ELGA MEDICA-R200 - US User manual

MEDICA-R200 - US
Operator Manual

MEDICA-R200 - US
Operator Manual

MEDICA - R200 US Version 01 08/14Page 1
Copyright Note
The information contained in this document is the property of VWS
(UK) Ltd. and is supplied without liability for errors or omissions.
No part of this document may be reproduced or used except as
authorized by contract or other written permission from VWS (UK)
Ltd. The copyright and all restrictions on reproduction and use
apply to all media in which this information may be placed.
VWS (UK) Ltd. pursue a policy of continual product improvement
and reserve the right to alter without notice the specification,
design, price or conditions of supply of any product or service.
ELGA LabWater is a trading name of VWS (UK) Ltd.
ELGA®is the global laboratory water brand name of Veolia Water.
ELGA®, PURELAB®, MEDICA® and CENTRA® are trademarks
of ELGA LabWater.
Minncare is a trademark of Minntech Corporation.
© VWS (UK) Ltd. 2014
All rights reserved.
Publication ref: MANU40608
Version 1 – 08/14

Page 2MEDICA - R200 US Version 01 08/14
TABLE OF CONTENTS
1. INTRODUCTION...................................................................4
1.1 Product Range ............................................................4
1.2 Use of this Manual.......................................................4
1.3 Customer Support.......................................................4
2. HEALTH AND SAFETY NOTES ..........................................5
2.1 Electricity.....................................................................5
2.2Pressure......................................................................5
2.3 Sanitization Chemicals................................................5
2.4 Control of Substances Hazardous to Health (COSHH)5
3. PRODUCT AND PROCESS DESCRIPTION........................6
3.1 Product Description.....................................................6
3.2 Process Description ....................................................7
3.3 Flow diagram for MEDICA - R200 US.........................8
3.4 Technical Specification................................................9
3.5 RO Permeate Flowrate vs. Temperature..................13
4. INSTALLATION INSTRUCTIONS......................................14
4.1 Unpacking the MEDICA ............................................14
4.2 Positioning the MEDICA............................................14
4.3 Connecting the MEDICA...........................................16
5. CONTROLS ........................................................................20
5.1 PASSkeys .................................................................21
5.2 System Preferences..................................................21
5.3 Setting Up Replacement Timers / Reminders...........28
6. COMMISSIONING...............................................................30
6.1 Initial Start Up............................................................30
7. OPERATION .......................................................................33
7.1 Night service/Operational day...................................33
7.2 Continuous Recirculation (24/7)................................33
8. MONITORING .....................................................................34
8.1 RO fill.........................................................................34
8.2 RO fill and recirculation.............................................34
8.3 Recirculation..............................................................34
8.4 Consumable dates ....................................................34
9. MAINTENANCE..................................................................35
9.1 Replacing the Composite Vent Filter / Air Filter........35
9.2 Replacing RO particulate filter LC159.......................36
9.3 Replacing bacterial and particulate filter LC160 .......37
9.4 Replacement of UV lamp LC158...............................38
9.5 Installation / replacement of ion-exchange cylinder..39
10. SANITIZATION PROCEDURES.........................................40
10.1 Sanitization selection (Process off)...........................41
10.2 RO sanitization (Process off) ....................................41

MEDICA - R200 US Version 01 08/14Page 3
10.3 RO sanitization (Process on) ....................................43
10.4 Recirculation sanitization ..........................................44
11. EMERGENCY BY-PASS ....................................................46
12. TROUBLE SHOOTING.......................................................47
13. CONSUMABLES AND ACCESSORIES ............................49
14. KEY TO CONTROL PANEL...............................................50
14.1 Alarm Conditions.......................................................52
14.2 Replacement Timers.................................................53
15. WARRANTY/CONDITIONS OF SALE ...............................54
16. USEFUL CONTACT DETAILS...........................................56

Page 4MEDICA - R200 US Version 01 08/14
1. INTRODUCTION
1.1 Product Range
This operator manual has been prepared for the product models:
MEDICA - R200 US 115 V ac 60 Hz
MEDICA - R200 US 230 V ac 50 Hz
1.2 Use of this Manual
This manual contains full details on installation, commissioning and
operation of the MEDICA unit. If the instructions in this handbook
are not followed then the performance of this product and/or the
safety of the user may be compromised.
1.3 Customer Support
Service support and consumable items are available from your
local supplier or distributor. Refer to customer service contact
details shown at the end of this publication.
MEDICA - R200 US

MEDICA - R200 US Version 01 08/14Page 5
2. HEALTH AND SAFETY NOTES
MEDICA products have been designed to be intrinsically safe,
however, it is important that personnel working on these units
understand any potential dangers. All safety information detailed in
this handbook is highlighted as WARNING and CAUTION
instructions. These are used as follows:
WARNING! WARNINGS ARE GIVEN W
HERE FAILING
TO OBSERVE THE INSTR
UCTION COULD
RESULT IN
INJURY OR DEATH TO
PERSONS.
CAUTION!
Cautions are given where failure to
observe the instruction could result in
damage to the equipment, associated
equipment and processes.
2.1 Electricity
It is essential that the electrical supply to the MEDICA is isolated
before any items are changed or maintenance work performed.
The external isolator proving power to the unit should be positioned
so that it is easily accessible by all users.
WARNING! THIS APPLIANCE MUST BE EARTHED.
2.2 Pressure
The main water supply should be isolated and residual pressure
released prior to removal of any components or carrying out work
on the unit.
Switch off the process and relieve pressure in the distribution loop
by opening a point-of-use.
2.3 Sanitization Chemicals
During the sanitization cycle Minncare Cold Sterilant is used and
relevant safety guidance is included in this handbook. Please refer
to the manufacturer for material safety data sheets.
Minncare Cold Sterilant is EPA registered as a sterilant, high level
disinfectant, and sanitizer.
Spent Minncare Cold Sterilant is acidic and requires normal
neutralization as specified by your local state and local regulations.
1% of Minncare Cold Sterilant has a pH of 3.5.
2.4 Control of Substances Hazardous to Health
(COSHH)
Material safety data sheets covering the various replaceable
components are available upon request. Contact your local ELGA
LabWater distributor.

Page 6MEDICA - R200 US Version 01 08/14
3. PRODUCT AND PROCESS
DESCRIPTION
3.1 Product Description
The MEDICA range of water purification units has been specifically
designed to distribute and maintain purified water for laboratory,
medical and industrial applications. The supply of purified water is
obtained from either an external source or internal technologies.
Purified water may be distributed around the installation under
pressure to single or multiple points of use.
A range of accessories is available to complement the unit (see
Section 13. - Consumables and Accessories, for detail).
MEDICA - R200 US
Control Panel
PASSkey
reader
Door

MEDICA - R200 US Version 01 08/14Page 7
3.2 Process Description
MEDICA - R200 US
•Feed water enters through a control valve (V1), and
through a particulate filter (FH1) into the inlet of the RO
pump (P1). Pressure in the pipework of the pump inlet is
monitored with a pressure switch (PSW1) to ensure that
the pump cannot run without sufficient water.
•P1 provides sufficient pressure and flow to the RO
module (M1). The RO concentrate flow is controlled
through a pressure relief valve (PRV2) or concentrate
flush valve (V3).
•Upon initial start-up, the system carries out a concentrate
flush to remove scale and debris from the membrane
surface to ensure RO performance is maintained.
•RO permeate water passes through:
•Temperature sensor (TS1).
•Water quality sensor (QS1), which measures the
conductivity of the water.
•RO permeate water is initially flushed to drain through the
overflow device until one of the following conditions
occurs:
•Minimum flush time is completed.
•Water quality is below set alarm point.
•4 minutes permeate flush has occurred. This will
result in an alarm condition that may be cleared
automatically as the RO performance improves.
•RO permeate water enters the reservoir through
permeate control valve (V2) and fills the reservoir until full
(350 liters). The RO system will only function if the level
in the reservoir is sufficiently low, less than 240 liters.
•When the reservoir contains 350 liters, the RO system
performs a further concentrate flush to reduce the
concentrate levels within the membrane housing and
reduce the possibilities of precipitation on the membrane
surface before going into stand-by.
•Water from the reservoir is distributed around the
installation at pressure (6 bar maximum) by the
recirculation pump (P2), controlled via the pressure-
sustaining valve (PSV1). An over-pressure switch
(PSW2) on the outlet of the pump will shut the system
down if operating pressures exceed 6 bar.
•Connections are available to incorporate a range of
cylinders containing water purification media, which
remove impurities and maintain water quality around the
system. The media can be selected to meet specific
requirements. Typically activated carbon and ion-
exchange media are used.
WARNING!
Any cylinders or additional equipment
installed (filters etc.) including ring
-
main pipework must be rated to the
operating pressure of the MEDICA
system (6 bar).

Page 8MEDICA - R200 US Version 01 08/14
•The purified water is then passed through the UV (UV1)
chamber where it is exposed to intense UV radiation to
provide continuous bacterial control and to promote the
cleavage of organic molecules before passing through an
absolute 0.2µm bacterial and particulate filter. The
difference in pressure between PG3 and PG4 can be
used to monitor the condition of the filter.
•Finally the purified water passes through a:
•Temperature sensor (TS2).
•Water quality sensor (QS2), which measures the
resistivity of the water.
•Air is drawn into the reservoir when water is used. To
maintain water purity in the reservoir and water
recirculation/distribution system, it is necessary to filter
the air. Water quality will be maintained within the
recirculation system using a composite vent filter, which
removes air-borne contaminants such as volatile organic
compounds and carbon dioxide as well as air-borne
particles and bacteria.
•The MEDICA - R200 US includes the ability to drain the
reservoir completely via V4 and sanitize the installation
semi-automatically via V8 to ensure that bacterial levels
within the installation are controlled.
3.3 Flow diagram for MEDICA - R200 US
MEDICA - R200 US flow diagram

MEDICA - R200 US Version 01 08/14Page 9
3.4 Technical Specification
The Technical Specifications for the MEDICA - R200 US are as
follows:
Feedwater
Source Potable tap water as detailed below.
Note: It is essential that the feedwater be suitably conditioned. Please refer to
the contaminants listed below and ensure that suitable pretreatment is included
in the installation.
If in doubt contact your local ELGA LabWater representative who will be able to
provide guidance and support on the pretreatment requirements for specific
water types.
Failure to comply with the minimum feedwater pretreatment recommendations
will affect the life and performance of key components within the MEDICA, which
may invalidate the warranty.
Contaminant Measure Range Pretreatment
Calcium Ca ppm as CaCO3< 250 None *
> 250 Softener or
use very low RO recovery *
Total chlorine Cl ppm < 0.2 None
0.1 to 0.5 20 inch carbon block
> 0.5 Cylinder of carbon sized correctly
to obtain <0.1ppm
Silica SiO2ppm < 30 None
> 30 20 inch cartridge depth filter or
use very low RO recovery **
Fouling Index FI < 10 None
10 to 20 20 inch cartridge depth filter
> 20 Backwashable media filter with a
minimum flow rate of 20l/min
Iron/manganese Fe/Mn ppm < 0.05 None
> 0.05 20 inch cartridge depth filter ***
> 0.1 Back-washable Fe filter ***
Organics TOC ppm C < 2 None
2 to 3 20 inch carbon block **
> 3 Cylinder of carbon sized correctly
for TOC demand **
TEMPERATURE 1 - 40ºC (Recommended 15 - 25ºC)
FLOWRATE (maximum requirement) 20 l/min (5.3 GPM)
Drain requirements (gravity fall with air gap). Maximum
during sanitization.45 l/min (12 GPM)
Feedwater Pressure 4 bar (60 psi) maximum, 2 bar (30 psi) minimum.
* Check LSI, increase frequency of acid cleaning.
** Increase frequency of alkaline cleaning.
*** Increase frequency of acid cleaning.
Note: For information on cleaning chemicals please
contact your local ELGA LabWater
representative.
Note: If feedwater purity is variable or values are close
to the top of one of the ranges, provide pre-
treatment for the higher range.

Page 10 MEDICA - R200 US Version 01 08/14
Dimensions
Height 1820 mm (71.7")
Width 730 mm (28.75")
Depth 890 mm (35")
Supply weight 180 kg (396 lb)
Operational weight 530 kg (1,168 lb)
Installation Floor
Connections
Inlet ¾" bsp
Sanitization Drain ¾" bsp
Reservoir drain ¾" bsp
Ion-exchange cylinder inlet ¾" bsp
Ion-exchange cylinder outlet ¾" bsp
Ion-exchange cylinder connection pressure rating 6 bar
Electrical Requirements
Mains input 230 V ac, 50 Hz
115V ac, 60 Hz
System control voltage (not including pumps and UV) 24 V dc
Power consumption (peak demand) 2000 VA
Electrical protection rating 20 amps
Noise level during recirculation <70 dBA

MEDICA - R200 US Version 01 08/14Page 11
User Interface
Display Continuous graphical quality display.
Graphical flow schematic on screen with mimic display.
Backlit display with Intuitive Icons.
Adjustable settings Date / time Adjustable
Display viewing Angle Adjustable electronically
RO permeate water quality
alarm Selectable Alarm setpoints
Product water quality unit Selectable (MΩ.cm or µS/cm)
Product water quality alarm Selectable Alarm setpoints
Product water temperature
alarm Selectable Alarm setpoints
Auto restart after power
failure Selectable (On/Off)
Audible alarm Selectable (On/Off)
Night/Weekend service Selectable (On/Off)
Operational day selection Selectable (Monday (1) to Sunday (7))
Data output - manual Selectable (On/Off)
Data output - timed Selectable (On/Off)
Remote display
configuration Mode address selection
Sanitization reminder Selectable (On/Off)
Indicators Pre-treatment feedwater
quality Conductivity
Product water quality Resistivity or conductivity
Temperature Degrees Centigrade
UV lamp Replacement date
Particle filter Replacement date
0.2µm filter Replacement date
Sanitization Sanitization date
Alarms-Audiovisual RO Permeate water quality Outside set point alarm
Permeate water
temperature Outside maximum operating temperature
Purified water purity Outside set point alarm
Purified water temperature Outside set point alarm
UV lamp Change reminder
Particle filter Change reminder
0.2µm filter Change reminder
Sanitization Reminder
Overflow Leak detection or hydraulic failure
Tank Level controls disconnected
Outputs RS232 Printer connection
RS485 Remote display connection
Remote process button (Optional)
Volt free contact*

Page 12 MEDICA - R200 US Version 01 08/14
Safety Features
Power fail safe
Water temperature alarm*.
Water purity alarm*.
Leak detection alarm.
Access restricted by PASSkey.
Miniature circuit breaker protection of incoming electrical supply (MCB).
Pump thermal overloads.
Low voltage control circuit – 24 V dc.
Visual alarms.
Audible alarms.
Remote process button (Optional).
Optional remote display.
Operational Features
Restart on power interrupt
Optional printer kit for record of operating parameters
Optional remote display
Product Water Specification
Frequency
50 Hz 60 Hz
Flowrate 18 l/min @ 3 bar (4.8 USGPM @ 45 psi) 21 l/min @ 3 bar (5.6 USGPM @ 45 psi)
Distribution Loop Pressure – typical 3 bar
Distribution Loop Pressure – maximum 6 bar
Daily usage - typical Up to 5000 L (1321 USG)
Daily usage - maximum Up to 6000 L (1585 USG)
Inorganic >10 MΩ.cm**
TOC ppb <10**
Bacteria <5 CFU/ml***
Particles 0.2 µm
* Output to operate 24 V dc relay.
** Ion-exchange cylinder installed (Nuclear or Hypex grade).
*** System to be regularly sanitized and installed following ELGA
LabWater installation design guidelines.
As part of our policy of continual improvement we reserve the right
to alter the specifications given in this document.

MEDICA - R200 US Version 01 08/14Page 13
3.5 RO Permeate Flowrate vs. Temperature
Nominal Permeate Flowrate vs Temperature
0
5
10
15
20
25
100 125 150 175 200 225 250
Flow (L/Hr)
Temperature (C)

Page 14 MEDICA - R200 US Version 01 08/14
4. INSTALLATION INSTRUCTIONS
WARNING! THIS UNIT IS HEAVY. NE
VER ATTEMPT TO
MOVE WITHOUT USING T
HE CORRECT
LIFTING EQUIPMENT.
4.1 Unpacking the MEDICA
The following items should be supplied with your MEDICA:
1. MEDICA - R200 US.
2. Operator Manual.
3. Composite Vent Filter (LC156).
4. 10µm 10" particle filter (LC159).
5. 0.2µm 10" micro filter (LC160).
6. PASSkeys (SP772).
7. 2 x Filter spanners.
8. 2 x Sanitization tubes.
Note: Ion-exchange cylinders external pipe work and
pre-treatment are not included with the MEDICA.
Please contact your local ELGA LabWater
representative to ensure that the correct water
treatment technologies are selected for your
application.
4.2 Positioning the MEDICA
Before installation and operation of the MEDICA unit, please read
and observe the following points.
Environment
The unit should be installed on a flat, level floor, in a
clean, dry environment.
WARNING! ENSURE THAT THE UNIT
IS POSITIONED
ON A FLOOR CAPABLE O
F SUPPORTING
THE MAXIMUM WORKING
LOAD OF THE
UNIT.
WARNING! ADDITIONAL EQUIPMENT
SHOULD NOT
BE MOUNTED ON TOP OF THE MEDICA
-
R200. FAILURE TO OBSERVE TH
IS
INSTRUCTION COULD RE
SULT IN
SERIOUS INJURY.
Note: Refer to Specifications for unit weights and
footprint size (Section 3.4 - Technical
Specification).
The unit is designed to operate safely under the following
conditions:
•Indoor Use.
•Altitude up to 2000m.
•Temperature Range 5 - 40°C.
•Maximum Relative Humidity 80% @ 31°C decreasing
linearly to 50% @ 40°C, non-condensating.

MEDICA - R200 US Version 01 08/14Page 15
The unit is in Installation Category II, Pollution Degree 2,
as per IEC1010-1.
Service Access
It is recommended that sufficient allowance be made for
accessing components on the rear of the product, which
may require servicing or replacement during its life in the
field.
WARNING! ONCE COMMISSIONED AN
D IN
OPERATION THE MEDICA
IS EXTREMELY
HEAVY AND MUST NOT B
E MOVED.
FAILURE TO OBSERVE
THIS
INSTRUCTION COULD RE
SULT IN
SERIOUS INJURY.
Electrical
MEDICA must be properly earthed and protected with the
correctly rated fuse or MCB.
Where possible, components are operated at low DC
voltage to reduce risk of electric shock.
Some components operate at mains supply voltage and
are suitably protected within the unit.
Power should be switched off and isolated before
commencing maintenance work.
WARNING! FAILURE TO ISOLATE T
HE INCOMING
ELECTRICITY SUPPLY B
EFORE
REMOVING COVERS OR C
OMMENCING
MAINTENANCE WORK COULD RE
SULT IN
DEATH.
Pipework and Pipework Installation
The precise details of each installation will vary according
to the individual customer requirements.
Note: Refer to Typical installation and layout diagram
(Section 4.3 - fig. 1).
If existing pipework installations are being utilized it is
recommended that Technical Support are contacted to
ensure suitability in terms of material and pressure drop,
and that correct installation and sanitization procedures
are adopted during system commissioning.
All connections to the unit are ¾"bspp female threads and
should be sealed with either PTFE tape or ‘o’ring fittings.
CAUTION!
The use of pipe sealant is not
recommended and may cause degradation
and failure of plastic components.
All pipework should be suitable for the quality of water
being distributed and installed to manufacturer
guidelines.
CAUTION!
All pipework should have a pressure
rating exceeding the maximum operating
pressure of the installation and suitably
de-rated for the maxim
um water
temperature.

Page 16 MEDICA - R200 US Version 01 08/14
Remote Display RS485 Network
The MEDICA has the ability to communicate to a number
of remote displays allowing operating and alarm
parameters to be changed and monitored throughout the
installation.
System constraints must be observed during installation
to ensure satisfactory network performance.
Further details are available from Technical Support.
4.3 Connecting the MEDICA
Once the MEDICA has been positioned the following hydraulic
connections should be made:
•Drain
•Concentrate drain
•Feed water inlet
•Ion-exchange cylinder feed
•Ion-exchange cylinder return
•Recirculation loop out
•Recirculation loop return
•Reservoir drain (Recommended)
•Overflow pipe to drain
Step 1 - Hydraulic connections
1. LOCATE all the hydraulic connections.
2. FOLLOW the manufacturer recommendations for
the selected pipework systems and install suitable
adapters into the connection manifolds of the
MEDICA.
3. Refer to ‘Ringmain/Loop Installation Guide’ available
from ELGA LabWater Technical Support for
examples of preferred pipework construction and
assembly.
Note: The connection size on the MEDICA is ¾"bspp in
all positions. The overflow connection (¾" flexible
hose) is located at the rear of the MEDICA unit
and should be connected to a suitable drain.
CAUTION! The use o
f pipe sealant is not
recommended and may cause degradation
and failure of plastic components.
CAUTION!
The drain installation should allow a
gravity fall to drain with no restrictions.
Fitting tubes
External hydraulic connections
Feedwater inlet
Ion-exchange
cylinder return
Ion-exchange
cylinder feed
Reservoir drain
(Recommended)
Recirculation
loop return
Recirculation
loop out
Drain (Sanitization)
Drain (RO)