AmeriWater 00MDP2-230, Operation & Maintenance Manual

Page 1: ...ter Purification Specialists Operation Maintenance Manual 3345 Stop 8 Rd Dayton OH 45414 800 535 5585 www ameriwater com 98 0157 Rev P Manufactured With Pride in The USA MediQA Reverse Osmosis System MODELS MSP AND MDP ...

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Page 3: ... Connections 10 3 2 1 Mains Supply 10 3 2 2 USB Connection Details 10 3 3 Environmental 11 3 4 Standards Applied 11 3 5 Specification Data 12 3 6 Performance Parameters 13 OPERATIONAL OVERVIEW 14 4 1 MediQA Basic Operation 14 4 2 Sequence of Operations 16 4 2 1 Introduction 16 4 2 2 Hi Recovery Mode 17 4 2 3 Standard Recovery Mode 18 4 2 4 Cleaning Procedure 19 4 2 5 Disinfection Procedure 20 4 2 ...

Page 4: ...u Screen 32 6 1 2 Operation Periods 35 6 2 Main Menu Screen 36 6 2 1 Viewer Screen 36 6 2 2 Activity Details Screen 37 6 2 3 Activity Log Screen 37 6 2 4 Status Monitor Screen 38 6 2 5 Alarms Screen 38 6 2 6 Alarm Log Screen 39 6 2 7 Diagnostics Screen 39 6 3 Operation Menu Screen 40 6 4 Settings Menu Screen 40 6 4 1 RO Supply Screen 41 6 4 2 RO Clean Screen 43 6 4 3 RO Heat Disinfect Screen 43 6 ...

Page 5: ...rface Cleaning 54 8 2 Chemical Cleaning 54 8 3 Approved Chemicals 56 8 4 RO Heat Disinfect Procedure 56 8 4 1 Manual RO Heat Disinfection 56 8 4 2 Automatic RO Heat Disinfection 57 MAINTENANCE 58 9 1 Thermostat Testing 58 9 2 Spare Parts 58 9 2 1 MSP Spare Parts 59 9 2 2 MDP Spare Parts 61 9 3 Replacement Part History Log Sheet 63 FLOW DIAGRAMS 64 WIRING SCHEMATIC 66 COMPONENT IDENTIFICATION 82 12...

Page 6: ...sitate to contact us as follows For all spares and consumables contact Customer Service Tel No 1 800 535 5585 For all service or technical support contact Technical Support Tel No 1 800 535 5585 Web address www ameriwater com Or your local authorized AmeriWater dealer Useful Telephone Nos Tel No Contact Name Tel No Contact Name ...

Page 7: ...oduces up to 10 gpm of product water The MediQA is a Medical Device as such modifications to the device are not permitted Modifications to the machine by anyone other than AmeriWater personnel will invalidate the marketing clearance for the device WARNING This Reverse Osmosis System RO contains a preservative solution to prevent microbiological growth and freezing Discard all product water for at ...

Page 8: ...chnical Support at telephone number 1 800 535 5585 Be prepared to provide the unit s serial number The unit must not be dismantled unless carried out by AmeriWater personnel or authorized trained personnel Under no circumstances should the unit be connected to the electrical supply with the front control panel open Always refer to the Material Safety Data Sheets before handling any of the recommen...

Page 9: ...safety requirements Country specific requirements standards and regulations must be observed Usage in accordance with intended purpose The MediQA units are used to purify water for the purpose of feeding medical devices dialysis machines The water produced must not be used for drinking as it may be harmful to the body or for any other purpose not described in this manual The units must only be ope...

Page 10: ...n unintentionally before all repair and maintenance tasks have been completed It is essential to observe the procedure described in these Operating Instructions for shutting down the system Before beginning tasks on the electrical equipment of the system a check must confirm that power has been disconnected from the corresponding section of the system In addition the system must be secured to prev...

Page 11: ...ays of the discovery of the defect There are no warranties on the AmeriWater system beyond those specifically described above All implied warranties including any implied warranty of merchantability or of fitness for a particular purpose are disclaimed to the extent they might extend beyond the above periods The sole obligation of the manufacturer under these warranties is to replace or repair the...

Page 12: ...re 3 2 Electrical Specifications Connections 3 2 1 Mains Supply See specification DANGER The earth leakage current of this equipment can exceed 3 5mA 5mA Therefore it is essential that the earth connection is made before the supply is established A warning label on the equipment states DANGER DISCONNECT THE MAINS SUPPLY BEFORE SERVICE 3 2 2 USB Connection Details Standard USB port suitable for FAT...

Page 13: ...disturbance of the unit If the RO is affected by such disturbance the source must be suppressed or moved 3 4 Standards Applied Applicable to all product variants Type Standard EMC BS EN 61326 1998 IEC 61326 1 1997 Class A Electrical equipment for measurement control and laboratory use EMC requirements BSEN 61000 3 2 1995 Incorporating Amendments 1 2 Mains Harmonic Emissions BS EN 61000 3 2 1995 In...

Page 14: ...lowing activated carbon total chlorine level must be 0 1 ppm Temperature For best performance feed water temperature should be 55 F to 95 F TDS Maximum feed water total dissolved solids 1000 ppm Total Hardness Softened feed water with a total hardness of 4 ppm as CaCO3 S D I Silt density index following final 5 micron filtration should be 5 Fluoride 1 2 ppm for Hi Recovery Mode Services Power Supp...

Page 15: ... 140 180 Feed Water Pressure PSI 30 80 30 80 30 80 30 80 Interstage Pressure Bar PSI NA NA 2 5 30 70 2 5 30 70 Temperature Feed Water Temperatures F 55 95 55 95 55 95 55 95 Conductivity Output Conductivity 94 Incoming 94 Incoming 94 Incoming 94 Incoming Water Water Water Water Based on Standard Recovery Mode Each MediQA should perform within these parameters Pressures may vary depending on the age...

Page 16: ...second stage RO module set may comprise of one or more RO modules In the dual pass two RO stages MediQA a portion of the concentrate reject water from the 1st stage RO module set is discharged to drain while the balance is returned to the tank Concentrate from the 2nd stage RO module set is returned to the feed water tank for reprocessing Permeate from the 2nd stage RO module set is fed via a mani...

Page 17: ... MODE HI RECOVERY MODE is the default setting See Section 6 4 1 for navigation instructions The MediQA also features routines to enable chemical cleaning of its RO membranes but not the connected distribution loop In addition to the above the MediQA incorporates process elements to enable heat disinfection of the reverse osmosis membranes and its pipe work Heat disinfection can be activated manual...

Page 18: ... to direct the water flow through the unit during each of the various stages of operation These valves are marked with yellow indicators that represent the openings of the valve The yellow markers are used as a visual indicator of the position of the ball valve as it relates to the flow of the water through the valve The following pictures illustrate the valves during operation Product to Loop Val...

Page 19: ...s during this process is the same as Figure 1 through Figure 3 The Rinse Mode continues until the unit meets a predetermined quality level or until the Rinse cycle runs for the max time If it reaches the max time and has not rinsed down to quality level an alarm will be triggered If it reaches quality it moves to the Supply Mode SUPPLY After Flush and Rinse cycles are completed the MediQA will go ...

Page 20: ...Loop Return Valve Product to Loop Valve Reject to Drain Reject water is dumped to the drain until the permeate quality reaches the HI RECOVERY QUALITY LOW LIMIT or BREAK TANK TEMPERATURE LOW LIMIT set point Valve position will remain the same for Loop Return and Product to Loop Valves The Concentrate to Drain Valve will rotate as shown in Figure 7 Figure 7 Concentrate to Drain Valve 4 2 3 Standard...

Page 21: ...QA tank The pump s turn on at a low speed to keep the pressure in the system below the alarm set point of the pressure switch Figure 8 Figure 9 Figure 10 Concentrate to Drain Valve Loop Return Valve Product to Loop Valve Tank Drain High Low Pressure Rinse During the Tank Drain High Pressure Rinse and Low Pressure Rinse the concentrate drain valve shown in Figure 11 opens allowing all of the residu...

Page 22: ...g the pre heat and hold period the RO disables its ability to call for water from its water supply The water in the unit is circulated throughout the plumbing and membranes until it reaches 185 F Once the temperature is reached the water is circulated for 30 minutes adjustable The valve positioning remains the same for both phases of the heat disinfection Figure 12 Figure 13 Figure 14 Concentrate ...

Page 23: ...re that MINT cable is connected between MediQA and Heatsan for fill procedure to function Figure 16 Figure 17 Figure 18 Concentrate to Drain Valve Loop Return Valve Product to Loop Valve LOOP HEATSAN During the Loop Heatsan mode the Heatsan prevents the MediQA from operating to make sure the loop can properly achieve the disinfection temperature Figure 19 Figure 20 Figure 21 Concentrate to Drain V...

Page 24: ...e Product to Loop Valve 4 3 Pump Operation The pump is automated and operates according to a factory installed program If there are up and down arrows on the face of the pump it is advised not to use these to adjust the run percentage Pump Models with screen If there is a yellow or red light on the pump face the alarm or warning message should be displayed with a description and Alarm Code For add...

Page 25: ...ust be level Ensure the following items have been provided MediQA Unit Key for control panel Operation Manual 5 3 Connections 5 3 1 Electrical Supply DANGER An electrical supply see specification Section 3 5 should be made to the control panel of the MediQA using a suitable armored cable The cable should be fitted using the gland provided and terminated to the Isolator connections L1 L2 L3 N and E...

Page 26: ...ze pretreatment lockout Pretreatment lockout will prevent the device from operating while the pretreatment is going through regeneration The MediQA is shipped from the factory with a jumper installed between wire terminal X24 and wire terminal 1 To enable the pretreatment lockout functionality remove the jumper wire between wire terminal X24 and wire terminal 1 After removing the jumper wire wire ...

Page 27: ... connections for the Alarm Panel The alarm output is normally closed so that when there is an alarm this opens AmeriWater supplies an alarm panel that can be set to either normally open or normally closed contacts As shipped the alarm panel will look for a closure to indicate an alarm condition See the manual for the AmeriWater alarm panel for detailed instructions on changing the input type To co...

Page 28: ...alled and ready for water All 6 leveling casters need the leveling pad lowered until it is pressed against the floor to relieve the wheel of the RO weight Pretreatment devices should already be in service and filter cartridges installed Post treatment equipment will be exposed to water the first time ensure all union fittings are tight Ensure all electrical connections are safe and secure The Medi...

Page 29: ...ace of the pump Do the same with RO2 PUMP if installing a Dual Pass Remove the lid to the MediQA tank and open the tank drain valve on the bottom of the tank Slowly open the feed water supply valve to the MediQA Watch the tank as it fills water may be cloudy and contain piping debris Flush debris from the break tank thru the overflow until water is clear and free of debris May need to close feed w...

Page 30: ...n under MEDIQA OPERATION MODE Hold the disable button for 2 seconds to put the unit into Standard Recovery Mode Open the bypass to drain valves located at the end of the loop after the product recovery kit before the loop return to MediQA This will allow water to run to drain to flush any construction debris from the loop Navigate to the OPERATIONS MENU and start the RO by pressing the CONTINUOUS ...

Page 31: ...ntinue to operate Monitor the status of the RO on the Activity Details screen under the Main Menu During this time there are a few things that need to be noted and checked Note the steady state conductivity level of the permeate water by looking at the OUTPUT CONDUCTIVITY Also note the steady range of values for TANK TEMPERATURE Verify the measured recovery is at or near 65 on the RO Parameters sc...

Page 32: ...ction is conducted on the RO May decide to program an automatic heat disinfect Make sure the pretreatment is not programmed to backwash or regenerate during the MediQA heat cycle May be necessary to unplug the pretreatment during this first initial heat disinfect To manually begin a heat disinfect from the OPERATION MENU press RO HEAT DISINFECT The controller will ask for confirmation press YES Th...

Page 33: ...ode It is recommended to start the RO at least 30 minutes before staff arrives This will allow the staff to take water system readings immediately upon arrival instead of waiting the required 15 minutes Once in the RO SUPPLY screen reset the flush and rinse times to 2 minutes each Navigate SETTINGS MENU RO HEAT DISINFECT RO HEAT DISINFECT SCHEDULE ENTER and set the desired day to heat disinfect th...

Page 34: ...Pressing any one of these selects the named function Only one function may be selected at any one time To switch between functions the OFF button must first be pressed Some functions when switched off using the OFF button will need to complete some process cycles It will not be possible to select another function until these process cycles have been completed 6 1 1 Operation Menu Screen On all scr...

Page 35: ...nd Heat Disinfect occurs at time programmed in the RO HEAT DISINFECT screen If the timer button is pressed part way through a timer period pressing the TRIGGER button will start operation CONTINOUS button Starts system operation whether times have or haven t been programmed to the RO SUPPLY TIMER screen Operation is continuous until OFF is selected Since starting and stopping incorporate essential...

Page 36: ... button operation When powered up the OFF button will be illuminated red To select another function press the OFF button this will turn gray and then press the desired function button The function button will illuminate green to show it has been selected To switch off a function press the OFF button this will illuminate red and the function button will turn gray If both the OFF button and the func...

Page 37: ... all of the water is redirected back into the MediQA tank RECIRC PERIOD is user settable Clean Tank Drain The MediQA is equipped with the ability to perform a chemical cleaning of itself once chemicals have been added in the tank This mode is also displayed after Clean Recirc when the Tank drains completely then refills Clean Rinse After the clean tank drain is completed the RO will go into a clea...

Page 38: ...n Figure 27 The VIEWER screen displays a flow schematic and highlights with colored indicators the status of specific process elements Red OFF Green ON Tank level switches are shown Yellow OPEN water level has not triggered float switch Green CLOSED water level has closed float switch MAIN MENU BUTTON Returns to the main menu screen ...

Page 39: ...ata logger Records are displayed in chronological order Scroll buttons are provided to move through the data shown on screen Pressing the down button goes to the most recent data while the up button moves back in time one page at a time This data may be downloaded to a data bar memory stick Insert a memory stick into the USB port found on the touch screen mounting arm Press the WRITE TO USB button...

Page 40: ...ing to specification Amber Warning active Red Alarm active Warning alarms are advisory they do not affect system operation They indicate that some element of the system needs attention Alarms stop the system The system will only restart once the problem giving rise to the Alarm has been corrected 6 2 5 Alarms Screen Figure 32 When triggered alarms and warnings are detailed in the table Alarms can ...

Page 41: ... scroll buttons to move through the data First press CURSOR ON and when completed CURSOR OFF 6 2 7 Diagnostics Screen Single Pass Screen Dual Pass Screen Figure 34 Figure 35 The DIAGNOSTICS screen details active system elements Active elements are highlighted with green markers in each of the indicator boxes ...

Page 42: ... 4 Settings Menu Screen Figure 37 When the SETTING MENU button is pressed the unit will request a password The password to enter the SETTINGS MENU is 01844 Punch in the number and press ENT If an error is made press backspace BS clear CLR or escape ESC Figure 38 The SETTINGS MENU allows key operating parameters and system alarms to be set ...

Page 43: ...gged AUTO FLUSH defines the duration of flush TARGET RECOVERY RO1 sets target water recovery of stage 1 RO modules TARGET RECOVERY RO2 sets target water recovery of stage 2 RO modules SUPPLY HEATING defines whether the tank heater is to be used to warm the incoming water supply When enabled the heater is turned on at 48 F 9 C and off at 52 F 11 C ENTER under SUPPLY TIME SCHEDULE opens to the scree...

Page 44: ...modes HI RECOVERY MODE is the default and can be disabled by holding the DISABLE button for two seconds Must have level 3 access to change the mode of operation Figure 42 HI RECOVERY QUALITY defines the high and low limits of permeate conductivity that the water will maintain The reject water will recirculate to the tank until the high limit of water quality is reached when the concentrate to drai...

Page 45: ...TIME REMAINING status bar activates when a CHEMICAL CLEAN is started This displays the time remaining to complete each of the clean cycle elements YELLOW prompt boxes pop up to instruct when to perform given activities during the clean cycle 6 4 3 RO Heat Disinfect Screen Figure 44 Here specific functions for the RO heat disinfect can be set TANK TEMP determines the maximum desired tank temperatur...

Page 46: ...ese times conflict with RO SUPPLY TIMER settings Figure 41 RO HEAT DISINFECTION will commence when SUPPLY ends To change pre set times press the highlighted blue boxes enter the time 24 hour clock on the pop up key pad and press enter Enter a time of 00 00 to prevent operation on any particular day 6 4 4 Activity Log Screen Figure 46 Setting a time to the ACTIVITY LOG CYCLE TIME determines the per...

Page 47: ...peration The warning or alarm is triggered if the value falls below the LOW FLOW set point or above the TANK QUALITY OUTPUT QUALITY or HIGH FLOW set points 6 4 6 Clock Screen Figure 48 Clock set enables the system clock to be set To adjust the clock press ACCESS TIME SETTING enter the desired time into the blue boxes adjacent to SYSTEM CLOCK TIME and press SET SYSTEM CLOCK to set the time The time...

Page 48: ...tion Menu is password protected and requires a level 2 login ____ The menu should only be accessed by trained personnel and AmeriWater Techs 6 5 1 Flowmeters Screen The Flow Meter menu allows access to the calibration settings Single Pass Screen Dual Pass Screen Figure 50 Figure 51 OFFSET and GAIN are calibration parameters Offset adds or subtracts a constant value to the signal Gain multiplies th...

Page 49: ... The Alarm Settings menu allows access to the alarm set points for various parameters of the unit The set points should be set before the unit is put into service and will only require alteration in special case situations Single Pass Screen Dual Pass Screen Figure 54 Figure 55 The set points on this screen are triggers for system warnings and alarms If a warning is triggered it will be displayed ...

Page 50: ...stant factor 6 5 5 RO Heat Disinfect Screen Figure 58 The RO Heat Disinfect menu allows access to the PUMP RUN SLOW and COOL DOWN END TEMP PUMP RUN SLOW TEMP is the set point at which the pump on the system will run at a lower pressure than normal This is required during a heat disinfection of the system because the membranes cannot handle high pressures with water over 113 degrees F at 45 psi of ...

Page 51: ...ced to the RO are gone before supplying water to the loop 6 5 7 Overrides Screen The Overrides menu allows various components of the RO to be turned on while the unit is in standby This is mainly used for testing or diagnostics purposes for the system The overrides can only be used while the unit is not in operation To reset any manual override use the OVERRIDE RESET button Single Pass Screen Dual...

Page 52: ...led in the MediQA INSTALL FACTORY DEFAULTS will erase all current settings on the unit and replace them with the factory default values listed in Section 13 1 This button should not be pressed unless a critical problem with the system occurs Requires level 6 access restricted to AmeriWater service personnel and 2 second hold to activate The Security Level Buttons will let a person Log In or Out di...

Page 53: ...Disinfect process X4 off Over Temperature Fault Alarm Any RO Heat Disinfection Temp Set point Exceeded Emergency Stop Activated Alarm E Stop button pressed on front of control panel X0 off PLC Analogue Card Error Alarm PLC Analog Card communicating fault condition PLC to PCB Comms Error Alarm Communication port where conductivity board connects to PLC not receiving information Output High Pressure...

Page 54: ...ssure switch X11 off Output High Pressure Warning Delivery Pressure Switch PS1 registers value higher than set point on pressure switch X12 off High Water Temperature Warning Loop Over Temp Warning Set point Exceeded Output Quality Warning Output Quality Warning Set point Exceeded Output Quality out of Range Warning Output Conductivity Sensor transmitting the maximum detectable value for 30 second...

Page 55: ...ermeate Conductivity Sensor transmitting over the maximum detectable value for 300 seconds Leak Detected Warning Conductivity Board Temperature Rise Warning After 30 minutes tank temperature is lower than previous reading during RO Heat Disinfection Temperature Hold Low Warning Tank Temperature Probe reading is lower than Tank Return Probe reading NOTE The pumps will run slow during the RO Heat Di...

Page 56: ...ment required Hand held conductivity meter or chemical test strips Approved cleaning chemical The quantity of chemical required is calculated according to the volume of water in the MediQA not to exceed the maximum concentration stated STIR SOLUTION WELL WHEN USING AMERICLEAN A AND B POWDER MediQA water volumes when full 00MSP2 230 30 gallons 00MDP2 230 32 gallons 00MSP3 230 32 gallons 00MDP4 230 ...

Page 57: ...eginning to know the end point of the cleaning When the water returns to this pH that means the chemical has been rinsed out Chemical cleaning of the unit can be initiated from the OPERATION MENU of the touch screen Stop the MediQA by pressing the OFF button on the OPERATION MENU Depress CHEMICAL CLEAN button Wait for prompt to ADD CLEANING CHEMICAL Remove the lid of the tank and add chemical to t...

Page 58: ...Clean B This is an alkaline liquid cleaner containing organic sequestrant inorganic sequestrant detergent and emulsifiers AmeriClean B is used for removing organics Silica inorganic colloids and biological material To test for the presence of AmeriClean B in permeate check that the conductivity is less than 30 μS cm and pH is at or near 7 NOTE Always refer to Safety Data Sheets before handling any...

Page 59: ...subject to the duration of OFF time When either CONTINUOUS or TIMER operation is selected the system will first perform a cool down routine before going into service i e supply of water to the distribution loop 8 4 2 Automatic RO Heat Disinfection Heat disinfections can be started automatically when times have been programmed to the RO heat disinfection timer schedule see Section 6 4 3 Automatic h...

Page 60: ...d Ensure the temperature can be determined without reaching into the tank Verify that the heater shuts off between 185 210 F If the thermometer on the heater does not shut off at the prescribed temperature contact AmeriWater for guidance Navigate to the OVERRIDES screen and open the fill solenoid valve and allow the tank to completely fill Close the fill solenoid Doing this will reduce the tempera...

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Page 65: ...63 98 0157 Rev P 9 3 Replacement Part History Log Sheet MediQA Replacement Parts Record Unit Serial No Location Date Replaced Description Reason for replacement Tech Initials ...

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Page 84: ...82 98 0157 Rev P COMPONENT IDENTIFICATION RO Modules membranes in housings High Pressure Pump Electrical Panel Feed Water Tank Touch Screen Display Emergency Stop ...

Page 85: ...83 98 0157 Rev P 12 1 Control Panel Labeling inside the control panel can be found on the back panel above the corresponding component MSP Units ...

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Page 89: ...od 25 min RO Heat Disinfect Over Temp permeate 2 183 F Rinse Pressure Period Low 40 min RO Heat Disinfect Over Temp Tank return 183 F Rinse Pressure Period High 15 min Setting Default Initial Setup User Setting Units Setting Default Initial Setup User Setting Units Tank Offset N A Tank Temp 185 F Tank Gain N A Tank Return Temp 180 F Output Offset N A Hold period 30 min Output Gain N A Setting Defa...

Page 90: ...ial Setup User Setting Units RO2 Pressure setpoint High 145 psi Clean Reminder 999 days Loop Supply Flow Setpoint Low 1 gpm Recirc Period 25 min Loop Supply Flow Setpoint High 18 gpm Rinse Pressure Period Low 40 min Low Pressure Alarm Delay 0 hrs Rinse Pressure Period High 15 min Setting Default Initial Setup User Setting Units Setting Default Initial Setup User Setting Units Tank Offset N A Tank ...

Page 91: ... every few seconds while the Dongle is on Connect the smartphone or iPod to the Grundfos dongle via Bluetooth Open the GO Remote app To connect the smartphone or iPod to the pump hold the Dongle end opposite of the power button close to the pump Infrared Receiver see picture below and go to the Connect tab in the Grundfos GO Remote app and connect via the IR connection option This first screen the...

Page 92: ... of the Dashboard screen under the Grundfos Eye as shown above Do not change any of the pump parameters these are factory set The Grundfos Dongle can be turned off by pressing and holding the power button on the top of the device until the green power button illumination light goes off ...

Page 93: ...ch mode of operation PLC Input and Output Identification Valve Positions in each mode of operation Alarm and Warning Checks and Proposed Actions Electrical Mechanical Faults Component Failures Instruction for Use IFU on the following topics o Setting MediQA Pressure Relief Valve o Updating PLC or HMI Software o Disinfecting the Cool Down Hose on old units o Changing Chem Clean Reminder o Membrane ...

Page 94: ...lifornia to cause cancer birth defects or other reproductive harm One such chemical is Vinyl Chloride a compound used to produce Polyvinyl Chloride PVC The AmeriWater system you have purchased may contain PVC or stainless steel parts While warnings are only required in the State of California AmeriWater has initiated the use of Prop 65 labeling for all products to ensure compliance with California...