4400hx ro type s1 manual

MAN-4400MHXS1 Rev. F

Mar Cor Purification -

Biolab Equipment Ltd.

4400M-HX TANK FEED HOT WATER SANITIZATION SYSTEM

(S1 TYPE)

Installation, Operation and Maintenance Manual


4400M-HX Hot Water Sanitization System

INTENDED USE: This system is intended to remove organic and inorganic substances and microbial contaminants from water that is used to dilute dialysis concentrate to form dialysate and to produce purified water for dialyzer reprocessing and equipment rinse and disinfection. This system has the additional ability to sanitize the loop and to sanitize the Heat Sanitizable RO with the Heater Unit.

USOFTWARE VERSION: S1 R1.05.16U

BIOLAB REFERENCE #:

PART #:

PANEL SERIAL #:

DATE MANUFACTURED:



UMANUAL REVISION HISTORY

Revision Author Date Changes

0.7 Richard Marmen Oct. 3, 2006

0.8 Richard Marmen July 2008 Formatting/Minncare® Chemical Overview/System Test Matrices Modification

0.9 Richard Marmen Sept 23 P

rdP 2008 HV4.22 Setup Procedure and UV alarm

added. 1.0 Richard Marmen June 2009 System valve matrix update A Brian Adkins October, 2009 Document Number Assignment

B Richard Marmen, Brian Adkins April, 2010 SAT Procedure Change, Remove

Medical References (pg 9-10)

C Richard Marmen August, 2010 Correct labels on Fig 4.2 (page 4-3) Format (page 2)

D Richard Marmen January, 2011 Tank Volume Size Change

E Richard Marmen August, 2011 Add Tank Fill And Drain Steps during a RO heat san TOX flush. Matrix and TOX flush description updated

F Richard Marmen February, 2012 Edit Update (verbiage & spelling)

UMANUAL PREPARATION

Richard Marmen – Engineering Manager Mar Cor Purification / Biolab Equipment Ltd.

13 Feb. 12 Date



ABOUT THIS MANUAL…

This Manual contains information that is CONFIDENTIAL to Mar Cor Purification – Biolab Equipment Ltd. and should not be disclosed to third parties or duplicated for any purposes, in whole or in part. This Manual has been divided as per the following headings:

• Preface Describes safety notes, along with important safety definitions, and label and equipment specifications.

• Section 1 – General Information

Provides basic product information.

• Section 2 – Installation and Start-up Describes procedures and requirements for installation and start-up of the system at customer sites.

• Section 3 – Operations and Monitoring

Explains the operations that the system can perform and guides the user through how to perform each operation. Information on each HMI display screen is provided to help the user understand and monitor critical system parameters.

• Section 4 – Maintenance

Provides maintenance schedules and procedures for replacement items. Also included in this section is a recommendation on scheduled system sanitization, procedures for chemical sanitization and basic product information on chemicals used for sanitization.

• Section 5 – Troubleshooting

Lists all the built-in alarms and messages displayed by the system with their possible causes and corrective actions.

• Warranty

• Contact Information

• Appendices

Reference materials and log sheets are provided here.



UTABLE OF CONTENTS

0HTSAFETYT

1HTDEFINITIONST

2HTLABELST

3HTSPECIFICATIONS T

T4HU1.0 U GENERAL INFORMATION

T2.0 INSTALLATION AND START-UP 5HTU2.1 UT TUUNPACKING THE SYSTEMUT ........................................................................................................ 2-48H1 6HTU2.2 UT TUSETTING UP THE SYSTEMUT ........................................................................................................ 2-49H1 7HTU2.3 UT TUINSTALLATION OF EXTERNAL CONNECTIONS TO THE 4400M-HX SYSTEMUT ..................... 2-1 8HTU2.4 UT TUSTART-UP UT.................................................................................................................................... 2- 50H2

9HTU2.4.1 UT TUElectrical Hook-up VerificationUT .............................................................................................. 2-2 10HTU2.4.2 UT TUPre-Start-up VerificationUT........................................................................................................ 2-51H2 11HTU2.4.3 UT TUControl Panel/Microprocessor Start-up UT................................................................................. 2-52H3 12HTU2.4.4 UT TUTank Feed Hot Water Sanitization System Start-up UT ............................................................. 2-53H3 13HTU2.4.5 UT TUChecking Circulation Pump Rotation UT .................................................................................... 2-54H4 14HTU2.4.6 UT TUUV Lamp Intensity Meter Start-up UT......................................................................................... 2-55H4 T2.4.7 Adjusting RO Force Cool Control Valve…………………………………..…………………… .2-5

3.0 OPERATIONS AND MONITORING

15HTU3.1 UT TUSYSTEM OPERATIONSUT .............................................................................................................. 3-56H1 16HTU3.1.1 UT TUHow Is The Hot Water Sanitization Performed? UT ................................................................... 3-57H1

17HTU3.2 UT TUSYSTEM OPERATION CONTROLSUT ........................................................................................... 3-58H4 18HTU3.2.1 UT TUThe HMI Display Navigation UT ................................................................................................. 3-59H4 19HTU3.2.2 UT TUScreen DescriptionsUT.............................................................................................................. 3-60H5 20HTU3.2.3 UT TUScreen Setting Ranges and Defaults TableUT........................................................................ 3-61H20

21HTU3.3 UT TUOPERATING PROCEDURESUT .................................................................................................... 3-62H22 T

3.3.1 Quick Start Guide…………………………………………………………………………..……. 3-23 22HU3.4 U USYSTEM MONITORINGU............................................................................................................. 3-63H24

4.0 MAINTENANCE

23HU4.1 U UMAINTENANCE REQUIREMENTSU ............................................................................................. 4-64H1 24H4.1.1 Scheduled Maintenance Log Sheet..................................................................................... 4-65H2 25HU4.2 U UINSTALLATION/REPLACEMENT PROCEDURESU..................................................................... 4-66H5

26HU4.2.1 U UPyrogen Filter Installation/Replacement Procedure U.............................................................. 4-67H5 27HU4.2.2 U UVent Filter Installation/Replacement Procedure U.................................................................... 4-68H6 28HU4.2.3 U UUltraviolet Lamp Installation/Replacement Procedure U .......................................................... 4-69H7 29HU4.2.4 U UQuartz Sleeve Installation/Replacement Procedure U ............................................................. 4-70H9 30HU4.2.5 U USolenoid Valve Seal Installation/Replacement Procedure U.................................................. 4-71H10



31HU4.2.6 U UTemperature/Conductivity Sensor Calibration Procedure U................................................... 4-11

32HU4.3 U UCHEMICAL CLEANING AND SANITIZATION U .......................................................................... 4-72H13 33HU4.3.1 U UChemical Cleaning and Sanitization Procedure Using the System Storage Tank U.............. 4-73H13 34HU4.3.2 U UNeutralizing Cleaning and Sanitization Solutions U ............................................................... 4-74H14 35HU4.3.3 U UOverview of MINNCAREUP

®P UDisinfectant Chemical and Test StripsU ...................................... 4-75H15

5.0 TROUBLESHOOTING 36HU5.1 U UTROUBLESHOOTING ALARMS/MESSAGES U ........................................................................... 5-76H1 37HU5.2 U USYSTEM DIAGNOSISU.................................................................................................................. 5-77H5

U 38HWARRANTY U

39HUCONTACT INFORMATIONU

U40HAPPENDICES 41HDESCRIPTION AND FUNCTION OF SYSTEM COMPONENTS............................................................. A1-1 42HHEATER CONTROL PANEL DISPLAY ................................................................................................... A2-1 43HHMI SCREEN DISPLAY NAVIGATION FLOW CHART........................................................................... A3-1

44HALARM LOG SHEET................................................................................................................................ A4-1 45HSYSTEM MATERIALS OF CONSTRUCTION.......................................................................................... A5-1 46HWATER SAMPLING PROCEDURE ......................................................................................................... A6-1 47HREQUIREMENTS FOR INSTALLATION OF EXTERNAL CONNECTIONS TO SYSTEM...................... A7-1 SITE ACCEPTANCE TEST (SAT) PROCEDURES ................................................................................. A8-1 SPARE PARTS LIST ................................................................................................................................ A9-1



SAFETY This Manual describes procedures necessary to install, operate, and maintain the 4400M-HX Tank Feed Hot Water Sanitization system. It makes references to the Component Manuals of other manufacturers and to the Mar Cor Purification - Biolab Equipment Ltd.’s 4400M – PLC REVERSE OSMOSIS SYSTEM (HOT WATER SANITIZABLE) MANUAL. 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 regulated system and changes to the design and substitution of components are performed only under design controls and are documented. Any changes without design controls are not allowed and are in contravention to regulation(s). Operation of this system outside of its intended use and without adequate pretreatment/post-treatment that meets AAMI RD62:2006 and CSA Z364.2.2-03 standard guidelines is not allowed and is in contravention to regulation(s).

DEFINITIONS WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious personal injury. CAUTION: Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate personal injury or possible damage to the system. NOTE: Information that requires special emphasis.

LABELS 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.



HX UNIT Maximum Flow Up to 15.0 US GPM (56.8 LPM)

# of Pumps 2

Total Motor Horsepower 3 hp

Heater Power 15 kw

UV Options Available

Filter Yes (Pyrogen Filter Housing is Field Mounted)

Face Pipe 1 Inch (25.4mm)

Operating Weight 3,000 lbs (1,361 kg)

Total Power 19 kw

TANK Tank Volume 175 US gal (660 litres)

Material T316 Stainless Steel C/W 1” Insulation and T304SS Cladding

Finish 25 Ra ID/OD

Opt. Weight 1800 lbs. (817 kg)

Vent Filter T316L Stainless Steel Electric Heat Traced Vent Filter Housing c/w 0.22 Micron Hydrophobic Vent Filter

Tank Rating +3 psig/-3 psig

DIMENSIONS – INCH (MM) 4400M - PLC RO Skid 38 (965) Width 29 (737) Depth 77 (1956) Height HX Skid 34 (864) Width 29 (737) Depth 77 (1956) Height Tank Skid 31 (787) Width 31 (787) Depth 110 (2794) Height

SPECIFICATIONS (S1 TYPE)

MAN-4400MHXS1 Rev. F 1-1 General Information


1. GENERAL INFORMATION The 4400M-HX Tank Feed Hot Water Sanitization system is a key component of a water treatment system that is able to distribute a flow rate of up to 15 US gallons per minute (57 litres per minute) of product water suitable for applications requiring biological and inorganic purity. The 4400M-HX system uses a PLC Reverse Osmosis (RO) system to produce the product water quality that meets AAMI RD62:2006 and CSA Z364.2.2-03 Standard requirements. The system is also able to heat the RO product water for hot water disinfection of the system. When used in conjunction with chemical disinfection, the system will reduce the biological load on a closed water distribution loop. The 4400M-HX Tank Feed Hot Water Sanitization system is supplied as a modular unit consisting of the 4400M – PLC RO system, a storage tank with pumps and controls, an electric heat exchanger, an optional ultraviolet sterilizer, a Pyrogen filter, interconnected piping and related controls and instruments ready for installation (FIGURE 1.1). The standard 4400M-HX system is equipped with the following components:

• 316 Stainless Steel Insulated Storage Tank • Electric Heat Exchanger • Micrologix Programmable Logic Controller • Stainless Steel VFD Circulation Pumps • Ultraviolet Sterilizer (Optional) • Digital Conductivity and Temperature Sensors • NEMA 4/12 Control Enclosures with incorporated TPLC keypad interface and display • All Stainless Steel Piping and Housings

The system skids and manifold are shipped fully assembled, pre-piped and pre-wired. The system is available in 208 VAC (60Hz) three phase.

NOTE: The 4400M-HX system does not include external pre-treatment and post-treatment devices, piping and fittings to the point of use of treated water

RO UNITHEATER UNITTANK UNIT

FIGURE 1.1 - 4400M-HX TANK FEED HOT WATER SANITIZATION

MAN-4400MHXS1 Rev. F 2-1 Installation & Start-up


2. INSTALLATION AND START-UP UNPACKING THE SYSTEM Unpack the system carefully and inspect all components for any possible signs of damage. Do not install the Tank Feed Hot Water Sanitization System if damage is apparent. Notify your representative and the carrier immediately. Retain all literature for future reference. SETTING UP THE SYSTEM 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. • 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, filters

and ultraviolet sterilizer lamps.

NOTE: A room with good ventilation is required to help remove heat and any chemical fumes.

NOTE: The floor must be capable of supporting the operating weight (3,000 lbs, 1,361 kg excluding weight of pretreatment or any other peripheral equipment installed).

NOTE: The room must have adequate lighting and safety equipment (safety shower, face

shield, gloves, chemical suits, spill equipment, etc.) INSTALLATION OF EXTERNAL CONNECTIONS TO THE 4400M-HX SYSTEM Installation of external connections to the 4400M-HX system such as drain connections, water distribution loop piping, pre-treatment 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 AAMI RD62:2006 and CSA Z364.2.2-03 Standard requirements. 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.

NOTE: It is the responsibility of the contractor or installer who incorporates any external device(s) to the 4400M-HX system to ensure that the incorporation of the device(s) does not compromise the ability of the overall system to deliver product water quality at the point of use. It must meet the AAMI RD62:2006 and CSA Z364.2.2-03 Standards. (Reference: AAMI RD62:2006, Element 4.2.1).



START-UP

1.1.3 Electrical Hook-up Verification Before starting the 4400M-HX system it is very important that electrical services have been checked for the following:

1. Fused (main disconnect) power supply to panel(s) is connected. 2. Proper voltage is connected and verified. 3. All input or output devices in the panel are hooked up properly and verified. 4. All electrical work meets or exceeds local electrical codes.

WARNING: Ensure that the system is connected to a power source in compliance with local and national electrical codes. Failure to comply may create a shock or fire hazard. Refer to the electrical drawing for connection points, voltage, phase and current load. WARNING: To prevent electrical shock, disconnect the electrical power to the system before servicing. WARNING: Use proper safety procedures when working in an electrical panel. Disconnect and/or lock out the power supply to the system and tag it out. The system must be properly grounded to prevent personal injury or damage to the system.

2.4.2 Pre-Start-up Verification The 4400M-HX system is pre-tested at the factory and the panel view is set to default values. The circulation pump(s) are preprogrammed and do not require any additional programming. After the overall water system has been installed, the following items should be checked before commissioning of the system is to begin:

Clean dry air supply is connected and verified if required. The 4400M - PLC RO system is tested and ready to fill tank. Electrical supply is connected and verified. Interconnect and loop piping including drains are completed and verified. All water piping line pressure must be tested and flushed to remove debris. Pretreatment devices are installed and a functional test is performed. Post treatment devices are installed and a functional test is performed. Final filter cartridges are installed as per instructions in SECTION 4.2.1 (Maintenance). Vent filter housing is installed as per instructions in SECTION 4.2.2 (Maintenance). Ultraviolet sterilizer lamps and quartz sleeves are installed as per instructions in SECTION

4.2.3 and SECTION 4.2.4 (Maintenance). Rotation on circulation pumps with 3-phase feed voltage inputs is verified. Refer to

SECTION 2.4.5. All tank accessories are installed and ready to receive water.

NOTE: A pressure test of the piping, connections and tanks must be performed before starting the system.



1.1.3 Control Panel/Microprocessor Start-up The following procedure will assist the technician in the commissioning of the main control panel and the Programmable Logic Controller of the HX system.

WARNING: Use proper safety procedures when working in an electrical panel. Disconnect and/or lock out the power supply to the system and tag it out. The system must be properly grounded to prevent personal injury or damage to the system. NOTE: Due to site conditions some of the procedures might have to be altered.

Open the panel and check the main voltage feed before the main disconnect with a multi-meter to verify it is within +10 /-10%. Set the pump(s) overload switch to the START position. Close the panel. Turn all panel switches to the OFF position. Turn the main disconnect to the ON position. Allow the panel view to initialize. Enter the desired set-up parameters. Refer to SECTION 3 of the Manual (Operations).

2.4.4 Tank Feed Hot Water Sanitization 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 HMI programming screens on the control panel.

1. Close all valves in the system. 2. Open the circulation pump(s) inlet and outlet valves. 3. Open the heat element discharge valve. 4. Open the ultraviolet sterilizer inlet and outlet valves. 5. Open the Pyrogen filter housing inlet and outlet valves. 6. Open the feed valve to loop. 7. Open the feed valve to the 4400M - PLC RO system. 8. Open the tank loop return relief valve all the way. 9. Open the loop return globe valve. 10. Check the circulation pump(s) rotation if the system has a 3 phase pump. 11. The 4400M - PLC RO is ready to fill tank. 12. Press RUN on the RO control panel screen. (Refer to the 4400M - PLC RO MANUAL). 13. On the heater control panel screen, press F8 to go to the Home screen and then F1 to go to the

Operations screen. In the GEN. RO operations screen, press F5 to awake the RO. 14. The RO will perform its start-up sequence. The tank will fill with RO product water to the full level

and stop. 15. Purge the air from the Pyrogen filter housing by opening the vent valve. Close valve when a

steady stream of water is seen. 16. If the system includes two circulation pumps, place the pump selector to the AUTO CYCLE

pump position. Refer to APPENDIX A2 to locate the switch on the control panel. 17. Place the circulation pump operation switch to the AUTO position. The pump will start and water

will begin to flow back to the tank. 18. Adjust the loop return globe valve until the pressure at the end of the loop reads 10 psig.



19. Turn the ultraviolet sterilizer switch to the AUTO position. Adjust the loop return pressure relief valve to the desired pressure

20. The RO device will automatically stop once the tank has reached its high level set point. 21. Adjust the ½” needle valve mounted just after the force cool solenoid valve at the back of the HX

unit as per the procedure described in SECTION 2.4.7. This adjustment is required to control the flow of the cooling water to the RO unit during the Force Cool Down mode of the RO hot water sanitization.

22. A complete chemical sanitization using the MINNCARE® disinfectant (See Maintenance SECTION 4.3.1) must be performed followed by a heat sanitization to assure the water meets or exceeds the AAMI RD62:2006 and CSAZ364.2.2-03 requirements.

23. 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 Procedure.

NOTE: The water cannot be used for dialysis until the water quality is verified and signed off by the physician. NOTE: Upon successful start-up, the Site Acceptance Test (S.A.T.) must be executed and approved by the customer. Refer to the S.A.T. document in APPENDIX A8 for details of the quality requirements. NOTE: After initial installation and subsequent use, if any component of the water treatment system is changed or replaced, the user should conduct appropriate tests to ensure the revised system meets the initial design criteria. (Reference: AAMI RD62:2006, Element 6.2, Item #29)

2.4.5 Checking Circulation 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. Turn the circulation pump operation switch to the OFF position. 2. Viewed from the side of the motor the pump must be rotating counter clockwise. 3. Cycle the controller from the OFF to the MAN position 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. 5. Switch any two lead wires on the load side of the pump starter and secure the panel door. 6. Turn the main disconnect ON and recheck pump rotation. 7. If the device is supplied with a second pump, repeat the above procedure.

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.

2.4.6 UV Lamp Intensity Meter Start-up The following procedure describes how to reset the intensity meter at the time of installation and replacement of UV lamps.

1. Turn the UV lamps on for a minimum of 15 minutes.



2. Open the meter door. 3. Locate the blue potentiometer for setting the sensitivity “R3L” and blue potentiometer for setting

the alarm “R8L” located on the top right side of the PCB board. 4. Using a flat screwdriver, adjust the R3L sensitivity potentiometer to 100%. 5. Using a flat screwdriver, adjust the R3L sensitivity potentiometer to 50%. 6. Using a flat screwdriver, adjust the R8L alarm potentiometer until the red LED barely comes on. 7. Using a flat screwdriver, set the R3L sensitivity potentiometer back to 100%. 8. Turn the R3L sensitivity potentiometer to 50%; the red LED should light up. 9. Turn the R3L sensitivity potentiometer back to 100%.

NOTE: The meter must be reset after the first 100 hours of operation on new UV lamps, both at the time of installation and each time the UV lamps are replaced.

2.4.7 Adjusting RO Force Cool Control Valve The following procedure describes how to adjust the flow of the cooling water to the 4400M RO during the Force Cool Down mode of the RO hot water sanitization.

1. Close the force cool manual control (needle) valve on the back of the HX unit. 2. On the HMI, reduce the heat hold time to 20 minutes Refer to APPENDIX A3 to navigate to the

set-up (“SET T”) screen. 3. Place the RO in a heat sanitization Refer to the Quick Start Guide in SECTION 3.3.1 for

instructions. 4. Allow the system to cycle through the Tank Adjust, Heat Ramp and Heat Hold modes. 5. As the system transition from the Heat Hold to the Force Cool mode, record the final product

temperature from the HX HMI. 6. Verify the force cool feed valve solenoid is open (Red L.E.D. is on) on the back the HX unit. 7. Open the force cool manual control valve ¼ turn.

NOTE: When either opening or closing any needle valve, DO NOT over-extend or over-tighten the valve as galling damage may occur. When fully opening the valve, do so till resistance is felt and then close the valve ¼ turn. When fully closing the valve, DO NOT use wrenches or other tightening tools. Close valve till snug.

8. Observe the RO feed water temperature on the RO HMI is decreasing. This will take a few

minutes. 9. Observe the final product temperature on the HX HMI is decreasing by 2-10°F per minute. This

will also take some time depending on how many membranes are used in the RO. If cooling rate is too slow, adjust by opening the force cool manual control valve by additional ¼ turn increment. Observe the temperature decrease rate between adjustments.

10. Once the temperature rate is within the limits, allow the system to complete the RO sanitization cycle.

11. Apply a colored sealant where the valve stem and the packing nut meet.

MAN-4400MHXS1 Rev. F 3-1 Operations & Monitoring


3. OPERATIONS AND MONITORING SYSTEMS OPERATIONS The 4400M-HX system works in conjunction with the 4400M – PLC RO system to produce RO product water and to sanitize the water treatment system. The main operations performed by the system are as follows (See FIGURE 3.1 - Operations Flow Chart): Normal RO - The HX system controller signals the 4400M - PLC RO system to operate in one of two modes:

• RO Awake – In this mode, the RO device performs a system flush operation at start-up and

normal RO run operations. The timing of the RO run can be scheduled on a daily basis by programming into the HMI screens. The RO device can also be run in the MANUAL mode.

• RO Sleep – In this mode, the RO device remains on and performs system flush at default

frequency and runs remotely during the auto schedules. Refer to the 4400M - PLC RO MANUAL for changing the flush duration time and frequency.

In both modes, the RO device will support the selected hot water sanitization functions such as the Tank Fill and the Force Cool Down. The RO device will remain locked out by the HX system during part of the hot water sanitization operation.

Sanitization - The 4400M-HX system performs hot water sanitization of the complete water system or segments of the system as required by the user to maintain product water quality that meets AAMI RD62:2006 and CSA Z364.2.2-03 requirements. The three modes of hot water sanitization are:

• Loop Sanitization – In this mode, the system only sanitizes the water distribution loop. • RO Sanitization – In this mode, the system only sanitizes the 4400M – PLC RO system.

• COMBO Sanitization – In this mode, the system sanitizes the water distribution loop, the RO

device and all associated piping. All three modes of sanitization operation can be performed in either MANUAL mode or AUTO mode and can be auto-scheduled by programming into the HMI screens.

For programming of each operation, refer to the Quick Start Guide (SECTION 3.3.1).

3.1.1 How Is The Hot Water Sanitization Performed? The 4400M-HX Tank Feed Hot Water Sanitization system heats a fixed volume of RO water in order to sanitize a closed loop water distribution system and/or 4400M - PLC RO system and its associated piping. The RO device and the water distribution loop are heat sanitized separately. The main modes of each hot water sanitization operation are as follows:

• Tank Adjust - The system automatically drains or fills the storage tank to a programmable heat sanitization level set-point with RO product water.



• Heat Ramp - The system heats the re-circulating product water and ramps up its temperature to a programmable set-point within a range of 149°-185°F (65°-85°C).

• Heat Hold - The system maintains the water temperature for a programmable time period from a

range of 20-120 minutes.

• Force Cool - Once the heat hold time elapses, the system cools down to a programmable set-point within a temperature range of 68°-120°F (20°-49°C).

• TOX RO Flush (during RO Sanitization Only) - After completion of RO heat sanitization, the RO

flush starts and operates for 15 minutes. This will assure the endotoxin is flushed out from the system and the RO product water quality meets or exceeds the AAMI RD62:2006 and CSA Z364.2.2-03 standard requirements.

The tank will fill with product water and once it reaches the low tank level, the pumps will start to recirculate through the loop. Once the tank reaches the high level set point the loop will recirculate for 10 minutes. The tank will then drain until the level reaches 0 plus 30 minutes and refill to the high set point level. The santitization is complete.



RO Awake

RO Sleep

RO Flush

At Start-up

RO Normal

Run Manual or Auto Sched

Loop Sani Manual or Auto

Tank Adjust

Heat Ramp

Heat Hold

Force Cool

Tank Drain

Sani End

Normal RO System Sanitization

RO Sani Manual or Auto

Tank Adjust

Heat Ramp

Heat Hold

Force Cool

TOX Flux

Sani End

Combo Sani Manual or Auto

Loop Sani

Loop to RO

Sani Trigger

Ro Sani

RO Locked-

out During Pre-

treatment &

Selected Sani

functions

RO Flush At Set Freq.

RO Normal

Run Auto

Sched.

Tank Fill & Force Cool

During Sani

Tank Fill & Force Cool

During Sani

FIGURE 3.1 – OPERATIONS FLOW CHART



SYSTEM OPERATION CONTROLS The HX system is controlled by a Programmable Logic Controller (PLC) that sends and receives signals to and from various components and sensors on the system. The user can set and view different parameters on the Human Machine Interface (HMI) display on the system control panel. Switches, push buttons and indicator lights mounted on the control panel provide indication and inputs to and from the controller. In this section, an overview of the operation of the PLC controller is provided to help the user gain familiarity and program basic system parameters. Refer to APPENDIX A1 for a description and function of system components, APPENDIX A2 for a pictorial view of the Heater Control Panel and APPENDIX A3 for the HMI Screen Display Navigation flow chart.

3.2.1 The HMI Display Navigation The user can switch to different groups of screens from the HOME screen. Most of the screens are composed in a similar format (See FIGURE 3.2). The top of the screen contains basic information, such as the system clock time and date, the day of week, an alarm flag and the screen label. At the bottom of the screen, there are instructions of screen switching; F6 to go back to the last screen, F7 to advance to the next screen, F8 to jump back to the HOME screen, or a screen switch selector to pick the day for scheduling. The F5 key is used to log out from the current user ID.

Some screens have security restrictions and require a password. There are four levels of security: Staff (Operator), Supervisor (Superv), Administration (Admin), and Factory (Mar Cor, USA/Biolab, Canada).

System Time and Date

Alarm Flag

Screen Label

System Parameters

FIGURE 3.2: SAMPLE HMI SCREEN



3.2.2 Screen Descriptions This section describes the different screens that can be viewed and accessed. A description of the function within the screens is provided. Refer to the Screen Navigation flow chart in APPENDIX A3 for all HMI screens.



Screen Title: HOME

Screen Description: HOME SCREEN

Security Access: ALL

From Home Screen: N/A

F1: OPERATIONS (for Supervisor and Administrator) Opens the General Screen Group for monitoring current operation parameters. F2: SETTING Opens the Setting Screen Group for modifying the alarm set points or operation parameters.

F3: SCHED SANI Opens the SANI Schedule Screen Group for programming sanitization schedules.

F4: SCHED RO Opens the RO Schedule Screen Group for programming timed RO runs.

F5: HSTR/SECR Opens the Security Screen Group for monitoring active alarm(s), alarm history, and administrator/factory security level operations.

F6: CHANGE DAY Toggles the current Day of Week. F7: HELP INFO Opens a screen to provide contact information for technical assistance from Mar Cor and to set date and time. F8: READINGS (for Staff) Opens a screen to provide current information on distribution loop quality, temperature and tank water level.



Screen Title: GEN RO

Screen Description: GENERAL RO SCREEN

Security Access: SUPERVISOR/ADMIN From Home Screen: F1

LOOP RET. TEMP: Displays current Loop Return Temperature (Display in PoPC or PoPF is selectable).

LOOP QUALITY: Displays current Loop Water Quality in μS/cm.

RO SLEEP: Displays the 4400M - PLC RO system mode: SLEEP OR AWAKE. Press F5 to open a pop-up window where the RO mode can be changed. The operator can select a RO operation by pressing F5 to put the RO into AWAKE/START mode, or by pressing F2 to put the RO into SLEEP/STOP mode. A password is required to change the mode.

NOTE: The 4400M - PLC RO controller must be set in RUN AVAIL mode and the feed water quality must be in the acceptable range for the RO to start. Failure to place and leave the RO in RUN AVAIL mode will result in an alarm state.



Screen Title: GEN S1

Screen Description: GENERAL SANI SCREEN 1

Security Access: SUPERVISOR/ADMIN

From Home Screen: F1 + F7

NO SANI: Indicates one of three sanitization targets: • NO SANI – no sanitization, • SANI RO – sanitize the RO device, • SANI LOOP – sanitize the water distribution loop. NORMAL RO OPERATION: Indicates current processing phase within each sanitization target: • NORMAL RO OPERATION – there is no SANI process in operation.

Only the Normal RO is in operation. • LEVEL ADJUST SET – drains or fills the storage tank to the preset

SANI Level. • HEAT RAMP – ramps up the SANI target temperature to the preset

temperature. • HEAT HOLD – holds the SANI target temperature for preset heat

hold duration. • IN FORCE COOL PHASE – the system temperature is cooled down

to the preset temperature. • TOX FLUSH – flushes the 4400M - PLC RO unit for a set duration

and fills the tank once and then drains. • IN END PHASE – the SANI process is near completion. SANI REMAINING TIMES: • RAMP: displays the remaining maximum allowable time for ramping

up the SANI target temperature. • HOLD: displays the remaining time for completing the SANI HOLD

phase. TEMP IN oC: A window contains three water temperature displays: • HEATER OUT: Current temperature reading taken at the loop feed

point. • LOOP RET: Current temperature reading taken at the loop return

point. • RO PROD: Current temperature reading of the RO product water.





Security Access: ADMIN

From Home Screen: F1 + F7 + F7 + F7

VALVE STATUS: Displays position of critical valves in the system.




From Home Screen: F1 + F7 + F7

NO SANI (See GEN S1 screen for description). NORMAL RO OPERATION (See GEN S1 screen for description). CURRENT TANK LEVEL: Displays the tank water level (Display in litres or gallons is selectable).

RECIRC PUMP OUTLET: Displays the pressure measured at the re-circulation pump outlet.

RECIRC PUMP SPEED: Displays the current controlled pump speed of the re-circulation pump.






From Home Screen: F1 + F7 + F7 + F7 + F7

F1 > PUMP CYCLING HOUR Opens a pop-up window for entering desired cycling time between two re-circulating pumps (0-23, default 4 AM).

F2 > PUMP CYCLING MINUTE Opens a pop-up window for entering desired cycling time, in minutes, between two re-circulating pumps (0-59, default 30 minutes).

Screen Title: SET T

Screen Description: SET TIME SCREEN


From Home Screen: F2

SET CURRENT DAY* : Use Up/Down Arrow keys (need to press and hold for 1.5 seconds to change) on the keypad to select the current day of the week and press the Ent key ( ) to confirm. (Also see HOME screen to set current day) MIN. SANI HOLD TIME*: Sets the desired duration of the SANI Hold phase (20–120, default 60 minutes).

MAX SANI RAMP UP TIME*: Sets the maximum allowable time for ramping up the SANI target temperature (60–480, default 480 minutes). * Place the cursor in the field first to input a value.



Screen Title: SET P1

Screen Description: SET PARAMETER SCREEN 1



SANI PROCESS LEVEL*: Sets the desired level of water in the tank for executing the SANI process (114 – 189 L, default 151 L; 30.2 – 50 US gal, default 40 US gal).

CIRC PMP NORMAL PSI*: Sets the desired circulation pump pressure of normal operation (50 – 99, default 99 psi).

CIRC PMP RO SANI PSI*: Sets the desired circulation pump pressure of RO SANI operation (15 – 25, default 20 psi).

CIRC PMP LOOP SANI PSI*: Sets the desired circulation pump pressure of LOOP SANI operation (50 – 99, default 99 psi). * Place the cursor in the field first to input a value.

Screen Title: SET P2

Screen Description: SET PARAMETER SCREEN 2



SYSTEM NORMAL TEMP*: Sets the Normal Temperature for system use (20o – 49 oC, default 35 oC; 68 o – 120oF, default 95oF). POST SANI COOL TEMP*: Sets the desired Temperature for completing the SANI Cool Down Phase (35 o – 49oC, default 45oC; 95 o – 120oF, default 113oF). SANI TEMP*: Sets the desired Temperature for hot water sanitization (65 o – 85 oC, default 80 oC; 149 o - 185 oF, default 176 oF). UA 4.01 DELAY TIME*: Sets the time delay for the ultraviolet sterilizer intensity alarm (0–1200 seconds, default 1200 seconds). UV Option Only, Refer to screen SEC FS to enable or disable the UV alarm. * Place the cursor in the field first to input a value.



Screen Title: SET A1

Screen Description: SET ALARM PARAM. SCREEN 1


From Home Screen: F2 + F7 + F7 + F7

TEMP HIGH ALARM*: Sets the high temperature alarm set point (90 o – 98 oC, default 95oC; 194o – 208 oF, default 203oF).

NORMAL RO STOP LEVEL*: Sets the desired water level in the tank to stop RO device from filling (570–662, default 662 L, 150–175, default 175 US gal).

NORMAL RO START LEVEL*: Sets the desired water level in the tank to start the RO product delivery to the tank. If the water level drops below the set point, the RO production resumes and fills the tank to the preset level (380–570, default 570 L, 100–150, default 150 US gal).

NORMAL LOW TANK ALARM*: Sets the alarm set point for low water level in the tank during Normal operation (190–285, default 285 L, 50– 75, default 75 US gal). * Place the cursor in the field first to input a value.



Security Access: ADMIN From Home Screen: F2 + F7 + F7 + F7 + F7

RO SANI HI PSI ALARM*: Sets the set point of the High Pressure alarm of RO SANI Operation (25–40, default 30 psi). RO SANI LO PSI ALARM*: Sets the set point of the Low Pressure alarm of RO SANI Operation (5-15, default 10 psi).

LOOP GEN HI PSI ALARM*: Sets the set point of the Loop High Pressure alarm of Normal Operation (60–99, default 80 psi).

LOOP SANI LO PSI ALARM*: Sets the set point of the Loop Low Pressure alarm of Loop SANI Operation (10–60, default 10 psi). * Place the cursor in the field first to input a value.





Security Access: ADMIN From Home Screen: F2 + F7 + F7 + F7 + F7 + F7

LP. FEED COND. SETTING: Displays the following loop feed conductivity settings in μS/cm. LP. FEED QUAL. LOW ALERT*: Sets the loop feed conductivity sensor set point to trigger low quality alert. LP. FEED QUAL. LOW ALARM*: Sets the loop feed conductivity sensor set point to trigger low quality alarm. The loop circulation pumps will stop operating if this value is exceeded.

LOOP QUALITY 3 HR MUTE: Press F1 to bypass Quality Alarm for 3 hours for use and when performing chemical cleaning. The controller automatically ends bypass alarm after 3 hours or when the alarm reset button is pressed. * Place the cursor in the field first to input a value.

Screen Title: SCH S1 & SCH S2

Screen Description: SANI SCHEDULE SCREEN 1 & 2


From Home Screen: F3 & F3 + F7

F1, F2, F3 and F4 (on SCH S1): Changes the SANI target as RO Only, RO & Loop, or Loop Only on the corresponding day Sunday through Wednesday. F1, F2 and F3 (on SCH S2): Changes the SANI target as RO Only, RO & Loop, or Loop Only on the corresponding day Thursday through Saturday. MANUAL SANI SET (on SCH S2): Sets SANI target in MANUAL mode (Loop SANI, RO SANI or Combo SANI). * Place the cursor in the field first to input SANI start time.



Screen Title: SCH RE1 & SCH RE2 Screen Description: RO AUTO RUN SCHEDULE - EVERY DAY SCREEN 1 & 2

Security Access: SUPERVISOR / ADMIN

From Home Screen: F4 & F4 + F7

EVERYDAY(1)…EVERYDAY(6): Every row contains four fields; the Hour and Minute fields of the scheduled START time, and the Hour and Minute fields of the scheduled STOP time.

To schedule different START and STOP times of RO operation for each day of the week, use the Screen Selector switch to select the RO Operation Schedule Screen of the RO EVERYDAY, RO SUNDAY, RO MONDAY, RO TUESDAY, RO WEDNESDAY, RO THURSDAY, RO FRIDAY or RO SATURDAY. On each of the RO Operation Schedule Screens, there are a total of six rows for setting the START and STOP time to run the RO remotely on that particular day. * Place the cursor in the field first to input SANI start time.

NOTE: The product water is diverted to drain whenever the tank is full. This operation is performed to prevent bacterial growth in the system during prolonged periods of non-dialysis storage.



Screen Title: SCH AL

Screen Description: SECURITY ALARM LIST



SEC.AL, Alarm List Screen: Displays active alarm(s). Use the Up/Down Arrow keys to scroll between the alarms on the list.

Screen Title: SCH AH

Screen Description: SECURITY ALARM HISTORY



SEC.AH, Alarm History Screen: Displays all the current or previously occurred alarm(s) in chronological order with the date and time stamp. Use the Up/Down Arrow keys to scroll between the Alarms on the list.



Screen Title: SCH PW

Screen Description: SECURITY PASSWORD



F1 USER ID: Enter the User ID whose password is to be modified (ADMIN, SUPERV, or STAFF).

F2 PASSWORD: Enter the new password for the user.

F3 VERIFY: Re-enter the password again for verification.



Screen Title: SEC FS

Screen Description: SECURITY FACTORY SET-UP

Security Access: FACTORY ONLY

From Home Screen: F5 + F7 +F7 + F7

F1 USE CAUTION! EMPTY TANK AND PRESS FOR ZERO: Drain tank and verify it is empty. Press F1 to zero the tank level reading. F2 TEMPERATURE LOSS COMPENSATE: Enter the desired amount of heat loss compensate. It is used to correct the heat loss on the distribution loop during SANI process (5o – 20oC, default 5oC, 41o – 68oF, default 41oF). F3 TO DISABLE UA4.01: If the UV option is not included with the system press F3 to disable. F4 US/F4 MET: Configures the display unit of the HMI.

Display By Metric Unit: All of the temperature parameters are displayed in Celsius oC; fluid volumetric parameters are displayed in Litres L.

Display By US Unit: All of the temperature parameters are displayed in Fahrenheit oF; fluid volumetric parameters are displayed in US gal.



Screen Title: SCH PC

Screen Description: SECURITY HEATER PUMP SPEED


From Home Screen: F5 + F7 + F7 + F7 + F7

CIRCULATION PUMP ### PSIG: Displays the current pressure at the circulation pump outlet.

CIRC PUMP SPEED %: (Progressive bar) Displays the controlled pump speed in percentage.

Screen Title: SCH FT

Screen Description: SECURITY FACTORY TEST


From Home Screen: F5 + F7 + F7 + F7 + F7 + F7

WARNING!!! ALL OUTPUT SHALL BE OFF SECURE ALL DEVICES BEFORE PROCEED: If you choose to continue the Factory Test, proceed to the next Factory Test Screen. The PLC will shut off every output instantly.



Screen Title: INFO

Screen Description: SYSTEM INFO



Provides contact information for technical assistance. The software revision code is listed for reference. T + D: Press the F1 key to make adjustments to the HMI internal time and date and for set-up.

Screen Title: NONE

Screen Description: READINGS

Security Access: ALL From Home Screen: F8

LOOP QUALITY: Displays quality of water in the distribution loop in μS/cm. The box will indicate an active 3 HR Mute. CURRENT TANK LEVEL: Displays water level in the tank (in preset unit Litre or Gallon). TEMP IN oF LOOP RET.: Displays water temperature in distribution loop return (in preset unit oC or oF). HEATER OUT: Displays temperature of water at loop feed point (in preset unit oC or oF).



3.2.3 UScreen Setting Ranges and Defaults Table U

The following table lists the factory settings for parameters that require inputs in the HMI setting screens. Record all the set point values in the Customer Setting column at the system start-up and every time a value is modified. Keep these log sheets for future reference.

Setting Range in Metric Setting Range in US

HMI Screen Name Parameter Name

Low

er L

imit

Upp

er L

imit

Def

ault

Cus

tom

er

Setti

ng

Uni

t

Low

er L

imit

Upp

er L

imit

Cus

tom

er

Setti

ng

Def

ault

Uni

t

Set System Time Screen Min. SANI Hold Time 20 120 60 min 20 120 60 min

Set System Time Screen Max. SANI Ramp Time 60 480 480 min 60 480 240 min

Set Operation Parameter Screen 1 SANI Process Level 114 189 151 L 30 50 40 US gal

Set Operation Parameter Screen 1

Circulation Pump Normal Pressure 50 99 99 psi 50 99 99 psi


Circulation Pump RO SANI Pressure 15 25 20 psi 15 25 20 psi

Set Operation Parameter Screen 1 LOOP SANI Pressure 50 99 99 psi 50 99 99 psi

Set Operation Parameter Screen 2 System Normal Temperature 20 49 35

P

oPC 68 120 95 P

oPF

Set Operation Parameter Screen 2 Post SANI Cool Temperature 35 49 45

P

oPC 95 120 113 P

oPF

Set Operation Parameter Screen 2 SANI Temperature 65 85 80

P

oPC 149 185 176 P

oPF

Set Alarm Parameter Screen 1 SANI Temperature High SP. 90 98 95

P

oPC 194 208 203 P

oPF





Low

er L

imit

Upp

er L

imit

Def

ault

Cus

tom

er

Setti

ng

Uni

t

Low

er L

imit

Upp

er L

imit

Cus

tom

er

Setti

ng

Def

ault

Uni

t

Set Alarm Parameter Screen 1 Normal RO Stop Level 570 663 663 L 150 175 175 US gal

Set Alarm Parameter Screen 1 Normal RO Start Level 380 570 570 L 100 150 150 US gal

Set Alarm Parameter Screen 1 Normal Low Tank Alarm 190 285 285 L 50 75 75 US gal

Set Alarm Parameter Screen 2 RO SANI Pressure High 25 40 30 psi 25 40 30 psi

Set Alarm Parameter Screen 2 RO SANI Pressure Low 5 15 10 psi 5 15 10 psi

Set Alarm Parameter Screen 2 Loop GEN Pressure High 60 99 80 psi 60 99 80 psi

Set Alarm Parameter Screen 2 Loop SANI Pressure Low 10 60 10 psi 10 60 10 psi

Set Alarm Parameter Screen 2 UA4.01 Alarm Delay 0 1200 1200 second 0 1200 1200 second

Set Alarm Parameter Screen 3

LOOP Feed Low Quality Alert 5 50 30

μS/cm 5 50 30 μS/cm


LOOP Feed Low Quality Alarm 30 100 60

μS/cm 30 100 60 μS/cm

Security Factory Setup Screen Heat Loss Compensate 5 20 5

P

oPC 9 27 9 P

oPF

4.

MAN-4400MHXS1 Rev.F 3-22 Operations & Monitoring


3.3 OPERATING PROCEDURES The procedures below describe how to operate the 4400M-HX system. Refer to the Heater Control Panel diagram (APPENDIX A2) and the information provided in SECTION 3.2 on HMI screens to provide inputs to the system. System Start-up – Refer to the start-up procedures in SECTION 2 (Installation and Start-up). Normal Operations – See the Quick Start Guide in SECTION 3.3.1 in order to perform Normal RO and Sanitization operations. System shut-down – The HX system can be shut down in one of three ways:

1) By turning the System Switch to the OFF position in normal condition. 2) By pressing the Emergency STOP button in an emergency situation. 3) By turning the Main Disconnect lever to the OFF position when access to the control

panel is required for repair. Shutting the HX system will stop all tank level operations of the RO device. To shut-down the RO device, refer to the 4400M - PLC RO SYSTEM MANUAL.

CAUTION: In an event of system stoppage, restart the system as per start-up instructions provided in SECTION 2 to avoid possible damage to the system.



3.3.1 USystem Quick Start Guide

Operation Procedures: In any screen

press F8 to switch to HOME Screen

In HOME screen press F1 to switch to GEN.RO

In GEN.RO screen press F5 to pop-up a screen to change the RO mode to AWAKE

Normal RO Run

If the 4400M – PLC RO system is set to AWAKE mode by the HX heater controller and the 4400M – PLC RO system controller has been set as RUN and there is no Pretreatment Lockout and the Storage Tank has not been filled to the Stop Fill Level, the RO device will run remotely by the HX system. The remote RO operation can be stopped simply by pressing F2 in the pop-up screen and setting the RO into SLEEP mode.

In HOME screen press F3 to switch to SCH.S1 Screen

From SCH.S1 Screen, press F7 to go to SCH.S2 Screen

Press F4 to Select the SANI Target: RO, LOOP or RO & LOOP

(For example, the SCH.S2 screen shows “RO & LOOP” as the current SANI target)

Set the Circ Pump switch to AUTO position

Set the UV Lamp switch to AUTO position (for optional UV)

Turn the SANI key switch to MAN position

Wait for three seconds and press Manual SANI Start button Manual

Sanitization Ensure the 4400M - PLC RO is set to RUN AVAIL mode. Manual Loop and RO Sanitization process will start and run in the following sequences: It will finish the SANI phases (Level Adjust Set phase, Heat Ramp phase, Heat Hold phase, and Force Cool Down phase) for the Loop SANI first and then it will repeat the SANI phases on the RO Sanitization process until all phases are completed. At completion of SANI END phase, the SANI Process light will turn OFF and the green SANI Complete light will turn ON. The SANI Process can be cancelled at anytime either by pressing the E-Stop button or by turning the SANI key switch to the OFF position. The status of SANI operation is logged in the Alarm History and can be viewed.

In HOME screen press F3 to switch to SCH.S1 Screen

Sunday through Wednesday is listed on SCH.S1. Press F7 to go to SCH.S2

Thursday through Saturday is listed on SCH.S2

In SCH.S1 and SCH.S2, press F1, F2, F3 or F4 to select the day for SANI is to be performed. (For example, the SCH.S2 screen shows no SANI on Thursday and Friday and Loop SANI on Saturday.)

Use Left/Right Arrow key to advance the cursor, and numeric key pad to enter the SANI Start time

Turn the SANI key switch to AUTO position

Schedule Sanitization

Schedule Sanitization process will be activated on the schedule Day of Week and Time automatically. It will start from Level Adjust Set phase, Heat Ramp, Heat Hold, Force Cool Down to End phase. During Sanitization, the RO operation is locked-out. When Sanitization is completed successfully, the GREEN SANI complete light on the HX heater control panel will turn ON.

In HOME screen press F4 to switch to SC.RE1 Screen

In SC.RE1 Screen, use Left/Right Arrow keys to advance the cursor and use numeric key pad to enter the Start/Stop time

(For example, the SC.RE1 screen setting shows RO to run from 8:00am to 12:00pm, 1:00pm to 3:00pm and 4:00pm to 8:00pm on Everyday of the week )

If there are more than 3 schedule that need to be entered, press F7 to go to the SC.RE2 screen.

Enter the Start/Stop time for up to six schedules

The operator can schedule same Start/Stop time(s) of RO run on SC.RE1 or SC.RE2 screens on Everyday of the week (as per instruction above) or different time(s) for each day of the week as per instruction below:

Schedule RO Auto-Run Operation

In SC.RE1 screen, use Left/Right Arrow keys to move cursor to the Screen Selector.

Use Up/Down Arrow key to select the day from “RO Everyday” through “RO Saturday”

Press the Enter key ( ) to confirm the selection.

(The example shows RO Saturday Schedule is selected. The HMI displays the RO Saturday Schedule screen SC.RE1. There are six Start/Stop Time slots for scheduling the RO operation on Saturday)

Alarm Monitoring

In HOME screen press F5 to switch to SEC.AL Screen

SEC.AL, Alarm List Screen shows all the current Active Alarm(s). Use Up/Down Arrow keys to scroll between active alarms messages.

In SEC.AL Screen press F7 to go to SEC.AH Screen

SEC.AH, Alarm History Screen shows all alarms logged in chronological order with the time and date stamp. Use Up/Down Arrow keys to scroll between each alarm message.

UNOTEU: The UV Lamp Switch is always set to the AUTO position and the Recirc Pump Switch is always set to the Cycle mode during all operations.



SYSTEM MONITORING The 4400M-HX system is PLC controlled and has the built-in ability to monitor system performance. See the Security Alarm List Screen (“SEC AL”) and the Alarm History Screen (“SEC AH”) on the HX HMI display for all detected alarms. The Alarm table in troubleshooting (SECTION 5) lists all the programmed alarms and messages in the system with their possible cause(s) and troubleshooting tips. Log all the alarms in the sample log sheet provided in APPENDIX A4. This will help the technician in troubleshooting.

NOTE: Product water 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: AAMI RD62:2006,

Element 6.2, Item#12) NOTE: The troubleshooting of the system must be performed by a Mar Cor Purification – Biolab Equipment certified technician.

MAN-4400MHXS1 Rev. F 4-1 Maintenance


4 MAINTENANCE 4.1 MAINTENANCE REQUIREMENTS After the system has been commissioned, the 4400M-HX system will require scheduled maintenance at defined frequency. Regular maintenance is necessary in order to:

• Ensure the product water quality meets or exceeds the AAMI RD62:2006 and CSA Z364.2.2-03 standard requirements for dialysis water.

• Ensure operating efficiency. • Ensure maximum membrane life. • Ensure warranty protection.

A Maintenance Log Sheet with reference pictorials is provided. It lists the items that need to be monitored at specific frequency.

NOTE: Maintenance of the 4400M-HX 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: AAMI RD62:2006, Element 6.2, Item#1). Appropriate hot water

sanitization at scheduled frequency and use of chemical cleaning must be performed to maintain acceptable product water quality. NOTE: This section does not cover maintenance of the pre-treatment device and the heating element. Refer to their Manufacturers’ Manual for maintenance requirements. NOTE: Use this system only with the specified feed water and pretreatment chemicals determined by a Mar Cor Purification - Biolab Equipment Ltd. water analysis. Use all sanitizing and cleaning agents according to the instructions in this Manual.



Scheduled Maintenance Log Sheet UT UNOTE: U All readings should be taken when the system is in operation. Failure to perform these checks at specified frequency will void the product warranty.

PARAMETER FREQ. D/M/Y UNITS EXPECTED

RESULTS SUN MON TUES WED THURS FRI SAT

Date d d/m/y Time d h/m Current Day d d Loop Return Pressure (Fig. 4.1) d psig <60 Pyrogen Filter Install Date y d/m/y Change Annually Pyrogen Filter Inlet Pressure (Fig. 4.2) w psig <80 Pyrogen Filter Outlet Pressure (Fig. 4.2) w psig <80 Pyrogen Filter Delta Pressure (1) w psig <30 clean Ultraviolet Lamp Install Date y d/m/y Change Annually Ultraviolet Sterilizer Lamp: Intensity(2) (Fig. 4.4) w % >50

Ultraviolet Sterilizer Lamp: Hours(3) (Fig. 4.3) w hours 8000 or Annually

Vent Filter Install Date(4) (Fig. 4.5) y d/m/y Change Annually

Quartz Sleeve y d/m/y 8000 or Change Every Two Years

Solenoid Valve Seals (Fig. 4.6) y d/m/y Change Once Every Two Years

Jumo Temperature/Conductivity Sensor Calibration y d/m/y Calibrate Annually

ADDITIONAL NOTES:

(1) If delta pressure >30 psig, the filter must be replaced. If not, it is to be changed once a year.

(2) If lamp intensity <50%, replace the lamps and inspect/clean the quartz sleeves.

(3) If lamp usage hours >8000 hours or two years of intermittent use, whichever comes first, replace lamps and inspect/clean the quartz sleeves.

(4) Open vent filter drain valve weekly. If water comes out, replace the vent filter.



ULOCATIONS FOR MAINTENANCE CHECKS

FIGURE 4.2: PYROGEN FILTER (MOUNTED ON

FLOOR)

INLET PRESSURE

GAUGE

FIGURE 4.3: UV LAMPS KIT (MOUNTED ON BACK OF HEATER

SKID)

FIGURE 4.4: UV LAMP INTENSITY METER (MOUNTED ON FRONT OF HEATER SKID)

FIGURE 4.5: VENT FILTER (MOUNTED ON TOP OF STORAGE

TANK)

FIGURE 4.1: LOOP RETURN PRESSURE GAUGE (MOUNTED

ON BACK OF HEATER SKID)

OUTLET PRESSURE

GAUGE



ITEM DESCRIPTION LABEL ID SKID LOCATION 1 Pretreatment Feed Valve YV4.00 Heater At back

2 Force Cool Feed Valve YV4.09 Heater At back

3 RO Feed Valve YV2.00 RO In front

4 RO Pump P2.00 RO In front

5 RO Reject Valve YV2.01 RO In front

6 RO Product To Drain Valve YV2.05 RO At top

7 RO Product To Tank Valve YV2.07 RO At top

8 RO Reject To Drain Valve YV2.02 RO At top

9 RO Reject To Tank Valve YV2.03 RO At top

10 RO Recycle Air Break Valve YV2.08 RO At back

11 RO Recycle To Tank Valve YV2.04 RO At back

12 Raw Cold Water Valve YV4.08 Field installed

13 Tank Drain Valve YV4.02 Tank Below tank

14 Circulation Pump(s) P4.00/P4.01 Heater Under panel

15 Heater Element HX4.00 Heater At back

16 Loop By-Pass Valve YV4.03 Heater At back

17 Loop Isolation Valve YV4.04 Heater At back

18 Ultraviolet Sterilizer UV4.00 Heater At back

ULOCATIONS FOR MAINTENANCE CHECKS

FIGURE 4.6 - LOCATION OF SOLENOID VALVES AND KEY COMPONENTS OF 4400M-HX SYSTEM

UNOTE: Location of some of the components may vary for individual 4400M-HX systems depending on membrane configuration and UV Sterilizer Selection.

RO Unit



4.2 INSTALLATION/REPLACEMENT PROCEDURES

4.2.1 Pyrogen Filter Installation/Replacement Procedure The following procedure will assist the operator in installing and replacing the Pyrogen filter cartridges. The filter must be changed at a maximum pressure differential of 30 PSI or once a year. This is determined when the circulation pump is in operation and water is circulating back to the tank. To calculate the differential pressure, subtract the inlet pressure to the filter housing by the outlet pressure.

NOTE: Filters must only be changed when water is not required. Due to site conditions, some of the procedures might have to be altered.

1. Turn the circulation pump switch to the OFF position on the control panel. 2. Close the inlet and outlet valves on the filter housing. 3. Connect a flexible line from the filter housing drain valve and open valve. 4. Open the filter housing vent valve on top of the housing. Allow the water to drain fully. 5. Using a wrench loosen the bolt on the filter housing cover band clamp and remove the band

clamp. 6. Remove the filter housing cover and inspect the o-ring seal for cracks or wear. If any wear is found

replace the o-ring. 7. Remove the filter cartridge hold down plate by loosening the centre bolt (bushing). 8. Remove and discard old filter cartridges. 9. Install the new filter cartridges. Wear clean gloves sprayed with 70% isopropyl alcohol to handle

the filters. Make sure the cartridges are secure in the cups at the bottom of the filter housing. NOTE: If gloves are not available, open the top of the filter cartridge bag and insert the filter in the housing as you remove the bag. Avoid touching the filter.

10. Place the hold down plate on top of the filter cartridges and align the filter cartridge fins with the three holes on the plate. Install and hand tighten the centre bolt (bushing).

11. Install the o-ring on the filter housing and place the filter housing cover on top. 12. Install the band clamp and tighten the bolt using a wrench. 13. Using a rubber mallet, tap the band clamp all the way around and re-tighten the bolt. 14. Close the drain valve and remove the flexible line to drain. 15. Leave the vent valve open and connect flexible line to drain and slowly open the filter housing inlet

valve. 16. When a steady stream of water is viewed flowing to drain, close the valve. This will make sure all

the air is purged from the housing. 17. Fully open the inlet and outlet valve on the filter housing. 18. Turn the circulation pump switch to the AUTO position on the control panel.



4.2.2 Vent Filter Installation/Replacement Procedure The following procedure will assist the operator in installing and replacing the vent filter cartridges. Filter must be changed a minimum of once a year or if the filter is suspected of being wet. This can be determined by opening the vent filter housing drain valve. The filter housing is continually kept hot to prevent condensation build up on the vent filter cartridge. NOTE: The filter housing must be kept hot at all times. The filter housing has an electrical heat trace

incorporated in the housing and must be plugged into a 230VAC electrical outlet. NOTE: Filters must only be changed when water is not required. Due to site conditions some of the procedures might have to be altered. NOTE: Use only the prescribed filter type for replacement.

1. Turn the circulation pump switch to the OFF position on the control panel. 2. Unplug the electrical cord for the filter housing heat trace from the receptacle/panel and allow the housing to cool.

CAUTION: The filter housing is always hot. Extreme caution must be taken when handling the housing. When servicing is required, disconnect power to the filter housing heat trace and allow it to cool prior to handling.

3. Undo the large tri-clamp wing nut and remove the clamp. 4. Remove the filter housing bell and inspect the o-ring seal for cracks or wear. If any wear is found replace the o-ring. 5. The filter cartridge is a locking 226 seal type. To remove the filter turn it clockwise and remove the cartridge. 6. Using clean gloves sprayed with 70% isopropyl alcohol to handle the filter cartridge, align the filter cartridge tabs to the notches on the filter housing base. Push the filter cartridge into the notches and turn counter clockwise.

NOTE: If gloves are not available, open the top of the filter cartridge bag and insert the filter in the housing as you remove the bag. Avoid touching the filter.

7. Install the o-ring on the filter housing and place the filter housing cover on top. 8. Install the tri clamp and hand tighten the wing nut. 9. Using a rubber mallet, tap the band clamp all the way around and re-tighten the bolt. 10. Plug in the heat trace cable into the electrical receptacle and allow the housing to heat up. 11. Turn the circulation pump switch to the AUTO position on the control panel.



4.2.3 Ultraviolet Lamp Installation/Replacement Procedure The following procedure will assist the operator in installing and replacing the ultraviolet sterilizer lamps. Replace UV lamps after 8,000 hours of use.

NOTE: This is based on no more than 3 ON/OFF power cycles per 24hr period.

Premature lamp failure or lamp life deterioration can be expected if the UV unit is cycled ON/OFF more than three (3) times a day. The Colorguard™ ultraviolet lamps are rated for 8,000 hours of continuous use or 24 months of intermittent use, whichever comes first. After this time, the lamp glass will photo chemically change and no longer allow sufficient 254-nm shortwave UV, the germicidal ray of the lamp, through the glass to effectively kill bacteria. Failure to replace the ultraviolet lamps on a timely basis of at least once every 8,000 hours may cause the equipment to fail. With intermittent use, in no case should the ultraviolet lamp be used for more than 24 months of operation without replacement, regardless of the number of hours of operation, due to normal operational degradation of the UV lamp.

NOTE: Ultraviolet lamps must only be changed when water is not required. Due to site

conditions some of the procedures might have to be altered. NOTE: When installing for the first time, install the ultraviolet sterilizer quartz sleeves first. It is recommended that the quartz sleeves be removed for inspection and cleaning each time the lamps are replaced.

1. Turn the ultraviolet sterilizer and circulation pump switch to the OFF position on the control panel.

WARNING: Verify the ultraviolet switch is turned to the OFF position to prevent personal injury or damage to the system.

2. Close the inlet and outlet valves on the ultraviolet sterilizer. 3. Remove front cover mounting screws and remove cover as well. 4. Unscrew and pull back the retainer cap from the rubber lamp socket at each end of the lamps. 5. Carefully grab the lamp just after the socket and pull the rubber socket off. Repeat this at each end

of the lamps. 6. Carefully remove each lamp. 7. Wear clean cotton gloves to prevent contamination of the UV lamps. 8. Carefully remove the UV Lamp from the factory packaging. Handle the lamp with care, as it is

fragile. 9. Insert one UV lamp into each open quartz sleeve and push it about 2”-3” (51-76mm) out beyond the

opposite compression nut, so as to be able to hold the lamp with one hand. 10. Unscrew and pull back the retainer cap from the rubber lamp socket if first time installation. 11. Insert the lamp base into the rubber socket. Push until you feel a firm “bottomed out” connection. 12. Carefully slide the rubber boot portion of the lamp socket over the end of the lamp. Verify no portion

of the rubber boot has folded under during this process.

CAUTION: Do not insert UV lamps with opposing retainer cap in place.

13. Screw the slotted retainer cap clockwise onto the compression nut, making sure the number on the socket lead wire and the end plate correspond.

14. Connect the right side rubber lamp sockets and spring-loaded lamp socket retainer assemblies onto each lamp. Pay special attention to match the numbers on the retainer assemblies with the numbers beside each steel nipple on the end plate.



15. Carefully pull out each rubber lamp socket from each spring-loaded socket retainer assembly. 16. With one hand, push the rubber socket boot onto the end of each ultraviolet lamp. When properly

attached, a slight “snap” can be felt, which indicates a proper connection. 17. Carefully slide each lamp socket retainer assembly up and over the rubber lamp socket boot, until

the retainer assembly reaches the male-threaded portion of the compression nut. 18. Then, turn clockwise until the socket retainer cap bottom is out against the compression nut. Avoid

over tightening. CAUTION: Prior to energizing the ballasts and lamps, ensure there is no water leaking into the quartz sleeves and compression nut cavities by properly installing these components. Even a small leak can flood a quartz sleeve and compression nut cavity. During operation, high voltage is present at the lamp pins and receptacles of the lamp connectors. Prolonged flooding of a quartz sleeve and compression nut cavity can cause premature failure of the lamp due to repeated arcing, overheating of the lamp connector cable, and may result in a meltdown of the cable insulation.

NOTE: Do not forget to calibrate the lamp intensity meter after installation of new lamps. Refer to SECTION 2.4.6 (Installation).



4.2.4 Quartz Sleeve Installation/Replacement Procedure The following procedure will assist the operator in installing and replacing the quartz sleeves. It is recommended that the quartz sleeves be replaced annually, in addition to routine cleaning.

NOTE: Quartz sleeves must only be changed when water is not required. Due to site conditions some of the procedures might have to be altered.

1. Turn the ultraviolet sterilizer and circulation pump switch to the OFF position on the control panel.

WARNING: Verify the ultraviolet switch is turned to the OFF position to prevent personal injury or damage to the system. Make sure the ultraviolet sterilizer is depressurized prior to removing the lamps.

2. Close the inlet and outlet valves on the ultraviolet sterilizer. 3. Drain the ultraviolet sterilizer of water. 4. Remove front cover mounting screws and remove cover. 5. Unscrew and pull back the retainer cap from the rubber lamp socket at each end of the lamps. 6. Carefully grab the lamp just after the socket and pull the rubber socket off. Repeat this at each end

of the lamps. 7. Carefully remove each lamp. 8. Using the appropriate compression nut tool, loosen the compression nuts and carefully remove the

quartz sleeves. Inspect the o-rings for signs of wear or cracking and replace if necessary. UNOTEU: It is recommended that the o-rings are replaced each time the quartz sleeves are replaced.

9. Inspect the quartz sleeve for debris or film. If any is found, wash the quartz sleeves with mild soap

and hot water and rinse clean using hot water. Should this be insufficient to clean the quartz sleeves, they must be replaced.

10. Wear clean cotton gloves to prevent contamination of the new or cleaned quartz sleeves. 11. If it is the first time installation, carefully remove the quartz sleeve from the factory packaging.

Handle with care as they are fragile. 12. Visually inspect all quartz sleeve(s) for cracks or other damage. Do not install damaged quartz

sleeve(s). 13. Remove the covers from the treatment chamber. 14. Remove all compression nuts and any packaging material from the end plate (if installed). 15. Place the end of the quartz sleeve into the threaded nipple and slowly push the sleeve into the

chamber through to the second end plate. 16. Install the compression nut and o-ring by placing the o-ring into the internal relief of the compression

nut below the threaded area. The o-ring should fit into the compression nut. 17. Place the compression nut and o-ring onto the end of the quartz sleeve. Allow the quartz sleeve to

extend an equal distance on both ends. Some pushing and twisting may be required. Deionized water may be used as a lubricant.

18. Tighten the compression nut approximately ½ turn after the threaded nipple and o- ring make contact.

19. Repeat this procedure for the second endplate. 20. Slowly pressurize the system and fill the chamber with water to check for leaks. 21. If the compression nut leaks, use the special tool to screw the compression nut assembly onto the

threaded nipple. Do not exceed 40 inch-pounds of torque. 22. You are now ready to install the UV lamp(s).



CAUTION: Prior to energizing the ballasts and lamps, ensure there is no water leaking into the quartz sleeves and compression nut cavities by properly installing these components. Even a small leak can flood a quartz sleeve and compression nut cavity. During operation, high voltage is present at the lamp pins and receptacles of the lamp connectors. Prolonged flooding of a quartz sleeve and compression nut cavity can cause premature failure of the lamp due to repeated arcing, overheating of the lamp connector cable, and may result in a meltdown of the cable insulation.

4.2.5 Solenoid Valve Seal Installation/Replacement Procedure The 4400M-HX system uses the Burkert Type 6213 solenoid valves. The location of each solenoid valve in the system is shown in FIGURE 4.6. It is recommended that the seals in these valves are replaced every two years. Please refer to the Manufacturer’s Manual for procedures on the installation and removal of seals.

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.

4.2.6 Temperature/Conductivity Sensor Calibration Procedure The HX system is equipped with a JUMO ecoTRANS Lf 03 Temperature/Conductivity Sensors to measure the loop feed water temperature and conductivity. The sensor controller is located inside the HX Control Panel. The procedures below describe calibration of the temperature coefficient and the cell constant. For maximum measurement accuracy both parameters should be calibrated once every year. For complete instructions please reference section 8 Calibration of the ecoTRANS Lf 03 manual, version 02.05.

NOTE: The sensors must be calibrated by a certified technician.

The calibration procedures are based on the following assumptions/conditions: • Calibration of the temperature coefficient is accomplished with automatic temperature

compensation, i.e. a temperature probe is hooked up to the Lf 03. • Calibration can be initiated via the set-up software, but for purposes of brevity only the method using

the front keys is described in detail below. • When using the set-up software for calibration, the measurement circuit of the transmitter must be

electrically isolated from ground. If this is not the case, either a) use a computer running on battery power only with the power cable disconnected, or b) disconnect the measurement inputs of the transmitter before hooking up the PC interface, then reconnect.



• The reference temperature is 25° / 77°F. This is dependent on the setting of UNIT.T in the parameter level.

Calibration via Front Keys Display

Start the calibration: 1 Calibration via the front keys can be initiated in two ways: Method 1) via Menu • Press for longer than 2 sec. • Use the arrow key to navigate to CALIB • Press to confirm • Enter the code 110. Method 2) via Shortcut • Press and buttons simultaneously

This requires enabling the shortcut combination once: • Press for longer than 2 sec. • Use the arrow keys to navigate ADMIN / CAL / CA.LVL • Set the CA.LVL value to 1 using the or keys.

2

Calibrating the temperature coefficient using automatic temperature compensation

2.1 Confirm automatic temp. compensation by pressing . (otherwise down arrow to manual temperature compensation, continue per the manual)

2.2 Place conductivity cell and temperature probe in the medium. The display will start to blink. This indicates the actual measured temperature.

2.3 Enter the second temperature using the arrow keys. This must differ by > 5°C / 9°F higher or lower than the reference temp. Press to continue.

2.4 Heat/cool the medium to the reference temperature. The display shows the actual temperature and the uncompensated conductivity value.

The conductivity will be automatically accepted when the temperature reaches the reference value, – or – when the button is held < 1 sec.



2.5 Acceptance of the first calibration point is indicated by the “NEXT” text. Press to continue.

2.6 Heat/cool the medium to the reference temperature. The display shows the actual temperature and the uncompensated conductivity value.

The conductivity will be automatically accepted when the temperature reaches the reference value, – or – when the button is held < 1 sec.

2.7 The temperature coefficient that was calculated is displayed. Press for more than 2 seconds to accept or EXIT to discard.

2.8 The display will now show the current measured values for compensation & temperature.

2.9 Potential error messages: 2 identical calibration temperatures temperature coefficient > 5.5%

Press or EXIT to start again at step 2.1.

3

Calibrating the relative cell constant

3.1 Confirm automatic temp. compensation by pressing .

3.2 Immerse the conductivity cell into a reference solution with known conductivity. The display alternates approx. every 3 seconds between showing the uncompensated conductivity of the reference solution and CAL.C.

3.3 When the reading has stabilized press and enter the

reference solution conductivity via the or keys. Briefly press to accept the value.

3.4 The relative cell constant that was calculated is displayed. Press for more than 2 seconds to accept or EXIT to discard.

3.5 Potential error messages: the conductivity is zero the calculated relative cell constant is < 20%

the calculated relative cell constant is > 500%

Press or EXIT to start again at step 3.1.



CHEMICAL CLEANING AND SANITIZATION The 4400M-HX system performs scheduled hot water sanitization for set exposure time and temperature to inactivate viable microbial in the water treatment system. The endotoxin reduction is not achieved from the hot water sanitization process. Based on the feed water source, system operating conditions and the user’s preventative maintenance practices, traditional chemical cleaning and sanitization processes may still be required. Generally, hot water sanitization is performed more frequently than chemical cleaning and sanitization, based on microbial counts and regular sanitization schedule.

4.3.1 Chemical Cleaning and Sanitization Procedure Using the System Storage Tank

The procedure below will assist the operator in sanitizing the tank, water distribution loop and associated components using the MINNCARE® disinfectant. For chemical cleaning and sanitization of the RO device, refer to the procedure in the 4400M - PLC RO MANUAL.

CAUTION: When performing a cleaning or sanitization it is very important to use the proper safety apparatus. Refer to the Material Safety Data Sheet (MSDS) provided with the cleaner before using it.

1. Place the 4400M – PLC RO in SLEEP mode. 2. Turn the circulation pump and ultraviolet sterilizer selector switch to the OFF position. 3. Drain the tank to the mid level using the tank drain valve. 4. From the display determine the amount of water in the tank to identify the amount of the

MINNCARE® solution that needs to be added. 5. Remove the tank hand-way cap. 6. Add appropriate amount of the MINNCARE® solution. 7. Re-install the tank hand-way cap. 8. Turn the circulation pump selector switch to the MANUAL position. 9. Allow the solution to circulate for 10 minutes. 10. Take a sample from the loop return to determine the concentration of the MINNCARE® using the

MINNCARE® 1% test strips (Refer to Instructions in SECTION 4.3.3). If not within limits, repeat Steps 5 to 6.

11. If the concentration is within limits, allow the solution to circulate for 30 to 60 minutes. If two circulation pumps are installed, cycle to the other pump half way through the circulation time. 12. It is recommended that 100ml of solution be drawn from each point of use to assure sanitization of all the points of use. 13. Once the sanitization time has elapsed turn the circulation pump switch to the OFF position. 14. Neutralize the MINNCARE® solution (Refer to SECTION 4.3.2). 15. Open the tank drain valve. Allow the tank to empty and then close the drain valve. 16. Place the 4400M – PLC RO in RUN mode and allow the tank to fill. 17. Turn the circulation pump switch to the AUTO position and allow the water to circulate for 10 minutes. 18. Using the MINNCARE® residual test strip, take a sample of the loop return water to determine if

there is any MINNCARE® solution left. Open each point of use (one at a time) to flush any solution out. If two circulation pumps are installed, cycle to the other pump to rinse out any solution.

19. If residual solution is still present, repeat Steps 14 to 19. 20. If no residual solution is detected, turn the ultraviolet sterilizer switch to the AUTO position. The sanitization is complete.



4.3.2 Neutralizing Cleaning and Sanitization Solutions After each batch of solution is used, the local municipality may require it to be neutralized before discharging. Each batch of solution will have a different concentration after each use. Therefore it will have to be calculated each time. Refer to the MINNCARE® MANUAL for instructions on neutralizing the solution.

NOTE: Check your local municipality for waste discharge regulations.



4.3.3 OVERVIEW OF MINNCARE® DISINFECTANT CHEMICAL AND TEST STRIPS

DIN (Canada): 02277484 Compound: Hydrogen Peroxide 22.0% / Peroxyacetic Acid 4.5% / Inert

Ingredients 73.5% Normal Cleaning:

1% Concentration

pH of Solution: 1.3 Foam Level: Moderate Cloud Point: None Rinsability: Good Storage: Store sealed container in a cool (<24°C) dry place. 1 year

shelf life

PRECAUTIONARY STATEMENTS

CAUTION: Hazard to humans and domestic animals. Corrosive. Causes irreversible eye damage. Harmful if absorbed through skin. Do not get in eyes, on skin, or on clothing. Avoid contact with skin. Prolonged or frequent repeated skin contact may cause an allergic reaction in certain individuals. Wash hands before eating, drinking, chewing gum, using tobacco or using the toilet. Remove contaminated clothing and wash hands before reuse. Caution should be used when applying indoors because pets may be at risk. KEEP OUT OF REACH OF CHILDREN. CAUTION: First Aid - If inhaled, move person to fresh air. If person is not breathing, call 911 or an ambulance, then give artificial respiration, preferably mouth-to-mouth, if possible. Call a poison control center or doctor for further treatment advice. If on skin or clothing, take of contaminated clothing, rinse skin immediately with plenty of water for 15-20 minutes. Remove contact lenses, if present, after first 5 minutes, then continue rinsing.

Call a poison control center or doctor for treatment advice. If swallowed, call a poison

control center or doctor immediately for treatment advice. Have a person sip a glass of water if able to swallow. Do not induce vomiting unless told to by a poison control center or doctor. Do not give anything by mouth to an unconscious person.

NOTE: Hot Line Number – For chemical emergency, spill, leak, fire, exposure and accident, call Chemtrec, day or night (800) 424-9300, (703) 527-3887. Have the product container or label with you when calling a poison control center or doctor, or going for treatment. You may also contact Chemtrec at 1-800-424-9300 for emergency medical treatment information. Note to Physician – Probable mucosal damage may contraindicate the use of gastric lavage.

NOTE: Personal Protective Equipment (PPE) – Handlers must wear: goggles or face shields, and protective rubber gloves.



WARNING: Environmental Hazards – This product is toxic to birds, fish and aquatic invertebrates. For guidance, contact your regional or local regulatory authority. Physical and Chemical Hazards – This product contains an oxidizing agent.

NOTE: Storage and Disposal – Do not contaminate water, food or feed by storage or disposal. Storage: Store upright in shipping carton. Do not expose to direct sunlight. Maintain temperature below 24oC (75oF). Avoid contact with combustible materials. Avoid contamination from any source, including metals, dust, etc. Such contamination may cause rapid decomposition, generation of large quantities of oxygen gas and high pressures. Store in original closed container – NEVER TAMPER WITH VENT. Disposal: Waste resulting from the use of this product may be disposed of on-site by dilution in a sanitary sewer or at an approved waste disposal facility. Container Disposal: Triple rinse empty container with water, then offer for recycling or reconditioning or puncture and dispose of in a sanitary landfill, incinerate, or, if allowed by state and local authorities, by burning. If burned, stay clear of the smoke.

UPRODUCT EFFICACY

Sporicidal 100X dilution, 11 hours 20oC Bactericidal 100X dilution, 11 hours 20oC Fungicidal 100X dilution, 11 hours 20oC Cleaner/Sanitizer

(Non-food contact surfaces) 32X dilution, 10 minutes 20oC (Food contact surfaces Staphylococcus aureus and Escherichia coli)

320X dilution, 1 minute 25oC Hospital Disinfectant 100X dilution, 10 minutes 20oC

Pseudomonacidal Broad Spectrum Disinfectant 100X dilution, 10 minutes 20oC Germicidal Spray Disinfectant 100X dilution, 10 minutes 20oC RO Membrane Sanitizer 100X dilution, 36 minutes 20oC

GENERAL DIRECTIONS FOR USE DO NOT USE AFTER EXPIRATION DATE. Do not allow MINNCARE® Liquid Disinfectant to mix with alkaline substances such as bleach (sodium hypochlorite). If spilled, flush away with large quantities of water. Use purified water when diluting MINNCARE® Liquid Disinfectant. MINNCARE® Liquid Disinfectant is a single-use product not intended for reuse. Fresh sanitizing solution should be prepared daily or more often if the solution becomes diluted or soiled.

DIRECTIONS FOR SANITIZING OF REVERSE OSMOSIS MEMBRANES MINNCARE® Liquid Disinfectant is recommended for sanitizing reverse osmosis membranes and their associated distribution systems. This product has been shown to be an effective disinfectant when tested by AOAC methods. MINNCARE® Liquid Disinfectant may not totally eliminate all vegetative microorganisms in reverse osmosis membranes and their associated piping systems due to their construction and//or assembly, but can be relied upon to reduce the number of microorganisms to acceptable levels when used as directed. The possibility of recontamination by the incoming water supply may exist.



MINNCARE® Liquid Disinfectant should be used in a sanitation program which includes bacteriological monitoring of the entire RO water system.

MINNCARE® Liquid Disinfectant may be used for reverse osmosis (RO) systems, which are compatible with diluted hydrogen peroxide solutions. The MINNCARE® Liquid Disinfectant has a shelf life of one year. MINNCARE® Liquid Disinfectant should not be stored at its 1% use dilution since this may compromise its effective concentration. This product is not registered for use on kidney dialyzers and dialysis machines. The RO manufacturer should be consulted prior to use of MINNCARE® Liquid Disinfectant to determine the temperature and pH range acceptable for the particular membranes. At a 100X dilution (1% concentration), the pH range for MINNCARE® Liquid Disinfectant is 3.0-3.5. RO water systems vary in design according to the particular needs of the user. Because of the variations in materials of construction at different facilities, some systems may have components of pumps, gasket, etc. that are not compatible with long term exposure to copper, brass, iron and certain other metals. MINNCARE® Liquid Disinfectant has also exhibited a decreased resistance to latex and Buna-N with extended exposure. MINNCARE® Liquid Disinfectant solution has been found compatible with typical system materials such as stainless steel. It is also compatible with polypropylene, high-density polyethylene, polysulfone, Teflon, polycarbonate, neoprene, ABS, nylon, acrylic silicone, Plexiglas, ethylene propylene, VITON, FLUOREL, PVC and CPVC. Because of the individuality of the RO water system in design and construction as well as the quality of raw feed water, all OR water does not contain the same components. Dependent upon your particular system, all or portions of the following procedure may be for sanitizing. Biological or organic fouling of the membrane or other parts of the system should be removed with appropriate cleaner. It is important to follow the membrane manufacturer’s recommended cleaning procedure. After cleaning, flush the system with RO permeate. Mineral deposits should be removed with an acidic cleaner prior to sanitizing of the membrane. Again, follow the membrane manufacturer’s recommended cleaning procedure. Then flush the unit with RO permeate. The presence of iron or other transition metals, in conjunction with the hydrogen peroxide in MINNCARE® Liquid Disinfectant, could cause membrane degradation. Prepare a 1% solution (1 part MINNCARE® Liquid Disinfectant to 99 parts water) by adding the MINNCARE® Liquid Disinfection solution to permeate water. Fill the entire water circuit to be sanitized with a 1% solution and allow the diluted solution to reach a minimum temperature of 20oC (68oF). Do not exceed the membrane manufacturer’s recommended temperature. Recirculate the 1% MINNCARE® Liquid Disinfectant until the entire system is filled. Allow the elements to soak in the 1% MINNCARE® Liquid Disinfection solution for a minimum of 36 minutes at 20oC (68oF). 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.



THE 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 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.

USpecifications

STORAGE 1. Containers that have not been opened must be stored in a refrigerator (5-15°C) DO NOT FREEZE. Once a container has been opened, do not put it back into the refrigerator. Repeated opening of a continuously refrigerated container will cause enough condensation to exceed the capacity of the container drying agent (located in stopper cap). The test strips are damaged by excessive moisture.

2. Store containers that have been opened in a cool and dry place without refrigerating.

3. Failure to store test strips properly will result in inaccurate readings.

4. To check the colour reaction, strips should be tested against a known 3 ppm concentration of hydrogen peroxide (0.1ml of 3% hydrogen peroxide in 1000ml of purified water). If the result is not greater than 1 ppm and less than 10 ppm per the colour chart, the strips must be discarded.

5. Each container has an expiry date. Do not use after date printed on the container.

TEST STRIPS USER INSTRUCTIONS MINNCARE® P/N 78338 Residual Test Strips

1. Collect a sample of the rinse solution. 2. Remove a test strip from the tube and immediately replace the lid. 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 5 and 10 seconds after exposure. NOTE: If test strip indicates dark blue to brown or green to brown, the concentrations are too high for the colour scale. Read the MINNCARE® disinfectant package insert instructions



for additional information.

MINNCARE® P/N 78339 1% 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 10 seconds, note the entire reaction pad colour development.

• 1% = Blue-gray or blue-black colour over the entire reaction pad within 2-5 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. NOTE: 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.

MAN-4400MHXS1 Rev. F 5-1 Troubleshooting


5 TROUBLESHOOTING TROUBLESHOOTING ALARMS/MESSAGES The following table lists all the programmed alarms and messages in the HX system with their cause(s) and troubleshooting tips.

NOTE: The troubleshooting of the system must be performed by a certified 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 in Operations and Monitoring) to ensure the range and default preset values of each alarm parameter are correct. Record any modified values in the table for future reference.

NO. DISPLAYED

ALARM/MESSAGE ON THE HMI SCREEN

POSSIBLE CAUSE CORRECTIVE ACTION

Check position of POWER button. Check power. Check outlet and circuit breaker/fuse panel for power with voltmeter.

RO is powered off.

Check fuses in RO system.

1 RO START FAILURE

No response from RO device.

Check RO is set to RUN AVAIL mode on the 4400M - PLC RO screen.

2 POWER CYCLE/CONFIRM DAY OF WEEK SETTING

Incorrect day setting - occurs during power disruption.

Set current day setting in SET T screen or the HOME screen.

3 LOOP RETURN TEMPERATURE SENSOR ERROR

Temperature sensor is malfunctioning.

Verify wiring from the sensor to the PLC and replace the temperature sensor if defective.

4 LOOP FEED TEMPERATURE SENSOR ERROR


Verify wiring from the sensor to the PLC and replace the temperature sensor if defective.

5 TANK LEVEL TRANSMITTER SENSOR ERROR

Transmitter sensor error. Verify wiring from the transmitter to the PLC. Replace transmitter if defective.

Incorrect alarm setting. Verify correct setting in the SET A1 screen.

6 TANK EMPTY ALARM

System is malfunctioning.

Perform a complete diagnosis for valve position (See VALVE MATRIX). Locate water loss point and fix.

7 TANK LEVEL LOW (EXAMINE RO PRODUCTION)


Perform a complete diagnosis for valve position (See VALVE MATRIX). Locate water loss point and fix.



NO. DISPLAYED



RO product water supply is too low.

Check RO device product output.

Feed water valve is plugged or closed.

Open valve and unclog.

Pre-filter/Post-filter is clogged.

Replace filters. Refer to MAINTENANCE procedure.

RO Membranes are fouled.

Clean membranes. Refer to MAINTENANCE procedures on RO Manual. Replace membranes if flow is not recoverable.

8 LOOP RETURN TEMPERATURE HIGH

Possible flow restrictions in loop.

Raise high temperature alarm set-point value in the SET A1 screen. Inspect loop for any blockage.

System is malfunctioning. Flow is restricted.

Perform a complete diagnosis for valve position (See VALVE MATRIX).

9 LOOP FEED TEMPERATURE HIGH

Heater stays on. Verify PLC output, contractor wiring.


Check temperature sensor probe. Replace sensor if damaged.

10 RO PRODUCT TEMPERATURE OUT OF LIMITS

Loose wiring. Verify wiring from the sensor to the PLC.



11 RO PRODUCT TEMPERATURE HIGH

Feed water temperature is high.

Check the feed water temperature.

12 RECIRC PUMP PRESSURE TRANSMITTER ERROR

Pump pressure transmitter error.

Verify wiring from the transmitter to the PLC. Replace transmitter if defective.

Incorrect alarm setting. Lower Loop SANI LO. PSI setting in the SET A2 screen.

Incorrect pump pressure setting.

Adjust loop return pressure regulator setting.



13 RECIRC PUMP PRESSURE LOW IN LOOP SANI MODE

Excessive water leak. Locate water leak point and fix.

14 SANI TEMPERATURE TOO LONG TO REACH SETTING

Heater element/wiring is damaged or malfunctioning.

Verify PLC output, element drive. Repair or replace.

15 SANI TEMPERATURE BELOW SETTING (HEATING PROBLEM)

Heater element/wiring is damaged or malfunctioning.

Verify PLC output, element drive. Repair or replace.

16 HEATER PUMP FAIL DURING SANI PROCESS

Heater pump is malfunctioning.

Verify and repair or replace. Refer to Pump Manual.



NO. DISPLAYED



Incorrect switch setting. Check the switch setting. 17 SANI ABORT BY CONTROL

SWITCH SETTINGS Sanitization cycle is aborted due to switching Sani key switch or pumps off.

Turn the SANI key switch to the ON position on the control panel and re-run cycle.

18 SANI END Message: Sanitization operation is stopped. Incorrect alarm setting. Raise Loop Gen. HI PSI

setting in the SET A2 screen. System is malfunctioning.


19 RECIRC PUMP PRESSURE HIGH IN LOOP

Loop flow is restricted. Check the hand valve and ensure it is open.

Power loss or blown fuse.

Verify and replace fuse if required.

20 RECIRC PUMP B NO FEEDBACK

Pump failed. Perform independent pump diagnosis.

Power loss or blown fuse.

Verify and replace fuse if required.

21 RECIRC PUMP A NO FEEDBACK

Pump failed. Perform independent pump diagnosis.

Incorrect alarm setting. Lower RO SANI LO. PSI setting in the SET A2 screen.



Hand valve is closed. Check the hand valve and ensure it is open.

Check valve is not opening.

Manually check the check valve and ensure it is functional.

22 RECIRC PUMP PRESSURE LOW IN RO SANI MODE

Excessive water leak. Locate the water loss point and fix.

Incorrect alarm setting. Raise RO SANI HI PSI setting in the SET A2 screen.



23 RECIRC PUMP PRESSURE HIGH IN RO SANI MODE

Restricted water flow. Check the hand valve and ensure it is open.

24 SANI LOOP HOLD TIME COMPLETED (PER SETTING)

Message: Distribution loop sanitization Temperature Hold phase is completed.

25 SANI RO HOLD TIME COMPLETED (PER SETTING)

Message: RO sanitization Temperature Hold phase is completed.

26 ABORT ACTION / HIGH TEMP/SAFETY COOL ACTIVE

Message: Sanitization operation is aborted due to high water temperature.



NO. DISPLAYED



Incorrect alert setting. Raise LP. Feed Qual. Low Alert setting in the SET A3 screen.

RO product quality is poor.

Fix RO product quality. Refer to 4400M - PLC RO Manual.

Infected loop. Conductivity sensor probe is malfunctioning.

27 LOOP QUALITY ALERT - EXAMINE WATER

Conductivity sensor wiring problem.

Check loop conductivity sensor for its functionality. Check wiring from this sensor to the PLC. If same alarm comes, disinfect loop (See MAINTENANCE section).

Incorrect alarm setting. Raise LP. Feed Qual. Low Alarm setting in the SET A3 screen.

RO product quality is poor.

Fix RO product quality. Refer to 4400M – PLC RO Manual.

Infected loop. Conductivity sensor probe is malfunctioning.

28 LOOP QUALITY SHUTDOWN ALARM

Conductivity sensor wiring problem.

Check loop conductivity sensor for its functionality. Check wiring from this sensor to the PLC. If same alarm comes, disinfect loop (See MAINTENANCE section).

29 EXTERNAL ALARM TRIGGER

Message: Sanitization operation is aborted by external device (optional input signal).

30 LOOP SENSOR ERROR - QUALITY DISPLAY INVALID!

Conductivity sensor probe is malfunctioning.

Check loop conductivity sensor for its functionality.

31 LOOP SANI STARTED Message: Loop sanitization operation is initiated. 32 RO SANI STARTED Message: RO sanitization operation is initiated. 33 DAY CHANGE BUTTON F6

PRESSED Message: Displayed each press and release of the key.

34 3 HOUR MUTE BUTTON PRESSED

Message: Displayed each press and release of the key.

35 CIRCULATION PUMPS REMOVED FROM AUTO MODE

Message: Switch to AUTO mode on the HX control panel to run pumps in AUTO mode. Pumps must stay in AUTO mode.

36 SANI TO OFF MODE BY KEY SWITCH

Message: To perform sanitization operations, turn the SANI key switch to AUTO/MANUAL position.

37 RO / SLEEP MODE BUTTON PRESSED


38 RO/AWAKE MODE BUTTON PRESSED


UV Auto/Off Switch In Off Position.

Turn switch to the auto position.

Lamp(s) Is burned out Replace lamp(s)

39 UV 4.00 UA 4.01 UV INTENSITY ALARM!

Lamp intensity is below set point.

Replace lamp(s)



SYSTEM DIAGNOSIS The test matrix in SECTION 5.2.1 list the state of each critical component during each sequence of the normal RO and sanitization operations. Perform a step-by-step diagnosis and record all the results in the test matrix. Refer to visual aids to locate the system components. If a discrepancy is noticed between the state of the expected condition and the actual condition, contact Mar Cor technical services for help.

NOTE: The system diagnosis must be performed by a Mar Cor certified technician. Failure to do so may void the product warranty.



SYSTEM TEST MATRIX (NORMAL RO OPERATIONS – NO SANI)

TAG NAME DESCRIPTION

Syst

em -

OFF

(STO

P)

(P)

Pas

s /

(F) F

ail

RO

Sys

tem

Flu

sh

(Sta

rtup

/ A

uto)

*

(P)

Pas

s /

(F) F

ail

RO

Run

(P)

Pas

s /

(F) F

ail

RO

Sle

ep

(P)

Pass

/ (F

) Fai

l

HX Panel

P4.00 / P4.01 Circulation Pump (A or B) ON: Either one or Both; OFF: Both OFF P F ON P F ON P F ON P F

HX4.00 Heating Element ON/OFF OFF P F OFF P F OFF P F OFF P F XI-RO RO Auto Run Indicator Light OFF P F ON P F ON P F OFF P F

XI-SANI Sani In Process Amber Light OFF P F OFF P F OFF P F OFF P F XI-SANI_Comp Sani Complete Green Light OFF P F OFF P F OFF P F OFF P F

UV4.00 UV Lamp (AUTO) OFF N/A OFF N/A ON N/A ON N/A RO Panel

YS-RO RO Lockout By SANI Control OFF P F OFF P F OFF P F OFF P F XS-RO SANI Control RO Start OFF P F ON P F N/F-L P F ON P F

Solenoid Valves YV4.00 Pre-treatment Feed Valve CL P F OP* P F OP* P F CL P F YV4.02 Tank Drain Valve CL P F CL P F CL P F CL P F YV4.03 Loop Bypass Valve CL CL CL CL YV4.04 Loop Isolation Valve CL

P F OP

P F OP

P F OP

P F

YV4.08 Raw Cold Water Valve CL P F CL P F CL P F CL P F YV4.09 Force Cool Feed Valve CL P F OP P F OP P F CL P F YV2.0 RO Feed Inlet Valve CL P F OP* P F OP* P F CL P F YV2.01 RO Reject Valve CL P F OP* P F CL* P F CL P F YV2.02 RO Reject To Drain Valve OP P F OP P F OP P F OP P F YV2.03 RO Reject To Tank Valve CL P F CL P F CL P F CL P F YV2.04 RO Recycle To Tank Valve CL CL CL CL YV2.08 RO Air Break Valve OP

P F OP

P F OP

P F OP

P F

YV2.05 RO Product To Drain Valve OP P F O/C-Q P F O/C-Q P F OP P F YV2.07 RO Product To Tank Valve (R13) (Force OP during SANI)

CL* P F C/O-Q* P F C/O-Q* P F CL P F

UInstructions: Place the system in each mode of normal operation. Observe and record the state of each component during each mode. Each solenoid valve has a LED indicator light that will turn on when the valve is open. Circle “P” for pass if the observed state of the component is same as the indicated state.

ULEGEND: OFF The device is OFF OP/CL The valve status changes from OPEN to CLOSE ON The device is ON CL/OP The valve status changes from CLOSE to OPEN N/F The device status changes from ON to OFF -Q* The valve status changes based on Water Quality F/N The device status changes from OFF to ON -L* The device status changes based on Tank Level CL The valve is CLOSED OP The valve is OPEN

COMMENTS: PERFORMED BY: DATE: VERIFIED BY: DATE:



S1 SYSTEM TEST MATRIX (FOR SANI OPERATIONS – LOOP ONLY, RO ONLY, COMBO (LOOP + RO))

ULEGEND: OFF The device is OFF OP/CL The valve status changes from OPEN to CLOSE ON The device is ON CL/OP The valve status changes from CLOSE to OPEN N/F The device status changes from ON to OFF -Q The valve status changes based on Water Quality F/N The device status changes from OFF to ON -L The device status changes based on Tank Level CL The valve is CLOSED OP The valve is OPEN

COMMENTS: PERFORMED BY: DATE: VERIFIED BY: DATE:

UInstructions: Initiate the sani cycle. Observe and record the state of each component as the system transition from one mode to the next. Each solenoid valve has a LED indicator light that will turn on when the valve is open. Circle “P” for pass if the observed state of the component is same as the indicated state. Circle “F” for fail if the observed state is different from the actual state.

UNOTE:U In the “COMBO” Sanitization, the system transition from the Force Cool Down mode in the Loop Sani to the Tank Adjust mode in the RO sani. It skips the Loop Sani End mode.



RO Unit

NORMAL SYSTEM OPERATION DESCRIPTION: SYSTEM OFF HEATER SCREEN: RO SLEEP RO SCREEN: STOP

OFFUltraviolet Sterilizer 18OPLoop Isolation Valve 17 CLLoop By-Pass Valve 16

OFFHeater Element 15 OFFCirculation Pump(s) 14CLTank Drain Valve 13 CLRaw Cold Water Valve 12 CLRO Recycle to Tank Valve 11 OPRO Recycle Air Break CLRO Reject to Tank Valve 9 OPRO Reject to Drain Valve 8 CLRO Product to Tank Valve 7 OPRO Product to Drain 6 CLRO Reject Valve 5

OFFRO Pump 4 CLRO Feed Valve 3 CLForce Cool Feed Valve 2 CLPretreatment Feed Valve 1

10



NORMAL SYSTEM OPERATION DESCRIPTION: RO LOCK-OUT (STANDBY) HEATER SCREEN: RO AWAKE RO SCREEN: LOCK-OUT

ONUltraviolet Sterilizer 18 OPLoop Isolation Valve 17 CLLoop By-Pass Valve 16

OFFHeater Element 15 ONCirculation Pump(s) 14 CLTank Drain Valve 13 CLRaw Cold Water Valve 12 CLRO Recycle to Tank Valve 11 OPRO Recycle Air Break 10 CLRO Reject to Tank Valve 9 OPRO Reject to Drain Valve 8 CLRO Product to Tank Valve 7 OPRO Product to Drain 6 CLRO Reject Valve 5


RO Unit RO Unit



NORMAL SYSTEM OPERATION DESCRIPTION: RO SYSTEM FLUSH (START-UP/AUTO) HEATER SCREEN: RO AWAKE RO SCREEN: MANUAL FLUSH

OFFUltraviolet Sterilizer 18 OPLoop Isolation Valve 17 CLLoop By-Pass Valve 16

OFFHeater Element 15 ONCirculation Pump(s) 14 CLTank Drain Valve 13 CLRaw Cold Water Valve 12 CLRO Recycle to Tank Valve 11 OPRO Recycle Air Break 10 CLRO Reject to Tank Valve 9 OPRO Reject to Drain Valve 8

CL/OP-Q RO Product to Tank Valve 7 OP/CL-Q RO Product to Drain Valve 6

OPRO Reject Valve 5 OFF/ORO Pump 4

OPRO Feed Valve 3 OPForce Cool Feed Valve 2 OPPretreatment Feed Valve 1

RO Unit



NORMAL SYSTEM OPERATION DESCRIPTION: RO AWAKE HEATER SCREEN: RO AWAKE RO SCREEN: RO RUN


OFFHeater Element 15 ONCirculation Pump(s) 14 CLTank Drain Valve 13 CLRaw Cold Water Valve 12 CLRO Recycle to Tank Valve11 OPRO Recycle Air Break 10 CLRO Reject to Tank Valve 9 OPRO Reject to Drain Valve 8

CL/OP -Q RO Product to Tank Valve7 OP/CL -Q RO Product to Drain Valve6

CLRO Reject Valve 5 OFF/ORO Pump 4

OPRO Feed Valve 3 OPForce Cool Feed Valve 2 OPPretreatment Feed Valve 1

RO Unit



NORMAL SYSTEM OPERATION DESCRIPTION: RO SLEEP HEATER SCREEN: RO SLEEP RO SCREEN: RO RUN AVAILABLE


OFFHeater Element 15 ONCirculation Pump(s) 14 CLTank Drain Valve 13 CLRaw Cold Water Valve 12 CLRO Recycle to Tank Valve11 OPRO Recycle Air Break Valve10 CLRO Reject to Tank Valve 9 OPRO Reject to Drain Valve8 CLRO Product to Tank Valve7 OPRO Product to Drain Valve6 CLRO Reject Valve 5

OFFRO Pump 4 CLRO Feed Valve 3 CLForce Cool Feed Valve 2 CLPretreatment Feed Valve1

RO Unit



LOOP HEAT SANITIZATION DESCRIPTION: TANK ADJUST BY TANK DRAIN HEATER SCREEN: LEVEL ADJUST SET RO SCREEN: RO LOCK-OUT


OFFHeater Element 15 OFFCirculation Pump(s) 14 OPTank Drain Valve 13 CLRaw Cold Water Valve 12 CLRO Recycle to Tank Valve11 OPRO Recycle Air Break Valve10 CLRO Reject to Tank Valve9 OPRO Reject to Drain Valve8 CLRO Product to Tank Valve7 OPRO Product to Drain Valve6 CLRO Reject Valve 5


RO Unit



LOOP HEAT SANITIZATION DESCRIPTION: LOOP HEAT SANITIZATION HEAT RAMP HEATER SCREEN: IN HEAT RAMP PHASE RO SCREEN: RO LOCK-OUT

OFFUltraviolet Sterilizer 18 OPLoop Isolation Valve 17 CLLoop By-Pass Valve 16 ONHeater Element 15 ONCirculation Pump(s)14CLTank Drain Valve 13 CLRaw Cold Water Valve 12 CLRO Recycle to Tank Valve11 OPRO Recycle Air Break Valve10 CLRO Reject to Tank Valve 9 OPRO Reject to Drain Valve8 CLRO Product to Tank Valve7 OPRO Product to Drain Valve6 CLRO Reject Valve 5


RO Unit



LOOP HEAT SANITIZATION DESCRIPTION: LOOP HEAT SANITIZATION HOLD HEATER SCREEN: IN HEAT HOLD PHASE RO SCREEN: RO LOCK-OUT

OFFUltraviolet Sterilizer 18 OPLoop Isolation Valve 17 CLLoop By-Pass Valve 16 ONHeater Element 15 ONCirculation Pump(s) 14 CLTank Drain Valve 13 CLRaw Cold Water Valve 12 CLRO Recycle to Tank Valve11 OPRO Recycle Air Break Valve10 CLRO Reject to Tank Valve9 OPRO Reject to Drain Valve8 CLRO Product to Tank Valve7 OPRO Product to Drain Valve6 CLRO Reject Valve 5


RO Unit



LOOP HEAT SANITIZATION DESCRIPTION: LOOP HEAT SANITIZATION TANK DRAIN HEATER SCREEN: IN FORCE COOL PHASE RO SCREEN: RO LOCK-OUT


OFFHeater Element 15 OFFCirculation Pump(s) 14 OPTank Drain Valve 13 OPRaw Cold Water Valve 12 CLRO Recycle to Tank Valve11 OPRO Recycle Air Break Valve10 CLRO Reject to Tank Valve9 OPRO Reject to Drain Valve8 CLRO Product to Tank Valve7 OPRO Product to Drain Valve6 CLRO Reject Valve 5


RO Unit



LOOP HEAT SANITIZATION DESCRIPTION: LOOP HEAT SANITIZATION FORCE COOL DOWN HEATER SCREEN: IN FORCE COOL PHASE RO SCREEN: RO LOCK-OUT

OFFUltraviolet Sterilizer18OPLoop Isolation Valve 17 CLLoop By-Pass Valve 16

OFFHeater Element 15 OFF/ON - L Circulation Pump(s) 14

CLTank Drain Valve 13 CLRaw Cold Water Valve 12 CLRO Recycle to Tank Valve11 OPRO Recycle Air Break Valve10 CLRO Reject to Tank Valve9 OPRO Reject to Drain Valve8

CL/OP - QRO Product to Tank Valve7 OP/CL - QRO Product to Drain Valve6 OP/CLRO Reject Valve 5

OFF/ONRO Pump 4 OPRO Feed Valve 3 OPForce Cool Feed Valve 2 OPPretreatment Feed Valve1

RO Unit



LOOP HEAT SANITIZATION DESCRIPTION: LOOP HEAT SANITIZATION ENDED HEATER SCREEN: LOOP SANI ENDED RO SCREEN: RO RUN AVAILABLE


OFFHeater Element 15 ONCirculation Pump(s) 14 CLTank Drain Valve 13 OPRaw Cold Water Valve 12 CLRO Recycle to Tank Valve11 OPRO Recycle Air Break Valve10 CLRO Reject to Tank Valve9 OPRO Reject to Drain Valve8

CL/OP-QRO Product to Tank Valve7 OP/CL-QRO Product to Drain Valve6 OP/CLRO Reject Valve 5


RO Unit



COMBO HEAT SANITIZATION DESCRIPTION: LOOP TO RO TRIGGER HEATER SCREEN: LEVEL ADJUST SET RO SCREEN: RO LOCK-OUT


OFFHeater Element 15 OFFCirculation Pump(s) 14 CLTank Drain Valve 13 CLRaw Cold Water Valve 12 CLRO Recycle to Tank Valve11 OPRO Recycle Air Break Valve10 CLRO Reject to Tank Valve 9 OPRO Reject to Drain Valve8

CL/OP-QRO Product to Tank Valve7 OP/CL-ARO Product to Drain Valve6 OP/CLRO Reject Valve 5


RO Unit RO Unit



RO Unit

RO HEAT SANITIZATION DESCRIPTION: TANK ADJUST BY TANK DRAIN HEATER SCREEN: LEVEL ADJUST SET RO SCREEN: RO LOCK-OUT

OFFUltraviolet Sterilizer 18 CLLoop Isolation Valve 17 OPLoop By-Pass Valve 16 OFFHeater Element 15 OFFCirculation Pump(s) 14 OPTank Drain Valve 13 CLRaw Cold Water Valve 12 OPRO Recycle to Tank Valve11 CLRO Recycle Air Break Valve10 CLRO Reject to Tank Valve 9 OPRO Reject to Drain Valve8 OPRO Product to Tank Valve7 CLRO Product to Drain Valve6 OPRO Reject Valve 5 OFFRO Pump 4 OPRO Feed Valve 3 CLForce Cool Feed Valve 2 CLPretreatment Feed Valve1

RO Unit



RO HEAT SANITIZATION DESCRIPTION: RO HEAT SANITIZATION HEAT RAMP HEATER SCREEN: IN HEAT RAMP PHASE RO SCREEN: RO LOCK-OUT

OFFUltraviolet Sterilizer 18 CLLoop Isolation Valve 17 OPLoop By-Pass Valve 16 ONHeater Element 15 ONCirculation Pump(s) 14 CLTank Drain Valve 13 CLRaw Cold Water Valve 12 OPRO Recycle to Tank Valve11 CLRO Recycle Air Break Valve10 OPRO Reject to Tank Valve 9 CLRO Reject to Drain Valve 8 OPRO Product to Tank Valve7 CLRO Product to Drain Valve6 OPRO Reject Valve 5 OFFRO Pump 4 OPRO Feed Valve 3 CLForce Cool Feed Valve 2 CLPretreatment Feed Valve 1

RO Unit



RO HEAT SANITIZATION DESCRIPTION: RO HEAT SANITIZATION HOLD HEATER SCREEN: IN HEAT HOLD PHASE RO SCREEN: RO LOCK-OUT

OFFUltraviolet Sterilizer 18 CLLoop Isolation Valve 17 OPLoop By-Pass Valve 16 ONHeater Element 15 ONCirculation Pump(s) 14 CLTank Drain Valve 13 CLRaw Cold Water Valve 12 OPRO Recycle to Tank Valve11 CLRO Recycle Air Break Valve10 OPRO Reject to Tank Valve9 CLRO Reject to Drain Valve8 OPRO Product to Tank Valve7 CLRO Product to Drain Valve6 OPRO Reject Valve 5 OFFRO Pump 4 OPRO Feed Valve 3 CLForce Cool Feed Valve 2 CLPretreatment Feed Valve

RO Unit



RO HEAT SANITIZATION DESCRIPTION: RO HEAT SANITIZATION FORCE COOL HEATER SCREEN: IN FORCE COOL PHASE RO SCREEN: RO LOCK-OUT


OFFHeater Element 15 OFFCirculation Pump(s) 14 OPTank Drain Valve 13 OPRaw Cold Water Valve 12 CLRO Recycle to Tank Valve11 OPRO Recycle Air Break Valve10 CLRO Reject to Tank Valve9 OPRO Reject to Drain Valve8 CLRO Product to Tank Valve7 OPRO Product to Drain Valve6 OPRO Reject Valve 5

OFFRO Pump 4 OPRO Feed Valve 3 OPForce Cool Feed Valve 2 CLPretreatment Feed Valve1

RO Unit



RO HEAT SANITIZATION DESCRIPTION: RO HEAT SANITIZATION TOX FLUSH HEATER SCREEN: IN FORCE COOL PHASE RO SCREEN: RO LOCK-OUT


OFFHeater Element 15 OFFCirculation Pump(s) 14 OPTank Drain Valve 13 CLRaw Cold Water Valve 12 CLRO Recycle to Tank Valve11 OPRO Recycle Air Break Valve10 CLRO Reject to Tank Valve 9 OPRO Reject to Drain Valve 8 CLRO Product to Tank Valve7 OPRO Product to Drain Valve6 CLRO Reject Valve 5

OFF/ONRO Pump 4 OPRO Feed Valve 3 OPForce Cool Feed Valve 2 OPPretreatment Feed Valve 1

RO Unit



RO HEAT SANITIZATION DESCRIPTION: RO HEAT SANITIZATION ENDED HEATER SCREEN: RO SANI ENDED RO SCREEN: RO RUN AVAILABLE


OFFHeater Element 15 OFF/ON -L Circulation Pump(s) 14

CLTank Drain Valve 13 CLRaw Cold Water Valve 12 CLRO Recycle to Tank Valve 11 OPRO Recycle Air Break Valve10 CLRO Reject to Tank Valve 9 OPRO Reject to Drain Valve 8

CL/OP-QRO Product to Tank Valve 7 OP/CL-QRO Product to Drain Valve6 OP/CLRO Reject Valve 5

OFF/ONRO Pump 4 OPRO Feed Valve 3 OPForce Cool Feed Valve 2 OPPretreatment Feed Valve 1

RO Unit



GENERAL LIMITED WARRANTY Mar Cor Purification and Biolab Equipment Ltd. (“Mar Cor”) warrants all products manufactured by Mar Cor

to be free from defects in material and workmanship under normal use for a period of one year from date of

shipment. Warranty is only provided when the equipment is properly maintained in accordance with Mar Cor

instructions. Our obligation shall be limited to the repair or replacement at our option of any parts we deem

defective. Consequential damages due to the failure of any part or system are not provided. Mar Cor

provides no other warranty, expressed or implied. There is no warranty of merchantability or fitness for a

particular purpose. Other manufacturer’s equipment offered, as part of any proposal shall carry the

manufacturer’s warranty. On site, labour is covered for the first 90 days. Travel time and expenses are not

covered.



CONTACT INFORMATION For further information regarding the operation or maintenance of the Mar Cor 4400M-HX - Tank Feed Hot Water Sanitization System and for ordering, please contact your local Mar Cor Purification office. When ordering replacement parts, please provide the Biolab Reference Number found on the cover page of this Manual.

UNITED STATES OF AMERICA Mar Cor Purification, Inc. 4450 Township Line Rd Skippack, PA 19474-1429 Tel: (484) 991-0220 Toll Free: (800) 346-0365 Fax: (484) 991-0230 [email protected]

---------------------------------------------------------------------------------------------------------------------------------------------- CANADA Mar Cor Purification - Biolab Equipment Ltd. 3250 Harvester Rd - Unit 6 Burlington, ON L7N 3W9 Tel: (905) 639-7025 Toll Free: (800) 268-5035 Fax: (905) 639-0425 WORLD WIDE WEB Uwww.mcpur.com

MAN-4400MHXS1 Rev. F A1-1 System Components


A1- 4400M-HX TANK FEED HOT WATER SANITIZATION SYSTEM

Heater

Optional Ultraviolet Sterilizer

HX Heater Control Panel

Tank

Vent Filter

Pyrogen Final Filter (not shown)

HMI Display

RO Pump

Pre-filter/ Inlet Filter

Membranes

RO Panel

RO Product Valve Nest

RO Recycle Valve Nest

RO Reject Valve Nest

HX Circulation Pump(s)



DESCRIPTION AND FUNCTION OF SYSTEM COMPONENTS TANK An insulated storage tank is used to store RO product water to feed the distribution loop. VENT FILTER HOUSING An insulated vent filter housing is installed on top of the tank. An electric heat trace is wrapped around the housing to keep condensation from occurring. A 0.2 micron filter cartridge is installed on the housing to filter the air entering and exiting the tank. TANK LEVEL TRANSMITTER A tank level transmitter is installed on the bottom of the tank and provides an indication of the amount of water in the tank. CIRCULATION PUMP(S) Two circulation pumps are installed on the base of the heater frame. The pumps are controlled by the PLC. A built in variable speed drive is integrally mounted on the pump and will produce the required pressure as programmed in the PLC. The water is distributed through the loop during normal and loop heat sanitization and diverted to the feed of the 4400M – PLC RO during hot water sanitization. PRESSURE TRANSMITTER A 0-100 psig pressure transmitter is installed on the discharge of the circulation pump(s). It provides indication of the pump discharge pressure. The transmitter is used to control the speed of the pump(s) during normal and heat sanitization. HEATING ELEMENT A stainless steel electric heating element is installed vertically on the back side of the frame and is installed in stainless steel housing. Water flows into the bottom of the housing and exits the top right side. The heat is turned off and on based on the water temperature set-point selected. Water continually flows through the stainless steel housing during normal operation and sanitization. TEMPERATURE TRANSMITTERS Two (one on 4400M - PLC RO) temperature transmitters are installed on the system. Their position and the purpose of the transmitter are as follows:

Loop Feed Temperature Transmitter A 0-200ºC (32-392 ºF) temperature transmitter is installed on the heater element housing discharge. It measures the temperature of the water exiting the discharge of the heater element during normal and heat sanitization. The heat element operation is controlled based on set-points programmed in the PLC.

Loop Return Temperature Transmitter A 0-200ºC (32-392 ºF) temperature transmitter is installed on the loop return prior to the return regulating valve. It measures the temperature of the water returning to the storage tank during normal and heat sanitization. The heat element operation is controlled based on set-points programmed in the PLC. 4400M Hot Product Temperature Transmitter A 0-200ºC (32-392 ºF) temperature transmitter is installed on the RO product line. It measures the temperature of the RO product during normal and heat sanitization. The heat element operation is controlled based on set-points programmed in the PLC.



ULTRAVIOLET STERILIZER One (optional position location) is installed on the back of the heater frame. It is used to control bacterial growth in the system. A local monitor measures and displays the light intensity. An alarm set point is set on the local display and is monitored by the PLC. The ultraviolet sterilizer is controlled from the PLC and is on during normal operation. PYROGEN FINAL FILTER One final stainless steel submicron filter housing is mounted off the heater skid containing 0.05µ 20” hollow membrane filters. The water exiting the heater housing passes through the filters and ensures that no endotoxin is discharged to the loop. PRESSURE GAUGE Three pressure gauges are mounted at various points on the system. Their location and purpose are as follows:

Final Filter Inlet Pressure A 0-100 psig pressure gauge is mounted on the inlet port of the final filter and provides a local indication of the pressure. Final Filter Outlet Pressure A 0-100 psig pressure gauge is mounted on the outlet port of the final filter and provides a local indication of the pressure. Subtracting the outlet by the inlet pressure will provide the filter delta pressure. Excessive delta pressure indicates that the filters are plugged and are required to be changed. Loop Return Pressure A 0-100 psig pressure gauge is mounted on the loop return prior to the back pressure regulator. It provides an indication of the back pressure on the loop.

SOLENOID VALVES Seven (one optional) solenoid valves are installed on the system. The position and purpose of the valves are as follows:

Tank Drain Valve A 1” solenoid valve is installed off a branch tee on the tank bottom connection and plumbed to drain. The valve is closed during normal operation and will open based on various control points in the PLC. Raw Cold Water Valve A 3/4” raw cold water solenoid valve mounted off the skid is plumbed to the tank common drain. This valve will automatically open when the tank drain valve is open to blend cold water with the hot water produced during a hot water sanitization. This will prevent damage to the drain material of construction and meet local plumbing regulation.

Pre-Treatment Feed Valve This solenoid valve (1” or 1 ½”) is mounted on the back of the heater. The valve will automatically open when the system is in normal operation allowing pre-treated water to enter the system and feed the 4400M - PLC RO system. Force Cool Feed Valve A ½” solenoid valve is mounted in parallel with the pre-treatment feed valve and in series with a flow control valve. The valve will automatically open during a 4400M – PLC RO force cool down.



Loop By-pass Valve A 1” solenoid valve is teed off just after the pre-treatment isolation valve. The valve will open during a 4400M – PLC RO heat sanitization and closed during normal operation and loop sanitization. Loop Isolation Valve A 1” solenoid valve is mounted just after the final filter housing prior to entering the loop. The valve will open during normal operation and loop sanitization is closed during a 4400M – PLC RO heat sanitization. Optional Loop Return By-Pass Valve A 1” solenoid valve is mounted in parallel with the loop return back pressure valve. The valve will open during a loop sanitization. This valve is used when a PEX plastic piping is installed. Back Pressure Regulating Valve A back pressure regulator is mounted on the loop return prior to returning to the tank. It is used to adjust the lowest amount of back pressure to achieve proper flow characteristics.

CONTROL PANEL The control panel is constructed from the following main components:

• Electrical enclosure • Programmable logic controller • Step Down Transformers • HMI Keypad interface and display • Pump motor protection devices • Fuses, Terminals

See APPENDIX A2 for a view of switches and indicators located on the HX heater control panel.

NOTE: Auxiliary components that interface with the system (i.e. softeners, pumps, filters, valves, tanks, gauge, etc.) are not described.

* Refer to Individual Manufacturers’ Component Manuals for detailed descriptions.

MAN-4400MHXS1 Rev. F A2-1 Control Panel Display


Circ Pump A/Cycle/B

CirculationPump B

Circulation Pump A

Circ Pump Man/Off/Auto

RO Timed Auto RunSani Manual

Start

Sanitization Complete

Local Audible Alarm

Emergency Stop

Local AlarmSilence

Reset Alarm

Sanitization In Progress

UV On/Auto

Sani Man/Off/Auto (Key Switch)

UV On

System Off/On

Tank Low

General Alarm

A2 - HEATER CONTROL PANEL DISPLAY

MAN-4400MHXS1 Rev. F A3-1 HMI Screen Navigation Flow Chart


UHOME SCREEN

General SANI Screen 1

General SANI Screen2

General SANI Screen 3

General SANI Screen4

UF1 GENREAL SCREENS

General RO Screen

UF2 SETTING SCREENS

Set Time Screen

Set Parameter Screen 1

Set Parameter Screen 2

Set Alarm Screen 1

Set Alarm Screen 2

Set Alarm Screen 3

UF3 SANI SCHEDULE SCREENS

SANI Schedule Screen 1

SANI Schedule Screen 2

UF4 RO SCHEDULE SCREENS

UF5 SECURITY SCREENS

Schedule RO Everyday Screen 1

Schedule RO Everyday Screen 2

Schedule RO Sunday Screen 1

Schedule RO Sunday Screen 2

Schedule RO Saturday Screen 1

Schedule RO Saturday Screen 2

Security Alarm List

Security Alarm History

Security Password

Security Factory Setup

Security Heater Pump Speed

Security Factory Test

Factory Screen 1

Factory Screen 2

F7

F6

UF7 INFORMATION

SCREEN

UF8 READING SCREEN

A3 - HMI SCREEN DISPLAY NAVIGATION FLOW CHART

MAN-4400MHXS1 Rev. F A4-1 Alarm Log Sheet


A4 – ALARM LOG

Time Alarm Description Corrective Measure

MAN-4400MHXS1 Rev. F A5-1 Materials of Construction


COMPONENT

STD. MATERIAL

Piping 316 SS

Tank 316 SS/EPDM

Vent Filter Housing 316 SS/Silicone

Final Filter Housing 316 SS/EPDM

Pumps 316 SS/Cast Iron/Tungsten carbide/Carbon/EPDM/Viton or Silicon carbide (Q)/Silicon carbide (Q) complete with EPDM (E) or FKM (V) seals

Solenoid Valves 316 SS/EPDM

Heater Element 316 SS

Ultraviolet Sterilizer 316 SS/Quartz/Viton

Pressure Gauges 316 SS

Valves 316 SS/Teflon

Sensors 316 SS

Vent Filter Cartridge PVDF/Polypropylene/Silicon

Final Filter Cartridge Polysulfone/Polypropylene/Polyurethane

Fittings 316 SS

Gaskets EPDM Tread Seal Teflon

Panel 304 SS

Frame 304 SS

A5 - DEVICE MATERIALS OF CONSTRUCTION

MAN-4400MHXS1 Rev. F A6-1 Water Sampling Procedure


Procedure: 1. Collect sample kits (sample containers, labels, etc). 2. Using the HX system settings, complete desired operation for which

samples are to be taken (see Table below).

WATER SAMPLE COLLECTION PORT FEED

WATER

RO PRODUCT

WATER

LOOP RETURN

SANITIZATION PRODUCT

WATER

LOOP RETURN SANITIZATION

WATER OPERATION SV2.00 SV2.01 SV4.00 SV2.01 SV4.00

NO SANITIZATION - RO MEMBRANE PERFORMANCE TESTING

RO SANITIZATION ONLY LOOP SANITIZATION ONLY RO AND LOOP SANITIZATION

3. Locate the ports where samples are to be taken (see Fig. 1 and 2 to the

right). 4. Wipe sampling ports with alcohol prior to use. 5. Open sampling port and allow water source to run freely for approximately

5 minutes. 6. 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.

7. Fill the container completely and tighten cap. 8. Check container for leaks by squeezing tightly. Repeat steps 5-7 if leaks

are found. 9. Label container as per sample in Fig. 3 (to the right). 10. Place sample in fridge immediately. 11. Submit sample to the lab in an iced cooler with accompanying paperwork

within 24 hours

URECORD OPERATION NAME & PORT NAME U

KEEP COLD S/N: ________________ Date: _______________ Time: _______________

Fig.1: Front View of RO Unit

Fig. 2: Rear View of Heater Unit

(Exact Location May Vary)

SV4.00

Fig.3: Sample Label

SV2.00

SV2.01

UNOTEU: Wear clean gloves while taking samples. Prevent mixing of any foreign particles with sample water.

MAN-4400MHXS1 Rev. F A7-1 Installation Requirements


A7 - REQUIREMENTS FOR INSTALLATION OF EXTERNAL CONNECTIONS TO THE 4400M-HX SYSTEM DRAIN CONNECTION REQUIREMENTS Facility must meet the following requirements:

• Drains must be sized for the maximum flow of the system. • Drain connections must be plumbed such that siphoning of the system will not occur. • Provide adequate air gaps for each drain connection. • Drains shall be routed in such a way to make sure the city water cooling valve from the HX

system is plumbed at the farthest point of the room‘s drain system. The ideal installation would be to have all the lines plumbed to the common drain.

• Drain material of construction must withstand temperature in excess of 85ºC (185ºF). PIPING REQUIREMENTS Installation piping that is exposed to hot water or is in contact with the product water must meet the following requirements:

• Compatible with RO product water. (316 Stainless Steel, 0.035 Inch wall tube is recommended) • Can handle water temperatures up to of 99°C (210°F). (316 Stainless Steel, 0.035 Inch wall tube

is recommended) • Stainless steel must be passivated prior to use and/or if welding is used for joining. • Material must meet the current AAMI RD62:2006 and CSA Z364.2.2-03 standards. • Piping must be routed in such a way as to minimize dead legs at points of use larger than 3

times the inside diameter of pipe. • Piping supports must have an insulated sleeve over pipe to prevent heat migration. • Exposed surfaces that cannot be insulated must be properly labeled. • The minimum flow velocity in the piping system is 3 ft/s.

PIPING INSULATION REQUIREMENTS Distribution loop piping and any other piping that can be exposed to hot water from the system must be insulated with a minimum thickness of ½ Inch. Insulation must be chloride free to prevent degradation of the stainless steel surfaces. POST-TREATMENT REQUIREMENTS To assure the maximum product quality to your process and to protect the system, the following recommendations are provided:

• Equipment that is connected to the loop must be constructed from materials that will withstand the high temperatures. Heat migration can occur even if the hot water is not flowing through the equipment.

• Exposed surfaces that cannot be insulated must be properly labeled. • Tubing between the point of use valve and the dialysis machine must be sanitized

independently. PRE-TREATMENT REQUIREMENTS

• Minimum of a 5 micron cartridge filter sized to the appropriate flow rate must be installed just prior to entering the 4400HX system.

MAN-4400MHXS1 Rev. F A7-2 Installation Requirements


FEED WATER REQUIREMENTS Feed water must meet at minimum the most current AAMI RD62:2006 and CSA Z364.2.2-03 requirements for dialysis purified water. PANEL ELECTRICAL TERMINATION Refer to the electrical schematic provided with the system. ELECTRICAL SUPPLY The equipment must be connected to a 3-phase 208VAC ± 5% Voltage fluctuation supply. The power must be free from damaging spikes, surges or sags.

MAN-4400MHXS1 Rev. F A8-1 Site Acceptance Test


A8 - SITE ACCEPTANCE TEST (SAT) PROCEDURES NOTE: This is a generic document for the Site Acceptable Test. It should be used to verify the functionality of the 4400M-HX system only. Do NOT use it for validation of the overall water system. This document must be completed by the installer upon successful start-up of the overall water system.

EXECUTION INFORMATION

Site Location:

Job # or B.M.# Date Installed:

TEST EXECUTED BY: Name: Company & Title:

Signature: Date Executed:

TEST APPROVED BY: Name: Company & Title:

Signature: Date Approved:

Instructions:

1) Verify system installation and complete the Installation Verification checklist. 2) Record the customer set-point values in the HMI Screen Settings and Default Set-points Table. 3) Place the system in the following modes and follow the instructions:

UCombo Sani Mode a) Schedule and start Combo Sani Operation in the Auto Schedule Mode. See the Quick Start

Guide in SECTION 3.3.1for instructions.

UNOTE: U Ensure the recirculation pump switch is set to the AUTO mode, the pump switch, if two recirculation pumps are used, set to the CYCLE mode and the UV lamp switch, if UV option is available, to the AUTO mode.

b) Complete the Verification Log Sheet at the end of the Combo Sani operation.

U

At the end of the test, record all discrepancies in the log sheet provided. Submit ALL documents and the Discrepancy Log Sheet to the Mar Cor Quality Department.



INSTALLATION VERIFICATION CHECKLIST

COMMENTS:

# Item Check (Yes/No)

1 The 4400M - PLC RO system is tested and ready to fill tank.

2 Electrical supply is connected and verified.

3 Interconnect and loop piping including drains are completed and verified.

4 All water piping line pressure is tested and flushed to remove debris.

5 Pretreatment devices are installed and a functional test is performed.

6 Post treatment devices are installed and a functional test is performed.

7 Final filter cartridges are installed as per instructions in SECTION 4.2.1.

8 Vent filter housing is installed as per instructions in SECTION 4.2.2.

9 Ultraviolet sterilizer lamps and quartz sleeves are installed as per instructions in SECTION 4.2.3 and SECTION 4.2.4. (If UV option is selected)

10 All tank accessories are installed and ready to receive water.

11 RO Force Cool Control Valve setting is completed as per instructions in SECTION 2.4.7.

Verified By:

Initial: Date:



HMI SCREEN SETTINGS AND DEFAULT SET-POINTS 5 Instructions: Record the actual values from the HMI screen in the “Customer Setting” Column.



Low

er L

imit

Upp

er L

imit

Def

ault

Cus

tom

er

Setti

ng

Uni

t

Low

er L

imit

Upp

er L

imit

Cus

tom

er

Setti

ng

Def

ault

Uni

t

Set System Time Screen Min. SANI Hold Time 20 120 60 min 20 120 60 min

Set System Time Screen Max. SANI Ramp Time 60 480 480 min 60 480 240 min

Set Operation Parameter Screen 1 SANI Process Level 114 189 151 L 30 50 40 US gal


Circulation Pump Normal Pressure 50 99 99 psi 50 99 99 psi


Circulation Pump RO SANI Pressure 15 25 20 psi 15 25 20 psi

Set Operation Parameter Screen 1 LOOP SANI Pressure 50 99 99 psi 50 99 99 psi


System Normal Temperature 20 49 35

P

oPC 68 120 95 P

oPF


Post SANI Cool Temperature 35 49 45

P

oPC 95 120 113 P

oPF

Set Operation Parameter Screen 2 SANI Temperature 65 85 80

P

oPC 149 185 176 P

oPF

Set Alarm Parameter Screen 2 UA4.01 Alarm Delay 0 1200 1200 second 0 1200 1200 second

Set Alarm Parameter Screen 1 SANI Temperature High SP. 90 98 95

P

oPC 194 208 203 P

oPF





Low

er L

imit

Upp

er L

imit

Def

ault

Cus

tom

er

Setti

ng

Uni

t

Low

er L

imit

Upp

er L

imit

Cus

tom

er

Setti

ng

Def

ault

Uni

t

Set Alarm Parameter Screen 1 Normal RO Stop Level 570 663 663 L 150 175 175 US gal

Set Alarm Parameter Screen 1 Normal RO Start Level 380 570 570 L 100 150 150 US gal

Set Alarm Parameter Screen 1 Normal Low Tank Alarm 190 285 285 L 50 75 75 US gal

Set Alarm Parameter Screen 2 RO SANI Pressure High 25 40 30 psi 25 40 30 psi

Set Alarm Parameter Screen 2 RO SANI Pressure Low 5 15 10 psi 5 15 10 psi

Set Alarm Parameter Screen 2 Loop GEN Pressure High 60 99 80 psi 60 99 80 psi

Set Alarm Parameter Screen 2 Loop SANI Pressure Low 10 60 10 psi 10 60 10 psi


LOOP Feed Low Quality Alert 5 50 30

μS/cm 5 50 30 μS/cm


LOOP Feed Low Quality Alarm 30 100 60

μS/cm 30 100 60 μS/cm

Security Factory Setup Screen Heat Loss Compensate 5 20 5

P

oPC 9 27 9 P

oPF

Verified By:

Initial: Date:



VERIFICATION LOG SHEET FOR COMBO SANI (LOOP & RO)

Sani Start Time: Sani Complete Time: Total Sani Time (hours:mins) :

Sanitization Complete Light came on? (Green Light ON) YES / NO

Verified By: Initial: Date:

Instructions (1) Allow the system to transition from Loop Sani to RO Sani to the RO Sani End phase. (2) Record the results below upon completion of RO Sani phase. When “Actual Results” match “Expected Results” circle “YES” in the “Actual Results Match’ column. If there is a discrepancy between “Expected Results” and “Actual Results”, circle “NO” in the “Actual Results Match” column and log it in the Discrepancy Log provided.



DISCREPANCY LOG

Instructions For every discrepancy that is found during this SAT, a discrepancy log entry shall be generated. Describe the discrepancy; keep the description concise, other rows can be used if necessary. Describe the discrepancy resolution; keep the description concise, other rows can be used if necessary. The person responsible for the correction initials and dates when the discrepancy is resolved.

Discrepancy Log Page ___ of ___

Responsibility No. Description of Discrepancy Discrepancy Resolution Party(ies) Date

Complete By (Initial/Date)

MAN-4400MHXS1 Rev. F A9-1 Spare Parts List


A9 - SPARE PARTS LIST

4400HX-S1 Spare Parts List

Tag # Part # Part Description AI/TI4.00 20-00441865 Controller - Conductivity / Temperature Sensor

F4.01 50-203 Filter Cartridge - Pyrogen Filter F4.0 ZCTP1-020CF-P Filter Cartridge - Vent Filter

F1 AJT70 Fuse - 70A/600V HX Control Panel, Main Disconnect

F2 ATQR10 Fuse - 10A/600V HX Control Panel F3, F4 ATDR15 Fuse - 15A/600V HX Control Panel

F6 AJT50 Fuse - 50A/600V HX Control Panel F7,F9 MDA-6 Fuse - 6A/250V HX Control Panel

F8 MDA-4 Fuse - 4A/250V HX Control Panel F16 MDA-0.5 Fuse - 0.5A/250V HX Control Panel

F11,F12,F13,F14, F15, F20 MDA-1 Fuse - 1A/250V HX Control Panel F10, F17, F18, F19 MDA-3 Fuse - 3A/250V HX Control Panel

HX 4.00 CXI315F332R-001 Heater, 15KW, 208/3/60

PE/PT4.00 8363515 Pressure Transmitter - C-10 SS, 0-100psi, 1/4" MNPT, 4-20mA

P4.00/4.01 G4JZ20127 Pumps, CHIE 4-60 Multi-Stage, BQBV 1.5hp, 230/1/60, 1-1/4" FNPT

AE/TE4.00 20-00477361 Sensor - Conductivity / Temperature, 1μS/cm - 1mS/cm, 1/2" MNPT

YV4.00,4.02,4.03, 4.04 163019 Seal & Repair Kit for 1" Solenoid Valve Burkert Type 6213 P/N 458729P

YV4.09 151003 Seal & Repair Kit for 1/2" Solenoid Valve Burkert Type 6213 P/N 458741K

YV4.00 458729P Solenoid Valve, 1" Pretreatment Feed Valve, Burkert Type 6213 SS

YV4.02 458729P Solenoid Valve, 1" Tank Drain Valve, Burkert Type 6213 SS

YV4.03 458729P Solenoid Valve, 1" Loop By-Pass Valve, Burkert Type 6213 SS

YV4.04 458729P Solenoid Valve, 1" Loop Isolation Valve, Burkert Type 6213 SS

YV4.08 (Field Installed) Solenoid Valve, 3/4" Raw Cold Water Valve, Burkert Type 6213

YV4.09 458721F Solenoid Valve, 1/2" Force Cool Valve, Burkert Type 6213 SS

TE4.01, TE4.02 3ESBK1-5BWPZZYZM Temperature Sensor Probe, RTD 1/4" Dia. X 1.5" Probe Length

TT4.01, TT4.02 8H30-200C4Z Temperature Transmitter, 4-20mA (TE/TT 4.02 is installed on RO Product line)

UV4.00 16518 UV - Ballast, 120V UV4.00 3084 UV - Lamps, Standard, DE 254nm Mauve, 30" UV4.00 16458 UV - O-Ring, Viton UV4.00 3184 UV - Quartz Sleeve UV4.00 15843 UV - Running Time Meter, 120V



6 Customer System Notes

4400hx ro type s1 manual

Documents