Mar Cor Purification 23G-SERIES Operation And Maintenance Manual
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Mar Cor Purification 23G-SERIES Operation And Maintenance Manual

23g-series reverse osmosis system
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Mar Cor Purification
23G-SERIES REVERSE OSMOSIS SYSTEM
Operation and Maintenance Manual
OS1157051 Rev. G
13July07

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Summary of Contents for Mar Cor Purification 23G-SERIES

  • Page 1 Mar Cor Purification 23G-SERIES REVERSE OSMOSIS SYSTEM Operation and Maintenance Manual OS1157051 Rev. G 13July07...
  • 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. OS1157051 REV. G 13-July-07...
  • Page 4 This page intentionally left blank. OS1157051 REV. G 13-July-07...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS GENERAL INFORMATION General Description The Manual Safety Summary 1.3.1 Read This Manual 1.3.2 Use Proper Power Connections 1.3.3 Device Labeling Flow Description Machine Nomenclature Machine Permeate Quality Machine Features Specifications for 23G Machine 1.8.1 RO Feedwater Specifications 1.8.2 Permeate (Product Water) Flow Rate 1.8.3...
  • Page 6 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 ECM-100 Passcode 4.2.7...
  • Page 7 Step-Wise Cleaning 5.7.1 Installation of the 23G CIP 5.7.2 General Clean-In-Place Procedure Sanitizing Using a CIP System Membrane Element Cleaners and Sanitizers for 23G Machines 5.10 Pre-filter Replacement Procedure 5.11 Recording Performance Data 5.12 Preparing Machine for Movement 5.13 Membrane Element Replacement 5.13.1 Membrane Element Removal 5.13.2...
  • Page 8 23G SOFTWARE Calibration Procedures – Version 2 Software pH Calibration Procedure – Software Version V2 V2 Logic Board Temperature Calibration Procedure – V2 8.4.1 Cleaning the Feed Conductivity Sensor 8.4.2 Calibrating the Temperature Conductivity Calibration Procedure – V2 8.5.1 Measuring the Conductivity of Feed and Permeate Samples 8.5.2 Verifying the Percent Rejection Reading on the ECM-100 8.5.3 Displaying the Feed Conductivity on the ECM-100 8.5.4 Calibrating the Feed Conductivity...
  • Page 9 List of Figures Figure Title Membrane Element with Interconnectors System Schematic Typical Flow Diagram for 23G Systems Three-Phase Motor Wiring ECM-100 Front Panel 23G Series ECM-100 Main Board Electrical Diagram 23G Series ECM-100 Relay Board Electrical Diagram Brine Seal at the Exit End Membrane Element Installation 5.10 Cross-Sectional View Membrane Element and Housing...

  • Page 10: Membrane Element With Interconnectors

    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 11: 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.
  • Page 12 23G-Series RO System Permeate Rate [Product Water Rate (Qp)] Permeate rate is the flow rate of purified water which has passed through the membrane and out of the membrane element; expressed in gal/min (gpm) or gal/hr (gph) [in metric, liter/min (Lpm) or cubic meters/hour (m3/h)].
  • Page 13 The elements that Mar Cor Purification uses are spiral-wound membrane elements with a turbulent flow design. The membrane element collects the permeate water within the central tube, called the permeate tube.

  • Page 14: Flow Description

    23G-Series RO System An example of how to calculate salt rejection and recovery: Average Concentration (C ) = (C ) + (C 100 mg/L + 400 mg/L = 250 mg/L TDS Rejection = (C ) - (C ) x 100 250 - 6.2 x 100 = 97.5%...
  • Page 15 23G-Series RO System The concentrate leaves the last membrane element housing and flows into the manifold block. This concentrated water is then divided into recycle and concentrate streams. The recycle portion mixes with the feedwater by returning to the inlet piping, allowing higher machine recovery while still maintaining adequate crossflow through the membrane elements.

  • Page 16: Typical Flow Diagram For 23G Systems

    23G-Series RO System Figure 1.3 Typical Flow Diagram for 23G Systems OS1157051 Rev G 13-July-07...

  • Page 17: 23G Model Number Matrix

    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 18: 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 19 23G-Series RO System • high/low primary pressure (immediate shutdown on primary high pressure) • low inlet post-filter pressure • high permeate pressure (immediate shutdown) • high/low pH • high temperature • high permeate conductivity • low permeate conductivity • low permeate flow •...

  • Page 20: Specifications For 23G Machine

    23G-Series RO System Specifications for 23G Machines 1.7.1 RO Feedwater Specifications The rated flow for all machines in this section is based upon the following feedwater specifications. Limits should not be exceeded without consulting the factory. Inlet Pressure Rated; 30 psi (2.1 bar) Maximum;...

  • Page 21: Permeate (Product Water) Flow Rate

    23G-Series RO System The Langelier Saturation Index (LSI) of the concentrate must be negative to minimize the possibility of calcium scale formation on the membrane surface. Refer to ASTM Standard D3739. Chlorine should be removed prior to the PA membrane in order to prolong the functional life of the membrane element.

  • Page 22: Primary Operating Pressure

    23G-Series RO System 1.8.4 Primary Operating Pressure Motor Frequency Pump Minimum Maximum (Hp) (Hz) Model Boost Primary Boost Primary Pressure (PSI) Pressure (PSI) QS1818VB QS2818VB QS2825VB QS1828VB QS2825VB NOTE: Boost pressure = (primary pressure — post-filter pressure). NOTE: Primary and final pressure parameters may vary depending upon machine design and installation conditions.

  • Page 23: Service Assistance

    23G-Series RO System Table 1.2 Approximate Shipping Weights and Dimensions Model Number Shipping Dimensions Shipping Weight 23G 2 Element 65” D x 34” W x 78” H 655 lbs (165 cm D x 86 cm W x 200 cm H)
  • Page 24 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 25: Machine Location

    23G-Series RO System INSTALLATION 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.

  • Page 26: Permeate Outlet Connection

    23G-Series RO System 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 permeate flow rate to the drain. 2.2.4 Permeate Outlet Connection Connect a 1.0-inch I.D.
  • Page 27 23G-Series RO System Connect the ECM-100 power cord to a properly grounded 15 A, 115 VAC/60Hz or 10 A 220 VAC/50Hz, single-phase outlet. An appropriate termination should be installed on the electrical cord for 220 VAC service. Surge protection for single-phase service is recommended.

  • Page 28: Machine Lockout

    23G-Series RO System 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 29: Single-Phase Electrical Connections

    23G-Series RO System Checking Procedure: BE SURE POWER IS TURNED OFF A. Main Overload Protector: (Check for continuity between the terminals.) 1. Ohmmeter Setting: R x 1. 2. Terminal Connections: Ohmmeter leads to overload terminals. Set switch of overload to on. Meter will read zero ohms.

  • Page 30: Three-Phase Motor Wiring

    23G-Series RO System Table 2.4 Three-Phase Electrical Connections Wire Color Motor Wire Starter/Thermal Source 60 Hz 50 Hz Overload Connection Note: The connections listed below apply to 23G models with THREE PHASE motor power Black Brown Elect White Blue Enclosure...

  • Page 31: Preparation And Start-Up

    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 32: 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 for a minimum of 8 hours before exposure to cleaners or disinfectants as irreversible membrane damage may occur.
  • Page 33 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.
  • Page 34 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.

  • Page 35: 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 36 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. OS1157051 Rev G 13-July-07...
  • Page 37 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 38 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 39 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 Q - Flow rate PERM - Permeate CONC - Concentrate...

  • Page 40: Ecm-100

    23G-Series RO System Figure 4.5 ECM-100 Front Panel OS1157051 Rev G 13-July-07...
  • Page 41 This data can be updated by following the procedure described as “Store Factory Settings.” Mar Cor Purification factory personnel saved a copy of menu settings before the machine was shipped. At installation, after timers and calibrations have been tailored...
  • Page 42 23G-Series RO System To recall factory settings: a. Go to the Factory Settings Menu (menu 11). b. Push ENTER switch. The screen will display two lines of factory settings. c. Enter passcode (Section 4.2.6) to restore factory settings. Contact your equipment supplier for assistance.
  • Page 43 23G-Series RO System 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. Enter the passcode to download the data tables to a printer or computer starting with the table in view on LCD.
  • Page 44 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.
  • Page 45 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.
  • Page 46 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 47 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.
  • Page 48 23G-Series RO System Table 4.5 ECM-100 Alarm Settings Alarms Range Factory Preset (Menu 02) 0 - 200 µS/cm (Note 1, 2) 30 µS/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)
  • Page 49 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...
  • Page 50 23G-Series RO System Figure 4.6 23G Series ECM-100 Main Board Electrical Diagram OS1157051 Rev G 13-July-07...
  • Page 51 23G-Series RO System Figure 4.7 23G ECM-100 Relay Board Electrical Diagram OS1157051 Rev G 13-July-07...
  • Page 52 23G-Series RO System ECM-100 Display Screens 4.4.1 ECM Display Screen Hierarchy OS1157051 Rev G 13-July-07...
  • Page 53 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: 1. HAND/AUTO 2. CIP 3. ALARM BYPASS Store Changes:...
  • Page 54 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.
  • Page 55 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 56 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 57 23G-Series RO System 4.4.7 Detail of Calibration Operation (Menu 06) PASSCODE REQUIRED TO ADJUST CALIBRATION VALUES OS1157051 Rev G 13-July-07...
  • Page 58 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 is sensors is equal to 2.0 psig (0.138 bar).
  • Page 59 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)
  • Page 60 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 OS1157051 Rev G 13-July-07...
  • Page 61 23G-Series RO System 4.4.13 Detail of Comm Port Speed Operation (Menu 13) PASSCODE REQUIRED OS1157051 Rev G 13-July-07...
  • Page 62 PRACTICES COULD POSE A RISK OF SERIOUS INJURY OR DEATH TO HEMODIALYSIS PATIENTS. Mar Cor Purification 23G RO systems have been designed to operate with a minimum of operator attention. Like all mechanical systems they will operate longer and with less trouble when routine maintenance is performed regularly.
  • Page 63 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 64 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 65 The machine should be flushed daily to remove sediment from membrane surfaces. For flushing during on-line operation, all Mar Cor Purification 23G machines are equipped with an Autoflush system, which automatically increases the concentrate flow rate on an intermittent basis.
  • Page 66 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 67 23G-Series RO System NOTE: Cleaning may be required as often as once every week or infrequently as once every two months, depending upon the local water supply conditions. For more information, or for instructions on long-term machine shutdown (greater than 72 hours), contact your equipment supplier.
  • Page 68 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 69 NOTE: The CIP system must provide positive feed pressure to the RO machine. Mar Cor Purification strongly recommends using a CIP pump to provide sufficient inlet pressure (20 - 30 psi [1.38 - 2.07 bar]) to the high pressure RO pump during cleaning. Failure to provide adequate inlet pressure will damage the RO high pressure pump.
  • Page 70 Press the OFF key on the ECM-100. The CIP LED light will turn off. Install new pre-filters. NOTE: Mar Cor Purification recommends sanitizing machine after cleaning. Proceed to sanitizing (Section 5.7). Place the machine in AUTO mode by pressing the HAND/AUTO key. The AUTO LED light will illuminate.
  • Page 71 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. CAUTION: RO units must be rinsed to drain with normal pressures for a minimum of 8 hours prior to first exposure to disinfectants or irreversible damage may occur.
  • Page 72 Weekly replacement is typical. An increase in pressure drop across the filter indicates the pre-filter cartridges need changing. Use only Mar Cor Purification approved filters rated for 5 microns or less. Do not attempt to clean used pre-filters.
  • Page 73 Operating performance data should be recorded daily and kept on file or submitted to your equipment supplier or Mar Cor Purification. Copies of data sheets will be required by Mar Cor Purification if a warranty question arises. Daily Log sheets are included in the instruction manual package and are useful for recording performance data.

  • Page 74: Membrane Element Installation

    23G-Series RO System 5.13 Membrane Element Replacement As time progresses, the efficiency of the membrane elements will begin to decline. Generally, the salt rejection of the membrane will not change significantly when properly operated on water until about two years after installation.
  • Page 75 23G-Series RO System Cut the bag open as close as possible to the seal at the end of the bag so that the bag may be reused for disposal of the old membrane element. Remove the membrane element from the bag and remove the foam protectors from each end of the membrane element.
  • Page 76 23G-Series RO System Housing Victaulic Clamp Victaulic Gasket Direction of Flow Endcap Assembly W/Load Transfer Device O-Rings (2) End Cap Adapter O-Rings (2) Membrane Element Concentrate U-cup Seal (Brine Seal) Load Transfer Device O-Rings (2) Plug / Adapter Figure 5.9...
  • Page 77 23G-Series RO System Determine the direction of feed flow in the membrane element housing. Be sure to look at the “Direction of Flow” arrow on each membrane element housing; they may be different within a given machine. Be sure element direction of flow matches housing direction of flow on the plastic component.
  • Page 78 23G-Series RO System Insert an interconnector into the permeate tube located closest to the open end of the housing. Install the end cap and affix the closure device. Reconnect the permeate tube to the permeate manifold. Repeat for other membrane elements as necessary.
  • Page 79 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 80: Flow Control Manifold

    23G-Series RO System 5.14.1 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 81 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. •...
  • Page 82 23G-Series RO System Adjusting the Orifices - requires two wrenches and a large screwdriver. a. Use one wrench to hold the large nut and prevent it from turning. b. Use another wrench to loosen the locking nut, adjust the flow with the screwdriver.
  • Page 83 23G-Series RO System 5.15 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 84 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 85 The pH probe may have to be cleaned or replaced some time after 6 to 24 months of operation, depending on the type of use. Refer to the Spare Parts List (Section 11.0) for specific Mar Cor Purification part numbers. Clean by soaking the glass electrode for10 minutes in a 2 pH acid (the type used for buffer).
  • Page 86 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 87 23G-Series RO System To capture data from ECM-100 to a PC using HyperTerminal® Go to the windows application (START menu) and choose “Programs”→”Accessories”→”Communications”→”HyperTerminal” You will then need to choose a file name, i.e. “23G RO data” click You will then need to choose the connection, i.e. COMM 1, COMM 2 etc.
  • Page 88 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...
  • Page 89 23G-Series RO System Table 6.11 Example ECM-100 History Log DATE TIME PRESSURES FLOWS TEMP ALARM 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 96.9...
  • Page 90 23G-Series RO System Hardware Requirements All new IBM personal computers and clones are supplied with a standard 9-pin male serial port, which uses the standard 9-pin extender cable. If your computer has only one serial port connection being used by your mouse,...
  • Page 91 23G-Series RO System Go to Section 6.4.5 and complete Print Test. Connecting to a Parallel Printer Requires a “Serial-to-Parallel” (S-P) converter box between the ECM-100 cable and the cable to the printer (which typically uses a 36-pin Centronix connector). NOTE: If a serial printer is not available, a S-P converter box is commercially available at computer and office supply stores.
  • Page 92 23G-Series RO System 6.4.6 Print Functions Printing Current Displays Connect printer to ECM-100 as described in Printer Connections. Print current displays as described in Print Test. Printing History Logs Connect printer to ECM-100 as described in Printer Connections. Perform print test as described in Print Test.
  • Page 93 23G-Series RO System Troubleshooting Guide - Machine Performance Symptom Possible Causes Remedies Low operating Pre-filters clogged. Replace pre-filter cartridges. pressure 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).
  • Page 94 23G-Series RO System Troubleshooting Guide - Machine Performance Symptom Possible Causes Remedies pressure drop [over 15 membranes. psi (1.0 bar)] per membrane (Note: membrane pressure drop equals primary pressure - final pressure) Restricted flow at housing inlet or Check for blockage of concentrate flow at inlets outlet.
  • Page 95 23G-Series RO System Troubleshooting Guide - Machine Performance Symptom Possible Causes Remedies 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 (possibly due to fouled turbine in and calibrated container.
  • Page 96 23G-Series RO System Troubleshooting Guide - Machine Performance Symptom Possible Causes Remedies Replace damaged parts. Recovery too high. Adjust concentrate/recycle orifices. Membrane elements oxidized due Verify proper operation of pretreatment to chlorine break through. (chlorine removal/carbon filtration). Damage is irreversible, replace membranes.
  • Page 97 23G-Series RO System Troubleshooting Guide - Machine Performance Symptom Possible Causes Remedies Declining rejection (or Overfeeding buffer solution due to Check the pH of the concentrate and adjust to high permeate improper adjustment of pump or 6.0. Check the inlet pressure to be sure conductivity) low inlet pressure.
  • Page 98 23G-Series RO System Troubleshooting Guide – EMC-100 Display Failures Symptom Possible Causes Remedies adjusted Water leaking from O-ring or diaphragm failure. Replace valve. permeate and/or Contact your equipment supplier for diaphragm valves assistance. Check fitting. Tank level control Faulty float/tank level control.
  • Page 99 23G-Series RO System Troubleshooting Guide – 23G System Failures Symptom Possible Causes Remedies 23G electrical machine ECM-100 “lockup” (usually due to Power down for 2 minutes, then restart. shutdown power fluctuation). Check alarms, timers, and calibration settings. Recall Factory Settings.
  • Page 100 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...
  • Page 101 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 µS). If this remedy does not work, contact your equipment supplier.
  • Page 102 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 103 23G-Series RO System General ECM-100 Reference/Troubleshooting Guidelines ECM-100 Main Board ECM-100 Relay Board Software Module Terminal Strip Terminal Strip ECM-100 Relay Board ECM-100 Main Board Figure 7.11 ECM 100 OS1157051 Rev G 13-July-07...
  • Page 104 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.
  • Page 105 23G-Series RO System 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. CAUTION: Do not apply too much pressure - you may damage the board.
  • Page 106 23G-Series RO System 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 low % rejection alarm.
  • Page 107 23G-Series RO System 7.2.5 Verifying the Temperature Circuitry of the Main Board Turn the machine OFF. Unplug the power cord for the ECM-100. Disconnect the temperature sensor wires from terminal posts 23 and 24. Cover the temperature sensor wires which were removed from terminal posts 23 and 24 with electrical tape.
  • Page 108 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.
  • Page 109 23G-Series RO System V1 and V2 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 contain Version 2 (V2) circuit boards. This new circuit board includes extra electronic components built into the circuit board.
  • Page 110 (QA) testing. Any “user” variation of these specifications (including any software upgrades) in the field (after the machine has left Mar Cor Purification shipping dock) is solely the responsibility of the user to document and control. Menu #2...
  • Page 111 23G-Series RO System a. Adjustment range of “Permeate Conductivity High” alarm is 0-50 µS/cm for Rev D3 software; 0-200 µS/cm for Rev E0 or higher software. b. Below 200 µS/cm, there are 2.5 units of specific conductance (µS/cm) per unit of Total Dissolved Solids (ppm or mg/L as CaCO c.
  • Page 112 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...
  • Page 113 23G-Series RO System Temperature Calibration Procedure 8.4.1 Cleaning the Feed Conductivity Sensor Turn machine OFF. 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 114 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 (µS). NOTE: Use a hand-held, recently calibrated conductivity meter. The meter should read in microSiemens (µS). NOTE: Some hand-held meters are not temperature compensated and, therefore only accurate at 77 F (25 C).
  • Page 115 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.
  • Page 116 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 117 23G-Series RO System If the permeate conductivity reading is 1.0 or less refer to ECM-100 Troubleshooting (Section 4.7). Take a sample of the permeate from the permeate sample port [about 8 ounces (0.24 L)] in order to establish the known conductivity.
  • Page 118 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: a. HAND/AUTO b. CIP c. ON d. ENTER Pressure Transducer Calibration Procedure De-energize the 23G pump and shut inlet valve to the 23G.
  • Page 119 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 120 (gpm) = x 60 # of seconds to fill container Mar Cor Purification recommends using a 5 gallon (19 L) container with 1 gallon (1 L) increments. Compare the flow reading from Step 1 to the flow rate calculated in Step 8.
  • Page 121 (gpm) = x 60 # of seconds to fill container Mar Cor Purification recommends using a 5 gallon (19 L) container with 1 gallon (1 L) increments. Compare the flow reading from Step 1 to the flow rate calculated in Step 8.
  • Page 122 23G-Series RO System The “Conc Flowrate Offset” should read 00. If it does not read • 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 Flowrate Offset"...
  • Page 123 23G-Series RO System The “Conc Flow Rate Slope” should read 37. If it does not read • Press the ARROW keys to set the “perm Flow Rate Slope” to 37. • Press ENTER to save the new value. The above steps verify the factory default sets for the concentrate and permeate flow rate slopes.
  • Page 124 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 812.2).
  • Page 125 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.”...
  • Page 126 If you wish to return goods 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 127 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...
  • Page 128 23G-Series RO System Flow Block and Connectors Part Number Hosebarb, Nylon, 3/4 inch Hosebarb, x 1 inch MPT OS1113279 Connector, PPL, 1/4 inch Tube x 1/4 inch MPT OS1110294 Connector, PPL, 3/8 inch Tube x 1/4 inch FPT OS1110293 Connector, PPL, 1/4 inch Tube x 1/8 inch MPT...
  • Page 129 23G-Series RO System Electrical Part Number PCB Assembly, Main Logic Board, ECM-100 60 Hz OS1163521 PCB Assembly, Main Logic Board, ECM-100 50 Hz 3013742 PCB Assembly, Relay Board, ECM-100 OS1163520 Motor Starter/Relay Kit, three-phase, 115 Volts (Includes Starter and Relay) 3.7 - 12.0 Amps...
  • Page 130 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...
  • Page 131 23G-Series RO System NOTE: Machine expansion may require a change in pump and motor assembly. Contact your equipment supplier. NOTE: Please provide the Model and Serial number of your machine when calling for information. Pump and Motor Assemblies (Three-Phase, 60 Hz)
  • Page 132 23G-Series RO System Pump and Motor Assemblies (Three-Phase, 50 Hz) Pump and Motor Assembly Part Pump Out Overall Length Motor Model* Number (Center to Flow (hp) # of Center) Pattern Elements Voltage Part (380) Number OS1221470 OS1203384 5.6” (14.2 cm)
  • Page 133 23G-Series RO System Pump and Motor Assemblies (Single-Phase, 60 Hz) Pump and Motor Assembly Part Pump Out Overall Length Motor Model* Number (Center to Flow (hp) # of Center) Pattern Elements Voltage Part (230) Number OS1221459 OS1223706 7.9” (17.5 cm)
  • Page 134 23G-Series RO System NOTES: OS1157051 Rev G 13-July-07...
  • Page 136 Call (800-633-3080) for additional information or visit www.mcpur.com.

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