane
Poor GSM signal
Service
SWPE
Membranes getting clogged
GSM signal below 20% Consult service agent
Inform service agent who will need to carry out an inspection of the internal parts of the pump and, if necessary, replace worn parts.
Time to service the high pressure pump is less than
500 hours
Note: When time to service is up, membrane icon is red. Service is now required
Fresh water tank full None Water tank full
Fresh water flush
System stopped
The machine flushes with fresh water
When manually stopped
None. Wait for production to start
Restart
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8. Trouble shooting guide
This Section summarises the most likely faults you may encounter as well as the likely cause and remedies recommended. It should be noted that any user intervention beyond what is described here will make the warranty invalid.
FAULT CAUSE REMEDY
Noisy operation
No pressure in system
Leakage from the machine
Pressure reading not correct or missing
Salinity (TDS) is not displayed correctly
Hydraulic problem
Air pockets in machine
Worn shaft seal and/or o-rings
Call your local service agent
Call your local service agent
Call your local service agent
Call your local service agent Pressure transducer malfunctioning
Salinity meter is malfunctioning Call your local service agent
System is not starting up, when pressing start button. No indication in display for change or service.
System is not starting up, when pressing start button. No indication in display for change or service.
System is not starting up, when pressing start button. No indication in display for change or service.
Too low flushing water pressure Call your local service agent to make adjustments to the fresh water flushing system hydraulics
Tank is full
If tank is not full, tank level switch is malfunctioning
Wait for water level to reduce to enable start
System stops after only 1 minute of operation.
Whenever display reads “Low feed pressure”
Too low feed water pressure
1) External pre-filters need cleaning/replacement or
2) Inadequate feed water supply
Note: Feed water is also fresh water flush supply
1) Check if tank level switch is stuck and release, or
2) Contact your local service agent to check wiring for loose connections. Replace tank level switch
1) Call you local service agent to check feed water hydraulics. If necessary increase capacity of hydraulic system (e.g. larger pump)
2) Check water quality against specifications
1) Call you local service agent to check feed water hydraulics.
2) Check water quality against specifications
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9. Service and Support
Contact details of your local AqSep approved service agent:
Name:
Address:
Telephone no.:
Fax no.: e-mail address:
AqSep Head Office contact:
AqSep A/S c/o Danfoss
E14 – N14
Nordborgvej 81
6430 Nordborg
Denmark
Tel.: (+45) 7488 4100 e-mail: [email protected]
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Specifications WaterCube2 January 2015
Specifications:
Number of membranes
Membranes
Pre-filters (does not eliminate other pre-treatment)
Typical power consumption*
Electrical motor
Water production*
High pressure pump
Efficiency
Energy recovery
Materials
Controller
Lubrication, coolants etc
Measurements
Weight
3
DOW Filmtec SWRO 3x21” custom made
Integrated, 1 no. 1 micron nom. and 1 no. 10 micron abs.
900 - 1100 W
AMHE 90S AA4 B14L 1.1kW 400VY 50Hz 1500rpm IP55 EFF1 approx. 4800 l/day (1270 GPD**) at 100% production
Danfoss APP 2.2
E total
: E vol
: 0.98; E mech
: 0.8
Yes, Danfoss APPM 2
High pressure pump and energy recovery: Duplex steel
All other wetted parts Duplex steel and 316 steel
Exterior: rota-moulded plastic
Integrated, custom made, non PLC
None
50 x 57 x 97 cm (l x b x h)
115 kg
*
Design parameter: Output 200 l/h, 3 phases 400 Volt 50 Hz, 25deg. C sea water at 35.000 TDS +/- 15%
** Measured in US Gallons
Connections:
Electrical specifications
Feed water inlet
Fresh water flush inlet
Brine outlet
Permeate outlet
*
Pipe connections: All measurements are internal diameters
Operating limits:
Feed water temperature
Ambient temperature
External feed pressure (inlet)
Ext. fresh water flush pressure (inlet)
Minimum feed water flow
Minimum fresh water flush flow
Maximum pressure drop permeate line
3 phases 400 V 50/60 Hz
1 phase 230V 50/60 Hz
Ø 19mm*
Ø 19mm*
Ø 19mm*
Ø 19mm*
5 – 45 deg. C (41 – 113 deg. F )
5 – 45 deg. C (41 – 113 deg. F )
2 – 6 bar ( 29 – 130.5 PSI ),
2 – 6 bar ( 29 – 130.5 PSI ),
1.2 m
1.2 m
3
3
/h (5.3 GPM )
/h (5.3 GPM )
0.2 bar (2.9 PSI )
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Feed water requirements*:
Pre-treatment
Total dissolved solids (TDS)
SDI rating (15 min.)
Turbidity
Free chlorine/total chlorine
Total Organic Carbon (TOC)
Hydrocarbons or silicone based oils
Ferrous iron
Min. filtration 3 micron (nom.) followed by 10 micron abs. or better**
1,000 – 50,000 mg/l
< 3 SDI
< 1 NTU
< 0.1 mg/l
< 3 mg/l
< 0.1 mg/l
< 4 mg/l (pH <6, oxygen <0.05 mg/l)
Ferric iron
Manganese
< 0.05 mg/l
< 0.05 mg/l
Aluminium < 0.05 mg/l
* 1 mg/litre = 1 ppm.
** Recommended minimum pre-treatment. However, if feed water is outside of the range given here, additional pre-treatment is required. Please note that the unit will shut down if conditions are not within operating limits. Full chemical and bacteriological analysis is recommended before design of the pretreatment system is carried out. In conditions where bio-fouling could be possible we recommend installation of UV in the pre-treatment system.
Fresh water requirements* (for fresh water flush of the system):
Total volume required
Free chlorine/total chlorine
Total dissolved solids (TDS)
Other parameters:
*1 mg/litre = 1 ppm.
Typical Water Quality Produced
< 50 litres/flush
< 0.1 mg/l
< 600 mg/l
Drinking water
Parameter
Total hardness
Total alkalinity
Suspended solids
Conductivity
Nitrate as N
Nitrite as N
Fluoride
Turbidity
Chloride
Sulphate
Aluminium
Sodium
Potassium
Magnesium
Calcium
True colour
Copper
Iron
Manganese
Zinc
Total coliforms e-coli
Units mg CaCo
3
/l mg CaCo
3
/l mg/l
µSiemens/cm mg NO
3
-N/l mg NO
2
-N/l mg F
-
/l
NTU mg Cl
mg SO
/l
4
2-
/l mg/l mg/l mg/l mg/l mg/l
PtCo units mg/l mg/l mg/l mg/l
MPN/100ml
MPN/100ml
Value
5
12
< 0.1
204
0.002
0.002
0.31
<0.1
124
3
<0.01
132
2.31
7.74
3.94
<5
<0.01
<0.01
<0.005
<0.005
<1
<1
-
-
-
-
2.0
0.2
0.05
-
0
0
EU Standards US standards
- -
- -
-
2500
50
250
-
10
0.50
1.5
-
250
250
0.2
250
1
2.0
-
250
-
0.2
-
-
-
-
-
1.0
0.3
-
5
0
0
Note: Results by Wide Bay Water Corporation, 29-31 Ellengowan St., Urangan, QLD, Australia. Date : 6 th
October 2010
Analyses on other parameters may be issued from time to time.
Date of issue: 6. October 2010.
AqSep can accept no responsibility for possible errors in catalogues and other printed material. AqSep reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without sub sequential changes being necessary in specifications already agreed. All trademarks in this material are the property of the respective companies.
WaterCube2, AqSep and the AqSep logotype are trademarks of AqSep A/S. All rights reserved.
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Key Features
- Produces clean drinking water from high salt content water
- Three-step filtration process: pre-filtration, particle filtration, and membrane filtration
- Automatic electronic monitoring system displays key performance indicators
- Automatic flushing system for membrane cleaning
- Easy-to-use interface with clear service messages