Mar Cor Purification M4-2200 User manual

M4-SERIES
WATER PURIFICATION MACHINES
M4-2200 – M4-13200
Operation
and Maintenance Manual
1238160 Rev. D 2 23 3M Ma ay y11

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1238160 Rev. D 23May11

OPERATION AND MAINTENANCE MANUAL
M4-SERIES WATER PURIFICATION MACHINES
M4-2200 – M4-13200
TABLE OF CONTENTS
Page
CHAPTER ONE: GENERAL INFORMATION 1-1
Section 1.1 General Information and Principles of
Operation 1-3
1.2 Machine Nomenclature 1-7
1.3 Machine Permeate Quality 1-7
1.4 Materials and Features 1-7
1.5 Specifications for M4-Series Machines 1-8
CHAPTER TWO: INSTALLATION 2-1
Section 2.1 Mounting 2-3
2.2 Plumbing 2-3
2.3 Electrical 2-4
CHAPTER THREE: PREPARATION AND START-UP 3-1
Section 3.1 Pretreatment for Water Purification 3-3
3.2 Start-Up 3-4
CHAPTER FOUR: OPERATION AND MAINTENANCE 4-1
Section 4.1
4.2 Daily Log Sheets Prefilter 4-3 4-3
4.3 Flushing 4-4
4.4 Cleaning 4-4
4.5 Sepralator Replacement 4-7
1238160 Rev. D A23May11

1238160 Rev. D B23May11
CHAPTER FIVE: OPTIONAL ACCESSORIES 5-1
Section 5.1 Level Controls 5-3
5.2 Conductivity Meter 5-3
5.3 Autoflush 5-3
5.4 Filters and Water Softeners 5-5
CHAPTER SIX: TROUBLESHOOTING 6-1
APPENDIX A: RETURN MATERIAL AUTHORIZATION (RMA)
PROCEDURE

M-Series Water Purification Machines
1238160 Rev. D 1 - 1 Description
M-Series Water Purification Machines
M4-2200 – M4-13200
CHAPTER ONE:
DESCRIPTION

M-Series Water Purification Machines
1238160 Rev. D 1 - 2 Description
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M-Series Water Purification Machines
1238160 Rev. D 1 - 3 Description
1.1 General Information and Principles of Operation
These instructions give operating and maintenance details vital to the sustained
performance of the machine.
Reverse Osmosis (RO) is the removal of ionic, organic, and suspended
impurities from water by means of a membrane. Unlike a filter (“normal”
filtration), the feedwater or solution is separated into two streams by collecting
fluids from both sides of a pressurized membrane (“crossflow” filtration). A
semipermeable RO membrane, under sufficient pressure, allows passage of
purified water while rejecting and concentrating dissolved and suspended solids.
Mar Cor Purification manufactures a patented spiral-wound membrane package,
with a turbulent flow design. The membrane module (i.e. sepralator), also called
an element collects the purified water within a central tube (permeate tube), see
Figure 1.
Some operating definitions are provided to help you further understand your
machine:
PERMEATE RATE (PRODUCT WATER RATE) [QP]
This is the flow rate of purified water which has passed through the membrane
and out of the sepralator; expressed in gal/min (gpm) or gal/h (gph) [in metric,
liter/min (Lpm) or cubic meters/hour (m3/h). Specified permeate rates are
normally specified at 77°F (25°C).

M-Series Water Purification Machines
1238160 Rev. D 1 - 4 Description
CONCENTRATION
Concentration equals the Total Dissolved Solids (TDS) concentration of a
solution expressed as milligrams per liter (mg/L) or conductivity
(microSiemens/cm).
C
f= Feed Concentration
Cp= Permeate Concentration
Cc = Concentrate Concentration
C
avg = Average Concentration in machine
SALT (IONIC) REJECTION:
This equals the percent of dissolved salt rejected by the membrane,
calculated from an average concentration over the membrane.
SALT (IONIC) PASSAGE:
This equals (100% - rejection) or the percent of dissolved salts passed
through the membrane.
CONCENTRATION RATE (WASTE WATER RATE) [Qc]:
This is the flow rate of water stream containing rejected solids to drain in
gpm or gph (pm or m3/h).
FEED RATE [Qf]:
This is the flow of incoming water in gpm or gph (Lp or m3/h). Feedwater
rate equals permeate rate plus concentrate rate.
An example of how to calculate salt rejection and recovery is given below:

M-Series Water Purification Machines
1238160 Rev. D 1 - 5 Description
Given the system case in Figure 2:
Average Concentration (Cavg) = (Cf) 100 mg/L + (Cc) 146.9 mg/L
2
(Cavg) = 123.5 mg/L TDS
Rejection = (Cavg) 123.5 – (Cp) 6.2 x 100 = 95%
(C
avg) 123.5
Passage = (Cp) = 6.2 x 100% = 5.0%
(Cavg) 123.5
Recovery = (Qp) 2 gpm x 100 = 33%
(Qf) 6 gpm
FLOW DESCRIPTION:
The feedwater passes through a replaceable 5-micron cartridge filter,
which removes bulk suspended solids. Filtered water then flows to the inlet
control valve. This solenoid-controlled diaphragm valve is wired to the
on/off switch and opens when the machine is turned on allowing water to
flow to the pump inlet. When the machine is turned off, the valve closes,
preventing non-turbulent flow through the sepralators, that would lead to
shortened membrane life.
The pump feeds water to the sepralator housings arranged in parallel and
serial combinations. An arrow on each element housing indicates the
direction of water flow. The water is sepralated by the membrane within
the elements and leaves the housings in two streams as permeate and
concentrate.
Permeate from each sepralator housing is collected in a common manifold.
A pressure relief valve is installed to alleviate excessive backpressure
build-up. The permeate then flows through a flow meter and to the outlet
point of the machine.
The concentrate leaves the last sepralator housing and flows to the flow
control center. At this point, the recycle valve channels a predetermined
amount of concentrate into the pump inlet. This achieves more efficient
water recovery while maintaining adequate crossflow through the
sepralators. The other two ports of the flow control center lead to the
concentrate valve and final pressure gauge. The concentrate valve has
three functions: It controls the amount of concentrate flowing to the drain; it
controls the pressure within the machine, and it helps control the system
recovery. An optional autoflush solenoid is added to the flow control center
with an additional tee. The concentrate then flows through a flow meter
and to the outlet point of the machine.

M-Series Water Purification Machines
1238160 Rev. D 1 - 6 Description
Typical P&ID

M-Series Water Purification Machines
1238160 Rev. D 1 - 7 Description
1.2 Machine Nomenclature
M-Series water purification are numbered in such a way as to indicate the
permeate flow and quality you can expect from the machine.
Example: M4-6600, 208, 6, 50-75
•M4 indicates the machine series
•6600 indicates the rated permeate flow in gallons per day
•208 indicates motor voltage
•6 indicates 60 Hz
•50-75 indicates the % recovery capability of the RO
1.3 Machine Permeate Quality
The permeate rejection performances are as follows:
M-Series machines use high rejection FASTEKu S4040 membrane, providing the
ultimate in high purity water.
1.4 Materials and Features
M-Series water purification machines have all the features necessary for safe,
continuous production of high purity water. Also, the M-series RO contains an
array of useful features for monitoring and data collection to help prolong
membrane life. This assumes good quality feedwater, adequate pretreatment
and regular operator attention, each shift or daily, to the operation of the system.
•50% or 75% recovery
•Multi-stage centrifugal pump, SB construction (nickel-plated cast iron
castings, Noryl*stages, remainder stainless steel) typically not
recommended for operation below pH 5.8
•Base model electrical package includes NEMA-4X enclosure with a 115
VAC, 60 Hz or 230 VAC, 50Hz single-phase control circuit.
•Automatic inlet shutoff valve
•Pre-filter, post-filter, primary, and final pressure gauges
•Concentrate and permeate flow meters
•Gauges, valves, and rigid plumbing of stainless steel, brass, or plastic
•Membrane element housings, all 304 stainless steel, with PVC end caps
•316 stainless steel concentrate and recycle valves
•All components in contact with the purified water (permeate) are either
non-leachable acceptable plastic (nylon, Noryl, polypropylene, PVC) or
stainless steel materials
•All high pressure fittings are 304 stainless steel

M-Series Water Purification Machines
1238160 Rev. D 1 - 8 Description
•Autoflush System – programmable, automated high velocity membrane
flushing for the longest membrane life; set at the factory and adjustable in
the field, includes a digital panel-mount timer, complete with push button
Manual Flush
•An electrical package that includes alarm delay shutdown for low inlet
pressure condition to prevent pump damage should pressure fall below 15
psig (1 bar)
•Conductivity monitor, panel-mounted, for permeate quality monitoring
•NEMA-4X fiberglass electrical enclosure
1.5 Specifications for M-Series Machines
1.5.1 Feedwater
TEMPERATURE:
35-77°(22-25°C) [Not to exceed 85°F (29°C) unless specifically designed for
higher temperatures]
INLET PRESSURE:
Minimum: 30 psig (2.1 bar)
Maximum: 60psig (4.1bar)
CHLORINE (CONTINUOUS FEED):
For FASTEK TLCmembranes 0 ppm
OPERATING pH:
Softwater [less than 1 grain per gallon 3.0-10.0 (gpg) or 17 mg/L hardness]
Unsoftened water (contact factory 5.5-6.0 with water analysis)
PRE-FILTER:
5-micron HYTREX cartridge (see machine label for part number)
INLET CONNECTIONS:
¾-inch FNPT (IPS)

M-Series Water Purification Machines
1238160 Rev. D 1 - 9 Description
1.5.2 Permeate (Product Water) Flow Rate
Stated on the RO test report form (assumes no permeate back pressure, 2000
mg/L TDS maximum feed concentration, and rated temperature).
To estimate permeate output with back pressure, use the formula below:
Permeate Flow on Label x Operating Pressure – (Permeate Back Pressure)
Operating Pressure
Permeate Back Pressure Maximum: 60 psig (5.5 bar)
Permeate Outlet 3/4-inch FNPT
1.5.3 Concentrate Flow Rate
Stated on the RO test report form
Concentrate Outlet 3/4-inch FNPT
1.5.4 Typical Pure Water
Recovery 50-75%
1.5.5 Operating Final Pressure
Minimum 100 psig
Maximum 140 psig

M-Series Water Purification Machines
1238160 Rev. D 1 - 10 Description
1.5.6 Pump
Multi-stage centrifugal, approximately primary operating pressure of 100 psig
excluding line pressure.
1.5.7 RO Membrane Rejection
FASTEK TLC
Typical Ionic Rejection (TDS) 95-98%
Average Molecular Weigh Cutoff* 150 MW
*The molecular weight cutoff is based on the pore size of the membranes and the
nature (shape/size) of the organic molecule.

M-Series Water Purification Machines
1238160 Rev. D 1 - 11 Description
NOTES:

M-Series Water Purification Machines
1238160 Rev. D 1 - 12 Description
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M-Series Water Purification Machines
1238160 Rev. D 2 - 1 Installation Guidelines and Instructions
M-Series Water Purification Machines
M4-2200 – M4-13200
CHAPTER TWO:
INSTALLATION

M-Series Water Purification Machines
1238160 Rev. D 2 - 2 Installation Guidelines and Instructions
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M-Series Water Purification Machines
1238160 Rev. D 2 - 3 Installation Guidelines and Instructions
2.1 Mounting
M-Series machines are equipped with a frame that supports the machine. Allow
at least 45 inches (114 cm) of space at the top of the sepralator housing(s) for
removal and loading of sepralators. If 45 inches (114 cm) are not available, the
entire membrane element housing may have to be removed for element
changes. At least 6 inches (15.2 cm) are required at the end of each sepralator
housing if the entire sepralator housing will be removed to replace sepralators.
2.2 Plumbing
2.2.1 Inlet Plumbing
The feedwater source is plumbed to the inlet using ¾-inch NPT fittings. A 1-inch
FNPT cleaning port is installed in the inlet plumbing. A pressure regulator is
installed between the permeate outlet and the membrane elements, so that if the
pressure exceeds 60 psig the regulator will allieviate the excess pressure.
2.2.2 Valves Required for (CIP) (Not Factory Installed)
A pipe tee is installed in the inlet line. Install a valve on the inlet and on the
cleaning port to facilitate cleaning the RO. Install a tee with 2 two-way valves or
a single three-way valve on the permeate and concentrate outlets to allow flow
back to the cleaning tank. Never operate the machine with the concentrate or
permeate lines blocked. Severe damage to the unit may result. (Refer to Figure
3 for representative system flow schmatic.)
2.2.3 Concentrate Outlet Connection
Install the CIP valve on the concentrate outlet and connect a ¾-inch hose or pipe
and run it to an open drain. The concentrate outlet plumbing should be placed at
a height at least equal to the height of the machine to avoid drainage from the
machine during non-operation. A siphon break may also be installed in the
concentrate line for added protection. The concentrate outlet hose can be any
length, and the diameter should match the outlet on the machine. [Maximum
back pressure is 60 psig (4.1bar).]
2.2.4 Permeate Outlet Connection
Install the CIP valve on the permeate outlet. The pure water (permeate) should
be transported to the point-of-use via non-corroding type tubing, pipe, or hose.
Examples are: food-grade flexible nylon tubing, stainless steel tubing, or PVC
hose. The permeate outlet is ¾-inch FNPT for all M-series RO’s.

M-Series Water Purification Machines
1238160 Rev. D 2 - 4 Installation Guidelines and Instructions
2.3 Electrical
M-Series models require two supply voltages, the control circuit voltage and a
separate motor voltage. All field wiring must comply with applicable local and
national electrical codes.
All M4 models are supplied with a single-phase, 115 VAC 60 Hz or 230 VAC 50
Hz control circuit with an 8-foot cord with plugs into a three-prong grounded
receptacle. A 20 amp dedicated service circuit is required for proper operation
(see wiring schematic).
The 2200 through 8800 models use a 1.5 Hp, 208-230/460 VAC, three-phase
motor. M-Series 11000 and 13200 models use a 2 Hp, 208-230/460 VAC, three-
phase motor. The motor is wired at the factory to an overload protection
magnetic motor starter. There is also a single-phase motor available on the 2200
and 4400 models only. These models use a 3Hp, 208-230VAC, 60 Hz, single-
phase motor.
A 50Hz option for all M-series models is available. The 2200 through 8800 uses
a 3 Hp 190/380 VAC, three-phase motor. The 11000 and 13200 use a 5 Hp
190/380, three phase motor. A single-phase option is also available for 50Hz
models 2200 and 4400. These models use a 1-1/2 Hp, 220VAC, 50Hz, single-
phase motor.
1. Connect the control circuit power cord to 115 VAC, 60 Hz, or 230 VAC 50
Hz single-phase power.
2. Connect the magnetic motor starter to 208-230/460 VAC or 190-220/380
VAC, three-phase or 115/230 VAC single-phase power to match the motor
voltage and phase. Check the tag (located on the motor starter) that
indicates the factory wiring. A separate, fused disconnect for the wiring with
proper protection for the Hp and the amp draw of the motor is
recommended.
WARNING:
Before obtaining access to terminals, all supply circuits must be
disconnected.