AmeriWater Heatsan 00HS208 Manual

98-0156G
Operation & Maintenance Manual
AmeriWater
The Water Purification Specialists
3345 Stop 8 Rd, Dayton, OH 45414 | 800 535 5585 | www.ameriwater.com 98-0156 Rev G
Manufactured With Pride in The USA
Heatsan
Heat Sanitization System

198-0156 Rev G
TABLE OF CONTENTS
1CONTACT DETAILS.................................................................................................... 3
2HEALTH AND SAFETY ............................................................................................... 4
Explanation of symbols and references ...................................................5
Additional safety requirements .................................................................5
Usage in accordance with intended purpose ..........................................5
Operating staff..............................................................................................6
Bringing the system to a stop in the event of an emergency................7
Safety information for maintenance tasks...............................................7
Disposing of system parts and operating materials ...............................7
Unauthorized conversion and manufacturing replacement parts.......7
Warranty claims and liability ......................................................................8
3SPECIFICATION.......................................................................................................... 9
Controls .........................................................................................................9
Alarms and Maintenance ............................................................................9
Weights and Dimensions ............................................................................9
Water Services Connection Schedule........................................................9
Electrical Supply Requirements............................................................... 10
IP Ratings .................................................................................................... 10
Feedwater................................................................................................... 10
Performance .............................................................................................. 10
Environment............................................................................................... 11
Classification and Standards Applied..................................................... 11
4PROCESS DESCRIPTION......................................................................................... 12
Operation ................................................................................................... 12
Preheat ............................................................................................... 12
Heating (Heatsan Operation) .......................................................... 13
Hold (Heatsan Operation)................................................................ 13
Draw off period ................................................................................. 13
Cool down period.............................................................................. 14
Drain in Operation............................................................................ 14
Standby............................................................................................... 14
Remote Light.............................................................................................. 14
Light Pattern ...................................................................................... 14
5INSTALLATION ........................................................................................................ 15
Environment............................................................................................... 15
Unpacking................................................................................................... 15
Electrical Supply......................................................................................... 15
Water Connections.................................................................................... 15
Drain............................................................................................................ 16
Overflow ..................................................................................................... 16
Hot Water Flow/Return............................................................................. 16
Fill................................................................................................................. 16
Input/Outputs ............................................................................................ 16
Installation Plan Layout ............................................................................ 17

298-0156 Rev G
Commissioning .......................................................................................... 17
6OPERATING PROCEDURES .................................................................................... 18
Operator Interface .................................................................................... 18
Operation (levels of access) ..................................................................... 18
Operation (password entry)..................................................................... 19
Log In .................................................................................................. 19
Operation ................................................................................................... 19
Daily Defaults Menu ......................................................................... 19
System Set-up.................................................................................... 22
Today Current Set-up menu............................................................ 23
Heatsan Immediate Start................................................................. 24
Monitor – Rates ................................................................................. 25
Monitor – Times ................................................................................ 26
Alarms and Events..................................................................................... 26
Factory set-up ............................................................................................ 28
Normal Operation..................................................................................... 34
Data Logging .............................................................................................. 35
Uploading New Software ......................................................................... 37
Factory Default Settings ........................................................................... 38
7FAULT FINDING....................................................................................................... 39
Data Alarm List ...................................................................................... 39
Event Listings ............................................................................................. 44
8DISINFECTION AND CLEANING ............................................................................ 45
Advisory Note............................................................................................. 45
Surface Cleaning........................................................................................ 45
9MAINTENANCE........................................................................................................ 46
Maintenance .............................................................................................. 46
Thermostat Testing................................................................................... 46
Recommended Spare Parts ..................................................................... 47
Calibration of Sensors .............................................................................. 48
10 APPENDIX ................................................................................................................ 49
Disposal of electrical parts....................................................................... 49
Heatsan Process Flow Diagram............................................................... 50
Wiring Diagrams........................................................................................ 51
Installation Layout..................................................................................... 57
Flow Diagram MediQA to Heatsan ......................................................... 58
Flow Diagram MROZ to Heatsan............................................................. 62
Optional Signal Tower Installation.......................................................... 67
Heatsan Valve Isolation Interface Kit...................................................... 68
11 IFU – Updating Mitsubishi FX3G PLC Software with the FX3G-EEPROM-32L
Module 70
12 IFU – Updating Mitsubishi GOT1000 HMI Software w/Jump Drive ................. 73

398-0156 Rev G
1CONTACT DETAILS
For all service, spares and consumables enquiries contact:
AmeriWater
3345 Stop 8 Rd
Dayton, Ohio 45414
Tel No. 800-535-5585
(Or your local authorized AmeriWater dealer)
Useful Telephone Nos.
Tel No………………………………Contact Name:……………………………….
Tel No………………………………Contact Name:……………………………….

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2HEALTH AND SAFETY
These instructions provide information on safe working practices. These
should be adopted to ensure safe and continuing operation of the
equipment. The manual should be read and understood before the
equipment is used.
AmeriWater reserves the right to make engineering refinements to the
equipment that may not be described herein. Any questions that cannot
be answered specifically by these instructions should be addressed to
AmeriWater or their agents for a response.
AmeriWater will not accept any responsibility for any equipment supplied
or the actions of such equipment or associated system if un-authorized
modifications are carried out that are considered by AmeriWater to
compromise the integrity of the original design philosophy.
If the unit’s performance becomes impaired and any remedial work
appears to be outside the scope of this manual, then seek advice from
AmeriWater, quoting the unit’s serial number (Refer to Section 1 Contact
Details).
The unit must not be disassembled in any way unless carried out by an
AmeriWater technician or authorized trained personnel.
During normal operation, the unit must not be operated with the control
panel door open. If access is required to the control panel, always isolate
the power supply using the door isolator.
The ‘Caution’ symbol is used throughout this manual to highlight where
particular care must be taken to ensure the safety of the operator, and
the protection provided by the equipment, is not impaired.

598-0156 Rev G
Explanation of symbols and references
This symbol refers to any immediate dangers. Failure to
follow the specified procedure could result in serious
personal Injury. Extreme caution should be observed
when conducting any activity where this symbol is shown.
Work should be completed by a trained competent
person.
Electrical shock. Do not touch electrical components.
Before performing tasks on parts of the electrical system,
disconnect the system from the power supply.
This symbol refers to a possible danger. Failure to follow
the specified procedure could result in personnel injury.
Caution should be observed when conducting any activity
where this symbol is shown. It is recommended work
should be completed by a trained competent person.
This symbol refers to a possibly hazardous situation.
Failure to observe these references may result in minor
injuries and/or damage to property.
I
This symbol points out important information for working
with the system in the proper manner. Failure to observe
these references may result in malfunctions in the system
or impact on the environment.
This symbol indicates a possible hot surface. Touching
parts of the machine showing this label should be
avoided.
Failure to observe these references may result in malfunctions in the
system or impact on the environment or result in injuries.
Additional safety requirements
National or provincial specific requirements/standards and regulations
must be observed.
Usage in accordance with intended purpose
This equipment is intended for indoor use only in a non-hazardous
environment to provide hot water, up to 194 °F for the purposes of
disinfection of water treatment equipment or other equipment.
Danger
Warning
Caution

698-0156 Rev G
When in use this equipment produces pressurized water at a
scalding temperature, up to 194 °F. Before using or working on the
equipment, ensure that personnel are aware of potential hot surface
areas on the equipment, identified by the hot surface symbol below.
Allow sufficient time after use for the water to have cooled to a safe
working temperature before carrying out any remedial works. The
un-flagged parts connected to parts marked with this symbol may
also have hot surfaces.
The unit should be wired to the electrical supply via an external
isolator or circuit breaker located near to the equipment.
When wiring AC three phase supplies to the equipment, the
‘Live’ wires should be connected to the ‘L1’, ‘L2’ and ‘L3’
terminals.
“RISK OF ELECTRICAL SHOCK”. ONLY QUALIFIED/APPROVED
ELECTRICAL ENGINEERS SHOULD BE USED TO CONNECT THE UNIT
TO THE ELECTRICAL SUPPLY.
Any references in this manual to installation requirements/procedures
are provided as information only. Installation of the unit will only be
carried out by AmeriWater or an approved installation technician.
If the unit is used in a manner not specified by AmeriWater or
procedures not followed as detailed in this manual, the protection
provided by this equipment may be impaired.
WARNING - DO NOT USE THIS EQUIPMENT IN ANY OTHER MANNER
THAN THOSE SPECIFIED UNDER SECTION 2.3.
Some parts of the system could be under pressure. Always make
sure the pressure has dispersed from the unit before repairs and
maintenance tasks are carried out.
Operating staff
Only persons who have read and understood these Instructions should
operate the unit. When operating the unit it is important to strictly
observe the safety information.
Caution
Danger
Caution

798-0156 Rev G
Bringing the system to a stop in the event of an emergency
To shut the unit down in the event of an emergency rotate the
yellow/red door isolator switch to the “OFF” position. Isolate the 3-
phase electrical supply to the unit at source. There will be no
requirement to isolate any of the hydraulic lines as all valves close
when de-energised.
Safety information for maintenance tasks
The owner of the unit must take care to ensure that only authorized
personnel who have been sufficiently informed for the task at hand
perform all maintenance and inspection tasks.
Before beginning tasks on the electrical equipment of the system, a
check must confirm that power has been disconnected. In addition, the
system must be secured to prevent it from being turned on again
unintentionally. The isolator switch is capable of accepting a lock-out
padlock when in its “OFF” position. The unit may contain water at
scalding temperatures; ensure it is drained down and safe to work on
before carrying out any maintenance tasks.
Disposing of system parts and operating materials
Refer to Section 10.1 for details.
Unauthorized conversion and manufacturing replacement
parts
Conversion or modification of the system is only permitted with the
approval of AmeriWater. Original replacement parts authorized /
supplied by the manufacturer enhance safety and ensure design
performance. The use of unauthorized parts may void the warranty on
the unit, impair its performance or compromise the safety of those
operating it.

898-0156 Rev G
Warranty claims and liability
The buyer has a one-year warranty on all equipment and parts,
excluding non-durable components (e.g., filter cartridges, reverse
osmosis membranes, filter media, consumable chemicals, etc.);
provided that the system is not subject to abuse, misuse, alteration,
neglect, freezing, accident or negligence; and provided further that the
system is not damaged as the result of any unusual force of nature
such as, but not limited to, flood, hurricane, tornado, or earthquake.
The warranty covers the replacement of equipment and/or parts only.
The warranty does not cover labor charges or travel expenses resulting
from the service of equipment. The manufacturer is excused if failure
to perform its warranty obligations is the result of strikes, government
regulation, materials shortages, or other circumstances beyond its
control.
To obtain warranty service, notice must be given to the manufacturer
within 30 days of the discovery of the defect.
There are no warranties on the AmeriWater system beyond those
specifically described above. All implied warranties, including any
implied warranty of merchantability or of fitness for a particular
purpose are disclaimed to the extent they might extend beyond the
above periods. The sole obligation of the manufacturer under these
warranties is to replace or repair the component or part which proves
to be defective within the specified time period, and the manufacturer
is not liable for consequential or incidental damages. No dealer, agent,
representative, or other person is authorized to extend or expand the
warranties expressly described above.
Some states do not allow limitations on how long an implied warranty
lasts or exclusions or limitations of incidental or consequential
damage, so the limitations and exclusions in the warranty may not
apply to you. This warranty gives you specific legal rights, and you may
also have other rights, which vary from state to state.

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3SPECIFICATION
The Heatsan Integrated hot water disinfection unit incorporates
equipment to heat water received from a water purification system and
circulate around a distribution loop at a controlled sanitizing temperature
for a specified length of time. On completion of disinfection the water is
then made available to be taken off to dialysis machines for their heat
disinfect cycle. At the end of the cycle the water is discharged from the
system to drain and the loop is cooled.
Models available:
00HS208 3-phase, 208V, 60hz, 15kW Heater
Controls
All the processes of the Heatsan unit are controlled automatically and
the unit operates via a touch screen which displays systems
performance data and unit status.
Alarms and Maintenance
The Heatsan unit incorporates monitoring devices and will report
alarms and warning messages via the user display. Reference to these
alarms and appropriate actions to be taken to rectify them can be
found in Section 7 “Fault Finding”.
Weights and Dimensions
Weight (lbs)
Height (ins)
Width (ins)
Depth (ins)
Shipping (700)
70 28 35
Working (1580)
Water Services Connection Schedule
Drain: 1½” sanitary Tri-clamp coupling
Overflow: 1½” sanitary Tri-clamp coupling
Fill: ½” sanitary Tri-clamp coupling
Hot water flow: 1½” sanitary Tri-clamp coupling
Hot water return: 1½” sanitary Tri-clamp coupling

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Electrical Supply Requirements
Electrical Supply*
Operation**
kW
rating
Current draw
(amps)
per phase
3-phase
+E,208V, 60hz
Heatsan /
Recirculation 16kW 47
Notes:
* Circuit isolation of the incoming supply should be provided external
to the unit.
** Maximum duty with one 9kW and two 3kW heaters on plus
recirculation pump.
The earth leakage current of this equipment can exceed 3.5mA
(<5mA). Therefore, it is essential that the Earth connection is
made before the supply is established.
A warning label on the equipment states:
IP Ratings
Control Panel -Type 2
Recirculation pump -IP55
Feedwater
Quality: RO permeate/Softened
Temperature: 55-194 0 F
Performance
Working tank volume: 100 Gallons
Pump output range: 317 Gallons/hr @ 5.5 Bar (80 psi)
to 1160 Gal/hr @ 2 Bar (30 psi)
Designed max water temp: 203 °F
Maximum no. Dialysis m/cs: See note below:
WARNING
HIGH LEAKAGE CURRENT
Earth connection essential before connecting to mains supply

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Note: The maximum number of dialysis machines that the unit can
supply depends on the volume of hot water required per machine and
the rate at which they draw water. So long as the total volume of water
required does not exceed the maximum available for draw off and the
maximum draw rate does not exceed the pump performance. See
pump limits above.
Environment
Parameter Limits
Room storage and operating
temperature range
(41-104°F)
Relative humidity 30 to 80%
Maximum altitude 6562 ft (2000m)
Transport and storage
temperature
23°F to 203°F (Dry unit)
RFI/EMI radiation
The EMC environment must be within the
limits to which the unit has been tested, see
Section 3.10 below.
Care must be taken not to place near the unit
any source of RFI/EMI, which is liable to cause
electromagnetic disturbance. If the unit is
affected by such disturbance, the source must
be suppressed or moved.
Classification and Standards Applied
Class 1 equipment
Electrical
Insulation
Category II
Pollution
Degree II
Type IIB applied part
EMC
UL 61010-1, Issue 07/12/2004, Ed:2,
Rev:10/28/2008 Standard for Electrical
Equipment for Measurement, Control,
and Laboratory Use Part 1: General
Requirements and CSA C22.2# 61010-1,
Issue: 07/12/2004, Ed:2 (R2009) Safety
Requirements for Electrical Equipment
for Measurement, Control, and
Laboratory Use Part 1: General
Requirements, with general instruction
No. 1:2008/10/28 – R2009.

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4PROCESS DESCRIPTION
This section provides general information regarding the heat disinfection
process utilized by the Heatsan unit.
Operation
General philosophy of operation:
The unit can be configured to disinfect up to two distribution loops,
either individually or together. The user can set for each day of the
week which loop is to be disinfected and in what configuration.
The unit has been designed to provide up to 95 gallons of hot water for
the purposes of sanitizing connected dialysis equipment.
The number of machines that can be disinfected at any one time will
be dependent on the requirement of those machines regarding the
amount of water each machine needs for disinfection, the time taken
to perform heat disinfection and the flow at which they require the hot
water.
The system allows the user to input the specific requirements of the
dialysis machines to be disinfected, the days requiring heat disinfection
and the times which heat disinfection can occur.
If the system detects that any of the entered user values cannot be
achieved by the Heatsan unit the unit will raise an “Invalid number”
alarm warning the user that the parameters loaded cannot be
achieved.
The typical stage duration times for disinfection can be found in
Section 6.10 Factory Default Settings.
Note: These values can be adjusted to fit requirements of your
particular distribution system. Verification of the efficacy of changes is
the responsibility of the medical director.
Preheat
The preheat stage is initiated prior to the Heatsan start time. The
start and return to service times being set by the clinical staff.
Water is taken off of the loop during the preheat stage.

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During this stage the unit fills the tank with only the amount of
permeate needed for the number of machines programmed in by
the operator. This feature saves on power and water consumption.
The heaters then raise the temperature to the tank preheat
temperature and hold it until the timed Heatsan start period is
reached. The pre-heat stage reduces the risk of thermal shock to
pipework and reduces the time taken to achieve disinfection
temperature.
Heating (Heatsan Operation)
Once the Heatsan Start time is reached, hot water will be
directed into the loop. Ensure that no patients will be on line
when the “Heatsan Start” time is reached.
Once the pre-programmed “Heatsan Start” time has been reached
the Heatsan will isolate the RO from the distribution loop. The
Heatsan will then be automatically connected to the loop using the
motorized valves on the associated manifold. The internal pump
will circulate the preheated water around the distribution loop(s) to
be disinfected. The system will continue to heat the water until the
preset disinfection temperature is achieved. The circulation period
is set by the loop pre-heat value on the HMI, the factory default can
be found in Section 6.10.
Hold (Heatsan Operation)
After the “loop pre-heat” stage has timed out, the system is then
held at the disinfection temperature for the hold time. The default
hold time can be found in Section 6.10. The temperature is
maintained by switching on 1, 2, or 3 heaters, depending on the
selection of loop size in Section 6.6 Factory set-up.
Draw off period
The default time for this stage can be found in Section 6.10. The
minimum time is adjustable. The maximum time is calculated from
the times pre-programmed in by the user relating to the stop/start
times and the duration for the heat disinfection cycle on the
connected dialysis machines.
Caution

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Cool down period
Once the water availability stage has timed out the system will
proceed into automatic “Cool down”. The system will perform a
series of tank drain downs and introduce cold RO permeate into the
distribution loops until the return temperature on the system falls
below the “maximum service temperature” setting. The factory
default for this can be found in Section 6.10. On reaching this
temperature the system automatically disconnects itself from the
loop(s) and re-introduces the RO unit(s).
Drain in Operation
Following the Cool down period the tank drain valve will remain
open until the tank level falls to zero at which point the unit will
return to STANDBY. To ensure that the tank remains empty during
STANDBY the drain valve will open for 5 minutes every 2 hours.
Standby
STANDBY will be displayed to indicate that the unit is “healthy” and
waiting for the next heat disinfection routine to initiate.
Remote Light
A four tier remote light is available to clearly and easily show the
operational state of the Heatsan.
Light Pattern
Light
Light
Pigtail
Wire
Termination
Heatsan
PLC
Output
Illumination
Description
Pattern
Time
Green Green K2 (12) Y21
System is in
standby mode
Steady
System is in drain
in operation mode
1 sec on
1 sec off
Amber Orange K3 (14) Y22
System is in tank
preheat
Steady
Blue Blue K4 (14) Y23
System is preparing
to send hot water
to distribution loop
1 sec on
1 sec off
Hot water is
circulating in
distribution loop
Steady
Red Red KAB (14) Y6
General Alarm
condition
Steady
Common
Yellow
TB1, 24C
N/A
N/A
N/A
N/A

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5INSTALLATION
This section provides the recommended method of installation for the
Heatsan unit.
Environment
The unit should be installed in a clean and dry, indoor, non-hazardous,
ventilated environment (see Section 3.9).
Unpacking
When transporting the unit either by pallet truck or by forklift observe
the centre of gravity markings and prevent from tipping. The dry
weight of the unit is 700 lbs.
Ensure the ground is level and can take the loading of the unit when full.
The maximum weight of the unit when full will be approximately 1580 lbs.
With the unit in its final position, remove all protective wrapping from the
metalwork and hydraulic connections. Inspect for any damage. Ensure
that the installation kit has been provided with the unit.
Electrical Supply
An electrical supply (see specification Section 3.5) should be made to
the control panel of the Heatsan 400 unit using suitably sized 3-phase
cable based upon the maximum current draw of the unit while
considering the length of the cable between the disconnect and the
Heatsan 400 unit by an authorized electrician. Please follow local
electrical code (for example NEC or CEC) for mains wiring connections
using a 60 A maximum service. The cable should be fitted using
appropriate sized gland and terminated to the isolator connections L1,
L2, L3 and Earth.
Water Connections
Refer to Section 10.4.

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Drain
A suitable, unrestricted, drain is required, capable of handling the
discharge flow of the Heatsan unit (see specification). The drain should
be capable of accepting 203°F water.
Overflow
An unrestricted overflow must be provided which terminates with an
air gap that conforms to any local or National regulations. The overflow
pipework must be capable of withstanding water up to 203°F.
Overflow and drain MUST be independently run to drain.
Hot Water Flow/Return
The flow and return connections should be connected directly to the
distribution loop via a manifold assembly with valves.
Fill
The source of the “Fill” water should be taken directly off of the end of
the distribution loop. The choice of pipework material depends on
maximum likely water temperature. Use Stainless steel or PEX for high
temperature systems (up to 203°F).
Input/Outputs
Refer to wiring diagram (see Section 10.3 Wiring diagrams) for details
of all inputs/outputs.
Outputs: (available for connection to external devices)
All outputs are 24Vdc
Y20 Loop-1 operation
Y21 Standby
Y22 Preheat indicator
Y23 Heatsan operation indicator
Y24 Water loss alarm
Y25 Connection to RO (System run either Loop 1 or 2)
Y26 Cool down required
Y27 RO run

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NB If connecting to external panel or override panels the
maximum cable length should be restricted to 330 ft.
Inputs:
X-10 Heatsan Interlock Signal
X-14 Connection from key switch on remote override panel
X-15 Heatsan to RO Interface, Power Supply Fault
Installation Plan Layout
Refer to Section 10.4 for suggested installation plan layout.
Commissioning
Commissioning of the Heatsan unit should only be carried out by
either an AmeriWater technician or authorized trained personnel.

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6OPERATING PROCEDURES
Operator Interface
The operation of the Heatsan unit is controlled entirely through the
touch screen located on the front of the main control box.
To access menus simply touch the area on the screen. Only use your
finger to touch the screen DO NOT use pens, pencils, or other sharp
implements to touch the screen or you could cause irreversible
damage to the display.
During an “Alarm” condition the screen will change to “Red” and
display the active alarm screen.
Access to the operating menus are password protected, see Section 6.2
Operation, for details of level of access available.
Operation (levels of access)
There are five levels of user access: LEVEL 0, 1, 2, 3, & 5
NB: Level 5 access is reserved for AmeriWater technical staff.
User Level Password Access
Level 0
No password
Today Current Setup Menu (view only)
Monitor Menu (View Time & Rate screens)
Alarm/Event History (view only)
Heatsan Abort
Level 1
141
Today Current Setup Menu (view & change
settings)
Monitor Menu
Alarm/Event History (view only)
Daily Default Menu (View & change settings)
Heatsan Abort
Access Data Logging Screen
Level 2
44810
As Level 1
System Setup Menu (View & change settings)
Reset Alarms
Level 3
Contact
AmeriWater
As per Level 2
Factory Setup Menu (view & change settings)
Alarm/Event History (View/Reset and
Clear/Delete Event history listings)
Level 5
Contact
AmeriWater
As per Level 3
Calibration Menu (view & change settings)

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Operation (password entry)
Log In
Screen Display Action
When power is applied to the Heatsan
unit the MAIN MENU screen will be
displayed. The first step will be to log in.
Press “USER LOGIN” to access the USER
LOGIN screen.
On pressing “LOGIN”you will be asked to
enter your Password code. Use the pop
up keypad to enter your code. Then press
“ENTER”. You will be notified of security
level change success. Press “OK”, then
close the menu by depressing the X in the
upper right corner. Depress, MAIN
MENU” to return to the MAIN MENU.
Details of User passwords can be found
in Section 6.2. After 20 minutes the Login
screen will automatically logout any
users.
Operation
Daily Defaults Menu
Screen Display Action
To access
the CURRENT SETUP menu,
press
“CURRENT SETUP”. Or to view the
MONITOR
or ALARM MENU screens,
de
press the appropriate button.
Information provided by th
ese two
screen
s can be found in 6.4.5 and 6.4.6.