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Cantel Medical MAR COR 23G Series Operation And Maintenance Manual

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Mar Cor Purification
23G-SERIES REVERSE OSMOSIS SYSTEM
Operation and Maintenance Manual
3024270 Rev. I
5Apr16

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  • Page 1 Mar Cor Purification 23G-SERIES REVERSE OSMOSIS SYSTEM Operation and Maintenance Manual 3024270 Rev. I 5Apr16...
  • Page 3 NOTICE For personal and system safety, and for optimum product performance, make sure you thoroughly read and understand the contents of this manual before installing, using, or maintaining this product. Trademarks Noryl® is a registered trademark of General Electric Company MINNCARE®...
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  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECT. DESCRIPTION PAGE GENERAL INFORMATION General Description The Manual Safety Summary 1.3.1 Read This Manual 1.3.2 Use Proper Power Connections 1.3.3 Contraindications 1.3.4 Flammable Atmosphere 1.3.5 Device Labeling Flow Description Machine Nomenclature Machine Permeate Quality Machine Features Environmental Requirement Specifications for 23G Machine 1.9.1...
  • Page 6 TABLE OF CONTENTS SECT. DESCRIPTION PAGE ECM-100 OPERATION ECM-100 General Description of Operation ECM-100 Displays and Controls 4.2.1 System Status Lights – Left Column 4.2.2 System Status Lights – Right Column 4.2.3 Keypad – Control Section 4.2.4 Keypad – Menu Select Section 4.2.5 Liquid Crystal Display (LCD) 4.2.6...
  • Page 7 TABLE OF CONTENTS SECT. DESCRIPTION PAGE Step-Wise Cleaning 5.8.1 Installation of the 23G CIP 5.8.2 General Clean-In-Place Procedure Sanitizing Using a CIP System 5.10 Membrane Element Cleaners and Sanitizers for 23G Machines 5.11 Pre-filter Replacement Procedure 5.12 Recording Performance Data 5.13 Preparing Machine for Movement 5.14...
  • Page 8 TABLE OF CONTENTS SECT. DESCRIPTION PAGE General ECM-100 Reference/Troubleshooting Guidelines 7.2.1 Resetting the ECM-100 7.2.2 Check the Main Board Terminal Strip for Good Connections 7.2.3 Check the Relay Board Terminal Strip for Good Connections 7.2.4 Low Rejection Warning (Due to High Purity Feedwater) 7.2.5 Verifying the Temperature Circuitry of the Main Board 7.2.6...
  • Page 9 TABLE OF CONTENTS SECT. DESCRIPTION PAGE 11.0 SPARE PARTS LISTS Valves Prefilters 6-Channel Remote Flow Block and Connectors 126/127 Sensor Electrical Membrane Elements 4-inch Housing Spare Parts Test Kits Clamps Miscellaneous Pump Outlet Pump and Motor Assemblies (Three-phase, 60 Hz) Pump and Motor Assemblies (Three-phase, 50 Hz) Pump and Motor Assemblies (Single-phase) 3024270 Rev I...
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  • Page 11: General Information

    23G-Series RO System GENERAL INFORMATION General Description CAUTION: When used as a medical device, Federal law restricts this device to sale by or on the order of a physician, per 21 CFR 801.109 (b). Your Mar Cor Purification 23G reverse osmosis machine is a durable piece of equipment which, with proper care, will last for many years.

  • Page 12: The Manual

    23G-Series RO System The Manual This manual has been prepared to provide the operator with information on the installation, operation, maintenance, and troubleshooting of 23G Water Purification Systems. The manual is supplemented with drawings and schematics for clarification whenever possible. Safety Summary The safety summary does not contain all of the safety statements in the manual.

  • Page 13: Flammable Atmosphere

    23G-Series RO System 1.3.4 DO NOT OPERATE IN A FLAMMABLE ATMOSPHERE: To avoid fire or explosion, do not operate this device in an explosive environment or near flammable anesthetics. 1.3.5 Device Labeling Do not, under any circumstances, remove any Caution, Warning, or other descriptive labels from the devices until the conditions warranting the label are eliminated.
  • Page 14 23G-Series RO System Salt (Ionic) Rejection Salt (Ionic) Rejection is the percent of dissolved salt rejected by the membrane, calculated from an average concentration over the membrane. Salt (Ionic) Passage Salt (Ionic) Passage is the percent of dissolved salts passed through the membrane.
  • Page 15 23G-Series RO System Recovery 75% 100 mg/L 100 mg/L Pump 375 mg/L Concentrate Feed 6 gpm 24 gpm 8.3 mg/L Permeate Membrane Porous 18 gpm Backing Material Figure 1.2 System Schematic An example of how to calculate salt rejection and recovery: Salt Rejection calculation: Assume C = 100mg/L...

  • Page 16: Flow Description

    23G-Series RO System Flow Description The pretreated feedwater passes through a disposable 5 micron cartridge filter (pre-filter) which removes suspended solids. Filtered water then flows to the inlet control valve. This solenoid-actuated valve is controlled by Enhanced Controller/Monitor (ECM-100) and opens when the machine is turned on, allowing water to flow to the pump inlet.
  • Page 17 23G-Series RO System Figure 1.3; Typical Flow Diagram for 23G Systems 3024270 Rev I 5Apr16...

  • Page 18: Machine Nomenclature

    23G-Series RO System Machine Nomenclature Mar Cor Purification water purification machines are numbered in such a way as to indicate the permeate flow and quality you can expect from the machine. The nomenclature (model number) of your machine is shown on the serial number label on the side panel of the machine.

  • Page 19: Machine Features

    23G-Series RO System Machine Features Mar Cor Purification 23G Series machines contain an array of useful standard features to provide additional system safety and reliability, to simplify system monitoring and data collection, and to ensure the longest membrane life. Standard features include: •...
  • Page 20 23G-Series RO System • low inlet post-filter pressure • high permeate pressure (immediate shutdown) • high/low pH • high temperature • high permeate conductivity • low permeate conductivity • low permeate flow • low percent rejection • high pre-filter pressure drop •...

  • Page 21: Environmental Requirement

    23G-Series RO System Environmental Requirement Minimum Maximum Ambient Temperature 4°C (39°F) 32°C (90°F) Storage Temperature 2°C (36°F) 32°C (90°F) Altitude 10,000 feet CAUTION: This equipment must not be allowed to freeze. Irreparable harm to various components, including RO membranes may result. NOTE: The user/operator should recognize that moisture can be caused by condensation and is not necessarily an equipment leak.

  • Page 22: Permeate (Product Water) Flow Rate

    23G-Series RO System Inlet Connection Thread; 1-inch Female National Pipe (FNPT) Continuous operation over 85F (29C) may cause permanent decline in the membrane element performance. Actual permeate flow rates typically increase/decrease by 1.4% for each 1F change temperature. other temperatures, “Temperature Factor Chart”...

  • Page 23: Concentrate Flow Rate

    23G-Series RO System 1.9.3 Concentrate Flow Rate Factory set as stated on serial number label. Concentrate Outlet 1-inch female NPT 1.9.4 Primary Operating Pressure Motor Frequency Pump Model Minimum Boost Maximum (Hp) (Hz) Primary Boost Primary Pressure (PSI) Pressure (PSI) CRN-3-21 CRN-5-18 CRN-5-24...
  • Page 24 23G-Series RO System Table 1.2 Approximate Shipping Weights and Dimensions Model Number Shipping Dimensions Shipping Weight 65” D x 34” W x 78” H 655 lbs 23G 2 Element (165 cm D x 86 cm W x 200 cm H) (298 kg) 65”...

  • Page 25: Power Ratings

    23G-Series RO System 1.9.7 Power Ratings Table 1.3; 23G Power Rating Table Machine Part Number Volts Amps Phase 3024274 208/230~ 3024275 460~ 3024277 208/230~ 3024279 460~ 3024280 460~ 3024281 460~ 3024283 460~ 3024285 208/230~ 3024286 460~ 3024288 460~ 3024289 208/230~ 3024291 460~ 3024292...
  • Page 26 23G-Series RO System Machine Part Number Volts Amps Phase 3024326 208/230~ 3024328 460~ 3024329 460~ 3024330 208/230~ 3024332 208/230~ 3024334 208/230~ 3024335 460~ 3024336 208/230~ 3024337 460~ 3024338 208/230~ 3024340 208/230~ 3024342 208/230~ 3024343 460~ 3024344 208/230~ 3024346 460~ 3024474 380~ 3024475 380~...

  • Page 27: Medical Membrane Element Specification For Water Purification

    23G-Series RO System 1.10 Medical Membrane Element Specification NaCl rejection: 99.0% Average (98.0% minimum) Based on a 2,000 mg/L NaCl solution at 225 psig (1,551 kPa) operating pressure, 77 °F (25 °C), pH 7.5, 15% recovery, after 24 hours. Individual element flow may vary 15%.

  • Page 28: Installation

    23G-Series RO System INSTALLATION 2.1 Machine Location At least 45 inches (114 cm) of space should be allowed above the membrane element housings for easy removal and loading of membrane elements. Provide adequate workspace on sides and front for easy access. NOTE: If necessary, housings may be detached from the frame for membrane element removal due to space restrictions around the machine.

  • Page 29: Permeate Outlet Connection

    23G-Series RO System hose or pipe can be any length, and the diameter should match the outlet of the machine. NOTE: Soft, flexible hose can be used, but must be installed in a manner which prevents “kinks” or other restrictions that will increase back pressure and reduce concentrate flow rate to the drain.
  • Page 30 23G-Series RO System The 23G pump is wired at the factory to an IEC overload protection magnetic motor starter that is controlled by the ECM-100. The procedure for connecting the electrical wiring for installation of the 23G follows: Connect the ECM-100 power cord to a properly grounded 15 A, 115 VAC/60Hz or 10 A 220 VAC/50Hz, single-phase outlet.
  • Page 31 23G-Series RO System Fuses Rating Voltage Type Location Number 0.5 Amp 250V Fast-Acting Remote Alarm 0.8 Amp 250V Slo-Blo ECM-100 2.5 Amp 250V Slo-Blo ECM-100 Table 2.3; Three-Phase Electrical Connections Wire Color Motor Wire Starter/Thermal Source Overload 60 Hz 50 Hz Connection Note: The connections listed below apply to 23G models with THREE PHASE motor power...
  • Page 32 23G-Series RO System GROUND WIRING DIAGRAM FOR 23G MOTOR STARTER USING ENCLOSURE P/N 3024381 Figure 2.4; Ground Wiring Diagram 3024270 Rev I 5Apr16...

  • Page 33: Machine Lockout

    23G-Series RO System 2.4 Machine Lockout In general, the machine should be operated in AUTO mode in which conditions are confirmed electronically. The ECM-100 terminal strip has terminals available for linking other treatment equipment, such as a softener, to the operation of the 23G machine or monitoring the status of other equipment.

  • Page 34: Preparation And Start-Up

    23G-Series RO System PREPARATION AND START-UP Pretreatment for Water Purification Mar Cor Purification 23G machines will operate most efficiently on filtered water with a pH less than negative concentration LSI (Langlier Saturation Index) and a Silt Density Index (SDI) of 3 or below. If the machine is operated on water with higher pHs, other forms of pretreatment may be necessary.

  • Page 35: Initial Start-Up

    23G-Series RO System Initial Start-Up CAUTION: When the 23G RO machine is first installed or membrane elements are changed, the RO unit must be rinsed to drain under normal pressures for a minimum of one (1) hour before exposing membranes to Minncare® HD and a minimum of six (6) hours before exposing membranes to formaldehyde or irreversible damage may occur.
  • Page 36 23G-Series RO System Switch off the 115/230 volt control circuit by pressing the OFF button on the ECM-100. Re-energize the high voltage power to the pump motor starter. The pump should not begin to operate. Close the machine concentrate valve. Start the machine by pressing the ON key on the ECM-100.
  • Page 37 23G-Series RO System During typical start-up/flushing check the primary and final pressures which should be below the typical maximum pressure of 280 psig. Field conditions may dictate slightly higher alarm setpoints (refer to Section 1.8.4). Continue to operate the machine in this manner for a period of 8 hours. NOTE: When the 23G RO machine is first installed or membrane elements are changed, the RO unit must be rinsed to drain under normal pressures for a minimum of...

  • Page 38: Daily Start-Up And Operation Checklist

    23G-Series RO System Daily Start-Up and Operation Checklist NOTE: This section may be copied for placement on the 23G machine. CAUTION: HAND mode is for diagnostic test and CIP. It should not be operated while unsupervised in this mode. Verify that all feedwater valves and outlet valves in the permeate and concentrate plumbing are open.
  • Page 39 23G-Series RO System Daily operating logs should be completed every 8 hours. Daily Pretreat and RO Log Sheets (Technotes 141 and 142) are provided in the system manual for this purpose. 3024270 Rev I 5Apr16...

  • Page 40: Operation

    23G-Series RO System ECM-100 OPERATION ECM-100 General Description of Operation The ECM-100 is a state-of-the-art electronic controller/monitor designed for 23G machines. The ECM-100 controls and monitors machine operation including operating performance. Data is stored automatically by the ECM-100 at preset run-time intervals and can be downloaded to a printer or PC port via a RS-232 communication port.

  • Page 41: Keypad - Control Section

    23G-Series RO System Auto-On Active Indicates that the Auto-On feature is active; the machine will start automatically and run a short time if left idle for more than a preset time. (This inhibits bacteria growth during periods of non-use). Auxiliary Indicates that an auxiliary component is on (such as a tank transfer pump).

  • Page 42: Liquid Crystal Display (Lcd)

    23G-Series RO System 4.2.5 Liquid Crystal Display (LCD) Displays date, time, 10 operating parameters, and alarm or menu messages. Menu Abbreviations: CVAL - Current value SETPT - Calibration set point Flow rate PERM - Permeate CONC - Concentrate NOTE: The LCD’s permeate and concentrate Flow rate readout has an acceptable deviation of 5% from the actual Flow rates.
  • Page 43 23G-Series RO System Figure 4.5; ECM-100 Front Panel 3024270 Rev I 5Apr16...

  • Page 44: Passcode

    23G-Series RO System 4.2.6 ECM-100 Passcode Your machine is equipped with an ECM-100 controller/monitor to perform the machines electrical operations. Selected functions of the ECM-100 require entry of a passcode. This passcode access allows three functions; it allows a user to make adjustments to setpoints, view, and download historical data.

  • Page 45: Display Menus

    23G-Series RO System To recall factory settings: Go to the Factory Settings Menu (menu 11). Push ENTER switch. The screen will display two lines of factory settings. Enter passcode (Section 4.2.6) to restore factory settings. Contact Mar Cor Technical Support for assistance. 4.2.8 Display Menus 01 Date and Time The Date and Time Menu should be used to change/update the...
  • Page 46 23G-Series RO System Press ENTER to view the accumulated hours for “RUN” time and “OFF” time. 05 Log Tables The Log Tables Menu allows the user to display and download historical machine operational data. Press ENTER to view the data tables. Use the ARROW keys to advance through the data tables.
  • Page 47 23G-Series RO System 08 Print Current Values The Print Current Values Menu is used to facilitate a download of current operational data. Press ENTER to print/send the data that is currently displayed on the ECM-100 screen to a printer or computer. 09 Metric/U.S.

  • Page 48: Operation

    23G-Series RO System 13 Comm Port Speed The Communication (Comm) Port Speed Menu is used to set the baud rate of the RS-232 serial port. NOTE: The computer or printer must be set to the same baud rate as the ECM-100. Press ENTER, and then use the ARROW keys to scroll through the choices.

  • Page 49: Selecting Parameters And Changing Settings

    23G-Series RO System 4.3.1 Selecting Parameters and Changing Settings To select a parameter: Scroll through the parameters using the ARROW keys until the desired parameter is shown on the LCD screen. Press the ENTER key. Scroll through the settings using the ARROW keys, until the desired setting is displayed on the LCD screen.

  • Page 50: Clean-In-Place (Cip Operation)

    23G-Series RO System 4.3.3 ECM-100 Clean-in-Place (CIP) Operation For CIP operation from the ECM-100 follow these steps: 1. Confirm the machine is in HAND mode (check LED light), as CIP will not work in AUTO mode. 2. Press the ON key to start the machine. 3.
  • Page 51 23G-Series RO System Table 4.5; ECM-100 Alarm Settings Alarms Range Factory Preset (Menu 02) 0 - 200 S/cm (Note 1, 2) 30 S/cm PERM COND HI 0 – 255 F (0-123 C) 90 F (32 C) TEMP HI pH HI 0.0 - 14 pH units (Note 3) 7.0 pH units pH LOW...
  • Page 52 23G-Series RO System Table 4.6; ECM-100 Timer Settings Timers (Menu 03) Range Factory Preset RO PUMP DELAY 1 - 99 sec 6 seconds START-UP PERM DIVERT 0 - 99 min 2 minutes AUF PERIOD 0 - 99 hr 1 hour AUF DURATION 0 - 99 min 6 minutes...
  • Page 53 23G-Series RO System Figure 4.6; 23G Series ECM-100 Main Board Electrical Diagram 3024270 Rev I 5Apr16...
  • Page 54 23G-Series RO System Figure 4.7; 23G ECM-100 Relay Board Electrical Diagram 3024270 Rev I 5Apr16...

  • Page 55: Display Screens

    23G-Series RO System ECM-100 Display Screens 4.4.1 ECM Display Screen Hierarchy 3024270 Rev I 5Apr16...

  • Page 56: Detail Of Date And Time Operation (Menu 01)

    23G-Series RO System 4.4.2 Detail of Date and Time Operation (Menu 01) PASSCODE REQUIRED FOR SETPOINT ADJUSTMENT (refer to Section 4.2.6) Passcode: Enter the passcode by pressing the following keys in sequence: HAND/AUTO ALARM BYPASS Store Changes: Once changes are made: Press ENTER to store changes or Press ESC to exit.

  • Page 57: Detail Of Alarm Limits Operation (Menu 02)

    23G-Series RO System 4.4.3 Detail of Alarm Limits Operation (Menu 02) * SHUTDOWN WITHIN 1 SECOND (NON-ADJUSTABLE) ‡ SHUTDOWN WITH ADJUSTABLE DELAY (1 – 99 SECONDS) Refer to Table 4.5 ECM-100 Alarm Set Points for notes 1, 2, 3, & 4. 3024270 Rev I 5Apr16...

  • Page 58: Detail Of Timer Presets Operation (Menu 03)

    23G-Series RO System 4.4.4 Detail of Timer Presets Operation (Menu 03) *MACHINE MUST BE IN AUTO MODE TO FUNCTION PASSCODE REQUIRED FOR SETPOINT ADJUSTMENT The time from when the inlet valve opens until the high pressure pump starts (at machine ON, and after tank full or pretreatment lockout).

  • Page 59: Detail Of Accumulated Hours Operation (Menu 04)

    23G-Series RO System 4.4.5 Detail of Accumulated Hours Operation (Menu 04) 4.4.6 Detail of Log Tables Operation (Menu 05) Records over 400 historical entries. Historical entries can be downloaded. Displays 10 operating parameters, date, and time of entry. Use arrow keys to scroll through entries.

  • Page 60: Detail Of Calibration Operation (Menu 06)

    23G-Series RO System 4.4.7 Detail of Calibration Operation (Menu 06) PASSCODE REQUIRED TO ADJUST CALIBRATION VALUES 3024270 Rev I 5Apr16...
  • Page 61 23G-Series RO System Adjustment ranges remain the same whether in U.S. or Metric units; the settings are dimensionless. Each offset unit for 100 psi sensors is equal to 0.50 psig (0.0345 bar). Each offset unit for 500 psi sensors is equal to 2.0 psig (0.138 bar). The standard 1-inch flow turbine should be calibrated with a flow offset of zero.

  • Page 62: Detail Of Print Current Values Operation (Menu 08)

    23G-Series RO System 4.4.8 Detail of Print Current Values Operation (Menu 08) Use the arrow keys to scroll through the maintenance menu. 4.4.9 Detail of Metric/US Select Operation (Menu 09) 4.4.10 Detail of Perm High Conductivity Alarm Operation (Menu 10) PASSCODE REQUIRE [HAND/AUTO] - [CIP] - [ALARM BYPASS 3024270 Rev I...

  • Page 63: Detail Of Factory Settings Operation (Menu 11)

    23G-Series RO System 4.4.11 Detail of Factory Settings Operation (Menu 11) STORAGE CODE REQUIRED Refer to Section 4.2.7 PASSCODE REQUIRED Refer to Section 4.2.6 4.4.12 Detail of Auto-On Tank Full Operation (Menu 12) PASSCODE REQUIRED 3024270 Rev I 5Apr16...

  • Page 64: Detail Of Comm Port Speed Operation (Menu 13)

    23G-Series RO System 4.4.13 Detail of Comm Port Speed Operation (Menu 13) PASSCODE REQUIRED 3024270 Rev I 5Apr16...

  • Page 65: Machine Operation And Maintenance

    23G-Series RO System MACHINE OPERATION AND MAINTENANCE Proper maintenance of the 23G RO system in accordance with this manual and good medical practices is essential when the system is used in a medical application for water purification for use in hemodialysis. FAILURE TO FOLLOW THE REQUIREMENTS SET FORTH IN THIS SECTION AND GOOD MEDICAL PRACTICES COULD POSE A RISK OF SERIOUS INJURY OR DEATH TO HEMODIALYSIS PATIENTS.
  • Page 66 23G-Series RO System WARNING: Determination of microbial culturing and disinfection frequency is the responsibility of the operating facility. Failure to conduct timely microbial culturing and disinfection could pose a risk of serious injury or death to hemodialysis patients. Observe and record hardness level in the feedwater to the RO (for systems with softener pretreatment).

  • Page 67: Weekly Requirements

    23G-Series RO System Observe and record the percent rejection and permeate conductivity displayed on the ECM-100 display. Measure and record the feed water temperature on the Operation Log. A hand held thermometer may be used. The water temperature has a significant effect on the flow rate of the RO membrane.

  • Page 68: Quarterly Requirements

    23G-Series RO System Quarterly Requirements Clean/sanitize the membrane elements. Refer to Section 5.8 for the membrane cleaning/sanitizing procedure. Cleaning/sanitizing the machine is vital because contaminants and/or biological materials accumulate on the membrane surface potentially reducing the permeate flow rate and affecting the permeate quality. A layer left on the membrane may cause permanent damage and reduce membrane life.

  • Page 69: Semi-Annual Requirements

    23G-Series RO System Semi-Annual requirements Tighten all electrical screws in the control box. NOTE: Disconnect from both sources of power prior to opening control box. Tighten high voltage wires to motor starter. Annual Requirements The actions below should be performed in addition to the monthly requirements.

  • Page 70: Step-Wise Cleaning

    23G-Series RO System CAUTION: Do not operate the machine with more than 30% additional concentrate flow without prior approval from Mar Cor Purification. Operation above this flow rate may damage the pump and motor. Use the AUTO-ON commands in the Timer Presets Menu (03) of the ECM- 100, to flush the machine automatically during extended shutdown periods (over 4 hours).

  • Page 71: Installation Of The 23G Cip

    23G-Series RO System NOTE: Cleaning may be required as often as once every week or infrequently as every quarter, depending upon the local water supply conditions. For more information, or for instructions on long-term machine shutdown (greater than 72 hours), contact Mar Cor Technical Support. Read and understand all instructions prior to beginning procedure.

  • Page 72: General Clean-In-Place Procedure

    23G-Series RO System Hook up the CIP feed hose to the quick connect fitting on the pump. Hook the other end of the hose to the quick connect fitting on the CIP tank. Place the CIP skid near the 23G so all CIP lines will reach CIP ports on the machine.
  • Page 73 23G-Series RO System Return to the ECM-100 controller and push the HAND/AUTO button to HAND. The Hand Mode light will illuminate. Push the On button, and both the 23G pump and the 23G skid pump will start. See Cleaning in the 23G Operator’s Manual for cleaning instructions.
  • Page 74 23G-Series RO System CAUTION: Do not leave cleaning solution in the machine for a period longer than one hour. The cleaning solution may damage the membranes and the machine during an extended period of contact. To flush the cleaner from the machine close the CIP inlet valve. Open the inlet feed valve.

  • Page 75: Sanitizing Using A Cip System

    23G-Series RO System Sanitizing Using a CIP System WARNING: Determination of microbial culturing and disinfection frequency is the responsibility of the operating facility. Failure to conduct timely microbial culturing and disinfection could pose a risk of serious injury or death to hemodialysis patients.

  • Page 76: Membrane Element Cleaners And Sanitizers For 23G Machines

    23G-Series RO System • Prior to peracetic acid-based chemical use, the membrane is cleaned with a low pH cleaner to free the membrane of iron and other transitional metals. • The peracetic acid-based chemical solution is mixed with water free from iron and other transitional metals.

  • Page 77: Recording Performance Data

    23G-Series RO System The pre-filters should be replaced before and after cleaning or sanitizing of the membranes elements. To change the pre-filter, turn the water supply off. The pre-filter inlet and outlet gauges should read zero psi. Remove the pre-filter bowl by rotating it counterclockwise. Remove the old filter.

  • Page 78: Membrane Element Removal

    23G-Series RO System after one to two years of operation. This period can be extended with frequent flushing and cleaning as outlined in these instructions. If the membranes are to be saved, they must be cleaned and then sanitized before removal from the machine. Verify the membranes’...
  • Page 79 23G-Series RO System CAUTION: Upon start-up of a new machine or installation of new membranes machine must be operated with permeate running to drain for a period of 3 hours in order to flush out all membrane preservatives. Failure to properly flush the membranes can result in patient safety issues.
  • Page 80 23G-Series RO System Apply a small amount of water-soluble lubricant to the outside surface area of all O-rings installed on the adapters. CAUTION: Do not use petroleum jelly or other petroleum based material as they may damage elastomer and/or thermoplastic. Housing Victaulic Clamp Victaulic Gasket...
  • Page 81 23G-Series RO System Once the membrane element orientation has been determined, install a housing adapter into the end of the permeate tube with a gradual twisting/turning motion. Install the plug adapter into the end of the permeate tube that will be closest to the lower end of the housing (e.g., nearest the floor).

  • Page 82: Flow Control Adjustments

    23G-Series RO System Flush the system to drain under normal pressures for a minimum of six (6) hours before exposing membranes to formaldehyde. Machine is ready for normal operation, however do not put into service until all applicable water tests have been completed.
  • Page 83 23G-Series RO System CAUTION: The flow control orifice valves are sealed to prevent tampering, and should not be adjusted by unauthorized personnel. Damage to the machine may occur and physical injury is possible. • The flow control orifices are factory set; according to the design specifications of the machine.

  • Page 84: Leaks

    23G-Series RO System 5.15.1 Leaks During adjustment it is normal for a very small amount of water to leak from under the larger nut of the orifice, and/or from around the locking nut on the orifice adjustment screw. • To correct leaking under the large nut, the two O-rings need to be replaced.
  • Page 85 23G-Series RO System Do not make adjustments when the Autoflush light is ON. Always wait until the Autoflush finishes and the light goes out before adjusting the orifices. Make sure concentrate valve is closed. Concentrate Orifice - screwdriver adjustment. • Adjusts the concentrate flow output to the drain.
  • Page 86 23G-Series RO System Adjusting the Orifices - requires two wrenches and a large screwdriver. Use one wrench to hold the large nut and prevent it from turning. Use another wrench to loosen the locking nut, adjust the flow with the screwdriver. Tighten the locking nut after.

  • Page 87: Permeate Divert

    23G-Series RO System 5.16 Permeate Divert Factory-installed valves divert the RO permeate to drain for a preset period of time upon machine start-up or when the RO permeate exceeds a preset conductivity level. This optional feature ensures good quality water flows to storage or to points of use.

  • Page 88: Level Controls

    23G-Series RO System Level Controls Float switches pressurized storage tank switches or other level controls may be connected to the ECM-100’s tank level control inputs. To recognize the tank level status, the ECM-100 must be in the AUTO mode. A level control system with “one” input signal may be connected to the ECM-100 across terminals 17 and 18 of the main strip.

  • Page 89: Ph Controller/Sensor (Ecm-100-Ph)

    23G-Series RO System pH Controller/Sensor (ECM-100-pH) A factory installed pH sensor can be connected to your ECM-100. A high/low pH alarm is included with the pH sensor and should be set at pH 7 and 4, respectively (unless special instructions or conditions indicate otherwise) to protect against excess or loss of buffer feed.

  • Page 90: Printer/Computer Interface

    23G-Series RO System Printer/Computer Interface The ECM-100 is designed to allow data downloads to a computer or a printer. The basic process of downloading the information to a printer or computer is the same. Data can be downloaded as individual lines of information (Current display), or large groups of information (Historical log).
  • Page 91 23G-Series RO System  Legacy RS-232 requires serial communications software on your computer, such as:  HyperTerminal® (included with Windows 95, 98, NT, ME, 2000, or XP)  Microsoft Terminal® (available separately for Windows 3.1)  Crosstalk® and Procomm® (versions available separately for almost any computer)or any of a number of similar commercial products.
  • Page 92 23G-Series RO System  On the next screen, select the correct COM port for the USB adapter and press the Configure button.  On the next screen, press the Restore Defaults button then press OK and then OK again on the next screen. ...
  • Page 93 23G-Series RO System  On the next screen, under Transfer dropdown select Capture Text.  On the next screen, enter a location and file name to save the file to. Suggested to place on your desktop. Suggested name is the type of data (displays or history logs) and the same name as used above (serial number or clinic name) and the date.
  • Page 94 23G-Series RO System  At this point, HyperTerminal is ready to receive data.  You are now ready to start downloading the information from the ECM-100. Go to Menu 05 “LOG TABLES” and press “ENTER”, “Historical Values” will be displayed. You then will need to enter the pass code “HAND/AUTO”, “CIP”, “ALARM BY-PASS”, at this point you will see the letter ”P”...
  • Page 95 23G-Series RO System Table 6.10; Two-Digit HyperTerminal Alarm Codes Number on Left Number on Right 0 No Alarm 0 No Alarm 1 Metric 1 Permeate Conductivity High 2 Permeate Divert 2 High Temperature 3 Metric and Divert 3 High pH 4 HAND mode 4 Low pH 5 Metric and HAND mode...
  • Page 96 23G-Series RO System Table 6.11; Example ECM-100 History Log PRESSURES FLOWS DATE TIME TEMP Cp ALARM PRE POS PRI 12/10/06 15:41 02.2 06.8 96.8 12/10/06 14:41 02.2 06.8 97.4 12/10/06 13:41 02.2 06.7 97.1 12/10/06 12:41 02.2 06.1 96.2 12/10/06 11:41 02.2 06.7...
  • Page 97 23G-Series RO System Hardware Requirements Preferred Setup  Windows 7 or Windows 8 computer with a free USB port.  USB 2.0 Type A/B cable, maximum 3 meters in length (used for both computer and printer connection; not supplied by Mar Cor) ...

  • Page 98: Printer Connection

    23G-Series RO System 6.3.4 Printer Connections Connecting to a USB Printer Plug the USB cable end (Type A, narrow rectangular end) into the ECM-100 USB port labeled PRINTER. Plug the other end of the cable into the printer. Connecting to a Serial Printer Nearly all serial printers have a 25-pin female connector, so you will need a 9-pin (M) to 25-pin (M) cable, or 9 x 25 adapter to use with the standard 9-pin extender cable, and a “Null Modem”...

  • Page 99: Print Test

    23G-Series RO System Converter settings (refer to the documentation provided with our converter): Baud Rate 1200, 2400, 4800, or 9600, (user must specify) Parity None Data Bits Handshake Xon/Xoff Direction Serial-to-parallel (S-P) 6.3.5 Print Test The print test below prints the current displays on the ECM-100. On the ECM-100 keypad, press the ARROW keys to scroll to the “Maintenance Menu”...

  • Page 100: Troubleshooting

    23G-Series RO System All historical data will be sent to the printer and printed in chronological order. TROUBLESHOOTING This troubleshooting guide can assist you in identifying common operating problems you may experience with your machine. Many of these problems can be easily corrected by the operator;...
  • Page 101 23G-Series RO System Troubleshooting Guide - Machine Performance Symptom Possible Causes Remedies Pre-filters clogged. Replace pre-filter cartridges. Faulty pressure transducer(s), Check terminal strip connections. Disconnect cable(s) or connection(s) (other the pressure transducer cable at the sensor pressures and flows normal). end and inspect for possible water corrosion damage.
  • Page 102 23G-Series RO System Troubleshooting Guide - Machine Performance Symptom Possible Causes Remedies Severely fouled or dirty Flush, clean, and sanitize the membranes. membranes. Excessive membrane Restricted flow at housing inlet or Check for blockage of concentrate flow at inlets pressure drop [over 15 outlet.
  • Page 103 23G-Series RO System Troubleshooting Guide - Machine Performance Symptom Possible Causes Remedies Cable or turbine element Repair or replace the cable or turbine. damaged. Sensor cable not fully inserted Insert the cable so it snaps into place. into flow turbine element housing. Flow indicator inaccurate Check the flow rate manually with a stopwatch Low permeate flow...
  • Page 104 23G-Series RO System Troubleshooting Guide - Machine Performance Symptom Possible Causes Remedies Membrane elements dirty or Flush, clean, and sanitize the membrane fouled. elements. O-ring seal broken or damaged. Check the sealing surfaces on the O-ring groove, interconnectors, and end caps. Replace damaged parts.
  • Page 105 23G-Series RO System Troubleshooting Guide - Machine Performance Symptom Possible Causes Remedies O-ring seal broken or damaged. Check the sealing surfaces on the O-ring groove, interconnectors, and end caps. Replace damaged parts. Declining rejection (or high permeate Damaged membrane elements. Replace membrane elements.
  • Page 106 23G-Series RO System Troubleshooting Guide – ECM-100 Display Failures Symptom Possible Causes Remedies Temperature in ECM- Temperature circuit failure. Refer to ECM-100 Troubleshooting 100 cannot be (Section 7.2). adjusted O-ring or diaphragm failure. Replace valve. Water leaking from Contact Mar Cor Technical Support for permeate and/or assistance.
  • Page 107 23G-Series RO System Troubleshooting Guide – 23G System Failures Symptom Possible Causes Remedies ECM-100 “lockup” (usually due to Power down for 2 minutes, and then restart. power fluctuation). Check alarms, timers, and calibration settings. Recall Factory Settings. 23G electrical machine Thermal overload relay tripped Turn the machine of, reset the relay, check shutdown...

  • Page 108: Emergency Alarm Bypass

    23G-Series RO System Emergency Alarm Bypass CAUTION: The following are regarded as emergency conditions. Bypass of the alarm will defeat the automatic safety protection features of the ECM-100. Bypass of these measures may cause damage to the machine or be severely detrimental to product water quality if the condition being monitored goes into an actual error state while the sensor is being bypassed.

  • Page 109: Rejection Low Alarm Due To Failed Feed Conductivity Probe

    23G-Series RO System 7.1.2 Rejection Low Alarm Due to Failed Feed Conductivity Probe Install a short piece of wire between terminals 24 and 25 on the Main Board terminal strip (forces reading to 2550 S). If this remedy does not work, contact Mar Cor Technical Support. 7.1.3 Temperature High Alarm Switch wires to use the temperature element which is encapsulated in the Permeate Conductivity probe.

  • Page 110: Permeate Flow (Stuck At Zero)

    23G-Series RO System • Power up and set the pressure offset in the Calibration Menu (06) to obtain a nearly normal reading for the pressure being bypassed. • Restore the offset settings and wiring when the new transducer is installed. •...

  • Page 111: General Ecm-100 Reference/Troubleshooting Guidelines

    23G-Series RO System General ECM-100 Reference/Troubleshooting Guidelines Software Module ECM-100 Main Board ECM-100 Relay Board Terminal Strip Terminal Strip ECM-100 Main Board ECM-100 Relay Board Figure 7.11; ECM 100 V2 Main & Relay Boards (Production from 1998 until mid-2016) 3024270 Rev I 5Apr16...
  • Page 112 23G-Series RO System USB Ports Software Module Figure 7.12 ECM-100 2016 Main & Relay Boards (Production starting mid-2016) 3024270 Rev I 5Apr16...

  • Page 113: Resetting The Ecm-100

    23G-Series RO System 7.2.1 Resetting the ECM-100 If exterior problems (such as power surges, lightening storm) have damaged the ECM-100. Power down (disconnect) to reset the ECM-100. A high quality inline surge protector suppressor is recommended to avoid related problems. 1.

  • Page 114: Check The Relay Board Terminal Strip For Good Connections

    23G-Series RO System 5. Contact Mar Cor Technical Support for assistance in repairing any loose or broken wires. 6. Ensure the terminal board is firmly connected to the main board by gently pressing on the top of the strip, pushing it toward the main board.

  • Page 115: Verifying The Temperature Circuitry Of The Main Board

    23G-Series RO System purity feed water. The permeate conductivity may be acceptable, but the percent (%) rejection may read low enough to cause an alarm. The ECM-100 calculates % rejection using the following equation: Permeate Conductivity % Rejection = x 100 Feed Conductivity Since the % rejection is based on a ratio between the feed conductivity and the permeate conductivity, higher quality feed water may result in a...
  • Page 116 23G-Series RO System 2. Unplug the power cord for the ECM-100. 3. Disconnect the temperature sensor wires from terminal posts 23 and 4. Cover the temperature sensor wires which were removed from terminal posts 23 and 24 with electrical tape. Secure these wires in a location that prevents contact with the main circuit board.

  • Page 117: Difficulty Calibrating Permeate Conductivity

    23G-Series RO System 7.2.6 Difficulty Calibrating Permeate Conductivity The integrity of the permeate conductivity circuitry on the main logic board can be verified by connecting a fixed resistor in place of the conductivity probe. Turn the machine OFF. Unplug the power cord for the ECM-100. Disconnect the permeate conductivity wires from terminal posts 27 and 28.

  • Page 118: Ph Calibration Procedure - Software Version V2/2016

    23G-Series RO System V1, V2 and 2016 main logic boards and relay boards are interchangeable (i.e., you could have a V1 main logic board and a V2 relay board and vice versa). 23G machines built after 1997 until mid-2016 contain Version 2 (V2) circuit boards and machines built mid-2016 and on contain the 2016 version board.

  • Page 119: V2/2016 Logic Board

    23G-Series RO System Calibration is now complete. To check it, rinse the probe with tap water and dip it into the low pH solution again to see if it reads accurately. Repeat the calibration if necessary. Rinse or blot away any remaining droplets of the pH solution and reinstall the pH sensor into the incoming waterline.
  • Page 120 23G-Series RO System a. Adjustment range of “Permeate Conductivity High” alarm is 0-50 S/cm for Rev D3 software; 0-200 S/cm for Rev E0 or higher software. b. Below 200 S/cm, there are 2.5 units of specific conductance (S/cm) per unit of Total Dissolved Solids (ppm or mg/L as CaCO3).
  • Page 121 23G-Series RO System Menu #6 Calibrate ECM Adjustment Range Alarm Limit 0 or 1 (Disable or Enable) PRE-FILT PRESS -99 to +99 OFFSET UNITS POST-FILT PRESS -99 to +99 OFFSET UNITS PRIMARY PRESS -99 to +99 OFFSET UNITS FINAL PRESS -99 to +99 OFFSET UNITS PERMEATE PRESS -99 to +99 OFFSET UNITS...

  • Page 122: Temperature Calibration Procedure - V2/2016

    23G-Series RO System Temperature Calibration Procedure 8.4.1 Cleaning the Feed Conductivity Sensor 1. Turn machine OFF. 2. Locate and remove the feed conductivity sensor The temperature sensor is encapsulated in the feed conductivity sensor. The feed conductivity sensor is located downstream of the pre-filters and above the inlet diaphragm valve.

  • Page 123: Conductivity Calibration Procedure - V2/2016

    23G-Series RO System Conductivity Calibration Procedure 8.5.1 Measuring the Conductivity of Feed and Permeate Samples NOTE: The 23G displays conductivity in microSiemens (S). NOTE: Use a hand-held, recently calibrated conductivity meter. The meter should read in microSiemens (S). NOTE: Some hand-held meters are not temperature compensated and, therefore only accurate at 77°F (25°C).

  • Page 124: Displaying The Feed Conductivity On The Ecm-100

    23G-Series RO System 8.5.3 Displaying the Feed Conductivity on the ECM-100 Press the ESC key twice to return to the default menu. Press the ARROW keys to scroll to Alarm Limits Menu (02). Press the ENTER key to select the Alarm Limits Menu. Press the ENTER key to scroll down to the “Rejection Low”...

  • Page 125: Restoring The Rejection Low Alarm Setting

    23G-Series RO System Locate the potentiometer marked “feed” on the main circuit board. The circuit board for the potentiometers is located in the door of the ECM-100 enclosure. The potentiometer marked “feed” is located in the center of the main circuit board.
  • Page 126 23G-Series RO System Take a sample of the permeate from the permeate sample port [about 8 ounces (0.24 L)] in order to establish the known conductivity. Measure the permeate conductivity reading from the sample collected. Be sure to rinse the conductivity meter thoroughly in a stream of water from the permeate sample valve before taking the reading.

  • Page 127: Pressure Transducer Calibration Procedure - V2/2016

    23G-Series RO System Two lines of factory settings will be displayed. • Enter the storage code using the following keys in sequence to save the settings: HAND/AUTO ENTER Pressure Transducer Calibration Procedure De-energize the 23G pump and shut inlet valve to the 23G. Energize the 23G controller.

  • Page 128: Flow Calibration Procedure - V2/2016

    23G-Series RO System Use the UP arrow on the controller to advance the pre-filter pressure reading on the screen to 6. Wait 15 seconds for the controller to accept calibration information. Then push the DOWN arrow slowly until it goes to the next lower number, waiting 15 seconds between number changes.

  • Page 129: Calculating Concentrate Flow Rate

    23G-Series RO System Close the permeate outlet valve. Secure the end of the hose attached to the CIP fitting. Turn machine ON. After 15 - 20 seconds of operation measure the permeate flow. Measure the permeate flow with an accurate stopwatch. Record the time needed to collect water in a container with a known volume.

  • Page 130: Calibrating The Concentrate And Permeate Flow Rate Offsets

    23G-Series RO System After 15 - 20 seconds of operation measure the concentrate flow. Measure the concentrate flow with an accurate stopwatch. Record the time needed to collect water in a container with a known volume. Use the formula below to calculate volume: # of gallons gallons per minute (gpm) = x 60...

  • Page 131: Verifying The Concentrate And Permeate Flow Rate Slopes

    23G-Series RO System The “Conc Flow rate Offset” should read 00. If it does not read 00: • Enter the passcode in the following sequence to adjust the reading: a. HAND/AUTO b. CIP c. ALARM BYPASS • Press the ARROW keys to set the "Conc Flow rate Offset" to 00. •...

  • Page 132: Calibrating The Concentrate And Permeate Flow Rate Slopes

    23G-Series RO System • Press ENTER to save the new value. The above steps verify the factory default sets for the concentrate and permeate flow rate slopes. The following procedure will calibrate the slopes. Verifying the Permeate Flow Rate Slope NOTE: It is not necessary to enter the passcode for additional adjustments in the Calibration Menu.
  • Page 133 23G-Series RO System Enter the passcode in the following sequence to adjust the reading: a. HAND/AUTO b. CIP c. ALARM BYPASS While machine is running, compare the concentrate flow rate on the ECM-100 to the bucket test concentrate flow rate measured in Step 8 of Calculating Concentrate Flow Rate (Section 8.7.2).
  • Page 134 23G-Series RO System Calibrating the Permeate Flow Rate Slope Press ESC twice to return to the ECM-100 default menu. Press ENTER to scroll to the Calibration Menu (06). Press ENTER to select the Calibration Menu. Press ENTER to scroll to the “Perm Flow Rate Slope.” Enter the passcode in the following sequence to adjust the reading: HAND/AUTO ALARM BYPASS...

  • Page 135: Returned Material Authorization Procedure

    23G-Series RO System RETURNED GOODS AUTHORIZATION PROCEDURE If you wish to return materials for warranty evaluation and/or credit, please have your original sales order, invoice, and device serial number available when you call Mar Cor Purification. Call Mar Cor Purification at (800) 633-3080 and request Technical Support. A 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.

  • Page 136: Spare Parts Lists

    23G-Series RO System 11.0 SPARE PARTS LISTS Valves Part Number Control Solenoid, Stainless Steel, 3-way, 1/4 inch (Inlet, Diverts Solenoid) 220 Volt, 50 Hz OS1202126 Control Solenoid, Stainless Steel, 3-Way, 1/4 inch, (Inlet, Diverts Solenoid) 110 Volt, 60 Hz OS1112563 Sampling Valve, PVC, 1/4 inch, (Feed Permeate and Concentrate) ME40291 Valve Needle, 316, 1/4 inch MPT, Straight (Concentrate Valve) (Flow Block)

  • Page 137: Flow Block And Connectors

    23G-Series RO System Flow Block and Connectors Part Number Hosebarb, Nylon, 90°, 3/4 inch Hosebarb x 1/2 inch MPT OS1111835 Hosebarb, Nylon, 90°, 3/4 inch Hosebarb x 1 inch MPT OS1114832 Hosebarb, Nylon, 3/4 inch Hosebarb, x 1/2 inch MPT 350-01-018 Hosebarb, Nylon, 3/4 inch Hosebarb, x 3/4 inch MPT 350-15-016...

  • Page 138: Electrical

    23G-Series RO System Electrical Part Number PCB Assembly, Main Logic Board 2016, ECM-100 50/60Hz 3031194 PCB Assembly, Relay Board 2016, ECM-100 50/60Hz 3031195 Motor Starter 115VAC (60HZ)-5HP Motor 3024188 230VAC (50HZ)-5HP Motor 3024189 115VAC (60HZ)-7.5HP Motor 3024351 Motor Overload 3.2-16AMPS-5HP Motor 3024187 5.4-27AMPS-5HP Motor 3024186...

  • Page 139: Test Kits

    23G-Series RO System Test Kits Part Number pH Test Kit, Range 4-10 Standard Units OS1155478 Clamps Part Number Victaulic Coupling, Complete with EPDM Gasket, 3/4 inch OS1157369 Victaulic Coupling, Complete with EPDM Gasket, 1-1/4 inch OS1157370 Victaulic Coupling, Complete with EPDM Gasket, 4 inch OS1153148 Miscellaneous Part Number...

  • Page 140: Pump And Motor Assemblies (Three-Phase, 60 Hz)

    23G-Series RO System NOTE: Machine expansion may require a change in pump and motor assembly. Contact Mar Cor Technical Support. NOTE: Because of Government mandates the pump motor changed in May 2011. Reference the table below for the correct part number. NOTE: Please provide the Model and Serial number of your machine when calling for information.

  • Page 141: Pump And Motor Assemblies (Three-Phase, 50 Hz)

    23G-Series RO System Pump and Motor Assembly Motor Model Part Number Flow (hp) # of Pattern Elements Voltage (380) 3024472 1-1-1-1 CRN 3-36 2-1-1-1 2-2-1-1 2-2-2-1 2-2-2-2 3024473 CRN 5-32 3-2-2-2 3-3-2-2 Pump and Motor Assembly Part Number Motor Model Flow (hp) # of...
  • Page 142 23G-Series RO System NOTES: 3024270 Rev I 5Apr16...
  • Page 144 Mar Cor Purification Mar Cor Purification Mar Cor Purification Mar Cor Purification Mar Cor Purification 4450 Township Line Road 14550 28th Avenue North 1119 Paulsun Street 160 Stedman Street 6351 Orangethorpe Ave. Skippack, PA 19474-1429 Plymouth, MN 55447 San Antonio, TX 78219 Lowell, MA 01851 Buena Park, CA 90620 Tel:...

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