Thermo Scientific ULTROpure 682 Series, Operation Manual

Page 1: ...ULTROpure Reverse Osmosis System OPERATION MANUAL AND PARTS LIST Series 682 Model Voltage D6821 120 D6822 230 D6823 100 LT682X1 8 8 08 ...

Page 2: ...n 18 Electrical Requirements 18 Operation 19 Controller and Rejection Monitor 22 Controller 22 Storage Reservoir Control 23 Rejection Monitor 24 Error Indications 25 Storage Reservoirs 26 Maintenance 27 Fuse Replacement 27 Membrane Replacement 27 Prefilter Replacement 28 Motor Bearing Lubrication 28 Membrane Cleaning 28 Membrane Cleaning Compound and Procedure Chart 30 Resistivity Cell Cleaning 30...

Page 3: ...cted to electrical service according to local and national electrical codes Failure to properly connect may create a fire or shock hazard 2 Do not mount the ULTROpure directly over equipment that requires electrical service Routine maintenance of this unit may involve water spillage and subsequent electrical shock hazard if improperly located 3 For continued protection against possible haz ard rep...

Page 4: ... depres surize chemical lines before disassembly Ensure adequate ventilation Follow carefully the manufacturerʼs safety instructions on labels of chemical containers and material data sheets 3 Make sure that the brackets are locked together by the locating pins Failure to properly engage the brackets will create an unsafe installation that may cause equipment damage or personal injury 4 Depressuri...

Page 5: ...5 Figure A Flow Diagram ...

Page 6: ...se Osmosis Systems Cat Nos D6821 D6822 D6823 Please take a few minutes to familiarize yourself with the hardware before beginning installation Warning This device is to be used only with water feeds and specified pretreatment chemicals determined by a H20 Select water analysis Sanitizing cleaning agents must be used in compliance with instructions in this manual Failure to comply with the above co...

Page 7: ...ur ULTROpure certain conditions refer to the Equipment Specifications section on page 17 must be established and maintained before and during operation The user should pay particular attention to the requirements for residual chlorine and pH specifications In some installa tions pH adjustment is required to prevent hard scale formation on the membrane surface or membrane hy drolysis In these cases...

Page 8: ...in the membrane cavity that contains the following hard ware Registered Trademark of DuPont INSTALLATION Note Extra fittings and parts are provided for use in installation and routine main tenance procedures Retain all fittings and parts not used during installation for future use y t i t n a u Q o N g o l a t a C n o i t p i r c s e D 1 1 X 3 8 5 L F g L 0 1 r e t l i F 2 4 3 0 3 0 T P N 8 3 x e ...

Page 9: ...e points to verify proper engagement of the two mating brackets E Install the rubber pads over the locating pins on the angle iron wall bracket The rubber pads are in the plumbing hardware package Note If you are installing additional equipment with the ULTROpure such as a Barnstead NANOpure refer to the individual ownerʼs manual for space requirements before installing the ULTROpure System If you...

Page 10: ...Package Reject Flow Meter Membrane Pressure Gauge Product Flow Meter Recycle Valve Reject Valve RO Product Connection RO Reject Connection Prefilter Housing Prefilter Outlet Pressure Gauge Prefilter Inlet Pressure Gauge Power Entry Module Remove before installing membrane A INSTALLATION ...

Page 11: ...he brackets lock together The line scribed in step D should be equal with the top of the ULTROpure If this is not the case repeat step F H Install 1 4 fasteners to further secure the ULTROpure on the wall These fasteners are to be installed in the upper cabinet The holes are located on the upper right hand and left hand corners of the back panel Locations indicated by point A on Figure B page 10 I...

Page 12: ...e grab ring and backup ring in the hex nut in the order and orientation shown in Figure C Thread the nut onto the adapter DO NOT use the O ring at this time D Push the tubing through the hex nut until it bot toms out in the adapter E Remove the adapter nut and tubing Place the O ring over the tubing Be careful not to push the backup ring or grab ring further back on the tubing when installing the ...

Page 13: ...to an atmospheric drain DO NOT RESTRICT THIS LINE IN ANY WAY C Connect Product line to drain until you finish flushing the membrane Membrane Installation Replacement Installation of the Barnstead reverse osmosis membrane in the ULTROpure requires the following tools large slot blade screwdriver and an open end 5 8 wrench Install the membrane by the following steps A If not previously removed remov...

Page 14: ...by removing the nut and the bolt F While holding the membrane in place with one hand take one end of the hold down clamp and place it into the slot located midway up the membrane on the back wall Repeat this with the other end of the clamp directly on the oppo site side G Secure the hold down clamp in place by replac ing the bolt Place one of the two supplied washers between the bolt head and the ...

Page 15: ... adapters from package 2 Open the access door by rotating the knob on the front Remove the canister from the head by pressing the thumb lever and rotating the ring 1 4 turn to the left 3 Lubricate the o rings on the adapters using water then install the adapters into the filter by turning the adapter as you push it into the filterʼs open end Note This tubing is attached to the pump outlet Caution ...

Page 16: ...ard over the filter and tight en on the head 1 4 turn to the right Caution Secure locking pin before operating locking pin must be fully released into hole on head before the system is operated See Figure D Figure D Canister locking pin position Note An extra head to canister O ring is supplied This can be used as a replacement if the O ring has been damaged or deformed in shipment INSTALLATION ...

Page 17: ...e 634 ppm D68211 membrane 634 ppm Max TDS 50 Recovery D6828 membrane 557 ppm D6829 membrane 591 ppm D68210 membrane 545 ppm D68211 membrane 545 ppm Product Water Flowrate 1 D6828 membrane 58 4 Iph 9 Iph 15 5 gph 2 4gph D6829 membrane 110 4 Iph 10 Iph 29 2 gph 2 6 gph D68210 membrane 157 7 Iph 24 Iph 41 6 gph 6 4 gph D68211 membrane 78 9 Iph 12 Iph 20 8 gph 3 2 gph Quality 1 NaCI System Rejection 1...

Page 18: ...56 3 Mounting Wall mount with bracket provided Floor mount with optional floor mounting stand Plumbing Connections Feedwater 1 2 OD tube Product Water 3 8 OD tube storage Reject 3 8 OD tube Electrical Requirements Voltage and Frequency nominal 100 VAC 50 60 Hz 85 110 VAC 47 63 Hz 1 phase 15 amp 120 VAC 60 Hz 98 127 VAC 57 63 Hz 1 phase 15 amp 230 VAC 50 Hz 196 253 VAC 47 53 Hz 1 phase 8 amp EQUIPM...

Page 19: ...erlock Jumper plug sup plied in the ULTROpure plumbing hardware package into the Storage Interlock on the right side of the ULTROpure D Connect the power cord to the power entry module on the right hand side of the unit and to an appropriate power supply E Press the Power button on the ULTROpure control panel F After the high pressure pump has started adjust the recycle valve until the membrane pr...

Page 20: ...ay cause a shutdown condition because of low pressure until the system is purged The elec tronics allow for a restart prior to shut down When the ULTROpure senses a low pressure situation it will wait 30 seconds then attempt a restart It will shut down if the unit senses low pressure the second time Should a shutdown condition occur while you are performing this startup shut the ULTROpure off and ...

Page 21: ...ed to protect the membrane during manufacture and stor age O You are now ready to collect and use the product water from your ULTROpure Turn unit off P If you are using a Barnstead storage reservoir or a reservoir with a level sensor connect the level sensor cable to the ULTROpure Storage Interlock Q If you are using a Barnstead 100 Liter Storage Reservoir or another manufacturers unit refer to Fi...

Page 22: ... pump starts During the first 10 seconds of this delay the low feedwater pressure switch is locked out to prevent premature shutdown triggered by the sudden ini tial pressure surge of the pump Running Mode The ULTROpure safety interlocks are activated in the run ning mode to respond if necessary to fault conditions The active interlocks and corresponding functions are Switches Functions Low feedwa...

Page 23: ... u p O R T L U e h t t i l s n i a m e r r o t a c i d n i y b e h t h s u l f e t u n i m 0 1 e h t g n i r u D s e t u n i m 0 1 r o f s e t a r e p o d n a e h t t A t i l s i t h g i l r o t a c i d n i h s u l f o t u a e h t d n a n o s i r o t i n o M n o i t c e j e R d e n r u t e r s i d n a n w o d t u h s s i e r u p O R T L U e h t e l c y c e h t f o n o i t e l p m o c s u t a t s y...

Page 24: ...s p o r d n o i t c e j e r n e h W y d a e t s s e h s a l f l o r t n o C l l i w e d o m e r u t a r e p m e T e h t n i s i y a l p s i d e l i h w d l e h n e h W r e t a w t c u d o r p e h t f o e r u t a r e p m e t e h t y a l p s i d o t y a l p s i d e l g g o t n i l o r t n o c n e h w e r u t a r e p m e t r e t a w t e l n i o t s t r e v e r y a l p s i D C e h t d n a e d o m y t ...

Page 25: ... t a c i d n I m e l b o r P c i r e m u n o n s l a m i c e d t i l y l s u o u n i t n o C y a l p s i d l l e c d n u o r a d e p p a r t r i A r o t c e n n o c d r a o b t i u c r i c d e t n i r p e h t t a d a e l l l e c t c e n n o c s i D r o t c e n n o c d r a o b t i u c r i c d e t n i r p e h t t a s d a e l f o g n i r i w t c e r r o c n I 0 0 t i l y l s u o u n i t n o C e c i v...

Page 26: ... certain precautions must be taken to assure proper operation of the combination ULTROpure storage systems Care must be used in installing the fill line in the reservoir Level sensing switches may be used to control the ULTROpure The ULTROpure will accommodate independent switches for the high and low water levels or a single high level switch may be used In the latter case the change in water lev...

Page 27: ... section of the ownerʼs manual for mainte nance requirements Fuse Replacement For continued protection against possible hazard replace fuses with same type and rating of fuse The main fuses are located in a fuse holder at the upper right side of the top housing To access remove top cover squeeze the clip on the fuse holder and remove Replace with slow blow 10 ampere fuses for 230 VAC units and slo...

Page 28: ... located at each end of the motor housing directly on top Membrane Cleaning Frequency of cleaning is difficult to determine because of the wide variety of feedwater supplies We recommend that the ULTROpure reverse osmosis membrane be cleaned on a regular basis every 3 months More frequent cleaning is required if the following conditions occur 1 A 5 decrease in rejection from initial values and or ...

Page 29: ...g from the membrane feed fitting to the discharge port of the cleaning pump used for recirculating the cleaning solution D Disconnect the tube fitting from the membrane housing bottom cap and connect a sufficient length of tubing to the membrane bottom cap fit ting Secure the free end of the tubing inside the cleaning tank E Disconnect the Product line at the ULTROpure Connect a sufficient length ...

Page 30: ...ove the cell from the outlet cell well located on the shelf to the right of the membrane C If you are cleaning the feed water cell remove the cell from its location to the right of the prefilter D Remove any excess Teflon tape from the cell threads e n a r b m e M o N t a C g n i n a e l C d n u o p m o C o N t a C n o i t u l o S g n i n a e l C p u e k a M n o i t a l u c r i c e R e m i T 8 2 8...

Page 31: ...everse osmosis water fol lowing the detergent or acid cleaning G After rinsing reinstall the cell Cell Lead Connections Wire Color Pin Number Clear White 15 Product Cell Red 13 Black 11 Shutdown If the ULTROpure is to be shut down for more than 4 days the membrane must be protected with a disinfectant We recommend that the membrane be cleaned as detailed in Membrane Cleaning of the Maintenance sec...

Page 32: ... unit on for 30 seconds and then shut it off Repeat 3 or 4 times to allow the solution to completely fill the membrane housing J Disconnect the Reject tubing at the ULTROpure The ULTROpure system can now be shut down indefinitely Clearly mark the ULTROpure unit stating that it is in a stor age shutdown condition to avoid system use without proper restart procedure Startup Procedure After Shutdown ...

Page 33: ...o L n i r o t a c i d n i e r u s s e r p e d o m h s u l f l a u n a m f i s r e t l i f e r p l a n r e t x e e v o m e R e d o m h s u l f l a u n a m n i t n e s e r p e r u s s e r p t e l n i e s a e r c n I e n a r b m e m h g i H r o t a c i d n i e r u s s e r p l i o c t u o d e n r u b r o e v i t c e f e D t a e r i w d e t c e n n o c s i d r o n e k o r B s n o i t c e n n o c d i o ...

Page 34: ...y of replacement or provides information on service life expectancy You thus may calculate a replacement schedule based on your usage pattern The replacement of consumable parts is discussed in the Maintenance section of this manual to assist you in accomplishing your own service Description Catalog No Quantity Prefilter FL583X1 2 Fuse Power Entry 100 120 V 15A FZX28 4 Fuse Power Entry 230 V 10A F...

Page 35: ...wn upon by yourself or our technicians thereby avoiding unneces sary delays in delivery of replacement parts Description Catalog No Quantity Pump 01405 1 Motor 100 120 Volt 01406 1 Motor 230 Volt 01411 1 Monitor PC Board Located rear of unit PC682X1 1 Main PC Board Located front of unit PC682X3A 1 Inlet cell E682X1 1 Product cell E550X1 1 Low Pressure Switch 01407 1 High Pressure Switch 01408 1 Re...

Page 36: ...c dealer from whom you purchased this unit or can be obtained promptly from the factory When service or replacement parts are needed we ask that you check first with your dealer If the dealer cannot handle your request then contact our Customer Service Department at 563 556 2241 or 800 553 0039 Prior to returning any materials please contact our Customer Service Department for a Return Materials A...

Page 37: ...37 Wiring Schematic for Customer Supplied Switches for Storage Reservoirs Schematics ...

Page 38: ...MODULE W FUSE POWER ENTRY DRAW POWER ENTRY M LINE 230V 10A GROUND RETURN 100V 15A FAN PUMP HIGH PRESSURE ICR HP 3 4 L1 L2 100V 15A 230V 10A MAIN POWER MAIN POWER 100 VAC 50 60 Hz 230 VAC 50 Hz 120 VAC 60 Hz 230 V 120 V TRANSFORMER OR 100 V 120 V Electrical Schematics SCHEMATICS ...

Page 39: ...RESSURE SWITCH LO HI ICR RED RED 6 7 START MANUAL FLUSH RED RED RED RED BLK BLK BLK BLK WHT WHT WHT BLK FAULT LED CLOSE AT 5 PSI DECREASING OPEN AT 250 PSI INCREASING RESERVOIR LOW RESTART SWITCH RESERVOIR FULL STANDBY SWITCH BLK WHT PERCENT REJECTION MONITOR CELL 1 CELL 2 BLK RED WHT BLK RED WHT 10 12 14 15 13 11 3 2 1 5 DISPLAY P C B MEMBRANE SWITCHES RED 3 2 1 4 3 FLOAT SWITCH ASSEMBLY JUMPER P...

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Page 44: ...isuse including use inconsistent with written operating instructions for the product mishandling contamination overheating modification or alteration of the product by any customer or third party or iii use of replacement parts that are obtained from a party who is not an authorized dealer of Thermo Scientific prod ucts Heating elements because of their susceptibility to overheating and contaminat...