AmeriWater Heatsan 00HS208, Operation & Maintenance Manual

Page 1: ...ation Maintenance Manual AmeriWater The Water Purification Specialists 3345 Stop 8 Rd Dayton OH 45414 800 535 5585 www ameriwater com 98 0156 Rev G Manufactured With Pride in The USA Heatsan Heat Sanitization System ...

Page 2: ...ability 8 3 SPECIFICATION 9 Controls 9 Alarms and Maintenance 9 Weights and Dimensions 9 Water Services Connection Schedule 9 Electrical Supply Requirements 10 IP Ratings 10 Feedwater 10 Performance 10 Environment 11 Classification and Standards Applied 11 4 PROCESS DESCRIPTION 12 Operation 12 Preheat 12 Heating Heatsan Operation 13 Hold Heatsan Operation 13 Draw off period 13 Cool down period 14 ...

Page 3: ...INDING 39 Data Alarm List 39 Event Listings 44 8 DISINFECTION AND CLEANING 45 Advisory Note 45 Surface Cleaning 45 9 MAINTENANCE 46 Maintenance 46 Thermostat Testing 46 Recommended Spare Parts 47 Calibration of Sensors 48 10 APPENDIX 49 Disposal of electrical parts 49 Heatsan Process Flow Diagram 50 Wiring Diagrams 51 Installation Layout 57 Flow Diagram MediQA to Heatsan 58 Flow Diagram MROZ to He...

Page 4: ...TAILS For all service spares and consumables enquiries contact AmeriWater 3345 Stop 8 Rd Dayton Ohio 45414 Tel No 800 535 5585 Or your local authorized AmeriWater dealer Useful Telephone Nos Tel No Contact Name Tel No Contact Name ...

Page 5: ... modifications are carried out that are considered by AmeriWater to compromise the integrity of the original design philosophy If the unit s performance becomes impaired and any remedial work appears to be outside the scope of this manual then seek advice from AmeriWater quoting the unit s serial number Refer to Section 1 Contact Details The unit must not be disassembled in any way unless carried ...

Page 6: ... symbol refers to a possibly hazardous situation Failure to observe these references may result in minor injuries and or damage to property I This symbol points out important information for working with the system in the proper manner Failure to observe these references may result in malfunctions in the system or impact on the environment This symbol indicates a possible hot surface Touching part...

Page 7: ...CAL SHOCK ONLY QUALIFIED APPROVED ELECTRICAL ENGINEERS SHOULD BE USED TO CONNECT THE UNIT TO THE ELECTRICAL SUPPLY Any references in this manual to installation requirements procedures are provided as information only Installation of the unit will only be carried out by AmeriWater or an approved installation technician If the unit is used in a manner not specified by AmeriWater or procedures not f...

Page 8: ...must confirm that power has been disconnected In addition the system must be secured to prevent it from being turned on again unintentionally The isolator switch is capable of accepting a lock out padlock when in its OFF position The unit may contain water at scalding temperatures ensure it is drained down and safe to work on before carrying out any maintenance tasks Disposing of system parts and ...

Page 9: ...ty service notice must be given to the manufacturer within 30 days 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 ...

Page 10: ...trols All the processes of the Heatsan unit are controlled automatically and the unit operates via a touch screen which displays systems performance data and unit status Alarms and Maintenance The Heatsan unit incorporates monitoring devices and will report alarms and warning messages via the user display Reference to these alarms and appropriate actions to be taken to rectify them can be found in...

Page 11: ...quipment 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 IP Ratings Control Panel Type 2 Recirculation pump IP55 Feedwater Quality RO permeate Softened Temperature 55 194 0 F Performance Working tank volume 100 Gallons Pump output range 317 Gallons hr 5 5 Bar 80 psi to 1160 Gal hr 2 Bar 30 psi...

Page 12: ...onment must be within the limits to which the unit has been tested see Section 3 10 below Care must be taken not to place near the unit any source of RFI EMI which is liable to cause electromagnetic disturbance If the unit is affected by such disturbance the source must be suppressed or moved Classification and Standards Applied Class 1 equipment Electrical Insulation Category II Pollution Degree ...

Page 13: ... disinfection and the flow at which they require the hot water The system allows the user to input the specific requirements of the dialysis machines to be disinfected the days requiring heat disinfection and the times which heat disinfection can occur If the system detects that any of the entered user values cannot be achieved by the Heatsan unit the unit will raise an Invalid number alarm warnin...

Page 14: ...d to the loop using the motorized valves on the associated manifold The internal pump will circulate the preheated water around the distribution loop s to be disinfected The system will continue to heat the water until the preset disinfection temperature is achieved The circulation period is set by the loop pre heat value on the HMI the factory default can be found in Section 6 10 Hold Heatsan Ope...

Page 15: ...o STANDBY To ensure that the tank remains empty during STANDBY the drain valve will open for 5 minutes every 2 hours Standby STANDBY will be displayed to indicate that the unit is healthy and waiting for the next heat disinfection routine to initiate Remote Light A four tier remote light is available to clearly and easily show the operational state of the Heatsan Light Pattern Light Light Pigtail ...

Page 16: ...al position remove all protective wrapping from the metalwork and hydraulic connections Inspect for any damage Ensure that the installation kit has been provided with the unit Electrical Supply An electrical supply see specification Section 3 5 should be made to the control panel of the Heatsan 400 unit using suitably sized 3 phase cable based upon the maximum current draw of the unit while consid...

Page 17: ...ns should be connected directly to the distribution loop via a manifold assembly with valves Fill The source of the Fill water should be taken directly off of the end of the distribution loop The choice of pipework material depends on maximum likely water temperature Use Stainless steel or PEX for high temperature systems up to 203 F Input Outputs Refer to wiring diagram see Section 10 3 Wiring di...

Page 18: ...Interlock Signal X 14 Connection from key switch on remote override panel X 15 Heatsan to RO Interface Power Supply Fault Installation Plan Layout Refer to Section 10 4 for suggested installation plan layout Commissioning Commissioning of the Heatsan unit should only be carried out by either an AmeriWater technician or authorized trained personnel ...

Page 19: ... available Operation levels of access There are five levels of user access LEVEL 0 1 2 3 5 NB Level 5 access is reserved for AmeriWater technical staff User Level Password Access Level 0 No password Today Current Setup Menu view only Monitor Menu View Time Rate screens Alarm Event History view only Heatsan Abort Level 1 141 Today Current Setup Menu view change settings Monitor Menu Alarm Event His...

Page 20: ...ER You will be notified of security level change success Press OK then close the menu by depressing the X in the upper right corner Depress MAIN MENU to return to the MAIN MENU Details of User passwords can be found in Section 6 2 After 20 minutes the Login screen will automatically logout any users Operation Daily Defaults Menu Screen Display Action To access the CURRENT SETUP menu press CURRENT ...

Page 21: ...umber of dialysis machines that will take water for disinfection on this day Next enter the HEATSAN START time To change the time select each digit to be changed individually A pop up number keypad will appear on the screen select the correct number and press ENTER After entering the Heatsan start time enter a time that the water system must be available for normal service Press the desired digit ...

Page 22: ... will cease NB If no machines are to be heat disinfected but the selected distribution loop requires disinfection input a value of 1 against NUMBER OF MACHINES Do not enter a zero value When details for MONDAY have been entered press NEXT to move to TUESDAY SETUP and so on until the program for every day of the week has been completed NB If time values are entered that will prevent operation a SER...

Page 23: ...CURRENT SETUP screen Press SYSTEM SETUP to access the SYSTEM SETUP menu NB The SYSTEM SETUP button can only be accessed by those users with Level 2 log in clearance Enter the required SANITIZATION TEMP The minimum default temperature can be found in Section 6 10 TANK PRE HEAT TEMP is the programmed temperature that the tank will heat up to prior to Heatsan Operation Press NEXT PAGE to enter SYSTEM...

Page 24: ...ill not affect the pre set parameters set for the DAILY DEFAULTS Press CURRENT SETUP Change parameters to suit NB The operating parameters for that day will be automatically loaded into TODAY at midnight This screen can be accessed to view without the need to log in To edit will require logging in as a Level 1 user or above Once you have entered all the required parameters the system is ready for ...

Page 25: ...ntil a single beep is heard The CURRENT SETUP screen will be populated with the necessary times If NO is pressed it will return to the CURRENT SETUP screen and display 00 00 for all times NB The unit needs to start the Loop Pre Heat process within the same day as the Tank Preheat If the calculated Heatsan Start exceeds 24 00 then this error message will come up on the screen The message is not sen...

Page 26: ...splayed This screen will display information relating to the tank level in the form of a bar chart and actual volume reading in gallons A graph is also displayed indicating the temperature of the water in the tank and the returning distribution loop water temperature The lights next to H1 H2 and H3 correspond to which heaters are on at the time Red signifies off while green signifies that the heat...

Page 27: ...OR to return to the SYSTEM MONITOR screen Monitor Times Screen Display Action The TIME MONITOR screen provides information regarding the unit s status during heat disinfection indicating remaining times for each step of the process Press MAIN MENU to return to the MAIN MENU screen or RATE MONITOR to return to the RATE MONITOR screen or SYSTEM MONITOR to return to the SYSTEM MONITOR screen Alarms a...

Page 28: ...reen will list in date and time order all recorded raised alarms and system events By pressing the arrows you will be able to navigate the listed entries The selected entry s message will scroll Users with Level 2 access or above can Clear All or Delete alarm event message s If an alarm is raised by the unit the screen will change to red and display the message ALARM ACTIVE A secondary message wil...

Page 29: ... Display Action To gain access as a Level 2 or 3 user press USER LOGIN and login as detailed in 6 3 1 Enter the appropriate password _ _ _ _ _ _ Then press ENTER The password will only be available to authorized personnel contact AmeriWater if this level of access is required Once logged in press CURRENT SETUP then select SYSTEM SETUP this will take you into the three system setup screen menus as ...

Page 30: ...me for the loop and tank to cool down Press NEXT PAGE to enter SYSTEM SETUP PAGE 3 In this final set up screen you will be able to change the date and time settings by pressing CLOCK SETTINGS This will take you to TIME SETTING AND DISPLAY screen The clock is a 24hr clock The date is displayed as mm dd yyyy Press X in the upper right corner of the window when finished If the unit is coupled to a Me...

Page 31: ...alue will affect the operation of the unit always refer to AmeriWater before changing any values The unit will already have been programmed with a set of factory default values Details of these can be found in Section 6 10 To change any values simply press the relevant digit a number keypad will be displayed select the desired value and press ENTER MAXIMUM OPERATING TEMP is the temperature that th...

Page 32: ...is is the time each machine takes to carry out a heat disinfection cycle Press NEXT PAGE to enter FACTORY SETUP PAGE 4 Refer to Section 6 10 for FACTORY SETUP PAGE 4 values COOL DOWN DROP is the pre set value that controls the opening of the cold water fill valve during cool down cycle Press NEXT PAGE to enter FACTORY SETUP PAGE 5 Refer to Section 6 10 for FACTORY SETUP PAGE 5 values WATER FEED ON...

Page 33: ...ect the dialysis machines Press NEXT PAGE to enter FACTORY SETUP PAGE 6 To save default settings press SAVE SETTINGS button for 5 10 seconds until you hear a single beep This will over write previously saved settings To recall the factory default settings press LOAD DEFAULTS To check on current versions of software loaded press SOFTWARE VERSIONS to access the following screen Details current softw...

Page 34: ...associated interlocks and safety control devices Pressing MONITOR will take you directly to the temperature and tank volume screen Press MAIN MENU to return to the MAIN MENU Press BACK button to return to the previous screen To gain access to sensor calibration screen press CALIBRATE refer to Section 9 4 for details The SYSTEM MONITOR screen displays both tank level tank and loop return temperatur...

Page 35: ...e process of heat disinfection the STANDBY screen will be displayed STAGE 2 The PREHEAT screen will be displayed during the first stage of heat disinfection to indicate the initial preheating of the stored water STAGE 3 Once the timed heat disinfection phase commences HEATSAN OPERATION message will be displayed This message will continue throughout the heat up and hold phases of the disinfection c...

Page 36: ... fully drain down the integral tank on the unit DRAIN IN OPERATION indicating that this stage is in process On completion the screen will revert back to STANDBY Data Logging The Heatsan disinfection system will automatically log data every 5 minutes during operation This will capture the information from the SYSTEM MONITOR screen It is recommended that this data be periodically transferred to a US...

Page 37: ...SB drive into the port on the front of the control panel The USB must be FAT 16 formatted After a short period of time the USB DRIVE READY light should illuminate green and the REMOVE USB DEVICE and WRITE TO USB buttons will appear Depress WRITE TO USB to write the data files to the USB drive The USB WRITE ACTIVE light will illuminate orange while data is being written to the USB drive Do not remo...

Page 38: ...LOGS button in the lower left corner of the screen NB Once the DELETE LOGS button is depressed all data stored on the HMI will be deleted Ensure that the data has been transferred to a USB drive prior to commencing Once the information has been deleted the logging count displayed on the bottom of the screen will be 0 Uploading New Software During normal operation it will not be necessary to change...

Page 39: ...1 Maximum Draw Off Available USGal Not Adjustable Factory Setup Page 2 Draw Off Gal Mach 3 Factory Setup Page 2 Rate GPM 1 Factory Setup Page 2 Time per Dialysis Machine Hr min 0 15 Factory Setup Page 3 Water Loss in Hold UsGal 5 Factory Setup Page 3 Heater 1 Level UsGal 15 Factory Setup Page 3 Heater 2 Level UsGal 21 Factory Setup Page 3 Heater 3 Level UsGal 32 Factory Setup Page 3 Cool Down Temp...

Page 40: ...ld be thoroughly investigated and cleared Alarm Message Reason Checks Proposed Actions Pump Fault Trip Condition 1 Caused by motor overload tripping Ref 1Q1 due to short circuit or thermal overload 1 Bearing failure 2 Obstruction in pump 3 Motor windings shorting out 4 Excess ambient temp 5 Faulty overload 6 Loss of a phase 7 Contactor set too close to run current 1 Inspect bearings and replace wh...

Page 41: ... Error 1 Caused by heater 2 contactor 3K1M not switching when requested The PLC should signal the contactor to operate when the contactor switches an auxiliary contact should give the PLC a signal If the PLC does not receive a return signal within a preset time then a fault alarm is raised 1 As per Heater 1 1 As per Heater 1 Heater 2 Over Temp 1 Caused by the heater internal temperature switch X6 ...

Page 42: ...Din connector or under sleeve adjust the pressure until the alarm clears 6 Replace Pressure Switch Loop Alarm Excess Temperature 1 Caused by the loop or tank temperature sensors exceeding preset MAXIMUM OPERATING TEMPERATURE settings 1 Faulty Tank Return temperature transmitter s 2 Faulty heater s thermostats 3 Incoming feedwater temperature greater than preset max limit 4 Check that set point is ...

Page 43: ...rm menu was pressed while the system was in Standby 1 This message is for information only and not linked to any specific fault condition 2 Check if the clinic is operating on a day that is not normally scheduled 1 System will allow the alarm to be cleared 24 hr after the button has been pressed If accidently pressed the power can be cycled then the alarm can be cleared Low water temperature 1 Tem...

Page 44: ...ers are ON 6 Check that there is enough Preheat Time to raise the water temp to Sanitization Value 7 Verify if any of the Setup Settings been changed recently System fault 1 If any ALARM is detected while the Heatsan is in Operation 1 Any Detected ALARM 1 Check ALARM log for latest registered ALARM Reset repair as necessary Drain operation failed 1 Pressure level transmitter detected positive wate...

Page 45: ...been taken in full by the dialysis machines the unit will automatically go into cool down Cold water from the RO units will be gradually introduced into the system and run to drain until the accepted temperature is achieved Drain in Operation The final stage of the heat disinfection cycle is to drain the internal tank down completely Drain in Operation indicates that the tank drain solenoid is in ...

Page 46: ...use of un approved chemicals is strictly forbidden and may invalidate any guarantees or warranty It is recommended that the tank and heaters are inspected annually for signs of fouling scaling and general integrity If the unit is to be decommissioned and placed in long term storage 6 months it should be fully drained i e drain the pipework and recirculation pump fully and isolate its feedwater sup...

Page 47: ...ring this testing the temperature of the water will be sufficient to create steam which is hot enough to scald during this test Ensure that you will be able to determine the temperature without reaching into the tank To begin remove the lid from the Heatsan system Log in as user level 3 see Section 6 2 Access the manual operation menu and open the fill solenoid valve Allow the unit to fill to 16 g...

Page 48: ...8 9 kW 208V Heater 38 0001 3 kW 208V Heater 38 0002 Temperature transmitter 39 0006 1 Pressure sustaining valve 44 0073 SS N C fill solenoid valve 59 0034 1 SS N C drain discharge to loop solenoid valve 59 0035 1 SS N O feed from loop solenoid valve 59 0055 Float switch 67 0012 Pressure switch 68 0004 Pressure transmitter 68 0005 Distribution pump 208V 80 0189 Only trained approved personnel or an...

Page 49: ...ter test screen FACTORY SETUP PAGE 6 and select CALIBRATE Three sensor options are displayed Identify the sensor to be calibrated Adjust the Offset To check adjust calibration of the temperature sensors the actual water temperature should be measured using an independent calibrated device Adjust the Gain and Bias such that the sensors match the reading of the independent device ...

Page 50: ...0 APPENDIX Disposal of electrical parts Disposal of the unit or any electrical component from the unit must be in accordance with local requirements in your province or state for the disposal of electrical waste E Waste ...

Page 51: ...50 98 0156 Rev G Heatsan Process Flow Diagram ...

Page 52: ...51 98 0156 Rev G Wiring Diagrams ...

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Page 58: ...57 98 0156 Rev G Installation Layout Water Connection Detail ...

Page 59: ...58 98 0156 Rev G Flow Diagram MediQA to Heatsan Ensure that the flow direction of the check and solenoid valves is as indicated above ...

Page 60: ...59 98 0156 Rev G Heatsan Discharge Solenoid SV3A NC Note The MediQA permeate on the tee connection above must be as close to the MediQA permeate discharge as possible ...

Page 61: ...ndicated above is labeled as SV3A and should be connected to the SV3A port on Heatsan panel The NO solenoid valve on the HS FILL line indicated above is labeled as SV3B and should be connected to the SV3B port on Heatsan panel Connect the straight end of the cable labeled as MINT to MINT on the Heatsan control panel Connect the 90 end of the MINT cable to the MINT connection made on the MediQA The...

Page 62: ...61 98 0156 Rev G Tubing with Heatsan and MediQA Hidden ...

Page 63: ...62 98 0156 Rev G Flow Diagram MROZ to Heatsan Ensure that the flow direction of the solenoid and check valves is as indicated above ...

Page 64: ...63 98 0156 Rev G RO Divert Valve and Heatsan Divert Valve 1 Heatsan Divert Valve 2 ...

Page 65: ...64 98 0156 Rev G Heatsan Discharge Solenoid SV3A NC Heatsan Fill Solenoid SV3B NO ...

Page 66: ...tween the MROZ and Heatsan close to the control valves Ensure that the cables for the valves will be able to reach the control panel 25 maximum cable length Connect the cables to the following connectors VC1 RO Divert Valve to VC1 VC2 Heatsan Divert Valve 1 to VC2 and VC3 Heatsan Divert Valve 2 to VC3 Run cable ICZ to the control panel interface connector ICZ Terminate the flying leads into the MR...

Page 67: ...66 98 0156 Rev G Tubing with Heatsan and MROZ Hidden Note PEX tubing and cooldown hose represented by dashed lines ...

Page 68: ...h provided screws and washers Connect male connector to connector labeled SGNL on the bottom side of the enclosure Route cable to Heatsan control panel Connect other male connector on cable to connector labeled SGNL on the bottom side of the control panel as shown in figure above ...

Page 69: ...e can occur to the external equipment not rated for high heat operations Removes the risk to personnel if they come into contact with equipment that might dispense hot water Prevents causing an error on the Heatsan for water loss and aborting a cycle before proper disinfection has occurred The side of the ISO cable with flying leads needs to be wired into the Heatsan Control Panel according to the...

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Page 71: ...TUP NEXT PAGE until FACTORY SETUP PAGE 5 is reached SOFTWARE VERSIONS PLC 2 Turn the panel power OFF via the power disconnect switch 3 Verify that the PLC Power Status LED is OFF 4 Place the PLC RUN STOP switch in the STOP position 5 Remove plastic cover from expansion board on the PLC 6 Gently install the FX3G EEPROM 32L module into the Optional Equipment Connector 7 With the electrical panel doo...

Page 72: ...PLC Run Status LED is ON 21 Shut and secure the panel front door 22 Navigate to the unit s SOFTWARE VERSIONS HMI screen Verify that the PLC software version matches the version upgrade documentation NAMES AND FUNCTIONS OF PARTS PLC 1 PLC Power Status LED Illuminated green while power is on the PLC 2 PLC Run Status LED Illuminated green while the PLC is running 3 RUN STOP switch Starts or stops PLC...

Page 73: ...72 98 0156 Rev G 1 Front Cover Can be used to remove module from PLC 2 WR Pushbutton Initiates module writing to PLC 3 WR LED Writing indicator 1 3 2 ...

Page 74: ...upload a program without the use of a laptop proper HMI software or the correct communication cable A customer can perform the upgrade without an onsite field service tech from AmeriWater Inc being present The USB port for the HMI is currently brought out to the front of the control panel as an access point REQUIRED ITEMS Flash Drive With Current project release of the HMI program ready for loadin...

Page 75: ...74 98 0156 Rev G 2 Plug the Jump Drive into the USB port 3 Press the Upper Left Corner of the Touch Screen The Screen should change to the following ...

Page 76: ...75 98 0156 Rev G 4 Press the Icon for Program data control The screen will switch to the following 5 Press the P icon for Project Information The Screen will switch to the following ...

Page 77: ...76 98 0156 Rev G 6 Press E USB Drive The screen will switch to the following 7 Press the Download Button The screen will switch to the following ...

Page 78: ...77 98 0156 Rev G 8 Press OK Button The screen will switch to the following 9 When the download is complete the screen will automatically switch to the following ...

Page 79: ...v G 10 Press the OK button The screen will change to the following 11 The screen is now rebooting and will be back in operation with an updated program Pull the jump drive from the USB port and store it as a backup ...

Page 80: ...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...