Millipore Helicon S10 User manual

Helicon™S10/S40
Spiral Cartridges
Installation Guide
NOTICE
The configuration of Helicon™S40 cartridges has been changed:
the limited by-pass seal (the “chevron”) has been moved to the inlet end.
Please follow these installation instructions carefully.

Notice
The information in this document is subject to change without notice and should
not be construed as a commitment by Millipore Corporation. Millipore
Corporation assumes no responsibility for any errors that may appear in this
document. This manual is believed to be complete and accurate at the time of
publication. In no event shall Millipore Corporation be liable for incidental or
consequential damages in connection with or arising from the use of this manual.
© 2002 MILLIPORE CORPORATION. PRINTED IN THE UNITED STATES OF
AMERICA. ALL RIGHTS RESERVED. THIS BOOK OR PARTS THEREOF MAY NOT
BE REPRODUCED IN ANY FORM WITHOUT THE WRITTEN PERMISSION OF
THE PUBLISHERS.
Millipore is a registered trademark of Millipore Corporation.
Helicon is a trademark of Millipore Corporation (registration pending).
P60215, Rev. -, 04/02

Contents
Introduction ........................................................................................................5
Safety and Environmental Compliance..................................................................5
S10: Installing an S10 Cartridge in the S10 Housing ............................................6
S10: Flushing and Cleaning................................................................................7
S10: Integrity Testing ..........................................................................................8
S40: Installing an S40 Cartridge in the S40 Housing ..........................................10
S120: Installing Three S40 Cartridges in the S120 Housing.................................12
S40/S120: Flushing and Cleaning ....................................................................16
S40/S120: Integrity Testing ..............................................................................17
Product Ordering Information ............................................................................19
Technical Assistance ..........................................................................................19
Standard Warranty...........................................................................................19

HeliconS10/S40 Spiral Cartridges Installation Guide 5
Introduction
This installation guide provides information on the installation, flushing and
integrity testing of the Helicon™S10 and S40 cartridges in their respective
housings.
Information is provided also on the installation and integrity testing of three
Helicon S40 cartridges in an S120 housing.
Safety and Environmental Compliance
Helicon S10 and S40 cartridges are packaged in a 3% formaldehyde solution.
Therefore, gloves and other appropriate safety equipment must be worn during
the installation of the cartridge. The bag in which the cartridge is shipped and the
used gloves, etc., must be disposed of appropriately.
During the initial flushing of the cartridge, the effluent must be directed into an
appropriate drain, consistent with applicable regulations.
For further information, consult the MSDS for formaldehyde. Millipore provides
internet access to Material Safety Data Sheets (MSDS) for any hazardous materials
contained in its products, on the MSDS page of our website, at http://
www.millipore.com/msds.nsf/home.

6www.millipore.com
S10: Installing an S10 Cartridge in the S10 Housing
Installation of the cartridge requires the S10 header kit (Millipore Cat. No. 540605).
The kit may be reused. For replacement of individual components, please see the
parts list provided with the kit.
Please review the Safety and Environmental Compliance section, before
proceeding with the installation.
1. Remove the bagged cartridge from its shipping box.
2. Open the bag and remove the cartridge.
3. Lubricate the O-rings on the permeate connector (supplied in the header kit)
with pure glycerin.
NOTE: Do not use silicone, petroleum jelly, or any other lubricant.
4. Install the permeate connector into the inlet header.
5. Install the inlet header onto the housing base.
6. Place a gasket on the inlet header.
7. The cartridge is labeled at the outlet end. Install the opposite end, the inlet
end, into the inlet header and tighten the clamp.
8. Install a gasket on top of the cartridge.
9. Lubricate the O-ring in the center of the outlet header with pure glycerin.
NOTE: Do not use silicone, petroleum jelly, or any other lubricant.
10. Connect the outlet header to the cartridge and clamp it in place.
After installation, follow the instructions for flushing and cleaning and integrity
testing, in the next two sections.
Figure 1 shows the completed installation of the S10 cartridge with the header kit.
Figure 1. Installation of the S10 Cartridge
Outlet Header Clamp
Inlet Header
Permeate Connector
Permeate Line

HeliconS10/S40 Spiral Cartridges Installation Guide 7
S10: Flushing and Cleaning
This procedure requires filtered purified water — reverse osmosis or water for
injection (WFI). The flush water must be extremely pure to avoid fouling the
membrane or introducing contaminants into the system. When flushing the
cartridge, the effluent must be directed into an appropriate drain, consistent with
applicable regulations.
▲▲
▲▲
▲WARNING: Do not let the pump run dry during flushing and cleaning,
to avoid damage to the pump and possible bodily injury.
Flush #1:
1. Connect the system to a source of filtered purified water.
2. Direct the permeate and retentate lines into the drain.
3. Start the feed pump and gradually adjust to the following conditions:
■Feed pressure = 25–30 psi
■Retentate pressure = approximately 5 psi less than the feed pressure,
for each module installed in series
NOTE: This will result in a feed flow rate of 15–20 lpm.
4. Flush the cartridge for 3–4 minutes.
5. Disconnect the purified water source.
6. Operate the pump only until the system is drained.
Clean:
1. Fill the system with warm 0.1 N NaOH (at 40 °C).
NOTE: There should be at least 5 L of NaOH per module.
2. Recirculate the permeate and retentate streams, with the following conditions:
■Feed pressure = 25–30 psi
■Retentate pressure = approx. 5 psi less than the feed pressure,
for each module installed in series (the same as in Flush #1 above)
3. Recirculate for 20 minutes.
4. Direct the retentate and permeate lines to the drain.
5. Operate the pump only until the system is drained.
Flush #2:
1. Repeat the water flush, as outlined in Flush #1 above.
2. Immediately perform the integrity test, as described in the following section.

8www.millipore.com
S10: Integrity Testing
Figure 2 shows the configuration for integrity testing a spiral cartridge.
Figure 2. Configuration for Integrity Testing a Spiral Cartridge
1. Drain the plumbing of water. To remove any residual water, purge with
filtered nitrogen or clean, dry air at 1–2 psi (0.07–0.14 bar), if necessary.
2. Attach a regulated and filtered supply of nitrogen or clean, dry air to the feed
side of the cartridge housing.
3. Isolate the retentate manifold by closing the back-pressure valve. The
permeate port valve should be open.
4. Slowly raise the gas pressure to the value recommended for your cartridge
type, as shown in Table 1.
Table 1. Integrity Test Specifications for S10
Catalogue Gas Flow Rate Test Pressure
Number cc/min psig (bar)
CDUF010LC ≤60 10 (0.7)
CDUF010LG ≤60 5 (0.35)
CDUF010LT ≤150 5 (0.35)
Feed
line
Cartridge, installed
Gas supply
Retentate line
Permeate line
Permeate pressure
gauge
Back-pressure valve
Permeate
port valve
Feed pressure gauge

HeliconS10/S40 Spiral Cartridges Installation Guide 9
S10: Integrity Testing, continued
5. Wait 5 minutes, to purge residual water from the permeate line.
NOTE: Do not exceed the recommended gas pressure, which would
displace water from the pores of the wetted cartridge, resulting in
excessively high gas flow. (If this occurs, rewet the membrane, using
the flushing procedure described previously.)
6. Measure and record the gas pressure and temperature and the gas flow rate
exiting the permeate line.
The gas flow rate may be measured with a gas flow meter. Alternatively, it
may be determined by measuring the displacement of water by gas flow (in a
submerged and inverted volumetric cylinder) during a known period of time.
This method is shown in Figure 3.
Figure 3. Measurement of Gas during Integrity Testing
7. Compare the measured gas flow rate to the flow rate specified in Table 1, for
your cartridge type.
8. If the measured gas flow rate exceeds the specified gas flow rate:
a. Disconnect the housing from the process line.
b. Remove the headers and examine the condition of all O-ring seals.
c. Replace any suspect O-rings, rewet the cartridge thoroughly and repeat
the test.
d. If the gas flow rate remains in excess of the specified value, contact
Millipore Technical Service for assistance.
If the measured gas flow rate does not exceed the specified gas flow rate, the
cartridge passes the test. Reconnect the process line to the cartridge and resume
operation.
Gas flow from
permeate port
Vessel, partially
filled with water
ubing
Volumetric cylinder,
submerged and
inverted

10 www.millipore.com
S40: Installing an S40 Cartridge in the S40 Housing
NOTICE
The configuration of Helicon S40 cartridges has been changed: the limited
by-pass seal (the “chevron”) has been moved to the inlet end. Please follow
these installation instructions carefully.
The S40 cartridge hardware kit (Millipore Cat. No. 540700) incorporates all the
hardware that is required for installation of a single S40 cartridge. The kit may be
reused. For replacement of individual components, please see the parts list
provided with the kit.
Please review the Safety and Environmental Compliance section, before
proceeding with the installation.
Figure 4 shows the installation of the S40 cartridge.
Figure 4. Installation of the S40 Cartridge in the S40 Housing
Outlet header
Anti-telescoping device
(A D)
Clamp
Inlet header Permeate port
Gasket
Gasket
Permeate plug
Cartridge
Housing sleeve
Clamp
Chevron
(limited by-pass)
seal
Permeate connector

HeliconS10/S40 Spiral Cartridges Installation Guide 11
S40: Installing an S40 Cartridge in the S40 Housing, continued
1. Remove the bagged cartridge from its shipping box.
2. Open the bag and remove the cartridge.
3. Inspect the white silicone chevron (limited by-pass) seal for nicks or cuts.
NOTE: If a seal is damaged, do not use the cartridge. A defective new
cartridge may be returned to Millipore for replacement.
4. Lubricate the permeate connector O-ring with pure glycerin.
NOTE: Do not use silicone, petroleum jelly, or any other lubricant.
5. Install the permeate connector in the inlet header.
6. Install the inlet end of the cartridge (with the chevron seal) onto the permeate
connector, in the inlet header. For proper seating, twist the cartridge slowly,
while gently pushing downward.
7. Lubricate the permeate plug with pure glycerin and install it in the outlet end
of the cartridge. For proper seating, twist the plug slowly, while gently
pushing downward.
8. With its circular groove facing towards the cartridge, install the anti-
telescoping device (ATD) over the permeate plug.
9. Place a gasket on the edge of the inlet header.
10. Install the housing sleeve over the cartridge assembly, and clamp it to the inlet
header.
11. Place a gasket on the top rim of the housing sleeve.
12. Install the outlet header on top of the housing sleeve and clamp it in place.
After installation, follow the instructions in the sections S40/S120: Flushing and
Cleaning and S40/S120: Integrity Testing.

12 www.millipore.com
S120: Installing Three S40 Cartridges in the S120 Housing
NOTICE
The configuration of Helicon S40 cartridges has been changed: the limited
by-pass seal (the “chevron”) has been moved to the inlet end. Please follow
these installation instructions carefully.
The S120 Cartridge Hardware Kit (Millipore Cat. No. 540710) is required for
installation of the cartridges. The kit may be reused. For replacement of individual
components, please see the parts list provided with the kit.
Please review the Safety and Environmental Compliance section, before
proceeding with the installation..
Preparing the Hardware
1. Snap O-rings into the grooves on the permeate plug and permeate connector,
if they are not already in place..
2. Slide a cartridge connector through the center hole of one of the anti-
telescoping devices (ATD’s), as shown in Figure 7. Snap O-rings into the
grooves on the cartridge connector.
3. Repeat step 2 with the second cartridge connector and another ATD. (The
third ATD will be used later.)
Preparing the Cartridges
NOTE: All O-rings and seals may be lubricated, as necessary, with pure
glycerin. Do not use silicone, petroleum jelly, or any other lubricant.
1. Remove three bagged cartridges from their individual shipping boxes.
2. Open the bags and remove the cartridges.
3. Inspect the white silicone chevron (limited by-pass) seal for nicks or cuts.
NOTE: If a seal is damaged, do not use the cartridge. A defective new
cartridge may be returned to Millipore for replacement.
4. Identify the outlet end of a cartridge, opposite the white silicone seal. Orient
the cartridge with the outlet end uppermost.
5. With the circular groove in the previously attached ATD facing down, insert a
cartridge connector into the permeate tube of the cartridge, at the outlet end.
For proper seating inside the permeate tube, twist the connector slowly,
while gently pushing downward.
6. Repeat steps 4 and 5 with a second cartridge.

HeliconS10/S40 Spiral Cartridges Installation Guide 13
Joining the Cartridges
Figure 7 shows how two S40 cartridges are connected, using a cartridge
connector (included in the S120 Cartridge Hardware Kit).
Figure 7. Two S40 Cartridges Connected by a Cartridge Connector
1. Re-lubricate the O-rings with glycerin, to facilitate joining the three cartridges
together.
2. Using a gentle twisting motion, join the cartridges together:
a. Push cartridge #2 over the connector extending from the outlet end of
cartridge #1.
b. Push cartridge #3 onto the connector extending from the outlet end of
cartridge #2.
Housing sleeve
Anti-telescoping device
(A D)
Cartridge
Cartridge
Cartridge connector
C
h
evron
(limited
by-pass)
seal
Permeate tube

14 www.millipore.com
Installing the Cartridge Assembly in the Housing
Figure 8 shows the installation of three S40 cartridges in an S120 housing, using
the S120 Cartridge Hardware Kit.
Figure 8. Installation of three S40 cartridges in an S120 housing
Outlet header Clamp
Cartridge #2
Permeate port
Inlet header
Housing sleeve
Cartridge #1
Cartridge #3
Gasket
Clamp
A D
Permeate plug
Chevron seal
Chevron seal
Cartridge connector
Permeate connector
Permeate tube
Chevron
(limited by-pass)
seal
A D Cartridge connector
Anti-telescoping device
(A D) Gasket

HeliconS10/S40 Spiral Cartridges Installation Guide 15
Installing the Cartridge Assembly in the Housing, continued
1. Remove the clamps at both ends of the housing sleeve, and remove the inlet
and outlet headers and gaskets.
2. Lubricate the white chevron seals on the cartridge assembly with pure
glycerin.
3. Slide the cartridge assembly into the housing sleeve, outlet end first (the end
without a chevron seal).
4. Lubricate the permeate connector O-rings with glycerin.
5. Push the short end of the permeate connector into the elbow inside the inlet
header.
6. Place a rubber gasket in the groove at the inlet end of the housing sleeve (the
end with a chevron seal visible on the cartridge assembly inside).
7. Place the inlet header onto the sleeve, directing the permeate connector into
the permeate tube in the center of the cartridge assembly.
8. While preventing the outlet end of the cartridge assembly from being pushed
out of the sleeve, push the inlet header towards the cartridge assembly, until
the permeate connector is seated within the cartridge assembly.
9. Clamp the sleeve and inlet header together, tightening the bolts evenly until
the header is secure.
10. Insert the permeate plug into the center hole of the third ATD.
11. With the circular groove in the ATD facing towards the cartridge assembly,
insert the permeate plug into the outlet end of the cartridge assembly.
For proper seating inside the permeate tube, twist the plug slowly, while
gently pushing towards the cartridge assembly.
12. Place a rubber gasket in the groove at the open end of the housing sleeve.
13. Place the outlet header onto the sleeve.
14. Push the outlet header towards the cartridge assembly, until the permeate
plug in the outlet end of the cartridge assembly is seated in the outlet header.
15. Clamp the sleeve and outlet header together, tightening the bolts evenly until
the header is secure.
After installation, follow the instructions in the sections S40/S120: Flushing and
Cleaning and S40/S120: Integrity Testing. Integrity test specifications for three S40
cartridges in an S120 housing are provided.

16 www.millipore.com
S40/S120: Flushing and Cleaning
These instructions for flushing and cleaning may be used either for a single S40
cartridge in an S40 housing, or for three S40 cartridges in an S120 housing.
The flushing and cleaning procedure requires filtered purified water — reverse
osmosis or water for injection (WFI). The flush water must be extremely pure, to
avoid fouling the membrane or introducing contaminants into the system. When
flushing the cartridge, the effluent must be directed into an appropriate drain,
consistent with applicable regulations.
▲▲
▲▲
▲WARNING: Do not let the pump run dry during flushing and cleaning,
to avoid damage to the pump and possible bodily injury.
Flush #1:
1. Connect the system to a source of filtered purified water.
2. Direct the permeate and retentate lines into the drain.
3. Start the feed pump and gradually adjust to the following conditions:
■Feed pressure = 25–30 psi
■Retentate pressure = approximately 5 psi less than the feed pressure,
for each module installed in series
NOTE: This will result in a feed flow rate of 150 lpm.
4. Flush the cartridge for 3–4 minutes.
5. Disconnect the purified water source.
6. Operate the pump only until the system is drained.
Clean:
1. Fill the system with warm 0.1 N NaOH (at 40 °C).
NOTE: There should be at least 5 L of NaOH per module.
2. Recirculate the permeate and retentate streams, with the following conditions:
■Feed pressure = 25–30 psi
■Retentate pressure = approx. 5 psi less than the feed pressure,
for each module installed in series (the same as in Flush #1 above)
3. Recirculate for 20 minutes.
4. Direct the retentate and permeate lines to the drain.
5. Operate the pump only until the system is drained.
Flush #2:
1. Repeat the water flush, as outlined in Flush #1 above.
2. Immediately perform the integrity test, as described in the following section.

HeliconS10/S40 Spiral Cartridges Installation Guide 17
S40/S120: Integrity Testing
These instructions may be used for integrity testing either a single S40 cartridge in
an S40 housing or three S40 cartridges in an S120 housing. Figure 5 shows the
configuration for integrity testing a spiral cartridge (or cartridge assembly).
Feed
line
Cartridge, installed
Gas supply
Retentate line
Permeate line
Permeate pressure
gauge
Back-pressure valve
Permeate
port valve
Feed pressure gauge
Figure 5. Configuration for Integrity Testing a Spiral Cartridge
1. Drain the plumbing of water. To remove any residual water, purge with
filtered nitrogen or clean, dry air at 1–2 psi (0.07–0.14 bar), if necessary.
2. Attach a regulated and filtered supply of nitrogen or clean, dry air to the feed
side of the cartridge housing.
3. Isolate the retentate manifold by closing the back-pressure valve. The
permeate port valve should be open.
4. Slowly raise the gas pressure to the value recommended for your cartridge
type, as shown in Table 2.
Table 2. Integrity Test Specifications for S40 and S120
Gas Flow Rate
Catalogue Test Pressure cc/min
Number psig (bar) S40 S120
CDUF040LC 10 (0.7) ≤240 ≤720
CDUF040LG 5 (0.35) ≤240 ≤720
CDUF040LT 5 (0.35) ≤600 ≤1800

18 www.millipore.com
S40/S120: Integrity Testing, continued
5. Wait 5 minutes, to purge residual water from the permeate line.
NOTE: Do not exceed the recommended gas pressure, which would
displace water from the pores of the wetted cartridge, resulting in
excessively high gas flow. (If this occurs, rewet the membrane, using
the flushing procedure described previously.)
6. Measure and record the gas pressure and temperature and the gas flow rate
exiting the permeate line.
The gas flow rate may be measured with a gas flow meter. Alternatively, it
may be determined by measuring the displacement of water by gas flow (in a
submerged and inverted volumetric cylinder) during a known period of time.
This method is shown in Figure 6.
Gas flow from
permeate port
Vessel, partially
filled with water
ubing
Volumetric cylinder,
submerged and
inverted
Figure 6. Measurement of Gas during Integrity Testing
7. Compare the measured gas flow rate to the flow rate specified for your
cartridge type and housing, in Table 2.
8. If the measured gas flow rate exceeds the specified gas flow rate:
a. Disconnect the housing from the process line.
b. Remove the headers and examine the condition of all O-ring seals.
c. Replace any suspect O-rings, rewet the cartridge(s) thoroughly and
repeat the test.
d. If the gas flow rate remains in excess of the specified value, contact
Millipore Technical Service for assistance.
If the measured gas flow rate does not exceed the specified gas flow rate, the
cartridge passes the test. Reconnect the process line to the cartridge and resume
operation.

HeliconS10/S40 Spiral Cartridges Installation Guide 19
Product Ordering Information
This section lists the catalogue numbers of the kits required for installing an S10
cartridge, a single S40 cartridge or a configuration of three S40 cartridges in an
S120 housing. For replacement of individual components, please see the parts list
provided with the relevant kit.
See the Technical Assistance section for information about contacting Millipore.
You can also get information about ordering Millipore products on-line at
www.millipore.com.
Description Qty. /Pk. Catalogue No.
S10 Kit 1 540605
S40 Kit 1 540700
S120 Kit 1 540710
Technical Assistance
For more information, contact the Millipore office nearest you. In the U.S., call
1-800-MILLIPORE (1-800-645-5476). Outside the U.S., see your Millipore
catalogue for the phone number of the office nearest you or go to our web site at
www.millipore.com/offices for up-to-date worldwide contact information. You
can also visit the tech service page on our web site at http://www.millipore.com/
techservice.
Standard Warranty
Millipore Corporation (“Millipore”) warrants its products will meet their
applicable published specifications when used in accordance with their applicable
instructions for a period of one year from shipment of the products. MILLIPORE
MAKES NO OTHER WARRANTY, EXPRESSED OR IMPLIED. THERE IS NO
WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE. The warranty provided herein and the data, specifications and
descriptions of Millipore products appearing in Millipore’s published catalogues
and product literature may not be altered except by express written agreement
signed by an officer of Millipore. Representations, oral or written, which are
inconsistent with this warranty or such publications are not authorized and if
given, should not be relied upon.
In the event of a breach of the foregoing warranty, Millipore’s sole obligation shall
be to repair or replace, at its option, the applicable product or part thereof,
provided the customer notifies Millipore promptly of any such breach. If after
exercising reasonable efforts, Millipore is unable to repair or replace the product
or part, then Millipore shall refund to the customer all monies paid for such
applicable product or part. MILLIPORE SHALL NOT BE LIABLE FOR
CONSEQUENTIAL, INCIDENTAL, SPECIAL OR ANY OTHER INDIRECT
DAMAGES RESULTING FROM ECONOMIC LOSS OR PROPERTY DAMAGE
SUSTAINED BY ANY CUSTOMER FROM THE USE OF ITS PRODUCTS.

P60215, Rev. -, 04/02