4400M Digital Reverse Osmosis System

Transcription

1 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.k)

2 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 PRODUCE PURIFIED WATER FOR DIALYZER REPROCESSING AND EQUIPMENT RINSE AND DISINFECTION. SOFTWARE VERSION: V6.7e.132 BIOLAB SERIAL #: DEVICE IDENTIFIER: DATE MANUFACTURED: MAN-4400MCOLD (rev.k) page 2 of 106

3 MANUAL REVISION HISTORY Revision Author Date Changes G J Parkin March, 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 / 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, K J Takacs January, 2017 Update: Spare Parts List / System Pictures; Remove HX references, Reformat System Test Matrix, Verbiage clarifications/corrections. Minor Punctuation / format changes. MANUAL PREPARATION Richard Marmen Engineering Manager Biolab Equipment Ltd o/a Mar Cor Purification 30-Jan-2017 Date MAN-4400MCOLD (rev.k) page 3 of 106

4 TABLE OF CONTENTS INTENDED USE... 2 SAFETY... 7 DEFINITIONS... 7 LABELS... 7 SPECIFICATIONS... 8 GENERAL PRECAUTIONS GENERAL INFORMATION HOW DOES THE RO PROCESS WORK? RO TECHNOLOGY USED IN MEDICAL APPLICATIONS INSTALLATION AND START-UP UNPACKING THE SYSTEM SPACE / ROOM REQUIREMENTS SETTING UP THE SYSTEM INSTALLATION OF EXTERNAL CONNECTIONS TO THE 4400M SYSTEM START-UP Electrical Hook-up Verification Pre-Start-up Verification Control Panel / Microprocessor Start-up M System Start-up Checking the RO Pump Rotation Purging Air from the RO Pump OPERATIONS AND MONITORING SYSTEM OPERATIONS SYSTEM OPERATION CONTROLS The Display Navigation Set-Up Screen Descriptions Set-Up Data Reference Table Controller Options OPERATING PROCEDURES System Start-up Normal Operations System Shut-down MONITORING SYSTEM PERFORMANCE MONITORING RO MEMBRANE PERFORMANCE Effects of Pressure on Membrane Performance Effects of Recovery on Membrane Performance Effects of Temperature on Membrane Performance MAINTENANCE MAINTENANCE REQUIREMENTS Scheduled Maintenance Log Sheet REPLACEMENT PROCEDURES Pre-filter Replacement Procedure MAN-4400MCOLD (rev.k) page 4 of 106

5 4.2.2 Solenoid Valve Seal Replacement Procedure OVERVIEW OF SYSTEM SANITIZATION & RO MEMBRANE CLEANING Dealing with a Hardness / Metal Oxide Fouling Problem Dealing with a Colloids / Silica Fouling Problem Dealing with an Aluminum / Polymer Fouling Problem CHEMICAL CLEANING AND SANITIZATION Clean-In-Place (CIP) Equipment Requirements Cleaning / Sanitization Chemicals Overview of Recommended Chemicals Cleaning / Sanitization Procedure Using a CIP System Skid Cleaning / Sanitization Procedure Using a Tank and RO Pump Tank Decommissioning and Chemical Storage Neutralizing Cleaning / Sanitization Solutions Restarting RO System after Chemical Cleaning / Sanitization Procedures MINNCARE Test Strips Overview RO MEMBRANE ELEMENT STORAGE TROUBLESHOOTING TROUBLESHOOTING ALARMS / MESSAGES SYSTEM DIAGNOSIS System Test Matrix WARRANTY CONTACT INFORMATION A1 4400M DIGITAL REVERSE OSMOSIS SYSTEM DESCRIPTION & FUNCTION OF SYSTEM COMPONENTS A2 4400M CONTROL PANEL DISPLAY A3 SET-UP MENU DISPLAY NAVIGATIONAL FLOW CHART A4 ALARM LOG SHEET A5 DEVICE MATERIALS OF CONSTRUCTION A6 WATER SAMPLING PROCEDURE A7 REQUIREMENTS FOR INSTALLATION OF EXTERNAL CONNECTIONS TO THE 4400M SYSTEM DRAIN CONNECTION REQUIREMENTS PIPING REQUIREMENTS PRE-TREATMENT REQUIREMENTS POST-TREATMENT REQUIREMENTS PANEL ELECTRICAL TERMINATION REQUIREMENTS FEED WATER REQUIREMENTS ELECTRICAL SUPPLY REQUIREMENTS A8 4400M RO TYPICAL FLOW RATES A9 TABLE OF SYSTEM MONITORING PARAMETERS A10 SITE ACCEPTANCE TEST (SAT) PROCEDURES INSTALLATION VERIFICATION CHECKLIST DISPLAY SCREEN SETTINGS & DEFAULT SETPOINTS MAN-4400MCOLD (rev.k) page 5 of 106

6 SYSTEM TEST MATRIX RO PERFORMANCE VERIFICATION LOG DISCREPANCY LOG A11 SAMPLE PROCESS & INSTRUMENT DRAWING A12 ELECTRICAL CONTROL INTERLOCKS FOR THE CONTROL PANEL PANEL ELECTRICAL FIELD TERMINATION DESCRIPTIONS FOR THE OPTIONAL FEATURES A13 SPARE PARTS LIST CUSTOMER SYSTEM S MAN-4400MCOLD (rev.k) page 6 of 106

7 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 pre-treatment / post-treatment that meets ISO 13959, ISO and ISO 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. 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.k) page 7 of 106

8 SPECIFICATIONS MACHINE NOMENCLATURE * X X M 1 X B - 2 X Number of RO Elements 2, 3, 4, 5, 6, 8, 9, 10, 12 Membrane Type 2 - Sanitary 5 - Low Fouling Medical Application 304 SS Housing Source Voltage (Volt / Phase / Hz) / 1 / / 3 / / 3 / / 1 / / 3 / / 3 / / 3 / / 3 / SS Pump Digital Control Feed Design 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 /CAN/CSA- C22.2 No (3 rd Edition) and FFC 47CFR 15B clb. RO Element Quantity Capacity 77 F (25 C) FLOW 75% RECOVERY Product Flow Rate GPM (LPM) Concentrate Flow Rate GPM (LPM) Motor Horse Power (hp) Weight (lbs.) 2 4, (10.5) 0.8 (3.0) , (15.9) 1.3 (4.9) , (21.2) 1.8 (6.8) , (26.1) 2.3 (8.7) , (31.4) 2.8 (10.6) , (41.6) 3.7 (14.0) , (47.3) 4.2 (15.9) , (53.0) 4.7 (17.8) , (64.4) 5.7 (21.6) Operating Pump Pressure OPERATING PARAMETERS < 250 psi Operating Temperature 2 35 o C (35 95 o F) Standard Electrical Requirement Feed Water Quality 208 VAC, 3-phase, 60 Hz Refer to Appendix A7 DIMENSIONS Inch (mm) 4400M - Digital RO Skid 38 (965) Width 29 (737) Depth 80.5 (2045) Height MAN-4400MCOLD (rev.k) page 8 of 106

9 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 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.k) page 9 of 106

10 WARNING While a water treatment system may produce water of sufficient quality to meet the requirements of ISO , 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.k) page 10 of 106

11 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 and ISO 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. The 4400M system does not include external pre-treatment and post-treatment 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, ultra-filtration and the more recent micro filtration. MAN-4400MCOLD (rev.k) page 11 of 106

12 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. 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 and ISO 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. 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 MAN-4400MCOLD (rev.k) page 12 of 106

13 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.k) page 13 of 106

14 2.0 INSTALLATION AND START-UP 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. 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 the membranes or 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. 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.k) page 14 of 106

15 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. A room with good ventilation is required to help remove heat and any chemical fumes. 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. 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 and ISO Standard requirements. MAN-4400MCOLD (rev.k) page 15 of 106

16 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. 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 and ISO Standards. (Reference: ISO Element ). START-UP 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 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: Plant clean dry air supply is connected and verified if required. MAN-4400MCOLD (rev.k) page 16 of 106

17 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 All appropriate valves are open in the overall water treatment system. Feed water tests are performed. All tank accessories are installed and ready to receive water. 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. 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%. 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 M 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. 1. Fully open the reject to drain valve and fully close the reject CIP (Clean-In-Place) valve. MAN-4400MCOLD (rev.k) page 17 of 106

18 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). 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. When either opening or closing any needle valve, DO NOT over-extend or overtighten 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 for instructions. 8. Check the RO pump rotation is correct. Refer to section 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. 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 A Adjust the reject recycle flow control needle valve to the flow rates shown in APPENDIX A8. When either opening or closing any needle valve, DO NOT over-extend or overtighten 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. Flow adjustment should be made slowly. The flow rates in steps 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). MAN-4400MCOLD (rev.k) page 18 of 106

19 15. Place the system back into the RUN mode. 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 and ISO 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. The water cannot be used for dialysis until the water quality is verified and signed off by the physician. 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. 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 Element 6.3, Item # aa) 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. 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. MAN-4400MCOLD (rev.k) page 19 of 106

20 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. MAN-4400MCOLD (rev.k) page 20 of 106

21 3.0 OPERATIONS AND MONITORING SYSTEM OPERATIONS The main operations performed by the 4400M - Digital RO system are as follows (See FIGURE 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 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 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. The RO system controller is locked-out by the 4400M System controller during part of the hot water sanitization of the distribution loop. Figure 3.1 Operations Flow Chart System Sanitization Normal RO Operations Chemical Sanitization / Cleaning (Using a CIP system or tank) Stop Standby Run Flush MAN-4400MCOLD (rev.k) page 21 of 106

22 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 non-volatile 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 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 MAN-4400MCOLD (rev.k) page 22 of 106

23 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 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 MAN-4400MCOLD (rev.k) page 23 of 106

24 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 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. MAN-4400MCOLD (rev.k) page 24 of 106

25 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 Selection 1> Clean Mode 2> Customize 3> Alarms <OK> : 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 5.5 horse power (hp). Damage to the system and pump can occur. System with greater than 5.5 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. MAN-4400MCOLD (rev.k) page 25 of 106

26 Screen Description: CLEAN MENU Access from Main Menu: <OK> READ INSTRUCTION MANUAL BEFORE DOING THIS COMMAND <CANCEL> First, follow the cleaning / sanitization procedure in section and for set-up. Press the OK key to start the cleaning / sanitization process or the CANCEL key to return to the set-up main menu. After the cleaning / sanitization process is completed, press the STOP key to end. 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 MAN-4400MCOLD (rev.k) page 26 of 106

27 selection NO, the system will flush with the pump running. Screen Description: CUSTOMIZE MENU #2 Access from Main Menu: Item Option Selection 1> Ω Resistivity or S Ω (Default) Conductivity 2> 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. : 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. MAN-4400MCOLD (rev.k) page 27 of 106

28 Screen Description: CUSTOMIZE MENU #3 Access from Main Menu: Item Option Selection 1> Temperature in C or F C (Default) 2> Clear ROP Timer NO (Default) 3> Flush Delays Sub-Menu s <SETUP=First> <OK> TEMPERATURE IN o C or o 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 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 <CANCEL> Flush Cycle <CANCEL> 9? (1, 60) X 10s 60? (30,120)nm (period included) <OK> <OK> 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. Press OK to go to next to the Flush Cycle screen. FLUSH CYCLE: Enter the time between the flush cycles in minutes. : The flush cycle time is calculated according to the current flush period. MAN-4400MCOLD (rev.k) page 28 of 106

29 Screen Description: ALARM MENU #1 Access from Main Menu: Item Option Selection 1> Alarm->Stop: YES (Default) 2> 1 retry (Default) Alarm->Stop->Restart retry every 010m (Default) 3> Poor Quality Delay 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: SELECT <<-> NUMBER OF RETRIES: (0..6): 1 SELECT <<-> NUMBER BETWEEN RETRIES: (10m..150m): 010m <OK> <OK> NUMBER OF RETRIES: Enter the number of retries (0-6) the system will perform before shut-down using the arrow key. Press the OK key to go to the next set-up screen. 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. : 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. MAN-4400MCOLD (rev.k) page 29 of 106

30 Screen Description: ALARM MENU #1 Item #3 (Poor Quality Delay) Sub-Menu Access from Main Menu: Poor Quality Delay <CANCEL> 120? (4,240) s <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. : 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> <OK> 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. 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) MAN-4400MCOLD (rev.k) page 30 of 106

31 Screen Description: ALARM MENU #2 Item #1 (Feed Temp SetPt) Sub-Menu Access from Main Menu: Feed Temp. SetPt <CANCEL> 35? (30,50) C Or 95? (86,122) F <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. : The processor uses temperature in o C to calculate the conductivity and resistivity measurements. When temperature unit is set in o F, rounding error may occur. Screen Description: ALARM MENU #2 Item #2 (Poor Quality SetPt) Sub-Menu Access from Main Menu: Conductivity or Resistivity. SetPt <CANCEL> 2? (1,100) μs Or 50? (1,100) x 10 K Ω <OK> CONDUCTIVITY or RESISTIVITY SETPOINT: 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. MAN-4400MCOLD (rev.k) page 31 of 106

32 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. Customize Screen Name Parameter Name Factory Default Customer Setting 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 Yes Menu #1 Alarm Stop Restart 1,10 min. Menu #1 Menu #2 Menu #2 Poor Quality Shutdown Delay Feed Temperature Setpoint Poor Quality Setpoint 120 s 35 C or 95 F Menu #2 Item #2 Sub-Menu Conductivity 2 μs Menu #2 Item #2 Sub-Menu Resistivity 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: MAN-4400MCOLD (rev.k) page 32 of 106

33 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. OPERATING PROCEDURES The procedures below describe how to operate the 4400M - Digital RO system. Refer to the information provided in section on Set-Up Screen Descriptions to provide inputs to the system controller. MAN-4400MCOLD (rev.k) page 33 of 106

34 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 Normal Operations See section 3.2 to perform RO operations and set-up system parameters 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: 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. 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 shut-down. 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 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.k) page 34 of 106

35 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 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. 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.k) page 35 of 106

36 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. 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 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.k) page 36 of 106

37 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. Temperature Feed Inlet C 2 35 (1) Total Chlorine Feed Inlet ppm 0.0 <0.1 Optimum ph Feed Inlet Operating ph Feed Inlet Cleaning ph Feed Inlet 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 Membrane Pressure Drop Pump Outlet To Reject psig 5 13 (2) Design Product (Flux) Flow Rate Product Outlet gpd 2,000 per membrane Product (Flux) Flow Rate Product Outlet % Rejection* Inlet To Product % >90 % WARNING: S: Percent Rejection target is based on ISO 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. (1) The Actual membrane maximum temperature is 45C (113 o F). The System alarm setpoint is 35C (95 o F). (2) The Maximum pressure drop includes piping and is shown per membrane 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.k) page 37 of 106

38 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). Never exceed a Trans-Membrane Pressure of 220 psi (15 bar) for TFC cartridges. Trans-Membrane Pressure should be reduced if the feed water temperature is greater than 25 o C (77 o F) to avoid exceeding the design flow rate 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 = Product Product + Reject + Reject Recycle X 100 % System Recovery = Product Product + Reject 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 = Product % Array Recovery - Product - Reject MAN-4400MCOLD (rev.k) page 38 of 106

39 # of Membranes In Series Delta P. - psig (kpa) 10 (69) 20 (138) 30 (207) 38 (262) 45 (310) Maximum Recovery Percentage 15% 25% 35% 45% 53% 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. 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. Do not exceed the design recovery as this can result in decreased salt rejection and membrane fouling or scaling. Never completely close the reject and reject recycle valve. When either opening or closing any needle valve, DO NOT over-extend or overtighten 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 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 (77 o F). 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 membranes. 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.k) page 39 of 106

40 : Temperature correction factors are listed for all RO elements. The reference temperature is 77 F (25 C). Temperature F ( C) Correction Factor 40 (4) (10) (16) (21) (25) (27) (32) 1.26 MAN-4400MCOLD (rev.k) page 40 of 106

41 4.0 MAINTENANCE 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 and ISO 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. 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 Element 6.3. Item a). Appropriate chemical cleaning / sanitization must be performed to maintain acceptable product water quality. This section does not cover maintenance of the pre-treatment devices. Refer to their manufacturers manual for maintenance requirements. 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.k) page 41 of 106

42 4.1.1 Scheduled Maintenance Log Sheet : 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. PARAMETER LOG FREQ. D/M/Y 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 Solenoid Valve Seals (Fig. 4.1) y d/m/y ADDITIONAL S: UNITS EXPECTED RESULTS SUN MON TUES WED THU FRI SAT <10 psi clean or Once a Month Change Once Every Two Years In addition to checks above, perform daily checks for the system performance parameters listed in APPENDIX A9. MAN-4400MCOLD (rev.k) page 42 of 106

43 Figure 4.1 LOCATIONS FOR MAINTENANCE CHECKS Reject Solenoid Valve Pre-filter Inlet Pressure Gauge Pre-filter outlet Pressure Gauge Feed Inlet Solenoid Valve Image shown may not reflect actual system MAN-4400MCOLD (rev.k) page 43 of 106

44 REPLACEMENT PROCEDURES 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. 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. 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. 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. CAUTION Do not energize a solenoid coil with the coil removed from the valve stem. Damage to the coil may occur. MAN-4400MCOLD (rev.k) page 44 of 106

45 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 buildup 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 pretreatment 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 water composition, persistent or severe fouling should be a cause for re-evaluation of the RO pretreatments. MAN-4400MCOLD (rev.k) page 45 of 106

46 The following basic discussions are of RO foulants, how to identify them, and what to do once they have affected membrane performance: 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 Dealing with a Colloids / Silica Fouling Problem What are Colloids? What is Silica? MAN-4400MCOLD (rev.k) page 46 of 106

47 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 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 or 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. Unfortunately, this property can present troublesome conditions for high efficiency RO systems, with over 33% recovery. The Problem MAN-4400MCOLD (rev.k) page 47 of 106

48 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. 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? 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 or 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 Clean-In-Place (CIP) Equipment Requirements MAN-4400MCOLD (rev.k) page 48 of 106

49 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: gpm per housing 60 psig 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 Membrane Element Volume Element Diameter (inches) Element Length (inches) Volume Per Element (gallons) 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. The pump must be flushed with clean water after a sanitization is completed to prevent corrosion and damage to the pump. MAN-4400MCOLD (rev.k) page 49 of 106

50 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.k) page 50 of 106

51 FIGURE 4.2 TYPICAL CLEAN-IN-PLACE (CIP) SETUP MAN-4400MCOLD (rev.k) page 51 of 106

52 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 Mineral scale and metal precipitates HCl or citric acid, ph 2 CHEMICAL 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 C (50-86 F). Recommended Chemicals TYPE OF FOULANT Mineral scale and metal precipitates Organics, silt, bacterial slime Bacteria CHEMICAL MINNCLEAN AC Cleaner MINNCLEAN TF Cleaner MINNCARE Disinfectant Chemical Concentrations CHEMICAL USED QUANTITIES RECOMMENDED TO CREATE 100 LITRES OF CLEANING / SANITIZATION SOLUTION. MINNCLEAN AC Cleaner 1.76 lbs. (0.798 kg), ph 2.0 to 2.4 MINNCLEAN TF Cleaner 1.76 lbs. (0.798 kg), ph 11.4 to 11.2 MINNCARE Disinfectant 0.26 US Gallons (1.00 litres), ph 3.0 to 3.5 CAUTION 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. MAN-4400MCOLD (rev.k) page 52 of 106

53 CAUTION 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. 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 buildup on the membranes, preventing oxidization. When cleaning a RO system follow membrane manufacturer s recommendations and/or customer approved cleaning / sanitization procedures 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 Normal Cleaning ph of Solution Foam Level Cloud Point Rinsability Storage Low ph Powder (Acidic) 1 pound (0.454 kg) cleaner per 15 gallons (57 litres) RO water Moderate None Good 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 Normal Cleaning ph of Solution 11.4 to 11.2 High ph Powder (Alkaline) 1 pound (0.454 kg) cleaner per 15 gallons (57 litres) RO water MAN-4400MCOLD (rev.k) page 53 of 106

54 Foam Level Cloud Point Rinsability Storage Moderate None Good Store sealed container in a cool dry place. Indefinite cleaner stability under good storage conditions. MINNCARE Disinfectant Specifications: DIN (Canada) 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-to-mouth, 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 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. MAN-4400MCOLD (rev.k) page 54 of 106

55 Hot Line Number For chemical emergency, spill, leak, fire, exposure and accident, call Chemtrec, day or night (800) , (703) 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 for emergency medical treatment information. Note to Physician Probable mucosal damage may contraindicate the use of gastric lavage. 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. 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 24 o C (75 o F). 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 Sporicidal 100X dilution, 11 hours 20 o C Bactericidal 100X dilution, 11 hours 20 o C Fungicidal 100X dilution, 11 hours 20 o C Cleaner / Sanitizer (Non-food contact surfaces) 32X dilution, 10 minutes 20 o C (Food contact surfaces Staphylococcus aureus and Escherichia coli) 320X dilution, 1 minute Hospital Disinfectant Pseudomonacidal 100X dilution, 10 minutes 25 o C Broad Spectrum Disinfectant 100X dilution, 10 minutes 20 o C Germicidal Spray Disinfectant 100X dilution, 10 minutes 20 o C RO Membrane Sanitizer 100X dilution, 36 minutes 20 o C 20 o C MAN-4400MCOLD (rev.k) page 55 of 106

56 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 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. MAN-4400MCOLD (rev.k) page 56 of 106

57 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 20 o C (68 o F). 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 20 o C (68 o F). 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 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 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. 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. Due to varying 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. MAN-4400MCOLD (rev.k) page 57 of 106

58 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. When either opening or closing any needle valve, DO NOT over-extend or overtighten 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 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. 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. 17. Prime the cleaning pump. 18. Place the cleaning skid selector switch in the ON position. 19. Adjust the tank recycle diaphragm valve until the pressure indicates approximately psig. 20. Fully open the RO CIP inlet valve. 21. Fully open the cleaning skid inlet and the outlet filter housing valves. 22. 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. 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 MAN-4400MCOLD (rev.k) page 58 of 106

59 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 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. If the solution concentration (ph) is too high, add some acid (HCl) or if the concentration (ph) is too low, add caustic (NaOH). 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. For sanitization process, use the MINNCARE residual test strips to check for residual level. Refer to 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 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 for decommissioning of the tank. 40. Restart the RO system as per instructions in section MAN-4400MCOLD (rev.k) page 59 of 106

60 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 CAUTION 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. 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. This procedure should only be used when the RO pump is less than 5.5 horse power (hp). Damage to system and pump can occur. System with greater than 5.5 hp RO pump should use only a separate cleaning pump (Clean-In-Place System) when a cleaning or sanitization is required. 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. When either opening or closing any needle valve, DO NOT over-extend or overtighten 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. 11. Fill the tank with RO quality water or better at C (68-86 F). MAN-4400MCOLD (rev.k) page 60 of 106

61 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. <OK> READ INSTRUCTION MANUAL BEFORE DOING THIS COMMAND <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. If the solution concentration (ph) is too high, add some acid (HCl) or if the concentration (ph) is too low, add caustic (NaOH). 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. For sanitization process, use the MINNCARE residual test strips to check for residual level. Refer to section for instructions. 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). MAN-4400MCOLD (rev.k) page 61 of 106

62 22. After the time has elapsed, press the STOP key on the keypad. 23. Neutralize the cleaning solution. Refer to section 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 for decommissioning of the tank. 31. Restart the RO system as per instructions in section 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 (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 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. Check with your local municipality for waste discharge regulations 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. MAN-4400MCOLD (rev.k) page 62 of 106

63 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. 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. When either opening or closing any needle valve, DO NOT over-extend or overtighten 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 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. The RO will not flush if the flush cycle has been disabled in the controller set-up 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. When either opening or closing any needle valve, DO NOT over-extend or overtighten 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. 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. 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. When sanitizing with Minncare refer to section Minncare Test Strips Overview MAN-4400MCOLD (rev.k) page 63 of 106

64 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 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. Each container has an expiry date. Do not use after date printed on the container. Test Strip Instructions: MINNCARE P/N RESIDUAL TEST STRIPS 1. Collect a sample of the rinse solution. 2. Remove a test strip from the tube and immediately replace the lid. 3. Dip the test strip into the solution to be tested for one second, such that the reaction zone is properly wetted. 4. Remove the test strip, gently shake off excess liquid, and compare the reaction zone with the colour scale between five and ten seconds after exposure. MAN-4400MCOLD (rev.k) page 64 of 106

65 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 % TEST STRIPS 1. Collect 1ml or greater of the MINNCARE sample. 2. Remove a test strip from the tube and immediately replace the lid. 3. Dip the test strip into the solution to be tested, such that the reaction zone is properly wetted. 4. Remove the test strip and gently shake off excess liquid. 5. Within ten seconds, note the entire reaction pad colour development. 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. 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.k) page 65 of 106

66 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 elements, prepare each membrane 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 membrane 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.k) page 66 of 106

67 5.0 TROUBLESHOOTING TROUBLESHOOTING ALARMS / MESSAGES The following table lists common problems with the 4400M system and their cause(s) and troubleshooting tips. 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. MAN-4400MCOLD (rev.k) page 67 of 106

68 NO. PROBLEM PROBABLE CAUSE CORRECTIVE ACTION 1 POOR PRODUCT QUALITY 2 HIGH PRESSURE DROP ACROSS PRE-FILTER OR MEMBRANE 3 LOW PRODUCT FLOW 4 SYSTEM WILL NOT START 5 LOW FEED PRESSURE High recovery Fouled membrane Feed water out-ofspecification Dirty Filter Fouled membrane Fouled membrane Low feed water temperature Tank full Pre-treatment in regeneration System stopped Flow restriction; upstream valve is closed. Low pressure; Building water supply Inlet solenoid valve malfunction Plugged pre-filter Re-adjust flow rates. Identify foulant. Follow appropriate cleaning / sanitization procedure. Check feed water quality. Replace filter. Identify the foulant. Follow appropriate cleaning procedure. Identify the foulant. Follow appropriate cleaning procedure. Check feed temperature. Check tank level. Drain to intermediate level. Check pre-treatment. Wait for regeneration process to end. Press the RUN key. Ensure the main disconnect is not turned OFF. Identify and open closed valve. Perform a complete diagnosis for valve position. Verify and/or install booster system. Perform a complete diagnosis for valve position. Change filter. 6 RO PUMP OVERLOAD 7 FEED TEMPERATURE HIGH 8 9 INCORRECT FEED TEMPERATURE READING INCORRECT PRODUCT TEMPERATURE READING Damaged motor or pump Feed water temperature is too high Faulty feed temperature sensor; probe error Faulty product temp. sensor; probe error Verify and replace. Correct feed water temperature. Add blending valve or adjust setting on feed line. Replace the sensor. Replace the sensor. SYSTEM DIAGNOSIS The test matrix in section Error! Reference source not found. lists the state of each critical component during each mode of RO operations. Perform a step-by-step diagnosis and record all MAN-4400MCOLD (rev.k) page 68 of 106

69 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. The system diagnosis must be performed by a Mar Cor Technician. Failure to do so may void the product warranty. MAN-4400MCOLD (rev.k) page 69 of 106

70 5.2.1 System Test Matrix Instructions: Place the RO system into each mode of operation and record the state of each component. 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. Any comments add at the end of the test matrix. All Item (Tang Name) DESCRIPTION System - OFF (STOP) (Pass / Fail) Standby (Pass / Fail) Standby (Auto Flush with Pump ON) (Pass / Fail) Standby (Auto Flush with Pump OFF) (Pass / Fail) RO Run (Pass / Fail) RO Run (Start-up Flush with Pump ON) (Pass / Fail) RO Run (Start-up Flush with Pump OFF) (Pass / Fail) RO Run (Auto Flush with Pump ON) (Pass / Fail) RO Run (Auto Flush with Pump OFF) (Pass / Fail) Pumps P2.00 RO Pump OFF OFF RO Panel YS-RO Solenoids RO Pretreatment Lockout (Amber Light) YV2.00 RO Feed Inlet Valve CL CL OFF / ON OFF ON ON OFF ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF CL / OP CL / OP OP OP OP OP OP YV2.01 RO Reject Valve CL CL CL / OP CL / OP CL OP OP CL / OP CL / OP YV2.03 RO Product to Drain Valve (Optional) OP OP OP OP O / C-Q OP OP CL / OP CL / OP Legend OFF Device is Off OFF / ON Device Status Change from Off to On OP / CL The Valve status changes from Open to Close ON Device is On OP The Valve is Open CL / OP The Valve status changes from Close to Open ON / OFF Device Status Change CL The Valve is Closed *-Q The Valve status changes based from On to Off on Quality Feedback Performed By: Date: Verified By: MAN-4400MCOLD (rev. K) page 70 of 106

71 All Item (Tang Name) DESCRIPTION RO Run (Run Available) (Pass / Fail) RO Run (To High Level) (Pass / Fail) RO Run (To Lock-out) During Pre-treatment (Pass / Fail) RO Run (OPTIONAL) (Product Divert to Drain) (Pass / Fail) RO Clean with RO Pump (Pass / Fail) RO Clean Start without RO Pump (Pass / Fail) RO Clean Hold without RO Pump (Pass / Fail) RO Clean Re-start without RO Pump (Pass / Fail) RO Clean Cancel without RO Pump (Pass / Fail) Pumps P2.00 RO Pump RO Panel YS-RO Solenoids YV2.00 RO Pretreatment Lockout (Amber Light) RO Feed Inlet Valve ON / OFF ON / OFF ON / OFF ON OFF / ON OFF OFF OFF OFF OFF OFF ON OFF ON ON ON ON OFF OP / CL OP / CL OP / CL OP CL CL CL CL CL YV2.01 RO Reject Valve CL CL CL CL CL / OP CL / OP CL / OP CL / OP OP / CL YV2.03 RO Product to Drain Valve (Optional) CL / OP CL / OP CL / OP CL / OP OP / CL OP OP OP OP Comments: Legend OFF Device is Off OFF / ON Device Status Change from Off to On OP / CL The Valve status changes from Open to Close ON Device is On OP The Valve is Open CL / OP The Valve status changes from Close to Open ON / OFF Device Status Change CL The Valve is Closed *-Q The Valve status changes based from On to Off on Quality Feedback Performed By: Date: Verified By: MAN-4400MCOLD (rev. K) page 71 of 106

72 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.k) page 72 of 106

73 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) Toll Free: (800) Fax: (905) UNITED STATES OF AMERICA Distributed By: Mar Cor Purification Inc Township Line Rd Skippack, PA Tel: (484) Toll Free: (800) Fax: (484) info@mcpur.com WORLD WIDE WEB MAN-4400MCOLD (rev.k) page 73 of 106

74 A1 4400M DIGITAL REVERSE OSMOSIS SYSTEM RO Product CIP Valve RO Reject CIP Valve RO Reject Flow Rotameter RO Recycle Flow Rotameter RO Product Flow Rotameter Electronic Digital Interface & Display Screen Control Panel Reject Pressure Gauge Membranes RO Pump Pressure Gauge Feed Pressure Gauges RO Pump Pre-filter / Inlet Filter CIP Inlet Valve Unit may not appear exactly as shown MAN-4400MCOLD (rev.k) page 74 of 106

75 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. On larger systems (6-12 membranes) 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 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 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 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.k) page 75 of 106

76 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 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 psig ( 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.k) page 76 of 106

77 % Rejection = 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 CAUTION Never fully close the reject and reject recycle valves when the system is in operation. Damage to equipment can occur. When either opening or closing any needle valve, DO NOT over-extend or overtighten 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. 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. The product rotameter is located to the right of the recycle rotameter. It indicates the amount of product water the RO system is producing. MAN-4400MCOLD (rev.k) page 77 of 106

78 From these flow readings, % Array Recovery and % System Recovery can be calculated. Refer to section 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 inlet block. It is used for performing the feed water chemistry test. A 1 or 1½ valve 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 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 above the recycle needle valve. 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. MAN-4400MCOLD (rev.k) page 78 of 106

79 Pressure Relief Valve 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 switch. 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. Auxiliary components that interface with the system (i.e. softeners, pumps, filters, valves, tanks, gauges, etc.) are not described. * Refer to Individual Manufacturers Component Manuals for detailed descriptions. MAN-4400MCOLD (rev.k) page 79 of 106

80 A2 4400M CONTROL PANEL DISPLAY DC Power Pre-treatment Lockout Main Disconnect Auto Run OFF / AUTO Switch (OPTIONAL) Alarm Mute Button Digital Interface Keypad & Display Screen Local Audible Alarm Unit may not appear exactly as shown MAN-4400MCOLD (rev. K) page 80 of 106

81 A3 SET-UP MENU DISPLAY NAVIGATIONAL FLOW CHART Set-up Menu Item Options Selection 1> Clean Mode 2> Customize 3> Alarms <OK> 1> Clean Mode Menu 2> Customize Menu 3> Alarms Menu Item Option Selection Item Option Selection READ INSTRUCTION MANUAL 1> Direct Feed: NO (Default) 1> Alarm->Stop: YES (Default) BEFORE DOING THIS 2> Flush-> Run Mode: YES (Default) 2> 1 retry (Default) Alarm->Stop->Restart COMMAND 3> Flush w /o Pump NO (Default) retry every 010m <OK> <CANCEL> <SETUP=next> <OK> 3> Poor Quality Delay Sub (Default) Menu <SETUP=next> <OK> Item Option Selection 1> Ω Resistivity or S Ω (Default) SELECT <<-> NUMBER OF RETRIES: Conductivity 2> Temp. comp NO (Default) (0..6): 1 3> Flush At Start YES (Default) <SETUP=next> <OK> <OK> Item Option Selection SELECT <<-> NUMBER BETWEEN RETRIES: 1> Temperature in C or F C (Default) (10m..150m): 010m 2> Clear ROP Timer NO (Default) 3> Flush Delays Sub-Menu s <OK> <SETUP=First> <OK> Poor Quality Delay Flush Period 120? (4,240) s 9? (1, 60) X 10s <CANCEL> <OK> <CANCEL> <OK> Flush Cycle Item Option Selection 60? (30,120)nm 1> Feed Temp. SetPt Sub Menu (period included) 2> Poor Quality SetPt Sub Menu <CANCEL> <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> <OK> MAN-4400MCOLD (rev. K) page 81 of 106

82 A4 ALARM LOG SHEET TIME ALARM DESCRIPTION CORRECTIVE MEASURE MAN-4400MCOLD (rev. K) page 82 of 106

83 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. K) page 83 of 106

84 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: : Wear clean gloves while taking samples. Prevent mixing of any foreign particles with sample water. Time: Fig 2: Sample Label MAN-4400MCOLD (rev. K) page 84 of 106