M4-SERIES WATER PURIFICATION MACHINES M4-2200 – M4-13200 Operation and Maintenance Manual 1238160 Rev.
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OPERATION AND MAINTENANCE MANUAL M4-SERIES WATER PURIFICATION MACHINES M4-2200 – M4-13200 TABLE OF CONTENTS Page 1-1 CHAPTER ONE: GENERAL INFORMATION Section General Information and Principles of Operation Machine Nomenclature Machine Permeate Quality Materials and Features Specifications for M4-Series Machines 1-7 1-7 1-7 1-8 CHAPTER TWO: INSTALLATION 2-1 Section Mounting Plumbing Electrical 2-3 2-3 2-4 CHAPTER THREE: PREPARATION AND START-UP 3-1 Section Pretreatment for Water Purification
CHAPTER FIVE: OPTIONAL ACCESSORIES 5-1 Section Level Controls Conductivity Meter Autoflush Filters and Water Softeners 5-3 5-3 5-3 5-5 CHAPTER SIX: TROUBLESHOOTING 6-1 APPENDIX A: RETURN MATERIAL AUTHORIZATION (RMA) PROCEDURE 1238160 Rev. D 5.1 5.2 5.3 5.
M-Series Water Purification Machines M-Series Water Purification Machines M4-2200 – M4-13200 CHAPTER ONE: DESCRIPTION 1238160 Rev.
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M-Series Water Purification Machines 1.1 General Information and Principles of Operation These instructions give operating and maintenance details vital to the sustained performance of the machine. Reverse Osmosis (RO) is the removal of ionic, organic, and suspended impurities from water by means of a membrane. Unlike a filter (“normal” filtration), the feedwater or solution is separated into two streams by collecting fluids from both sides of a pressurized membrane (“crossflow” filtration).
M-Series Water Purification Machines CONCENTRATION Concentration equals the Total Dissolved Solids (TDS) concentration of a solution expressed as milligrams per liter (mg/L) or conductivity (microSiemens/cm). Cf Cp Cc Cavg = = = = Feed Concentration Permeate Concentration Concentrate Concentration Average Concentration in machine SALT (IONIC) REJECTION: This equals the percent of dissolved salt rejected by the membrane, calculated from an average concentration over the membrane.
M-Series Water Purification Machines Given the system case in Figure 2: Average Concentration (Cavg) = (Cf) 100 mg/L + (Cc) 146.9 mg/L 2 (Cavg) = 123.5 mg/L TDS Rejection = (Cavg) 123.5 – (Cp) 6.2 x 100 = 95% (Cavg) 123.5 Passage = (Cp) = 6.2 x 100% = 5.0% (Cavg) 123.5 Recovery = (Qp) 2 gpm x 100 = 33% (Qf) 6 gpm FLOW DESCRIPTION: The feedwater passes through a replaceable 5-micron cartridge filter, which removes bulk suspended solids. Filtered water then flows to the inlet control valve.
M-Series Water Purification Machines Typical P&ID 1238160 Rev.
M-Series Water Purification Machines 1.2 Machine Nomenclature M-Series water purification are numbered in such a way as to indicate the permeate flow and quality you can expect from the machine. Example: M4-6600, 208, 6, 50-75 • M4 indicates the machine series • 6600 indicates the rated permeate flow in gallons per day • 208 indicates motor voltage • 6 indicates 60 Hz • 50-75 indicates the % recovery capability of the RO 1.
M-Series Water Purification Machines • Autoflush System – programmable, automated high velocity membrane flushing for the longest membrane life; set at the factory and adjustable in the field, includes a digital panel-mount timer, complete with push button Manual Flush • An electrical package that includes alarm delay shutdown for low inlet pressure condition to prevent pump damage should pressure fall below 15 psig (1 bar) • Conductivity monitor, panel-mounted, for permeate quality monitoring • NEM
M-Series Water Purification Machines 1.5.2 Permeate (Product Water) Flow Rate Stated on the RO test report form (assumes no permeate back pressure, 2000 mg/L TDS maximum feed concentration, and rated temperature). To estimate permeate output with back pressure, use the formula below: Permeate Flow on Label x Operating Pressure – (Permeate Back Pressure) Operating Pressure Permeate Back Pressure Maximum: 60 psig (5.5 bar) Permeate Outlet 3/4-inch FNPT 1.5.
M-Series Water Purification Machines 1.5.6 Pump Multi-stage centrifugal, approximately primary operating pressure of 100 psig excluding line pressure. 1.5.7 RO Membrane Rejection FASTEK TLC Typical Ionic Rejection (TDS) 95-98% Average Molecular Weigh Cutoff* 150 MW *The molecular weight cutoff is based on the pore size of the membranes and the nature (shape/size) of the organic molecule. 1238160 Rev.
M-Series Water Purification Machines NOTES: 1238160 Rev.
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M-Series Water Purification Machines M-Series Water Purification Machines M4-2200 – M4-13200 CHAPTER TWO: INSTALLATION 1238160 Rev.
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M-Series Water Purification Machines 2.1 Mounting M-Series machines are equipped with a frame that supports the machine. Allow at least 45 inches (114 cm) of space at the top of the sepralator housing(s) for removal and loading of sepralators. If 45 inches (114 cm) are not available, the entire membrane element housing may have to be removed for element changes. At least 6 inches (15.
M-Series Water Purification Machines 2.3 Electrical M-Series models require two supply voltages, the control circuit voltage and a separate motor voltage. All field wiring must comply with applicable local and national electrical codes. All M4 models are supplied with a single-phase, 115 VAC 60 Hz or 230 VAC 50 Hz control circuit with an 8-foot cord with plugs into a three-prong grounded receptacle. A 20 amp dedicated service circuit is required for proper operation (see wiring schematic).
M-Series Water Purification Machines 1238160 Rev.
M-Series Water Purification Machines NOTES: 1238160 Rev.
M-Series Water Purification Machines M-Series Water Purification Machines M4-2200 – M4-13200 CHAPTER THREE: PREPARATION AND START-UP 1238160 Rev.
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M-Series Water Purification Machines 3.1 Pretreatment for Water Purification All systems will operate most efficiently on filtered water with a pH of less than 6.5 and a Silt Density Index (SDI) of 5 or below. If the machine is operated on higher pH water, other forms of pretreatment may be necessary. A water analysis prior to start-up of the machine is required.
M-Series Water Purification Machines 3.2 Start-Up 1. Re-check the function and integrity of your pretreatment equipment. Ensure that your water softener, activated carbon filters and iron filters (where applicable) have been leak checked, backwashed, and thoroughly rinsed for service, before starting up your RO unit. 2. Attach the feedwater pipe work to the inlet of the machine. 3. Check for leaks at all connection points. 4.
M-Series Water Purification Machines The proper adjustment of these valves is critical to the operation of the RO machine. The concentrate valve determines the amount of rejected water leaving the machine, and creates the operating pressure shown on the pressure gauge. The recycle valve returns unused reject flow back into the inlet stream to the RO pump. It is important to balance the operating pressure and the respective flows of these valves, to ensure that your machine is operating correctly.
M-Series Water Purification Machines 15. Turn the ON/OFF switch to the ON position. The high-pressure pump will operate and the machine will begin to build pressure. As you are operating, make sure to watch the pressure gauge on the instrument panel. The machine is designed to operate at 115 psi (15.2 bar). NOTE: Do not allow the pressure to exceed 140 psi. If the pressure exceeds 140 psi, open the concentrate flow control valve until the pressure gauge shows 140 psi or less.
M-Series Water Purification Machines 18. Your machine is equipped with flow meters, and a pressure gauge that will assist you in setting alternative flow rates for variable recoveries. If you wish to operate at a recovery lower than 75%, you must ensure that the flow rates for the permeate and the concentrate are at desired levels. Some minor adjustments in the concentrate and recycle flow control valves may be necessary. See Table 1 for specified flow rates for various machine recoveries.
M-Series Water Purification Machines 19. The system is now operational. 20. Before putting the machine into final operation, continue to run the permeate and concentrate streams to drain for at least 60 minutes. This is done to ensure that all of the bactericide has been removed from the sepralators. 21. Connect the permeate line to the point-of-use of the permeate.
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M-Series Water Purification Machines M-Series Water Purification Machines M4-2200 – M4-13200 CHAPTER FOUR: OPERATION AND MAINTENANCE 1238160 Rev.
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M-Series Water Purification Machines The operation and maintenance of your Mar Cor Purification M4 RO Machine is relatively simple but requires regular data recording and routine preventative maintenance. We cannot emphasize too strongly the importance of filling out the daily log sheet during each operating shift. A data sheet was filled out upon start-up containing pertinent facts on the operation of your machine.
M-Series Water Purification Machines NOTE: Failure to change the filter according to these requirements will void the warranty. 4.3 Flushing The machine should be flushed at least once daily to remove sediment from membrane surfaces. The autoflush should be utilized to accomplish system flushing. . NOTE: The Autoflush (AUF) system automatically flushes the machine and eliminates the need for frequent manual flushing. 4.
M-Series Water Purification Machines 2. With the machine off, close the feedwater inlet valve and open the CIP inlet valve. The permeate and concentrate streams must be diverted to the cleaning container for recirculation. Ensure that the prefilter is clean. A CIP pump is recommended to supply feed pressure in the machine. 3. To circulate the cleaning solution through the machine with suction, the low-pressure switch must be bypassed. Use a noncollapsible suction hose or pipe to feed the machine.
M-Series Water Purification Machines 5. To flush the detergent from the machine, close the CIP inlet valve, open the feedwater valve, and divert the permeate and concentrate to drain by opening the CIP drain valve. Operate the machine as described in the flushing section for at least 1 hour. The detergent is sufficiently flushed when the permeate conductivity is restored to nearly its previous level. 6.
M-Series Water Purification Machines 4.5 Sepralator Replacement As time progresses, the efficiency of the sepralator will be reduced. In general, the salt rejection does not change much until 2-3 years after installation, when operated on properly pretreated feedwater. The permeate flow rate will begin to decline slightly after one year of operation, but can be extended with diligent flushing and cleaning of the machine.
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M-Series Water Purification Machines M-Series Water Purification Machines M4-2200 – M4-13200 CHAPTER FIVE: ACCESSORIES 1238160 Rev.
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M-Series Water Purification Machines 5.1 Level Controls (Not Factory Installed) Wire float switches, pressure switches or other level controls into the control circuit line (prior to the switch as noted on the electrical schematic on the unit). The following assures that the inlet valve, instruments, and pumps are not powered when storage tanks are full: float switch assembly with cord, counterweight, and plastic float (used with an atmospheric storage tank). 5.
M-Series Water Purification Machines 5.3.1.3 Set Minute 1. Press the clock key and the minute (min+) key simultaneously. The minutes will change. Hold the clock key and the minute (min+) key more than three seconds and the minutes will shift faster. Release both keys. The minutes will be set. 2. 3. 5.3.2 To Set Programs 1. 2. 3. • • • • • • • • • • 4. 5. 6. 7. 8. Press the timer key to enter the program mode. Program 1’s turn-on time is ready to be set.
M-Series Water Purification Machines 5.3.4 To Select ON/AUTO/OFF Mode 1. 2. 3. Press the MANUAL key to select the appropriate mode ON will turn on the timer. AUTO will set the timer to the Program Time. NOTE: Moving from ON to AUTO will turn on the timer according to the next Program’s turn-on time. Moving from OFF to AUTO will turn off the timer according to the next program’s turn-off time. OFF will turn off the timer. 5.
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M-Series Water Purification Machines M-Series Water Purification Machines M4-2200 – M4-13200 CHAPTER SIX: TROUBLESHOOTING GUIDE 1238160 Rev.
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M-Series Water Purification Machines TROUBLESHOOTING GUIDE Symptom Low operating pressure Possible Causes Remedies Insufficient feedwater pressure or Open the feed pressure, open the feedwater flow valve, check for restrictions. Clogged pre-filter Replace the cartridge High flow rates Close the concentrate valve, check the permeate and concentrate flow rates and adjust if necessary. Excessive permeate flow may indicate a damaged O-ring.
M-Series Water Purification Machines TROUBLESHOOTING GUIDE Symptom Low permeate flow rate Possible Causes Remedies Low operating pressure See the possible causes for low pressure Dirty or fouled sepralators Flush and clean the sepralators Operating on cold water less than 55°F (13°C) Sepralators installed backwards or damaged concentrate seal Flow meter inaccurate Install a hot/cold feedwater tempering valve if more permeate flow is needed.
M-Series Water Purification Machines TROUBLESHOOTING GUIDE Symptom Low concentrate flow rate, normal or higher than normal pressure Possible Causes Concentrate valve plugged Concentrate outlet line restricted Remedies Remove the concentrate valve step and/or disassemble the piping. Clean the valve. Examine the concentrate line for obstructions or kinks; repair or replace the tubing.
M-Series Water Purification Machines TROUBLESHOOTING GUIDE Symptom Possible Causes Excessive Restricted flow after pump pressure drop outlet [over 50 psig (3.5 bar)] (high primary pressure – low final pressure) Telescoped sepralator covering sepralator housing outlet port Severely fouled or dirty sepralators Water flowing when machine is turned off 1238160 Rev.
M-Series Water Purification Machines TROUBLESHOOTING GUIDE Symptom Declining rejection (high permeate conductivity) Possible Causes Remedies Dirty or fouled sepralators Flush and clean the sepralators. O-ring seal broken or damaged Replace the O-ring, check the sealing surfaces on the O-ring groove, interconnectors and end caps. Replace the damaged parts. Change in incoming water quality Open the concentrate valve and flush. Test the water for pH hardness, TDS and iron content.
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M-Series Water Purification Machines M-Series Water Purification Machines M4-2200 – M4-13200 APPENDIX A: RETURNED MATERIAL AUTHORIZATION (RMA) PROCEDURE 1238160 Rev.
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M-Series Water Purification Machines Returned Material Authorization Procedure If you wish to return good for repair, warranty evaluation and/or credit, please have your original sales order or invoice available when you call Mar Cor Purification. Call (800) 633-3080 and speak with Technical Support. A Mar Cor Purification Technical Support representative will provide instructions and a return authorization number which needs to be clearly written on the outside of the box used to ship your materials.
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Call (800-633-3080) for additional information or visit www.mcpur.com.
