IONIC Zero PPM User manual

1
Operators Manual

2
Warnings
Throughout this manual these symbols and notes are used to indicate the following:
Danger
Imminent Danger that is likely to cause serious injury or loss of life
Warning
Safety situations that may cause serious injury or loss of life
Caution
Safety situations that may cause problems or damage to the equipment.
Note
To draw attention to procedures which are essential to observe
for correct operation
Electrical Hazard
Electrical equipment that is likely to cause serious injury or loss of life
CO2 Hazard
CO2 Hazard that is likely to cause serious injury or loss of life
Noise Levels
The noise level produced from the equipment is low level
The Reach & Wash™ System has been crash-tested at the Thatcham to the Federal Motor Vehicle Safety
Standard 208. The equipment must only be installed into motor vehicles by Ionic Systems approved installers. It
is recommended that annual safety inspections are carried out by an approved Ionic Systems Limited agent.

3
Contents Page Page
Introduction ……………….. 4
The Zero™ System
Dimensions ……………….. 5
Component Identification
- Machine Overview ……………….. 7
- Control Panel ……………….. 8
- System Housing ……………….. 10
- Holding Tank ……………….. 12
- Filter Function ……………….. 13
- Filter Function ……………….. 14
- Filter ID Discs ……………….. 15
Water Connection ……………….. 16
Effects of Low Pressure &
Temperature on Water Production……. 17
Electrical Connection ……………….. 18
General Guidance for Static Systems ... 19
Machine Warning Labels ……… 20
Zero Water Softening ……………….. 21
Zero Operation (Vehicle Mounted Machine) 22
Maintenance Procedures
General Maintenance ……………….. 31
Filter Replacement ……………….. 32
Cleaning your RO ……………….. 38
Salt Replenishment ……………….. 39
Battery Charging ……………….. 39
UV Filter Maintenance ……………….. 41
Winterisation & Storage ……………….. 44
Operational Procedure:
Cleaning Windows ……………….. 46
Warranty ……………….. 53
Annual Servicing ……………….. 54
About Ionic Systems
In 1997 Ionic Systems Ltd introduced the very first
vehicle mounted waterfed pole system, known as
the Reach & Wash™ system. Since then Ionic
Systems has continued to lead the field with its
proven designs. Ionic’s customers can be
reassured by the company’s commitment to quality
and testing of its products.
Window Cleaning has become a safety driven
industry. Ionic Systems focus is to provide up to the
minute products that are proven to be safe.
Ionic Systems Ltd manufactures the Reach & Wash™ ionic window cleaning system as well as a wide range of
other ionic cleaning products. We specialise in making the tools that do the job in the safest, most effective,
efficient and economical way. We offer the largest range of mobile water treatment systems and Waterfed Poles
in the World and are sure you’ll find our great range of ionic cleaning products to be the solutions that prove to be
immediate benefit to your business.

Zero PPM and PPB System
4
Welcome
Congratulations you are the proud owner of the Worlds most advanced yet user-friendly water
fed pole system for window and solar panel cleaning.
When it comes to everyday electronic products that we are all used too, most people manage
to get by without ever reading the ‘Instructions’ past the first few lines. But if you have read
this far then you are strongly advised to read on.
Generally, there are those who read instructions and follow simple maintenance procedures,
and those who do not. Those who take the time to follow these instructions usually enjoy
many years of service and avoid unexpected repair bills. For the other group the opposite is
true. The machine you have purchased is a water filtration system with multiple filters that
work together as a team to produce ultra pure water from any suitable potable water supply
anywhere in the World. Each and every Reach & Wash™ machine is thoroughly tested before
it leaves our manufacturing facility. Unlike electricity however, water differs from place to
place. Certainly water is water however, its delivery pressure, flow and quality changes
sometimes significantly within short distances and even at different times of the day.
Furthermore water density changes with the seasons, water is at its most dense at 4 degrees.
In winter the performance of a filter system will be different to the summer.
Ionic Systems is not responsible for your local water supply; we have no control over its
quality, delivery pressure or flow rate. Further we have no control over how you use the
machine or whether it is operated, serviced or maintained correctly. The following pages
provide guidance as well as instruction. There is a solution (usually simple) to each and every
problem that you may encounter and we have done our best to advise you well in the pages
that follow.
If you have read this far then you are encouraged to read to the end and follow the guidance
and simple maintenance procedures. If you will not be the routine operator of the machine
and you have purchased it for your staff to operate then you are encouraged to put ‘standard
operating procedures’ in place for your staff to follow.
The automated filtration system of the Zero™ PPB Reach & Wash™ System produces pure
water that is 1,000 times purer than machines that produce water of 0ppm quality. Although
the Zero™ PPB Reach & Wash™ System has 1,000 times more cleaning power than
conventional water fed pole cleaning systems, it is still important to follow the correct cleaning
procedure set out on pages 46-51.
The machines ability to produce 0ppb water is wholly dependent on the timely replacement of
filters. Failure to replace filters as necessary will reduce the machines ability to produce 0ppb
water leading to a poor window cleaning finish, customer complaints, lost profits and higher
maintenance costs. Information about filter replacement can be found on page 32.

Zero Weights & Dimensions
5
Dimensions

Zero Weights & Dimensions
6
Weights
Zero™&
System&
Weight&(Dry)&
Weight&(Wet)&
1000 Ltr
205 – 222kg
1225 – 1242 kg
900 Ltr
200 – 212kg
1112 – 1129 kg
800 Ltr
195 – 212kg
1015 – 1032 kg
700 Ltr
190 – 207kg
910 – 927 kg
600 Ltr
185 – 202kg
810 – 827 kg
500 Ltr
180 – 197kg
705 722 kg
400 Ltr
169 – 186kg
594 – 511kg
300 Ltr
164 – 190kg
489 – 506 kg
Note: Weights are given as a guide only. Actual weight may vary

Machine Component Identification
7
Component Identification

Machine Component Identification
8
Control Panel

Machine Component Identification
9
System Fuse
Box
The fuse-box holds all the fuses for the 12v side of the system. Depending upon the
specification, up to five fuses may be installed. The position, application and value are
depicted in the table below.
Fuse Box Diagram
(Fuse box positions 6-8 are not used)
Function
Amps
Position
Supply
15 A
1
Pump 1
15 A
2
Pump 2 (Hot pump on ThermoPure™ system)
15 A
3
Thermopure™ Heating Unit
20 A
4
Thermopure™ Switch
5 A
5

Machine Component Identification
10
Zero™ System
(Filters Removed)

Machine Component Identification
11
8) Split Charger
Automatically charges machine’s battery when vehicle engine is running.
The split charger should not be relied upon as the sole source of charging
for the vehicle’s battery. Regular charging using the mains-powered
charger is recommended.
When the vehicle’s engine is running, a
green LED illuminates to indicate that
charging is taking place.
9) Recirculation Pump
12v pump re-circulates pure water from tank through NGDI filter.
(0PPB Machines only).
10) Delivery Pumps
12v Pure Water delivery pumps
11 A & B
Incoming and outgoing water connections. The system has optional water connections
for both left/right hand drive vehicles.
12) Battery
The machine’s 12volt power source
13) Fast Fill Pump (Optional upgrade)
A 240v pump to boost water pressure to increase pure water production (reduces holding
tank filling time).
14) Thermopure™ Burner (Thermopure™ Systems Only)
The Thermopure™ burner situated behind the carbon filter.
When the Thermopure™ is operating, the burner components become
very hot and injury could occur if touched. (Do not operate the
Thermopure™ with the filters removed)

Machine Component Identification
12
Zero™ System Holding Tank
1) Tank Breather
Allows air in and out of the tank as it empties and fills (Do not cover or block)
2) Float Switch
The float switch stops ultrapure water production when the tank is full.
3) Tank Level Sight Gauge
Coloured float indicates ultrapure water level in tank
4) Tank Spirit Bubble
To indicate if machine is level for filling.

Machine Component Identification
13
Filter Identification
Zero™ PPB System

Machine Component Identification
14
Filter Identification
Carbon
The Carbon filter removes chlorine, chloramines, sediment and volatile
organic compounds (VOCs) from water. Protects the RO membrane.
5 Micron (Sediment Filter)
The sediment filter removes all particulates larger than 0.00005mm.
Protects the RO membrane
Softener
Exchanges Calcium and Magnesium ions for Sodium ions.
Protects the RO membrane
RO Filter (Reverse Osmosis)
A semi-permeable membrane that filters out 95-98% of dissolved solids
De-ionisation (PPM)
Mixed-bed ion-exchange resin filter that purifies water
between 0.9 – 0.5ppm
De-ionisation (PPB Machines only)
Mixed-bed ion-exchange resin filter that purifies water
between 0.055 – 0.0371ppm
Ultra Violet Sterilisation
Germicidal water treatment to eliminate water-borne hazards such as
the Legionella bacterium.

Machine Component Identification
15
Filter ID Discs
The ID Discs can be found on the top of each filter housing (1)
ID discs provide information about the filter contained within the housing (2)
It also provides information about the maximum estimated filter life (3)
Estimated Filter Life
Information about filter life and subsequent replacement frequencies is
provided for guidance purposes only. Actual filter life is dependent on local
water conditions, usage and care in routine operation and maintenance.
Information printed on filter ID discs and in the table below provides
estimates about likely filter replacement frequencies.
Filter T ype
Estimated Life
Order No.
Carbon (C)
Replace every 4 months.
IF CARBON
5 Micron
Replace every 4 months
IF SED
Softener (CA)
Replace after 3 years
IF SOFT
Reverse Osmosis (RO)
When water quality or production speed
is reduced by more than 10%
IF RO
PPM
When water quality rises above 1-2 ppm
IF DI
PPB
At Every 4th PPM Filter replacement
IF NGDI
UV
Replace Lamp every 12 months
NB: Snap Rings and ‘O’ Rings must be replaced every twelve months.

General Guidance
16
WATER CONNECTION
This section deals with the procedure and recommendations for connecting a suitable water
supply to the Zero™.
Connection
Follow the guidance on this page and connect a suitable water supply to the connection
marked ‘Water Connection” and open supply fully.
Suitable Water Supply
A suitable water supply means water drawn from the mains potable water supply with a
minimum delivery pressure of 40psi for machines with boosted fill and a minimum delivery
pressure of 65psi for machines without the boosted fill option.
As well as water pressure, the flow rate of the water supply is an equally important factor. The
chosen water supply needs to flow a sufficient volume of water to satisfy the machines needs.
To ascertain the flow rate simply count the number of litres on open flow that is produced in 1
minute from the chosen water supply (ltrs per min). For example, a machine that is capable of
producing 5 litres of pure water per minute requires a minimum flow of 10 litres per minute
from the mains water supply. This is because up to 5 litres per minute is rejected by the
machine carrying impurities to drain.
A machine capable of producing more than 5 litres of pure water per minute shall require a
flow rate of at least double its design capability. Where mains water pressure/flow is low the
use of a break tank will avoid cavitation in the water supply. The size of the break tank will
depend upon the volume of pure water required and the speed at which it can be refilled.
Sufficient pressure and flow are both relevant for the machine to perform to its design
specification.
Unsuitable Water Supply
In addition to low pressure and low flow, unsuitable water supplies include lakes, reservoirs,
and rivers, bore holes, and seawater.
Recommendations
1) In the case of static machines water connection should be by means of a permanent hard
piped connection.
2) In the case of mobile/vehicle mounted/portable machines a flexible hosepipe connection
will be suitable.
3) In all cases the machine should be sited as close to the water supply so that the
connecting hose can be kept as short as possible. Hoses of 13mm or 1/2inch are suitable
however hoses of 22mm or 3/4 inch are more desirable especially when the machine is
sited further away from the water supply.
4) Care should be taken to ensure that accidental disconnection from the water supply does
not occur. Beware of vehicles stopping on hoses, poor connections, and disconnection by
third parties, flattening of hoses during hot weather, kinking of hoses. Take precautions
such as placing hoses in the shade, protecting hoses from compression by vehicles,
placing “do not disconnect” signs at mains water connections.
5) Avoid dirt ingress and flush hoses prior to connection.
6) Replace damaged or leaking hoses and connections.

General Guidance
17
EFFECTS OF LOW PRESSURE AND TEMPERATURE
ON PURE WATER PRODUCTION
Each stage of filtration serves a particular function. It is good to understand that the first four
stages of filtration (UVO3, Carbon, 5 Micron and Softener) are in place to protect the RO
membrane. The RO membrane is in turn, is in place to reduce the workload of the PPM filter,
and the PPM filter is in place to reduce the workload of the PPB filter.
The RO Membrane is the filter where there is a restrictive back-pressure.
Aminimum mains feed pressure of 4.2 bars or 60 PSI is required in order
for the system to function correctly. Should the feed pressure drop below
this limit, damage to the RO membrane may occur. In low-pressure areas
a fast fill/boost pump option is strongly recommended. Low pressure feed
will result in premature failure of the RO. This will be due to membrane
blockage, as the reject water will fail to flow rejected dissolved solids to
drain.
Temperature has a major effect on pure water production.
Industry standards for pure water production through an
RO membrane are referenced at 25°C the following table
gives guidance to temperature correction figures
(When the water temperature drops to 4°C the correction
factor is 0.48 so pure water production is nearly halved)
The lower the temperature of the feed water, the slower pure water production will be.
Therefore, the three most important factors to consider for RO water production are;
1. Feed Temperature
2. Feed Pressure
3. Feed TDS
Each machine is tested at manufacture and pure water production values are recorded as
part of a comprehensive testing regime.
As filter life is used up over time, pure water production speed and quality degenerates.
Degeneration is determined by the factors listed above.
Machine performance can only be maintained by filter replacement dictated by local water
conditions.
T emp
Correction Factor
multiply by
4
0.48
10
0.60
16
0.73
21
0.88
25
1.00
27
1.06
32
1.26

General Guidance
18
ELECTRICAL CONNECTION
This section deals with the procedure and recommendations for connecting a suitable
electricity supply to Zero™ machines fitted with boosted fill pumps.
Connection
Follow the guidance on this page and connect an electricity supply to the machine and switch
on.
Suitable Electric Supply
A suitable electric supply means connection to either the mains power supply, or a generator
of sufficient capacity. Machines are supplied in both 220-240v and 110v formats dependent
on territory or type of use.
Caution
Ensure that the machine is only connected to the correct voltage power supply.
Recommendations
1) In the case of static machines electrical connection should be by means of a permanent
hard wired fused connection.
2) In the case of mobile/vehicle mounted/portable machines a flexible cable connection will
be suitable. It is highly recommended that an RCD is used at the end of the cable
connected to the mains electricity supply.
3) In all cases the machine should be sited as close to the electric supply so that the
connecting cable can be kept as short as possible. Cables stowed on reels should be
fully unwound from reel when connected to the machine.
4) Care should be taken to ensure that accidental disconnection from the electric supply
does not occur. Beware of vehicles stopping on cables, poor connections, and
disconnection by third parties. Take precautions such as placing cables in such a way as
to avoid trip hazards, protect cable from compression by vehicles, place “do not
disconnect” signs at mains connections.
5) Replace damaged cables and connections.
6) Always use an RCD

General Guidance
19
STATIC SYSTEMS
For the purpose of this guidance, any water treatment system used to produce purified water
within any building, whether permanently or temporarily is considered to be a ‘Static’ system.
Not to be understated is the risk of serious damage caused by a water leak from any water
treatment machine operated within the confines of a building. Any person procuring, installing,
operating or having responsibility for such a machine should expect that it may leak at some
time in its life. Any person with responsibility for any building and its contents in which a
‘Static’ system is installed should undertake a ‘Risk Assessment’ and satisfy themselves that
all reasonable precautions have been taken to protect against the inevitability of a water leak.
Precautions could include but are not limited to;
1) The equipment only be installed by qualified plumbers and electricians.
2) The equipment should be installed on a level surface able to support the total load,
ideally positioned on the ground floor level, or otherwise within a suitably designed
‘plant room’.
3) Hard pipe water connections to the mains water supply and drainage system are
made.
4) A water isolator be fitted to the hard piped water supply.
5) Isolating the water supply when not in use.
6) Installing the water treatment machine, holding tanks, transfer pumps and pipe work
within the confines of a suitably designed and installed bunded area with adequate
drainage capability.
7) Offices, storerooms and other vulnerable areas are protected from water ingress.
8) Vulnerable goods and equipment are stored off the ground when kept on the same
floor space.
9) Vulnerable electrics are suitably protected.
Likely Causes of Water Leaks
For guidance purposes the following conditions are likely to cause water leakage. These
include but are not limited to;
1) Poor installation.
2) Frost Damage.
3) Accidental damage.
4) Malicious damage.
5) Blocked breathers.
6) Blocked drainage.
7) Blocked overflows
8) Failed float switches
9) Component failure.
10) Lack of servicing/improper maintenance.
11) Modification.
12) Wear and tear.
13) Unsupervised first use.
Ionic Systems Ltd is a manufacturer and supplier of water treatment machines. If required
by the customer following completion of an installation by qualified plumbers and
electricians, Ionic Systems Ltd or its agents may commission a ‘Static’ machine but its
responsibility shall only be to ensure the correct working of the machine and the provision
of training to the operator. Ionic Systems Ltd will not be responsible in anyway for
damage of any kind, howsoever caused by the use of its machines within any building.
The use of any water treatment machine manufactured by Ionic Systems Ltd within any
building shall be at the discretion and sole risk of the building occupier.

General Guidance
20
CAUTION LABELS
‘CAUTION’ labels are fitted to each machine to
draw the operator’s attention to important
information about the safe use and operation of the
machine.
“CAUTION” labels fitted to Filter Housings detail the
Operating Specifications relating to the Maximum
Pressure and Maximum & Minimum Temperature
as well as specific instructions about safe use.
Local conditions may mean that the pump pressure
has to be adjusted from time to time to ensure that
the Maximum Pressure is never exceeded.
Locate the pressure adjustment screw on the
side of the Brass Pump Body, using a
screwdriver turn the screw clockwise to increase
the pressure and anti-clockwise to decrease the
pressure. Refer to the machines own pressure
gauge when adjusting the pressure adjustment
screw. Please refer to diagram.
IT IS THE OPERATORS RESPONSIBILITY TO
ENSURE CORRECT ADJUSTMENT TO
ENSURE THAT THE MAXIMUM PRESSURE
RELATIVE TO TEMPERATURE IS NEVER
EXCEEDED.
DO NOT TO EXCEED THE MAXIMUM
PRESSURE & TEMPERATURE RANGES.
WARNING LABELS
Like many other cleaning machines, Ionic Systems machines
with mains powered pumps have no ‘Run Dry” protection. In the
field it is possible to operate Ionic’s range of machines in ways
that would not be possible if ‘Run Dry’ protection was fitted.
For example Solar Panel sites seldom benefit from any mains water supply, instead operators
work from water storage tanks that provide a good flow of water to machines but with very low
pressure. In such circumstances ‘Run Dry’ devices may prevent the machine from working.
‘WARNING’ labels are fitted to all machines with mains powered pumps warning that
“DAMAGE WILL OCCUR IF PUMP IS RUN DRY”. It is the operators responsibility to ensure
that a constant and suitable water supply is maintained at all times when the machine is in
operation. In practice ‘DRY’ means bone dry. If a pump has been running correctly for some
time and is ‘WET’ then if the water supply is temporally interrupted then it is unlikely that
damage will occur. PUMPS THAT HAVE BEEN ‘RUN DRY’ FOR LONG ENOUGH FOR
DAMAGE TO HAVE OCCURRED, ARE NOT COVERED BY THE WARRANTY.