Barnstead|Thermolyne EASYpure D7421 Guide

1
EASYpure™ RO
Reverse Osmosis System
SERIES 742
INSTALLATION,
OPERATION,
SERVICE AND REPAIR MANUAL,
AND PARTS LIST
LT742X16 • 8/20/97
Model Voltage
D7421 120
D7422 240
D7422-33 230
D7423 100 Low Pressure
D7428 120 Low Pressure
D7429 240 Low Pressure
D7429-33 230 Low Pressure
BARNSTEAD|THERMOLYNE CORPORATION

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Figure 1 EASYpure RO
Ventgard
Back
Door
Latch Pressure
Gauge Indicator LED's
Tank
Water
Level
Sight

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Table of Contents
Safety Information ........................................................................................................................................4
Alert Boxes................................................................................................................................................4
Warnings....................................................................................................................................................4
Specifications................................................................................................................................................6
Feedwater Requirements1........................................................................................................................6
Product Water Specifications ....................................................................................................................6
Electrical Requirements ............................................................................................................................6
Environmental Conditions..........................................................................................................................6
Product Water Rejection Rates ....................................................................................................................6
Declaration of Conformity ............................................................................................................................7
Unpacking ....................................................................................................................................................8
Installation ....................................................................................................................................................9
Locating your EASYpure RO ....................................................................................................................9
General Usage ..........................................................................................................................................9
Bench Mounting ......................................................................................................................................10
Wall Mounting ..........................................................................................................................................11
Utility Connections ..................................................................................................................................12
Feedwater Connection ........................................................................................................................12
Reject Water Connection ....................................................................................................................13
Tank Overflow Connection ..................................................................................................................14
Connections to Equipment Supplied By the EASYpure RO. ..................................................................15
Installing The Prefilter and Membranes ..................................................................................................16
Prefilter Installation ..............................................................................................................................16
Membrane Installation..........................................................................................................................17
Electrical Connections ............................................................................................................................20
Membrane Flush......................................................................................................................................20
Set "Replace Prefilter" Indicator ............................................................................................................21
Operation....................................................................................................................................................24
Indicators ................................................................................................................................................24
Pressure Gauge ..................................................................................................................................24
LED's....................................................................................................................................................24
Maintenance ..............................................................................................................................................27
Caring For Your EASYpure RO ..............................................................................................................27
System Sanitization..............................................................................................................................27
Ventgard® Filter Replacement ............................................................................................................30
General Cleaning Instructions..............................................................................................................30
Service and Repair ....................................................................................................................................31
Normal Unit Operation ............................................................................................................................31
Fuse Replacement ..............................................................................................................................33
Membrane Replacement......................................................................................................................33
Prefilter Replacement ..........................................................................................................................34
Parts List ....................................................................................................................................................35
Recommended Spares ........................................................................................................................35
Ordering Procedures............................................................................................................................37
Troubleshooting ..........................................................................................................................................38
Wiring Diagrams ........................................................................................................................................39
Exploded View............................................................................................................................................42
Exploded View Key ....................................................................................................................................43
One Year Limited Warranty ........................................................................................................................44

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Safety Information
Your Barnstead EASYpure RO has been designed
with function, reliability, and safety in mind. It is
your responsibility to install it in conformance with
local electrical codes. For safe operation, please
pay attention to the alert signals throughout the
manual.
Warnings
To avoid electrical shock, always:
1. Use a properly grounded electrical outlet
of correct voltage and current handling
capacity.
2. Do not mount the EASYpure RO directly
over equipment that requires electrical
service. Routine maintenance of this unit
may involve water spillage and subse-
quent electrical shock hazard if improperly
located.
3. Replace fuses with those of the same type
and rating.
4. Disconnect from the power supply prior to
maintenance and servicing.
To avoid personal injury:
Warning
Warnings alert you to a
possibility of personal injury.
Caution
Cautions alert you to a
possibility of damage to the
equipment.
Note
Notes alert you to pertinent
facts and conditions.
Alert Signals

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SAFETY INFORMATION
1. Do not use in the presence of flammable or
combustible materials; fire or explosion may
result. This device contains components
which may ignite such materials.
2. Ensure all piping connections are tight to
avoid leakage of chemicals.
3. Ensure adequate ventilation when using
chemicals for cleaning.
4. Follow carefully the manufacturers’ safety
instructions on labels of chemical containers
and Material Safety Data Sheets (M.S.D.S.).
5. Refer servicing to qualified personnel.
C. To ensure safe mounting:
1. Wall composition and construction, as well
as fastener type, must be considered when
mounting this unit. The mounting surface
and fasteners selected must be capable of
supporting a minimum of 120 lbs.; inade-
quate support and/or fasteners may result in
damage to mounting surface and/or equip-
ment. If you are unsure of mounting surface
composition, condition and construction, or
correct fasteners, consult your building
maintenance group or contractor.

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Specifications
Dimensions
30.5 cm W x 46.7 cm W x 46 cm H.
Feedwater Requirements1, 5
Max. Temperature ........................48.8°C
Min. Pressure (standard unit) ......30 psig
(2.1 bar)
Min. Pressure (low pressure unit) 9 psig
(0.62 bar)
Max. Pressure (standard unit)......100 psig
(6.8 bar)
Max. Pressure (low pressure unit)
15 psig (1.1 bar)
Inlet Flow Requirements ..............53.5 lph
pH ................................................4 - 11
TDS (Max. ppm as CaCO3) ........500
Silt Density Index ........................<5%
Free Chlorine................................<0.1 ppm2
Langlier Saturation Index ............Negative
Turbidity........................................<1 NTU
Iron (Total as Fe)..........................<0.5 ppm
Product Water
Specifications5
Product Water Flow Rate ............12 lph3
% Recovery..................................20%-26%
1 Feedwater suitability must be determined by a water analysis.
2 Free chlorine removed by pretreatment cartridge.
3 ±1.5 lph, feedwater at 25°C and 60 psig pressure.
4 Membrane performance is dependent on condition, pressure, recovery, water temperature and water composition. Listed membrane
performance for a new membrane is based on optimum operating conditions of 60 psig, 15% recovery, 25°C (77°F) feedwater tempera-
ture and feedwater composition of a maximum of 500 ppm NaCl at a pH of 6.0-6.5.
5 Membrane performance, flowrates and recovery information are nominal values. Variations in the feedwater temperature, pumps and
reject orifice may slightly alter these results.
Membrane Rejection Rates4
Monovalent Ions ..........................90-95%
Polyvalent Ions ............................95-99%
Particles........................................>99%
Microorganisms............................>99%
Dissolved Organics (300 MW) ....>99%
Reject Water Flow Rate 650 ml/min
at
60 PSIG ±5
PSIG
Electrical Requirements
Model D7422-33 - 230 VAC ±10%, 47-63 Hz
Model D7429-33 - 230 VAC ±10%, 47-63 Hz
Environmental Conditions
Operating: 17°C - 27°C; 20% - 80% relative
humidity, non-condensing. Installation
Category II (over-voltage) in
accordance with IEC 664. Pollution
Degree 2 in accordance with IEC
664. Altitude limit: 2,000 meters.
Storage: -25°C - 65°C; 20% - 80% relative
humidity.

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Declaration of Conformity
Barnstead|Thermolyne hereby declares under its sole responsibility that this product con-
forms with the technical requirements of the following standards:
EMC: EN50081-1 Generic Emission Standard; EN 50082-1 Generic Immunity
Standard.
Safety: IEC 1010-1-92 Safety requirements for electrical equipment for measure-
ment, control and laboratory use; Part 1: General Requirements
per the provisions of the Electromagnetic Compatibility Directive 89/336/EEC, as amended
by 92/ 31/EEC and 93/68/EEC, and per the provisions of the Low Voltage Directive
73/23/EEC, as amended by 93/68/EEC.
The authorized representative located within the European Community is:
European manager
Barnstead|Thermolyne
Saarbrückener Str. 248
D-38116 Braunschweig
Germany
Copies of the Declaration of Conformity are available upon request.

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Unpacking
Carefully remove the unit from its shipping contain-
er.
The following items are shipped separately and
must be removed from the packaging prior to dis-
carding the packaging:
1. EASYpure RO Ventgard air filter.
2. Power cord.
3. Pump interlock cord.
4. Membrane bypass tubing.
The following items are located inside the mem-
brane access door:
1. Feedwater tubing.
2. Reject water tubing.
3. Product tubing to connect accessory
reservoir.
4. Product tubing to connect another
EASYpure unit.

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Locating your EASYpure RO
Your EASYpure RO must be located within six feet
of an electrical outlet appropriate for your unit, with-
in five feet of your feedwater supply and close to
an atmospherically vented drain. If you are using
the accessory 30 Liter Reservoir (Part Number
TY742X2A), the tank overflow on the EASYpure
RO's integral 6.5 liter tank should be located below
the level of the storage reservoir's overflow. This
will ensure that the EASYpure RO's internal float
switches will control the operation of the system. If
the EASYpure RO is to be used with the accesso-
ry 30 Liter Reservoir, the reservoir must not be
mounted farther than 4 feet away from the
EASYpure RO. The EASYpure RO Bench Stand
(Part Number D7424) will be required for a bench
mounted installation with an accessory 30 Liter
Reservoir.
General usage
Do not use this product for anything other than its
intended usage.
Do not mount the EASYpure
RO directly over equipment
that requires electrical ser-
vice. Routine maintenance of
this unit may involve water
spillage and subsequent
electrical shock hazard if
improperly located.
Warning
Installation

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INSTALLATION
Bench Mounting
If you are bench mounting the EASYpure
RO without the accessory 30 Liter Reservoir
(Part Number TY742X2A), simply place the
EASYpure RO on a bench.
If you are bench mounting the EASYpure
RO and using it in conjunction with the
accessory 30 Liter Reservoir (Part Number
TY742X2A), the EASYpure RO Bench Stand
(Part Number D7424) must be added to the
EASYpure RO to ensure automatic opera-
tion. Install the EASYpure RO Bench Stand
as follows:
1. Remove the 4 feet from the
EASYpure RO and retain the
screws.
2. Place the EASYpure RO on the
Bench Stand so that the screw
holes where the feet were attached
line up with the holes in the Bench
Stand.
3. Install the 4 screws removed in
step 1 through the bottom of the
Bench Stand and into the
EASYpure RO.
4. Install the accessory 30 Liter
Reservoir according to the instruc-
tions in the accessory 30 Liter
Reservoir manual.

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Wall Mounting
If you are wall mounting the EASYpure RO using
the optional wall mounting bracket, mount the unit
as follows:
Wall Mounting the EASYpure RO
1. Install the wall bracket (Part Number
D7384) on the wall in a location that is
accessible to water, power and an atmos-
pherically vented drain, and that is conve-
nient to use. A minimum of 4 fasteners
must be used.
2. Remove the 4 feet from the EASYpure
RO. Retain the screws.
3. Place the EASYpure RO on the wall
bracket swivel base so that the screw
holes where the feet were attached line up
with the holes in the wall bracket. There
are guides on the wall bracket that will
mate with the EASYpure RO.
INSTALLATION
Figure 2 Wall Mounting the EASYpure RO
Wall composition and con-
struction, as well as fastener
type, must be considered
when mounting this unit. The
mounting surface and fasten-
ers selected must be capable
of supporting a minimum of
120 lbs.; inadequate support
and/or fasteners may result in
damage to mounting surface
and/or equipment. If you are
unsure of mounting surface
composition, condition and
construction, or correct fas-
teners, consult your building
maintenance group or con-
tractor.
Do not mount the EASYpure
RO directly over equipment
that requires electrical ser-
vice. Routine maintenance of
this unit may involve water
spillage and subsequent elec-
trical shock hazard if improp-
erly located.
Note
If you are bench mounting the
unit, proceed to Utility
Connections.
Warning

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4. Install the four screws removed in step 2
through the bottom of the wall bracket and
into the EASYpure RO.
Utility Connections
The EASYpure RO is supplied with four separate
lengths of tubing to be used for feedwater, reject
water, feed to accessory storage reservoir and feed
to another EASYpure unit's connections. Each
length of tubing is six feet long and has the neces-
sary fittings installed.
Feedwater Connection
1. Locate the length of 3/8" O.D. tubing pro-
vided with a quick disconnect insert on
one end and a 3/8" O.D. X 1/4NPT tubing
adapter on the other.
2. Insert the quick disconnect insert into the
feedwater inlet on the EASYpure RO.
(See Figure 3 for location.) Install the tub-
ing adapter onto your incoming water line.
We recommend a customer supplied shut
off valve be installed in your feed water
line.
INSTALLATION
Power Entry
Module/
ON-OFF Switch
Product
Water
Outlets
Pump
Interlock
Tank Overflow
Reject Water Connection
Feedwater Inlet
Figure 3 Connections
Note
We recommend a customer
supplied shut off valve be
installed in your feed water
line.
Note
The quick disconnect fittings
have built-in shutoff valves in
both the coupling and the
insert.

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Reject Water Connection
1. Locate the reject water tubing. This is the
piece of 3/8" O.D. tubing that has an
adapter on one end and no connector on
the other end. Remove the nut, grab ring,
backup ring and o-ring from the reject
water fitting located at the lower right of
the unit. (See Figure 4 for part identifica-
tion and Figure 3 for fitting location.)
2. Thread the nut, grab ring and backup ring
on the reject adapter. Do not use the o-
ring at this time.
3. Push the tubing through the hex nut until it
bottoms out in the adapter.
4. Remove the adapter nut and tubing. Place
the o-ring over the tubing. Be careful not
to push the backup ring or grab ring fur-
ther back on the tubing when installing the
o-ring. Connect the tubing to the reject
connection on the EASYpure RO.
INSTALLATION
Figure 4 Typical Polypropylene Tubing Adapter Installation

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5. Route the other end of the reject
water tubing with the adapter
installed to an atmospherically
vented drain. Ensure there are no
kinks in the tubing and that it pro-
ceeds in a downward plane.
6. If possible, use the tubing adapter
to permanently install the reject
water tubing in the drain.
Tank Overflow Connection
1. Refer to Figure 3 and attach a cus-
tomer supplied hose barb connec-
tor and 5⁄8" O.D. tubing to the tub-
ing located at the lower right of the
unit as you look at the rear of the
unit.
2. Route tubing to an atmospherically
vented drain. Ensure there are no
kinks in the tubing and that it pro-
ceeds in a downward plane.
INSTALLATION

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Connections to Equipment
Supplied By the EASYpure
RO.
Your EASYpure RO also includes two
lengths of tubing with quick disconnect
inserts attached. One is 1/4" O.D. tubing and
one is 3/8" O.D. tubing. Use the 1/4" tubing
to feed directly from the EASYpure RO to
another EASYpure unit. Use the 3/8" O.D.
tubing to feed the accessory 30 Liter
Reservoir if one is being used.
1. Install the quick disconnect insert
attached to the tubing into one of
the product water quick disconnect
couplings on the EASYpure RO.
(See page 11.)
2. Install the other end of the tubing
into the unit being fed by the
EASYpure RO according to the
instructions in that unit's manual.
3. Locate the pump interlock cord
supplied with the EASYpure RO.
Plug one end of the pump interlock
cord into the pump interlock on the
EASYpure RO. (See page 11.)
Remove the jumper plug from the
pump interlock on the other
EASYpure unit and save it for
future use. Plug the other end of
the cord into the pump interlock on
the other EASYpure unit.
INSTALLATION
Do not connect the product water
tubing to a connected EASYpure unit
until you have completed the mem-
brane flush procedure for the
EASYpure RO.
Note
The product water quick dis-
connect inserts can be
installed in either product water
quick disconnect coupling. The
quick disconnect ends of the
inserts are the same size.
Note
Note
If you are not now feeding another
EASYpure unit, save the pump
interlock cord for possible future
use.

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Installing The Prefilter and
Membranes
1. Disconnect the unit from the power
supply.
2. Pull the rear side of the door latch
up and toward the front of the unit
until the front of the door latch
unhooks.
3. Lift the front of the door latch and
open door.
Prefilter Installation
Chlorine and particulates will damage your
membranes, resulting in premature mem-
brane failure. Therefore, your EASYpure RO
uses an extruded carbon prefilter to remove
chlorine and particulates from your feed
water.
Install the prefilter as follows:
1. Remove a new prefilter (Part
Number D50246) from its plastic
bag.
INSTALLATION

17
2. Wet the o-rings on both end caps
of the prefilter.
3. Insert the upper end cap into upper
center position until it bottoms out
in the connector. (The upper end
cap is the one with the right angle
turn and the two flanges.) The two
flanges on the end cap slide down
on each side of the keyway wall.
(See Figure 7.)
4. Lower the prefilter and insert the
lower end cap into the lower center
socket until it is firmly seated.
Membrane Installation
1. Remove the membrane bypass
tubing from the EASYpure RO (see
Figure 5). The membrane bypass
tubing may be stored inside the
EASYpure RO case for easy
access when needed for the sys-
tem sanitization procedure.
INSTALLATION
Figure 5 Membrane Bypass Tubing Installed
Membrane By-Pass Tubing
Note
The membrane by-pass tubing will
be needed for sanitizing the
EASYpure RO. Do not discard it.

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2. Remove an RO membrane car-
tridge (Part Number D7425) from
its plastic bag.
3. Remove the nut, stainless steel
grab ring, backup ring and o-ring
from the connectors on the mem-
brane.
4. Connect the product and reject
tubes in the right-hand membrane
position on the EASYpure RO to
the product and reject outlet con-
nectors on the RO membrane car-
tridge. Ensure that the o-ring, back-
up ring, stainless steel grab ring
and nut are in place on the product
and reject tubing on the EASYpure
RO (see Figure 4, page 12).
Ensure that the product tube is
connected to the product connector
and the reject tube is connected to
the reject connector. Hand-tighten
the connections.
INSTALLATION
Figure 6 Proper Position of Prefilter and Membranes
Prefilter
Right-hand
Membrane
Position
Left-hand
Membrane
Spring Metal
Membrane Retainer
Do not use a wrench on the
tubing adapter connections.
A sufficiently tight connection
can be made by hand.
Caution

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5. Wet the o-rings on the bottom of the mem-
brane cartridge. Insert the RO membrane
cartridge into the right-hand spring metal
retainer.
6. Slide the RO membrane cartridge down
until the lower end cap is firmly seated in
the lower right-hand socket.
7. Remove the second RO membrane car-
tridge (Part Number D7425) from its plas-
tic bag. Install the second membrane in
the left hand membrane position following
the instructions in steps 3-6 above for the
left hand connections.
8. Close and latch membrane access door.
INSTALLATION
Figure 7 Prefilter and Membrane Connections
Product
Reject
Flanges on
either side of
keyway wall
Product
Reject

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Electrical Connections
1. Plug power cord into the unit's power
entry module.
2. Connect your EASYpure RO to a properly
grounded outlet of correct voltage and
current handling capacity.
Membrane Flush
1. If not already done, disconnect the prod-
uct water tubing from any EASYpure unit
connected to your EASYpure RO. Direct
the product water tubing to drain. If you
are feeding an accessory 30 Liter
Reservoir, disconnect the product water
tubing from the accessory 30 Liter
Reservoir. Direct the product water tubing
to drain.
2. Disconnect the pump interlock cord from
the other EASYpure unit.
3. Open the customer-supplied feed water
valve.
INSTALLATION
Power Entry
Module
Figure 8 Power Cord Attachment
Use a properly grounded
electrical outlet of correct
voltage and current handling
capacity.
Warning