IONIC Zero PPM Operator's Manual

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Operators Manual

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Page 1 Operators Manual...
Page 2 The Reach & Wash™ System has been crash-tested at the Thatcham to the Federal Motor Vehicle Safety Standard 208. The equipment must only be installed into motor vehicles by Ionic Systems approved installers. It is recommended that annual safety inspections are carried out by an approved Ionic Systems Limited agent.
Page 3: Table Of Contents
We offer the largest range of mobile water treatment systems and Waterfed Poles in the World and are sure you’ll find our great range of ionic cleaning products to be the solutions that prove to be...
Page 4: Introduction
In winter the performance of a filter system will be different to the summer. Ionic Systems is not responsible for your local water supply; we have no control over its quality, delivery pressure or flow rate. Further we have no control over how you use the machine or whether it is operated, serviced or maintained correctly.
Page 5: Dimensions
Zero Weights & Dimensions Dimensions...
Page 6 Zero Weights & Dimensions Weights Zero™ Weight ( Dry) Weight ( Wet) System 1000 Ltr 205 – 222kg 1225 – 1242 kg 900 Ltr 200 – 212kg 1112 – 1129 kg 800 Ltr 195 – 212kg 1015 –...
Page 7: Component Identification
Machine Component Identification Component Identification...
Page 8: Control Panel
Machine Component Identification Control Panel...
Page 9 Machine Component Identification System Fuse Box The fuse-box holds all the fuses for the 12v side of the system. Depending upon the specification, up to five fuses may be installed. The position, application and value are depicted in the table below. Fuse Box Diagram Function Amps...
Page 10: System Housing
Machine Component Identification Zero™ System (Filters Removed)
Page 11 Machine Component Identification 8) Split Charger Automatically charges machine’s battery when vehicle engine is running. The split charger should not be relied upon as the sole source of charging for the vehicle’s battery. Regular charging using the mains-powered charger is recommended. When the vehicle’s engine is running, a green LED illuminates to indicate that charging is taking place.
Page 12: Holding Tank
Machine Component Identification Zero™ System Holding Tank 1) Tank Breather Allows air in and out of the tank as it empties and fills (Do not cover or block) 2) Float Switch The float switch stops ultrapure water production when the tank is full. 3) Tank Level Sight Gauge Coloured float indicates ultrapure water level in tank 4) Tank Spirit Bubble...
Page 13: Filter Function
Machine Component Identification Filter Identification Zero™ PPB System...
Page 14: Filter Function
Machine Component Identification Filter Identification Carbon The Carbon filter removes chlorine, chloramines, sediment and volatile organic compounds (VOCs) from water. Protects the RO membrane. 5 Micron (Sediment Filter) The sediment filter removes all particulates larger than 0.00005mm. Protects the RO membrane Softener Exchanges Calcium and Magnesium ions for Sodium ions.
Page 15: Filter Id Discs
Machine Component Identification Filter ID Discs The ID Discs can be found on the top of each filter housing (1) ID discs provide information about the filter contained within the housing (2) It also provides information about the maximum estimated filter life (3) Estimated Filter Life Information about filter life and subsequent replacement frequencies is provided for guidance purposes only.
Page 16: Water Connection
General Guidance WATER CONNECTION This section deals with the procedure and recommendations for connecting a suitable water supply to the Zero™. Connection Follow the guidance on this page and connect a suitable water supply to the connection marked ‘Water Connection” and open supply fully. Suitable Water Supply A suitable water supply means water drawn from the mains potable water supply with a minimum delivery pressure of 40psi for machines with boosted fill and a minimum delivery...
Page 17: Effects Of Low Pressure
General Guidance EFFECTS OF LOW PRESSURE AND TEMPERATURE ON PURE WATER PRODUCTION Each stage of filtration serves a particular function. It is good to understand that the first four stages of filtration (UVO , Carbon, 5 Micron and Softener) are in place to protect the RO membrane.
Page 18: Electrical Connection
General Guidance ELECTRICAL CONNECTION This section deals with the procedure and recommendations for connecting a suitable electricity supply to Zero™ machines fitted with boosted fill pumps. Connection Follow the guidance on this page and connect an electricity supply to the machine and switch Suitable Electric Supply A suitable electric supply means connection to either the mains power supply, or a generator of sufficient capacity.
Page 19: General Guidance For Static Systems
Ionic Systems Ltd will not be responsible in anyway for damage of any kind, howsoever caused by the use of its machines within any building.
Page 20: Machine Warning Labels
Like many other cleaning machines, Ionic Systems machines with mains powered pumps have no ‘Run Dry” protection. In the field it is possible to operate Ionic’s range of machines in ways that would not be possible if ‘Run Dry’ protection was fitted.
Page 21: Zero Water Softening
(salt) for calcium. To select the capacity of the pre-machine water softener recommended for your geographical area refer to the table below or visit www.ionicsystems.com/hardwatermaps or consult your Ionic Systems dealer. Water softener Capacity Litres before backwash* Hardness CaCO3 (ppm) Single...
Page 22: Zero Operation (Vehicle Mounted Machine)
For any servicing or repairs other than routine filter replacement please refer to Ionic Systems Ltd or an approved agent of Ionic Systems Ltd. Step 1 Connect a suitable water supply to the mains water ‘IN’...
Page 23 Machine Operation Explanation of Events Stage 1 On pressing the green ‘START’ button the ‘SYSTEM PURGING’ light will illuminate to indicate that standing water in the UV/03, Carbon Filter and both Sediment Filters is being replaced with fresh water. Purging of these filters prepares them for use. This process takes four minutes to complete.
Page 24 Machine Operation Stage 3 After two minutes the ‘SYSTEM FLUSHING’ light extinguishes and the ‘TANK FILLING’ light illuminates. During this stage pure water enters the holding tank via the DI filter and will continue to do so until the tank is filled with pure water. During this stage the digital TDS monitor can be used to measure the quality of water produced by the RO filter as well as the water quality following the DI filter.
Page 25 Machine Operation Step 5 When the tank is full the water supply to the filters will be stopped and the mains powered boost pump (if fitted) will stop. The ‘SYSTEM REGENERATING’ light will illuminate and Pump 1 will operate for a period of eight minutes. During regeneration purified water is pumped from the tank into both RO filter housings.
Page 26 Operating the Thermo-pure™ system with an under charged battery may lead to aborted starts and subsequent component failure requiring specialist technical attention from an Ionic approved technician The Thermo-pure™ system burns diesel drawn from either the vehicles fuel tank or an ancillary remote tank The Thermopure™...
Page 27 Ionic Systems technical support. The types of malfunctions are indicated by code flashing signals via the operation indicator light during the after-run period of the heater.
Page 28 Maintenance Procedures Delivery Pump Operation The Control Panel (See Diagram on page 8) also houses the Delivery Pump Controllers. They allow control of the volume of water to the water fed poles as well as switching on and off. The left Pump (1) is the hot pump on a Thermopure™ system and the right pump (2) is always a cold delivery pump.
Page 29 Maintenance Procedures Step 1 - Depress the ‘Pump on/off’ (1) for the desired pump. The Pump Active light will illuminate. 2 Step 2 - Select the desired volume for delivery using the + or –. The normal operating volume is less than 50%.
Page 30 Maintenance Procedures If the RE-SET button (1) is depressed at any time the pumps will be switched off. If this happens simply depress the Pump On/Off (2) and pump will operate once more at the last volume setting On some models pump remote control is fitted. This feature means that pumps can be operated from distances of up to 200mtrs.
Page 31: Maintenance Procedures
Maintenance Procedures Maintenance Procedures General Maintenance ……………………… Filter Replacement ……………………… RO Cleaning ……………………… Battery Charging ……………………… UV Lamp Replacement ……………………… Winterising and Storage ……………………… General Maintenance Before any maintenance activities are undertaken care must be taken to ensure that all mains electrical power has been removed.
Page 32: Filter Replacement
Maintenance Procedures – Filter Replacement Filter Cartridge Replacement Filter Snap Ring Filter Top Cap Filter O ring Seal RO Filter RO Filter Housing NB: Snap Rings and ‘O’ Rings must be replaced every twelve months.
Page 33 Maintenance Procedures – Filter Replacement ‘S’ Model Step 1 Use the Ionic key-ring tool to push down on the retaining ring (1) in the filter housing cap, then pull the fitting (2) upwards and out of the filter cap.(3) Step 2 Move the pipe and fitting clear of the filter cap.
Page 34 Maintenance Procedures – Filter Replacement ‘S’ Model Step 4 Moving the filter housing forward gives access to remove the filter cap. If there is sufficient headroom above the filter housing then the filter housing cap can be removed and the cartridge can be removed and replaced.
Page 35 Maintenance Procedures – Filter Replacement ‘S’ Model Step 7 With the snap ring removed, gently ease the cap over to one side by pressing against the top port, This will allow the cap to pop out from it’s housing. Notice in this image the sealing ‘O’ ring has remained in the top of the filter canister, this must also be removed Step 8...
Page 36 Maintenance Procedures – Filter Replacement ‘S’ Model Step 10 When reinstalling the cap and seal, ensure the seal is lubricated lightly with silicone grease and pushed onto the cap. Step 11 Line up the arrows on the cap and the filter housing. Push down the cap evenly and firmly.
Page 37 Maintenance Procedures – Filter Replacement ‘S’ Model Filter Replacement for Stainless Steel Housings Because of a ‘tight’ fit, it may not be possible to remove filter cartridges from ‘S’ model filter housings as easily as in the standard plastic housings. Therefore it may sometimes be necessary to connect a water supply to give a helping hand by hydraulicing out the cartridge.
Page 38: Cleaning Your Ro
There are a number of factors involved in the selection of a suitable cleaning chemical (or chemicals) and proper cleaning protocol. The first time you consider that RO performance has deteriorated it is recommended to contact Ionic Systems Ltd or one of its agents.
Page 39: Salt Replenishment
Maintenance Procedures – Battery Charging Battery Charging with the CTEK XS7000 FOR PROPER FUNCTION OF THE THERMOPURE SYSTEM, ENSURE THE BATTERY IS CHARGED EVERY DAY. Settings are made by pressing the “MODE” button and stepping forward by pressing the button one step at a time, releasing the button when the required mode is reached. After approx .2 seconds, the charger activates the chosen mode.
Page 40 Maintenance Procedures – Battery Charging Technical Specification Model 1007 Voltage AC 170 - 260VAC, 50 - 60 Hz Back Current Drain * <1mA Voltage Charging Voltage Nominal 12 v 13.6v; 14,4 v 12.7 v or 15.7 v Ripple ** Max 150 mV rms, max 0.3 A (=4%) Current 7A Max Ambient Temperature...
Page 41: Uv Filter Maintenance
Maintenance Procedures UV Filter Maintenance (PPB Machines only) Ultra-violet light kills biological components in the feed water such as Legionella. It also creates low-level ozone gas. This gas has strong oxidisation properties capable of destroying a wide range of pathogens including prions. It prevents bio-film thereby prolonging filter life. IN ORDER TO PRESERVE THE BENEFITS OF UV/03 STERILISATION THE UV LAMP MUST BE REPLACED EVERY 12 MONTHS UV LAMP REPLACEMENT...
Page 42 Maintenance Procedures Step 1 Loosen the cable grip on each end of the UV housing (This allows the housing to be unscrewed without twisting the power cables) Step 2 Unscrew the end caps at each end of the UV unit. Some water inside the housing may escape, so it is advisable to have a suitable container to hand to catch any spillage.
Page 43 Maintenance Procedures Step 3 Unclip the white plastic connector from each end of the UV lamp Step 4 The UV lamp may now be withdrawn from the housing and replaced. Step 5 Installing the new lamp is a reversal of the above procedure.
Page 44: Winterisation & Storage
The following procedure should be followed if the machine will not to be used during Winter or stored for any period longer than 1 month. A storage kit with all parts required is available from Ionic Systems Ltd. Holding Tank The holding tank should be completely drained.
Page 45 Maintenance Procedures – Winterising and Storage DI Filter If the DI filter is still in serviceable condition it may be left fitted to the machine. As a precaution, remove the snap ring but leave the filter cap in place. DO NOT EXPOSE TO FREEZING CONDITIONS.
Page 46: Operational Procedure: Cleaning Windows
Operational Procedure – Cleaning Windows Operational Procedure – Cleaning Windows When tasked with cleaning windows or facade surfaces park the vehicle/trailer containing the Reach & Wash system in a suitable position adjacent to the building. Parking close to one corner of the building is a good idea as two elevations can be reached from one position. When working in areas accessible to others, deploy warning signs to indicate the presence of potential slip and trip hazards.
Page 47 Operational Procedure – Cleaning Windows Experience will lead to the user developing correct pole technique, in time operators will learn to use the stored energy in the pole. Downward movement of the pole will cause the pole to bend, as the pole seeks to straighten itself, using the spring in the pole will help the operator to raise the pole.
Page 48 Operational Procedure – Cleaning Windows Hazards associated with the use of waterfed poles • Trip hazard presented by trailing hoses. • Slip hazard presented from wet pathways. • Trip hazard for operator while concentrating at work. • Falls whilst working from flat roofs. •...
Page 49 Operational Procedure – Cleaning Windows Road Safety Journeys to and from the workplace are subject to documented risk assessment. Assessment of these risks will include security of the load to ensure that it does not shift under normal driving conditions, emergency braking or during a minor collision. Responsibility rests with the driver of the vehicle, however business owners have a responsibility to provide suitable vehicles, equipment and means of securing the load.
Page 50 Operational Procedure – Cleaning Windows Choice of Equipment The choice of equipment will be determined by: • The duration and extent of work. • The height of windows to be cleaned. • The site conditions. For some jobs waterfed poles may be used in support of other access methods, for domestic properties to reach conservatory roofs or other windows inaccessible to ladders.
Page 51 Approved Code of Practice (L8): The Control of Legionella Bacteria in Water Systems 2000. Workplace Health, Safety and Welfare Regulations 1992. Manual Handling Operations Regulations 1992. Copyright Ionic Systems Ltd: Author C R Mawlam: First published 01/09/03 - Re Published 21/5/12...
Page 52 1 year subject to the following conditions and exclusions; 1) The Warranty shall operate for a period of twelve months from the date on Ionic Systems Ltd original invoice, subject to Ionic Systems Ltd receiving either a completed, signed Handover Form or a completed, on-line Warranty Registration.
Page 53: Warranty
4. Limitations and Exclusions Ionic Systems shall not be responsible for any implied warranty, including those of merchant ability and fitness for a particular purpose. Ionic Systems Ltd shall not be responsible for any incidental or consequential damages including travel expense, telephone charges, loss of income, loss of time, inconvenience, loss of use of the equipment caused by the equipment and its failure to function properly.
Page 54: Annual Servicing
Annual Servicing Annual Servicing Servicing described in the manual is only to be performed by a qualified person. Installation - Safety Inspection Reach & Wash™ systems are installed in accordance with BS EN 12195 Load Restraint Regulations, the Road Traffic Act 1986, the Road Vehicle (construction & use) Regulations and to FMVSS - 208 crash test specification.

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