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Millipore Water Filtration Instructions
Millipore Water Filtration Instructions
AFS-8D AFS-16D
User Manual
Notice
The information in this document is subject to change without notice and should not be construed as a commitment by Millipore Corporation. Millipore Corporation assumes no responsibility for any errors that might appear in this document. This manual is believed to be complete and accurate at the time of publication. In no event shall Millipore Corporation be liable for incidental or consequential damages in connection with or arising from the use of this manual. We manufacture and sell water purification systems designed to produce pure or ultrapure water with specific characteristics (mS/cm, T, TOC, CFU/ml, Eu/ml, etc...) when it leaves the water purification system provided that the systems are fed with water quality within specifications, and properly maintained as required by the supplier. We do not warrant these systems for any specific applications. It is up to the end user to determine if the quality of the water produced by our systems matches his expectations, fits with norms / legal requirements and to bear responsibility resulting from the usage of the water
Copyright Copyright 2003, all rights reserved, Millipore Corporation. Documentation : PF08616 (Rev 2 - 11/05) CD-ROM : PF08884 (Rev 2 - 11/05) Manufacturer: Millipore S.A.S., 67120 Molsheim, France
Trademarks Millipore is a registered trademark of Millipore Corporation. AFS, Millipak, Millex and Q-Gard are registered trademarks of Millipore Corporation. Progard and RoClean are trademarks of Millipore Corporation. Teflon is a registered trademark of E.I. du Pont de Nemours & Co. All other trademarks are trademarks of their respective manufacturer.
ii
Warranty
Millipore Corporation (Millipore) warrants the products manufactured by it against defects in materials and workmanship when used in accordance with the applicable instructions for a period of one year from the date of shipment of the products. MILLIPORE MAKES NO OTHER WARRANTY, EXPRESSED OR IMPLIED. THERE IS NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. The warranty provided herein and the data, specification and descriptions of Millipore products appearing in Millipores published catalogues and product literature may not be altered except by express written agreement signed by an officer of Millipore. Representations, oral or written, which are inconsistent with this warranty or such publications are not authorized and if given, should not be relied upon. In the event of a breach of the foregoing warranty, Millipores sole obligation shall be to repair or replace, at its option, any product or part thereof that proves defective in materials or workmanship within the warranty period, provided the customer notifies Millipore promptly of any such defect. The exclusive remedy provided herein shall not be deemed to have failed of its essential purpose so long as Millipore is willing to repair or replace any nonconforming Millipore product or part. Millipore shall not be liable for consequential damages resulting from economic loss or property damages sustained by a customer from the use of its products. However, in some states the purchaser may have rights under state law in addition to those provided by this warranty.
iii
AFS 8-8D-16-16D
The system mentioned above is manufactured in Millipore SAS - 67120 Molsheim - FRANCE -facilities whose quality management system is approved by an accredited registering body to the ISO9001 Quality System Standards. We certify that these Lab Water Systems are designed and manufactured in application of the following European Council directives : - 89/336/CEE relating to Electromagnetic compatibility - 73/23/CEE relating to electrical equipment designed for use within certain voltage limits
Standards to which conformity is declared as applicable are the following : - EN 55022 Class B: 1998: Limits and method of radio-disturbance characteristics of information technology equipments - EN 50082-1: 1997: Electromagnetic compatibility: generic immunity standard - EN 61000-3-2 Edition 1995/ A1 and A2 EDITION 1998/ A14 Edition 2000: Limits for harmonic current emissions (equipment input current up to and including 16A per phase) - EN 61000-3-3 Edition 1995: Limitation of voltage fluctuation and flicker in low-voltage supply systems for equipment with rated current of 16 A. - EN 61010-1: 1993 /A2: 1995: Safety requirements for electrical equipment for measurement, control and laboratory use.
Guy REYMANN
iv
Directive 2002/96 EC: For European users only The symbol crossed bin on a product or its packaging indicates that the product should not be treated like household waste when discarded. Instead the product should be disposed of at a location that handles discarded electric or electronic equipment. Proper disposal of equipment containing electric or electronic components will help to reduce pollution effects to the environment or to human health. Proper recycling of these products helps in environmental preservation and helps to protect natural resources. For more information about recycling of products containing electric or electronic components, please contact your local recycling representative or organisation.
TABLE OF CONTENTS
CHAPTER 1
1-1 1-2 1-3 1-4 1-5
INTRODUCTION .............................................................................1
USING THIS MANUAL ................................................................................................................. 1 GENERAL INFORMATION ............................................................................................................. 2 FLOW SCHEMATIC .................................................................................................................... 2 OPERATING PRINCIPLE ................................................................................................................ 3 SPECIFICATIONS ....................................................................................................................... 3
Electrical specifications .................................................................................................................. 3 Water connections ....................................................................................................................... 3 Feed water requirements * ............................................................................................................. 4 Environmental Specifications ........................................................................................................... 4 Product Water Quality and Product Water Flowrate Specifications ......................................................... 4 Dissolved Gas Based Upon the Measured Oxygen (O2) Content (AFS-8D and AFS-16D) ........................... 5 Dimensions and Weight ................................................................................................................ 5
1-6 CONTACTING MILLIPORE ............................................................................................................ 6
CHAPTER 2
2-1
OPERATION ..................................................................................7
CHAPTER 3
3-1
MAINTENANCE ............................................................................11
Installing the Millex Tank Vent Filter on the 10 Liter tank ...................................................................... 14 Cleaning of the Screen filter.......................................................................................................... 15
3-2 ROUTINE MAINTENANCE .......................................................................................................... 15
Chlorine Sanitization of the reverse osmosis cartridge ........................................................................ 15 pH cleaning of the reverse osmosis cartridge ................................................................................... 16
AFS-8 - AFS-8D - AFS-16 - AFS-16D vi
TABLE OF CONTENTS
CHAPTER 4 CHAPTER 5 TROUBLESHOOTING ......................................................................17 ORDERING INFORMATION ..............................................................21
SYSTEMS:............................................................................................21
CHAPTER 6
APPENDIX A
APPENDIXES ................................................................................22
INSTALLATION ...............................................................................................................22
16D
DAILY MAINTENANCE LOG SHEETS .......................................................................................33 MONITORING BACTERIA LEVELS IN WATER ..............................................................................36
INDEX .........................................................................................................................................37
vii
INTRODUCTION
Chapter 1
1-1
INTRODUCTION
This manual is for the Analyzer Feed System 8 and 16 (AFS 8, 8D, 16, 16D). AFS will be used to refer to the AFS 8, AFS 8D, AFS 16, and AFS 16D system unless specified in the text. Please review the manual before using the system. The INSTALLATION section is located in Appendix A. Since the INSTALLATION section is normally used only one time, this will provide quicker access to the Operating and Troubleshooting sections in the future. There are locations in the text which refer the user to certain Figures. These are located at the end of the manual. These warning symbols are placed at certain points of the manual to draw your attention to actions where a risk of damage to the system or possible personal injury can occur. Safety Symbols found in this manual or on the Water System Cabinet:
Symbol
What it means This HAZARD symbol is used to refer to instructions in this manual that need to be done safely and carefully. This ATTENTION symbol is used to refer to instructions in this manual that need to be done carefully. This DANGER sticker is used to refer to a position on the AFS System Cabinet or inside of it that could be hazardous. This ELECTRICAL GROUND sticker is used to refer to a position on the AFS System Cabinet or inside where an electrical ground connection is made. This ELECTRICAL DANGER sticker is used to refer to a position on the AFS System Cabinet or inside where an electrical danger could exist.
The AFS is a water purification system that produces NCCLS Type I Product Water directly from potable tap water. These parameters are listed in the table below. The system combines Reverse Osmosis (RO) and Ion Exchange technology to accomplish this. The product water then feeds the analyzer directly, without any extra user interaction. A flow schematic is shown in the following section. The AFS system is designed to produce NCCLS Type I quality water. NCCLS Type I water guidelines are as follows:
Parameter Maximum Bacterial Content Minimum Resistivity Maximum Silicate Level Particulate Matter Organic Contaminants pH
0.05 mg/L 0.22 micron filter Activated carbon*** or Reverse Osmosis or Distillation Not Specified
* CFU/ml = Colony Forming Units per ml ** M.cm = Megohm.cm compensated to 25 C *** Not required by CAP NCCLS stands for the National Committee for Clinical Laboratory Standards CAP stands for the College of American Pathologists
1-3
FLOW SCHEMATIC
TAP WATER
10 L TANK
RO PUMP
RO
DISTRIBUTION PUMP
QGARD A CARTRIDGE
BACTERIA FILTER
RO REJECT
PRODUCT WATER
Potable tap water enters the Progard 3 Pretreatment Pack. The Progard 3 is used to prevent mineral scaling, organic fouling and chlorine oxidation of the Reverse Osmosis (RO) cartridge. The Progard 3 is a consumable item. The RO Pump is used to boost the tap water pressure. This will create more permeate flow from the RO cartridge. The RO cartridge removes a large percentage of ions from the tap water. In addition, a large percentage of bacteria and organic material is removed by the RO cartridge. The RO has a waste (reject) stream which is directed to drain. All ions, bacteria and organic material removed by the RO are directed to the waste stream. The permeate flow from the RO is stored temporarily in the 10 Liter (L) Tank. When AFS Product Water is sent to the analyzer, the water pressure in the tubing between the AFS and the analyzer will decrease. A pressure switch located inside the AFS will sense the drop in pressure and turn on the Distribution Pump. This pump is used to send water from the 10 L tank through the Q-Gard A Cartridge, Degasser, and the Bacteria Filter. The Q-Gard A Cartridge contains ion exchange resin and other purification media which remove trace ions and trace organic molecules from the water stored in the 10 L Tank. The Q-Gard A Cartridge is a consumable item. The Degasser is an item that removes trapped gas found in the product water. The Bacteria Filter is a consumable item that removes bacteria and any particles larger than 0.05 m in the Product Water. NOTE: Millipore water systems are designed to stay in operation mode and will perform best as such. The systems should be placed in Standby mode or switched off ONLY for maintenance or repairs.
1-5
SPECIFICATIONS
50/60 Hz 60 Hz 50/60 Hz main fuse: 2.0 Amp T (Time Lag) (5x20mm) Power: 70 VA main fuse: 2.0 Amp T (5x20mm) Power: 70 VA main fuse: 1.0 Amp T (5x20mm) Power: 70 VA
ELECTRICAL SPECIFICATIONS
100 10% VAC 120 10% VAC 230 10% VAC
Internal Fuses (All Systems): 1.0 Amp T (5x20mm) (All Internal Fuses must be replaced by authorized Millipore personnel only)
The electrical source must be located within 1 meter (m.) from the system. The electrical source must also be earth grounded.
WATER CONNECTIONS
Feed water connection (Customer Must Supply 1/2 inch Female National Pipe Thread (FNPT) Connection To This Fitting) 8 millimeters (mm) outer diameter (OD), length: 2 meters (m) maximum (6.5 ft. (feet)) 8 mm OD, length: 4 m. maximum (13 ft.) Cannot exceed 1 m (3 ft.) above system 6 mm OD, length: 2.0 m. maximum (6.5 ft.) 6 mm OD, lentgh: 2.0 m. maximum (6.5 ft.) 8 mm OD, length: 2.5 m. maximum (8 ft.) 120 liters per hour (LPH)
Feed water tubing Reject tubing - Maximum height of Reject tubing Product water tubing Product Line Drain Valve tubing Emergency Kit tubing Drain capacity
INTRODUCTION
FEED WATER REQUIREMENTS *
Minimum pressure and flowrate Maximum feed water pressure Conductivity Temperature pH Fouling Index (SDI) Total chlorine 1.5 bar (22 psi) at 120 LPH ** 3.0 bar (50 psi) < 2000 s/cm 2 - 35 C (35.6 - 95 F) 4 - 10 <5 1.0 ppm without PrePak < 3 ppm with PrePak
The pretreatment pack (Progard 3) has been developed to be fed with potable water meeting the specifications above. Additional pretreatment or pre-filtration may be necessary when these levels are exceeded or due to specific local water characteristics. Call Your Local Millipore Office for additional information.
** Call Your Local Millipore Office if the Tap water pressure is below 1.5 bar (22 psi) at 120 LPH
ENVIRONMENTAL SPECIFICATIONS
Indoor Use Only Storage Temperature Operating Temperature Relative Humidity Altitude Installation Category Pollution Degree 5 C < T < 40 C 5 C < T < 40 C Should not exceed 80% for temperatures below 31 C Should stay within 50% to 80% between 31 C and 40 C. < 3000 metres II 2
97 % - 94 %
> 99 %
> 99 %
10 CFU/ml
>10 M-cm @ 25 C
INTRODUCTION
The specifications shown above are dependent on the maintenance and operating status of the RO membrane.
Reject Flow Rate 7 C < T < 30 C AFS 8(D) 20 LPH AFS 16(D) 25 LPH
Peak Dispensing rate of Product Water (to atmosphere) Up to 0.6 Liters per minute for 18 minutes
Maximum Product Pressure AFS 8D, 16D 1 bar (15 psi) AFS 8, 16 2 bar (30 psi)
DISSOLVED GAS BASED UPON THE MEASURED OXYGEN (O2) CONTENT (AFS-8D AFS-16D)
Adjustable down to approximately 3 parts per million (ppm).
AND
MANUFACTURING SITE
Millipore SAS 67120 Molsheim FRANCE
OPERATION
Chapter 2
2-1
OPERATION
The keypad (Figure 1, A) allows you to interface with the system. Changing the software modes, reviewing the systems performance, and initiating maintenance procedures can be done via the keypad. The results of your actions can be seen on the display (Figure 1, B) located directly above the keypad.
Hold the OPERATE / STANDBY button down for 2 seconds. The display will show the changes from one operating mode to another (see the descriptions of these operating modes below). STANDBY: This operating mode is displayed when the system is not operating any of the internal components. Normally this operating mode is used when starting a maintenance procedure. The system performs an automatic flush of the RO cartridge every 6 hours (all operating modes). The flush mode rinses the RO to remove anything that has built up on the membrane surface. No water will be sent to the analyzer when the system is in this mode.
S T AND B Y
F I L L I NG
T A NK 21 . 3 C
>1 0 M c m
FILLING TANK: This operating mode is displayed when the 10 Liter tank is being filled with RO water. If the analyzer requires water, the distribution pump will send the water to the analyzer as needed. TANK FULL: This operating mode is displayed when the 10 Liter Tank is full of RO permeate water. If the analyzer requires water, the distribution pump will send the water to the analyzer as needed. PRODUCTION: This operating mode is displayed when water is being sent from the AFS to the analyzer. The AFS switches automatically to PRODUCTION mode if the system is in TANK FULL or in FILLING TANK mode. The Resistivity of the product water is shown in the bottom left corner of the display. The displayed resistivity is temperature compensated to 25 C. The actual temperature of the product water is displayed in the bottom right corner of the display.
T ANK
FUL L 21 . 3 C
>1 0 M c m
P R O D U C T I ON >1 0 M c m 21 . 3 C
P R O D U C T I ON DI SP . T I ME OV E R
You can get product water from the AFS for a maximum of 18 continuous minutes. This is a software feature which prevents the Distribution Pump from running dry. The Distribution Pump will stop after 18 minutes of continuous use. DISP. TIME OVER (Dispensing Time Over) will alternate with PRESS OPERATE in the display. You must change the system into STANDBY mode in order to reset the timer. (Hold down the OPERATE/STANDBY button for two seconds). After the timer is reset, the AFS should be changed to FILLING TANK or TANK FULL mode so that water can be sent to the analyzer if needed. DISP TIME OVER will reset automatically as soon as the tank is full. If you use a tank greater than 10 liters, contact your local Millipore office.
OPERATION
MEASURE BUTTON
OPERATE MEASURE STANDBY CLEANING MENU
The Measure Button allows you to see various water quality related parameters.
MODE
Various measurements are made when the Tank is being filled with permeate water from the RO membrane. Reminder: The permeate from the RO membrane is not the final product water.
RO PRES: 4 .0bar R E J E C T I ON: 97. 9%
Press the MEASURE button The top line of the display will show the pressure of the water that is going into the RO cartridge. This pressure results from the RO Pump increasing the tap water pressure. The bottom line of the display shows the ionic percent rejection of the RO membrane. This is determined using the feedwater conductivity and permeate conductivity values. The RO ionic % rejection represents the percentage of ions that are rejected by the RO membrane and then sent to the drain. Press the MEASURE button again The top line of the display shows the pressure of the water that is going into the RO cartridge. The electrical conductivity of the RO feed water is shown on the bottom line of the display. Press the MEASURE button again The top line of the display shows the pressure of the water that is going into the RO cartridge. The electrical conductivity of the RO permeate water is shown on the bottom line of the display. Press the MEASURE button again The system returns to FILLING TANK or TANK FULL mode.
F I L L I NG
T A NK 21 . 3 C
>1 0 M c m
CLEANING BUTTON
OPERATE MEASURE STANDBY CLEANING MENU
The Cleaning button is used to initiate either the Chlorine Sanitization cycle or the pH Cleaning cycle. A complete description of both cycles can be found in the Maintenance Section of this manual.
OPERATION
MENU BUTTON
OPERATE MEASURE STANDBY CLEANING MENU
The Menu Button can be used to access various Customer Menus (example: changing the displayed language). Hold down the MENU button for 2 seconds to access the Customer Menu. The Customer Menu can be accessed in any Operating Mode PAK LIFE The first screen shows the number of days remaining before the Progard 3 Pretreatment Pack needs to be exchanged. The number of days remaining is calculated by both a day-by-day timer and a measurement of water usage by the system. The number of days will count down (decrease). When a new Progard 3 Pretreatment Pack is installed, the display will show NO DATA for seven days. This message is necessary so the system can determine an accurate rate of water usage. Press the MENU Button. This scrolls the display over to the OPTIONS portion of the Customer Menu. LANGUAGE This gives you the option to change the language seen on the display. The Arrow Buttons (MEASURE or CLEANING) can be used to scroll between various languages. The languages that can be chosen include English, Franais (French), Deutsch (German), Italiano (Italian), Espaol (Spanish), and Japanese. Press the OPERATE / STANDBY Keypad Button to scroll down to the next choice in the OPTIONS selection. EXTERNAL ALARM An external alarm (buzzer, light, etc.) can be connected to the AFS system. When an Alarm or Service message is shown on the display, the system will send either a 100/120/230 volt signal to an external alarm connected to the system. The voltage of the signal depends upon the voltage supplied to the system. Use the Arrow Buttons (MEASURE or CLEANING) to activate (ON) or deactivate (OFF) the External Alarm.
S ERV I CE : L I F E T I M E PAK L I FE 25 DA Y S
S ERV I CE : L I F E T I M E PAK L I FE NO D A T A
MENU
S E R V I C E : O P T I ON S L A NGU A G E E NG L I S H
OPERATE
STANDBY
S E R V I C E : O P T I ON S E X T . ALARM : OF F
OPERATE
STANDBY
Press the OPERATE / STANDBY Keypad Button to scroll down to the next choice in the OPTIONS selection. PRESSURE UNITS You can change the units that are displayed for the pressure measurement when the system is in operation. Use the Arrow Buttons (MEASURE or CLEANING) to choose between bar, psi or kPa. Press the OPERATE / STANDBY Keypad Button to scroll down to the next choice in the OPTIONS selection.
S E R V I C E : OP T I O N S P R E S . UN I T : b a r
OPERATE
STANDBY
OPERATION
RESISTIVITY OR CONDUCTIVITY DISPLAY
S E R V I C E : O P T I ON S P R OD . U N I T : M c m
This option changes the displayed units during PRODUCTION mode. These units include resistivity (M.cm) or conductivity (S/cm). Use the Arrow Keypad Buttons (Measure and Cleaning) to choose between M.cm or S/cm. NOTE: When you scroll to the following menu option, you will have 10 seconds before the software automatically starts the System Rinse. In order to prevent this from happening, press the MENU again before the end of 10 seconds.
MENU
Press the MENU Keypad Button to scroll over to the next menu option.
SYSTEM RINSE
S E R V I C E : F U NC T I ON SYSTEM R I NS E
The System Rinse starts automatically after a 10 second delay. If you want to start a 240 minute System Rinse, wait 10 seconds when this display is shown. If you accidentally start a System Rinse and want to cancel it, call Your Local Millipore Office for assistance. The purpose of the System Rinse is to rinse the preservatives in the RO membrane. The 10 Liter Tank will not fill during the 240 minutes of the System Rinse. NOTE: Poor water quality could result if a new RO cartridge is not rinsed for the required time.
MENU
Press the MENU Keypad Button to scroll over to the next menu option.
PRINTER It is possible to print out various information about the AFS Water System. A cable is necessary to connect between the AFS and a printer. The cable is not supplied with the AFS. Call Your Local Millipore Office for further information regarding the cable and use of the printer function.
MENU
Press the MENU Keypad Button to exit the Customer Menu. STANDBY, FILLING TANK, TANK FULL, or PRODUCTION mode should be shown on the display.
10
MAINTENANCE
Chapter 3
3-1
MAINTENANCE
The following table is a quick reference for when the consumables (packs, cartridges, and filters) should be exchanged. Whenever a service or alarm LED is lit, see the Troubleshooting section for a detailed description of the problem and possible solutions. The procedures for replacing the packs and filters are described after the table. See "Ordering Information" for the correct catalogue numbers.
Consumable names
When to change the Consumables (See Troubleshooting Section for more information if the system is producing Low Flow) Replace the Progard when the message "EXCHANGE PROGARD" is shown on the display. Also replace the Progard if the system has been turned off for more than 48 hours. System should be powered on and in STANDBY mode when the Progard is replaced.
Bacteria Filter
Replace the Simfilter or Millipak when the Progard is exchanged (See above)
Q-Gard A Cartridge
Replace the Q-Gard A Cartridge when the system displays "EXCHANGE CARTRIDGE" message. Replace it only after opening the manual Product Line Drain Valve and draining any water that may have stayed stagnant in the cartridge.
11
MAINTENANCE
Q-GARD A CARTRIDGE
(See Figure 2) What you will need: Q-Gard A Cartridge, at least 5 liters of water in the Tank (approximately half the Tank). 1. 2. 3. 4. Make sure the AFS system is in STANDBY mode. Wait for the STANDBY display to stop flashing if necessary. Open the Product Line Drain Valve (Figure 4) and release any pressure in the distribution tubing. Close the Product Line Drain Valve. If there is a Q-Gard A installed, wait until the STANDBY display stops flashing lift the pack adapter cover (E) to the top position remove the metal locking clip pull out the Q-Gard A Cartridge
5. 6.
Remove the protective caps from the new Q-Gard A Cartridge (D), and wet the pack o-rings using a few drops of purified water. Slide the pack onto the metal guide pin (F). - Lift up the pack slightly in order to push the bottom of the pack into the slot at the bottom of the system. - Push the pack completely onto the pack adapter. The metal guide pin (D) should be visible now. Lock the pack in place with the metal locking clip on the end of the metal guide pin (F). Lower the adapter cover (E) over the newly installed Q-Gard A Cartridge. Press the OPERATE / STANDBY button to change the system into FILLING TANK or TANK FULL mode. The system may initially display PRODUCTION until the pressure rises.
7. 8. 9.
10. With the tubing from the Product Line Drain Valve secure in the drain, open the Product Line Drain Valve to change the system into PRODUCTION mode. 11. Allow approximately 5 Liters of water (half of the Tank) to pass through the Q-Gard A Cartridge in order to rinse the ion exchange resin correctly.
12
MAINTENANCE
BACTERIA FILTER
MILLIPAK
The Millipak should be changed at the same time as the Progard 3. The Millipak can be used immediately after installation. 1. 2. 3. Make sure the AFS system is in STANDBY mode. Wait for the STANDBY display to stop flashing if necessary. Remove the O-ring used to affix the Millipak to the bracket. Unscrew the fittings on both ends of the Millipak. Screw the Millipak (clear side up) into the top and bottom connectors and finger-tighten the connections. Secure the Millipak on the bracket using the O-ring. Discard the old Millipak. Press the OPERATE / STANDBY button to change the system into FILLING TANK or TANK FULL mode. The system may initially display PRODUCTION until the pressure rises. With the tubing from the Product Line Drain Valve secure in the drain, open the Product Line Drain Valve to change the system into PRODUCTION mode. Verify that there are no visible leaks after the Millipak fills. Vent the Millipak after filling.
4.
5.
6.
SIMFILTER
Fitting
Tubing from AFS
SIMFILTER
The Simfilter should be changed at the same time as the Progard 3. The Simfilter can be used immediately after installation. 1. Locate the Quick Disconnect Fitting which is normally connected to the analyzer. Separate the fitting by pushing down on the metal piece and pulling the fitting apart. If a Quick Disconnect fitting is not used, remove the tubing connected to the fitting on the analyzer. Unscrew the metal nut and remove the tubing from the Quick Disconnect fitting. Screw the nut back on the fitting so it does not get misplaced. Connected directly onto the Simfilter is a fitting. Unscrew the nut and remove the tubing coming from the AFS. Discard the Simfilter, including the attached fitting. The new Simfilter comes with a fitting and tubing already attached. The new Simfilter can be installed at this time. Unscrew the nut from the fitting and place the nut on the tubing coming from the AFS. Push the tubing onto the fitting on the Simfilter. Screw the nut back onto the fitting to secure the tubing. Connect the tubing on the other side of the Simfilter to the fitting connected to the analyzer. If this fitting is the Quick Disconnect fitting coming with the system, follow the instructions below: 1. Unscrew the nut on the Quick Disconnect fitting 2. Slide the nut onto the tubing from the Simfilter 3. Push the tubing onto the fitting 4. Tighten the nut onto the fitting so that the tubing is locked into place 5. Reconnect the Quick Disconnect fitting to the analyzer
2. 3.
4. 5. 6.
13
MAINTENANCE
2.
14
MAINTENANCE
CLEANING OF THE SCREEN FILTER
If possible, the screen filter should be cleaned each time the Progard 3 is replaced. Cleaning the screen filter will allow a better flowrate to reach the system. It also aides in preventing any large foreign particles from causing damage to the system. The screen filter is in the 1/2 inch FNPT fitting connected to the feed water valve. This is the valve which supplies water to the system. 1. 2. 3. 4. 5. 6. 7. Put system into STANDBY mode. Hold the OPERATE / STANDBY button down for two seconds if you are in one of the operating modes Close the feed water valve. Disconnect the tubing from the fitting connected to the feed water. Unscrew the fitting from the 1/2 inch FNPT fitting connected to the feed water. Locate the screen filter. Clean the screen filter to remove any particles that were trapped by the filter. This can be done by running water through it in the opposite direction as normal. Reconnect the tubing to the feed water. More Teflon tape may be needed on the 1/2 inch MNPT fitting to prevent leaks. Open the feed water valve.
3-2
ROUTINE MAINTENANCE
Hold the CLEANING button down for two seconds. The chlorine cleaning cycle starts after a 10 second delay. The remaining time of the cleaning cycle is displayed. NOTE: During the cleaning cycle, water can be drawn from the 10 Liter tank to feed the analyzer. The cleaning cycle is 15 minutes. At the end of this cycle the system automatically changes to FILLING TANK or TANK FULL mode
Cl
C L EAN
1 4 mn
15
MAINTENANCE
PH CLEANING OF THE REVERSE OSMOSIS CARTRIDGE
A pH cleaning should be performed as needed. If the % ionic rejection drops several points or if the flow rate coming from the AFS has decreased, a pH cleaning of the RO could renew the cartridge. Use the RoClean-A (acid) once a month or when necessary when the feedwater entering the AFS has a high level of hardness. A high level of hardness is defined as > 150 ppm Calcium / Magnesium and > 30 ppm Alkalinity Use the RoClean -B (base) once a month or when necessary in order to remove organic buildup on the membrane. It is recommended to use the RoClean -B if the Fouling index of the feedwater is greater than 5. 1. 2. 3. 4. Place the system in STANDBY mode by holding the OPERATE / STANDBY button down for 2 seconds. The STANDBY display flashes to indicate depressurization of the system. Once the STANDBY display stops flashing, unscrew the sanitization port plug (Figure 1, C) and add the RoClean -A or RoClean -B cleaning pouch. Screw the sanitization port plug back in place. Start the additional cleaning cycle as follows:
CLEANING MENU
Cl
C L EAN
pH
C L EAN
The pH cleaning cycle will start after a 10 second delay. The remaining time of the cleaning cycle is displayed. NOTE: During the pH cleaning cycle, water can be drawn from the 10 Liter tank to feed the analyzer. The pH cleaning cycle is 90 minutes. At the end of this cycle the system automatically changes to FILLING TANK mode or TANK FULL mode.
16
TROUBLESHOOTING
Chapter 4
WHATS WRONG ? Display is empty. Green Power LED is off.
TROUBLESHOOTING
WHAT CAUSED THIS ? Power Switch turned off. Power Cord not plugged in. No source of electrical power. Blown fuse on water system. HOW TO FIX IT Check power switch on back of system. Check that power cord is plugged in. Check the source of electrical power. Replace fuse on the back of the system. System will change into PRODUCTION mode when the analyzer starts to draw water and the system was in FILLING TANK or TANK FULL mode. Check water level in 10 l reservoir. Check all external tubing. When tank is full, put the system into PRODUCTION mode by opening the Product Line Drain Valve between the system and the analyzer. Allow water to fill the Q-Gard A Cartridge. Open the Product Line Drain Valve to see it there is a lot of flow going to drain. If there is, then the Simfilter is clogged and should be replaced. Locate the air vent valve on the top side (clear side) of the MilliPak. Open this slowly, but do not remove it from the MilliPak. Allow any air on the clear side of the MilliPak to be vented out. Measure water flow and without Millipak installed. Change Millipak and air vent out. Blown Motor fuse or Voltage setting is too low on Interface PC Board Call Your Local Millipore Office. If the solutions above have been tried without any success, call Your Local Millipore Office and follow the instructions on how to use the EMERGENCY KIT if water is needed.
Low Water Flow from system. Water flow to analyzer is < 500 ml/min.
10 L tank is empty of water. Tubing to/from the Tank is kinked. Q-Gard A Cartridge is not full of water (recently installed).
Millipak is airlocked
Millipak is clogged and will not allow water through it. Distribution Pump voltage low or pump is not operating.
17
TROUBLESHOOTING
WHATS WRONG ? No aeration of 10 Liter tank WHAT CAUSED THIS ? No aeration pump installed Filter is clogged HOW TO FIX IT Order AerationPump if desired Water can not pass through the Millex membrane. Remove the Millex filter, allow the pump to run for 30 seconds without the filter to force out any trapped water. Install a new Millex
Open the Product Line Drain Valve and put the system into PRODUCTION for several minutes Go to Appendix C, To Increase the Vacuum Level
REJECTION < S.P. is displayed. The red Alarm LED is flashing. The system continues to operate.
The RO cartridge % ionic rejection is below a pre-specified setpoint in the software (normally 90%). This condition has to exist for 3-6 minutes for the alarm to be displayed.
Clean the RO cartridge with an Acid or Base Cleaner (RoClean -A or RoClean -B) depending upon feedwater. Check RO % rejection setpoint in software Call Your Local Millipore Office.
PRODUCT < S.P. is displayed. The Red Alarm LED is flashing. The system continues to operate.
Resistivity of the AFS Product water is below a pre-specified setpoint in the software. This occurs when the resistivity (compensated to 25 C) is below the resistivity setpoint for at least four times of a duration of 5 seconds or more.
Open the Product Line Drain Valve between the AFS and the analyzer. Allow some water to rinse the Q-Gard A Cartridge and go to drain. If the procedure above does not increase the Resistivity, replace Q-Gard A Cartridge ion exchange resin is exhausted.
PAK NOT IN PLACE is displayed. A microswitch which detects the The red Alarm LED is flashing. Progard 3 presence is not fully The system has stopped operating. closed.
Install the Progard 3 Pretreatment Pack again. Check for the proper function of the Progard microswitch
18
TROUBLESHOOTING
WHATS WRONG ? LOW PRESSURE is displayed. The red Alarm LED is flashing. The system has stopped operating. WHAT CAUSED THIS ? The system pressure sensor has measured less then 0.5 bar (7 psi) for more then 20 seconds. HOW TO FIX IT No water is reaching the pressure sensor or water pressure on pressure sensor is < 0.5 bar for 10 seconds. Verify that the feed water is reaching the system. Perform the action below and then Call Your Local Millipore Office. Action 1 - Go to STANDBY mode. Press MEASURE. Record highest displayed pressure. Action 2 - Turn off, then on power. Locate RO reject tubing. While system is in FLUSH mode, determine RO reject flow to drain. Record this value.
EXCHANGE PROGARD is displayed. The yellow Service LED is flashing. The system continues to operate.
The system has determined that the Progard has processed a predetermined volume of water and/or the timer for the Progard has reached 0 Days.
Replace the Progard using the instructions found in the Maintenance Section of this manual. It is highly recommended to replace the Simfilter and Millex vent filter at the same time.
START AUTOCLEAN is displayed. The yellow Service LED is flashing. The system continues to operate.
The AUTOCLEAN message is displayed automatically when the timer has reached 0 days.
Perform a chlorine sanitization of the RO membrane. Use the instructions for Cleaning the RO Membrane in the Maintenance section of this manual.
CHECK PUMP is displayed. The yellow Service LED is flashing. The system continues to operate.
The system has determined that the pump pressure is not high enough at a particular temperature.
ERROR 6 is displayed. The red Alarm LED is flashing. The system continues to operate.
The measured water temperature is < 0 C. This is indicative of a sensor error. This error takes 3-6 minutes to become activated.
ERROR 7 is displayed. The red Alarm LED is flashing. The system continues to operate.
The measured water temperature is > 45 C. This error takes 3-6 minutes to become activated.
Check / lower the feedwater temperature. Call Your Local Millipore Office.
19
TROUBLESHOOTING
WHATS WRONG ? ERROR 12 is displayed. The red Alarm LED is flashing. The system continues to operate. WHAT CAUSED THIS ? The resistivity of the product water is below a predetermined value in the software. This value is much lower than the Resistivity Setpoint. This is indicative of a sensor problem. This error occurs after 3-6 minutes of system operation. HOW TO FIX IT Turn off / on the system power. Return to PRODUCTION mode. If the problem occurs again in 3-6 minutes, then Call Your Local Millipore Office.
ERROR 13 is displayed. The red Alarm LED is flashing. The system continues to operate.
ERROR 15 is displayed. The red Alarm LED is flashing. The system continues to operate.
There was a problem writing data to the electronic memory of the system.
Turn off/on the power. Put the system into PRODUCTION by opening the Product Line Drain Valve for 5-10 minutes, then go to STANDBY mode. If the error returns, then call Your Local Millipore Office.
20
ORDERING INFORMATION
Chapter 5
ORDERING INFORMATION
Description Progard 3, Millipak 100, and Millex filter Progard 3 Pre-treatment Pack , 1/pk Q-Gard A Polishing Cartridge, 1/pk Simfilter Bacteria Filter and Millex Vent Filter, 1 of each/pk Millipak100 0.22 um final filter PrePaK 1 Pretreatment Pack 2/box Reverse Osmosis (RO) Cartridge (without housing) Chlorine tablets (Quantity: 45) ROCLEAN -A: Acid Cleaning Pouch ROCLEAN -B: Base Cleaning Pouch Accessories Pack Support (2 tube, 2 gauges) System Floor Stand Wall Mounting Bracket for AFS Millipak Mounting Kit (included with AFS-8D/16D) Aeration Kit 120V (included with AFS-8D/16D) Aeration Kit 230V (included with AFS-8D/16D) Printer Cable
Catalogue Number CPAFS8PRM PR0G00003 CP2ALLRES HFBCTFAFS MPGL10ZW1 PRPK00001 CDRC60201 ZWCL01F50 ZWACID012 ZWBASE012 ZFPACKSP2 ZAF3STAND SYSTFIX01 MPKMNTKIT ZAFS6AKIT ZAFS5AKIT PRNTCBL01
21
APPENDIXES
Chapter 6
APPENDIX A
UNPACKING
APPENDIXES
INSTALLATION
The AFS is shipped as several different items within one box. A check list of these items is shown below to use as a reference while unpacking the box. Please note that the Q-Gard A Cartridge, the Progard Pretreatment Pack, and the Bacteria Filter are not supplied with the system. These must be ordered separately. See Figure 5 in the back of the manual for visual identification Present Present Yes (A) (B) (C) (D) (E) (F) (G) (H) Water purification system Power cord Operating manual 8 mm OD Feed and Reject water tubing (6 meters) 6 mm OD Product water tubing (2 meters) 6 mm OD Product Line Drain Valve reject tubing (2 meters) 10 Liter Tank (with connections already attached) Pressure Regulator Bag of fittings for connection of system Use the checklist included in the bag of fittings to make sure all items were shipped and are accounted for. Q-Gard A Cartridge (ordered separately) Progard Pretreatment Pack (ordered separately) Millex Vent Filter Simfilter (ordered separately) or Millipak (ordered separately) Millipak Mounting Kit (only with AFS 8D and 16D systems) Bacteria Samplers Aeration Pump (only with AFS 8D and 16D systems) Aeration Tubing Kit (only with AFS 8D and 16D systems) Plastic Drain Connector (Airgap) (only with AFS 8D and 16D systems) _____________________ Signature _____________________ Signature ____________________ Date ____________________ Date No
22
APPENDIXES
INSTALLATION OF THE SYSTEM
The AFS system can be placed on a bench or fixed to a wall. The instructions vary slightly depending upon where the system will be placed. However the system must be located within 2 meters of the analyzer and within 2 meters of the feedwater source.
2.
3. 4.
Connect the tubing at the opposite end of the pressure regulator into FEED 1 (Figure 3, H) by inserting it firmly in the elbow fitting. Verify that the connection is secure by pulling on the tubing. It should not come loose if pulled. Connect the tubing to the feed water supply. The feed water valve or fitting should terminate in a 1/2 inch MNPT fitting. Apply some White tape (supplied with the system) to the 1/2 inch MNPT fitting. This will create a good seal and help prevent leaks. Screw the 1/2 inch FNPT fitting (attached to the feed water tubing) onto this 1/2 inch MNPT valve or fitting.
5.
AND THE
10 LITER TANK
Decide where the system and tank will be located (on the wall or on a flat surface).
If the system is to be bench or wall mounted, proceed with the bench or wall installation at this time (Go to Bench Mounting, or Wall Mounting). Continue with the installation from this point after the system is in place.
23
APPENDIXES
2. Cut and connect a piece of 6mm tubing to connect from IN 4 (Figure 3, M) on the back of the system to the fitting on the top of the tank. Cut and connect a piece of 6mm tubing to connect from OUT 5 (Figure 3, J) to either of the fittings on the bottom of the tank. Use as much tubing as necessary to connect the tank to the system without having a kink in the tubing. A kink (or bend) in the tubing would restrict the flow to and from the system and tank. Cut the tubing to the appropriate size.
OVERFLOW TUBING
1. Push the double fitting (Tubing side) onto the stem fitting on the top of the tank (Figure 1, F). If the Aeration Pump is connected to the 10 Liter tank: Connect the clear tubing to the double fitting (Barbed side). Connect the other end of the tubing to the plastic drain connector (Air gap). The Air Gap needs to placed over or in a drain. If the Aeration Pump is NOT connected to the 10 Liter tank: Connect the clear tubing with the check valve attached to the double fitting (Barbed side) Connect the loop of clear tubing to the other side of the check valve. Use as much tubing as necessary to connect to the drain
!
1.
This system is equipped with an electrical cord having a grounding wire with an appropriate grounding plug. The plug must be plugged into an outlet that is properly installed and grounded.
Connect the power cord (Figure 5, B) to the back of the AFS (Figure 1, D). Connect the other end of the power cord to an earth grounded power source.
24
APPENDIXES
FIXING THE EMERGENCY KIT TUBING
The Emergency Kit tubing is the union fitting connected to a reducing fitting. It is to be attached next to the Inlet tubing using the white clips that come with the system. The tubing is to be used only if the system is not able to produce water. 1. Using the white clips supplied with the system, connect the Emergency Kit tubing to the feed water tubing.
See Emergency Kit for how to connect the kit to the system if water is needed and for the proper usage of the kit.
AND
10 LITER TANK
The AFS can be placed on a bench, provided that the bench can support the weight of the tank and the system when both are filled with water. 1. 2. After the water connections have been made, the system and the tank can then be fixed together using the 2 nuts, bolts, and washers coming with the system. Place a washer on one of the bolts. Push the bolt through one of the two holes on the mounting bracket of the 10 Liter tank. Screw one of the nuts onto the end of the bolt so that it barely rests on the end of the bolt. Do not fully tighten the nut at this time. The result should look similar to the photo on the right. Repeat the same procedure for the other nut, bolt and washer on the other hole on the mounting bracket of the 10 Liter tank. Align the 2 nuts to the corresponding mounting holes on the back of the AFS system. Push the nut into the mounting hole and then slide it upwards. It is easier to insert the nut into the mounting hole of the system if the tank is angled slightly (See the photo above for the location of one of the mounting holes on the AFS). With access on the side of the system, use your finger to hold the nut in place. Hand tighten the bolt as much as possible while holding the nut with your finger. Tighten the nut and bolt on the other side of the system. Further tighten the bolts by using the 6 sided hex wrench coming with the system.
3.
4.
5.
6.
7.
25
APPENDIXES
WALL MOUNTING THE AFS
AND
10-LITER TANK
If the system is to be wall mounted, verify that the wall is able to support the operating weight of the system and the tank. Do not mount the tank lower than the system. The system and the tank must be mounted to the wall separately. CALL YOUR LOCAL MILLIPORE OFFICE FOR MORE DETAILS IF NECESSARY 1. Using the appropriate screws for your wall surface, mount the wall bracket for the AFS system according to the instructions that come with SYSTFIX01 (Wall Mounting Bracket). This bracket must be ordered separately. Make certain to leave enough space to mount the 10 Liter tank next to the system. Use the appropriate screws to attach the 10 Liter tank to your wall surface. Use all four mounting holes on the mounting bracket of the tank. When mounting the 10 Liter tank to the wall, make sure that the tubing connected to the tank will be able to reach the fittings on the back of the AFS system. Remember that when the tubing is connected, there can not be any kinks (bends) in the tubing. The result of a kink is that the flow of water will be restricted to and from the tank. Return to step number 2 in the section Connections between the AFS and the 10-Liter tank. Continue with the installation.
2.
3.
(If you are using a Millipak, follow the instructions that come with the Millipak Mounting Kit) (See Figure 4) It is highly recommended to place the system within 2 meters of the analyzer. One piece of 6 mm tubing is used to connect the AFS to the Product Line Drain Valve Tee and then continue to the Simfilter. The Simfilter is connected to the analyzer. The other 6 mm piece connects the Product Line Drain Valve to the drain. 1. 2. Insert the end of one of the pieces into the elbow fitting on the back of the AFS labelled PRODUCT 2 (Figure 3, K). Cut the tubing to the desired length to connect the system to the Product Line Drain Valve Tee. Remember that the remaining tubing from this piece will be used to connect from the Product Line Drain Valve Tee to the Simfilter. Push the tubing onto the fitting. With the remaining 6 mm tubing, cut to the desired length in order to go from the Product Line Drain Valve Tee to the Bacteria Filter. Push the tubing onto the fitting. Push the tubing from the other 6 mm piece onto the fitting on the Product Line Drain Valve. After cutting to the desired length, secure the other end of the tubing into the drain.
3. 4.
26
APPENDIXES
INSTALLING THE SIMFILTER
Fitting
Tubing from AFS
SIMFILTER
1. 2. 3.
Unscrew the nut from the fitting on the Simfilter and place the nut on the tubing coming from the Product Line Drain Valve Tee. Push the tubing onto the fitting (If necessary, use sandpaper to hold the tubing). Screw the nut back onto the fitting to keep the tubing secure. Connect the tubing attached to the other side of the Simfilter to the fitting connected to the analyzer. If this fitting is the Quick Disconnect fitting coming with the system, follow the directions below: 1. 2. 3. 4. Unscrew the nut on the Quick Disconnect fitting Slide the nut onto the tubing from the Simfilter Push the tubing onto the fitting Tighten the nut onto the fitting so that the tubing is secured
5.
27
APPENDIXES
STARTING THE SYSTEM FOR THE FIRST TIME
Before starting the system, verify that all of these steps have been completed:
Yes (1) (2) (3) System is in the desired location (wall mounted or bench mounted) Power cord is connected Inlet tubing is connected securely - Inlet tubing is connected to a feed water source - Regulator is installed before the system - The other end of the Inlet tubing is connected to the system at INLET 1 on the back of the system Reject tubing is connected securely - Reject tubing is connected securely to the drain - The other end of the reject tubing is connected to DRAIN 3 on the back of the system The tubing between the system (IN 4( and (OUT 5) to the 10 Liter tank is securely in place. Make sure there are no kinks in the tubing The tubing between the system (PRODUCT 2) and the analyzer is connected - This includes the Product Line Drain Valve Tee and Simfilter Overflow tubing is connected from the 10 Liter tank to the drain Tank Level Switch is connected to the AFS system from the 10 Liter tank to the system The Emergency Kit tubing is in place attached next to the Inlet tubing Millex Vent Filter is in place on the lid of the 10 Liter tank
No
(4)
After the system is installed and mounted, the system startup procedure can be started. 1. 2. 3. Install the Progard Pretreatment Pack (See Maintenance, Installation and Replacement of Packs, Progard Pretreatment Pack. Open the feed water valve. Switch on power to the system by moving switch (Figure 3, L) to position I The first display will show you the type of system (AFS8) as well as the serial number of your system. This is displayed for 10 seconds. Display of operating mode (FLUSH and STANDBY alternating)
AF S8 SR . N V1 .01 F 0 A N5 6 8 A 5 C
F L USH
28
APPENDIXES
System rinsing required (Duration: 4 hours) Reminder: SYSTEM RINSE will remove the preservatives in the RO cartridge. Poor quality water could result if the RO cartridge is not rinsed.
OPERATE MEASURE STANDBY CLEANING MENU
S T AND B Y
Press the MENU button twice and you will see this display
S ERV I CE : L I F E T I ME PAK L I FE : 5 5 DA Y S
The system rinse will begin after a 10 second delay. The remaining time of the system rinse is shown in the display.
S E R V I C E : F U NC T I ON SYSTEM R I NS E
After the SYSTEM RINSE is completed, the system automatically goes into STANDBY mode. 4.
S Y S T . R I NS E : 2 4 0 m n
Install the Q-Gard A Cartridge (See Maintenance, Installation and Replacement of Packs, Q-Gard A Cartridge).
29
Use the Emergency Kit only after the suggestions in the Troubleshooting Section have been tried with no effect. Call your Local Millipore Office and proceed with the Emergency Kit procedure. The Emergency Kit Tubing should be attached to the feedwater line. What you will need before you continue: New Q-Gard A Cartridge, Emergency Kit 1. 2. 3. 4. 5. 6. 7. 8. 9. After it has been confirmed that the system is not producing water, make sure the system displays STANDBY. Turn off the power to the system. The emergency kit is to be used only with the power off. Close the feed water valve. Disconnect the tubing attached to FEED 1 (Figure 3, H) on the back of the system. Connect the tubing from the pressure regulator into the union fitting on the Emergency Kit Tubing. Disconnect the tubing attached to OUT 5 (Figure 3, J). Be warned that if there is water in the reservoir, it could spill out. Push the tubing from the other side of the Emergency Kit Tubing into "OUT 5" (Figure 3, J) Open the Product Line Drain Valve (See Drawing Below) Leave the Product Line Drain Valve open.
10. Install a new Q-Gard A Cartridge. 11. Open the Feed water valve. After the Q-Gard A Cartridge is filled, water should be seen going through to the drain through the open Product Line Drain Valve. Decrease the pressure going to the system using the Pressure Regulator attached to the tubing before the Emergency Kit Tubing. The correct setting is 1.5 bar. 12. Allow water to flow through the Q-Gard A Cartridge to the drain for 10 minutes. This will rinse the resin in the Q-Gard A Cartridge and prepare it for use. 13. Close the Product Line Drain Valve (See Drawing Below) after 10 minutes. 14. The system is now ready for use. The analyzer can draw water now.
The feed water valve should be closed when the analyzer will not need water for a long period of time (weekends, overnight, etc.).
FEED WATER
/STANDBY
EMERGENCY KIT
OUT 5
AFS
1
PRODUCT LINE DRAIN VALVE (CLOSED POSITION)
ANALYZER
30
APPENDIXES APPENDIX C ADJUSTING THE VACUUM LEVEL (AFS-8D AND 16D SYSTEMS ONLY)
A B
To adjust the vacuum level, use the following procedures: To increase the vacuum level : Verify that the tank is at least half full. Place the AFS in PRODUCTION mode by opening the Product Line Drain Valve (located between the AFS and the analyzer). Allow the system to run for at least 3 minutes. Using a screw driver, slowly turn the vacuum adjustment screw clockwise (A in the figure above). CAUTION: To prevent regulator damage do not force or over-turn adjustment screw. The vacuum gauge (B in the figure above) will indicate the level of vacuum during adjustment. To decrease the vacuum level; Verify that the tank is at least half full. Place the system in STANDBY mode. Open the Product Line Drain Valve. Remove the Q-Gard A Cartridge. This will reduce the vacuum level when in STANDBY mode. (The Product Line Drain Valve must be located below the system in order to reduce the vacuum to zero)
31
APPENDIXES
Using a screw driver, turn the adjustment screw counter clockwise a few complete turns (A in the figure above). CAUTION: To prevent regulator damage do not force or over-turn the adjustment screw. Re-install the Q-Gard A Cartridge and close the door. Place the AFS in PRODUCTION mode by opening the Product Line Drain Valve (located between the AFS and the analyzer). Allow the system to run for at least 3 minutes. Wait for RINSING mode to finish if necessary. Allow a few minutes for the vacuum level to stabilize. The vacuum gauge (B in the figure above) will indicate the level of vacuum during adjustment.
32
Attached is a maintenance log sheet for you to monitor daily AFS parameters. accreditation, and troubleshooting purposes that you complete this log. Photocopy the sheet, then record the following information:
The date you complete maintenance procedures (such as cleaning or sanitizing the RO cartridge or changing the Progard, Q-Gard A, Millex Vent Filter, or Bacteria Filter). Control panel display readings (i.e., product quality, temperature, feed and permeate conductivity and percent rejection of the RO cartridge). Bacteria counts.
33
APPENDIXES
Date
1
2
34
APPENDIXES
Date
1
2
35
Sample According to NCCLS/CAP Guidelines To meet NCCLS requirements for the specification of bacteria count, periodic testing is recommended. Each laboratory has to establish a guideline on how often they need to do a bacteria count. NCCLS recommends that a bacteria culture be done weekly. Refer to NCCLS document C3-A3, volume 17/No. 18. NCCLS recommends the use of the Heterotrophic sampler count (HPC). NCCLS document C3-A3 Volume 11 No. 13. How to Use the Millipore HPC Total Count Sampler Millipores HPC Total Count Sampler meets NCCLS guidelines. To use the sampler, follow these steps: 1. 2. 3. 4. Remove the sampler paddle from the bag. Write the date, type, and sampling site on the outside case. Sanitize the sampling port: Working from the inside out, wash the port with a 10% bleach solution. Open the sampling port on the AFS product line and let it run for at least one minute. Pour a sample into the sampler case up to the 18 mL line. Insert the sampler firmly into its case.
CAUTION: Wet the membrane uniformly but do not shake the sampler case.
5. 6.
Carefully lay the sampler, membrane down, on a flat surface. Wait 30 seconds while the sample filters through the membrane. Remove the paddle from the sampler case. Shake off any excess liquid from the paddle with a firm snap of your wrist. Empty the case and reinsert the paddle.
CAUTION: Make sure the sampler has an air-tight seal to prevent drying during incubation.
7. 8. 9.
Incubate the sampler at 25C 1C for 48-72 hours. Total incubation time must be at least 48 hours. Remove the sampler from the incubator and the paddle from the sampler case. Examine the filter surface on the paddle with either an illuminated stereoscopic microscope (10x to 20x) or an illuminated magnifier (5x). Record the results as cfu/mL.
36
INDEX
10 Liter tank, 7, 10, 14, 15, 16, 18, 22, 23, 24, 25, 26, 27, 28 CHECK PUMP, 19 CLEANING, 9, 15, 16 Conductivity, 4, 8, 10, 33 DRAIN, 3, 8, 11, 12, 13, 17, 18, 19, 20, 22, 23, 28, 30, 31, 32 ERROR, 19, 20 EXCHANGE PROGARD, 11, 19 EXTERNAL ALARM, 9 FEED, 1, 3, 4, 8, 15, 16, 18, 19, 22, 23, 25, 28, 30, 33 FILLING TANK, 7, 8, 10, 11, 12, 13, 15, 16, 17 Language, 9 LOW PRESSURE, 19 Maintenance, 5, 7, 8, 11, 15, 19, 28, 29, 33 MEASURE, 9, 19 MENU, 9, 10, 29 Millipak, 13, 26 NCCLS, 2, 36 PAK NOT IN PLACE, 18 pH, 2, 4, 8, 16 Pressure, 3, 4, 5, 8, 9, 11, 12, 13, 18, 19, 22, 23, 30 Printer, 10, 21 PRODUCT < S.P., 18 PRODUCTION, 7, 8, 10, 11, 12, 13, 17, 18, 20, 31, 32 Progard, 3, 4, 9, 11, 13, 14, 15, 18, 19, 21, 22, 27, 28, 33 Pump, 3, 7, 8, 17, 18, 19, 22, 24 Q-Gard A, 3, 11, 12, 17, 18, 21, 22, 29, 30, 31, 32 REJECTION < S.P., 18 Resistivity, 2, 4, 7, 8, 10, 18, 20 RINSING, 32 RO, 2, 3, 5, 7, 8, 10, 16, 18, 19, 21, 23, 29, 33 Screen filter, 15 Simfilter, 11, 13, 17, 19, 21, 22, 26, 27, 28 STANDBY, 7, 9, 10, 11, 12, 13, 15, 16, 19, 20, 28, 29, 30, 31 START AUTOCLEAN, 15, 19 SYSTEM RINSE, 10, 29 TANK FULL, 7, 10, 11, 12, 13, 15, 16, 17
37
FIGURE 1
Power Service Alarm
C
OPERATE/STANDBY MEASURE CLEANING
MENU
AFS D
o
I
FIGURE 2
AFS
FIGURE 3
A B C
o
I
K M J
FIGURE 4
AFS
Analyzer
Simfilter
To Drain
FIGURE 5
E
Power Service OPERATE/S TANDBY Alarme MESURE CLEANING MENU
MAN
AFS
UAL
MILL IPOR E
K (Ordered separately) L
SIMFILTER
More