Manual Servicio Pretratamiento

8/18/2019 Manual Servicio Pretratamiento

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FreseniusMedicalCare

Pretreatment ComponentsBASIC / STANDARD

Service ManualEdition: 1/03.11

Part no.: 636 210 1


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Fresenius Medical Care Service Manual SM-EN 1/03.11 iii

Table of contents

1 Index

2 Important information

2.1 Preface........................................................................................................................................ 2-12.1.1 Structure of the Service Manual .................................................................................................. 2-1

2.2 How to use the Service Manual ................................................................................................ 2-2

2.3 Notes........................................................................................................................................... 2-32.3.1 Significance of the warnings........................................................................................................ 2-3

2.3.2 Significance of the note ............................................................................................................... 2-32.3.3 Significance of the tip .................................................................................................................. 2-3

2.4 Brief description ........................................................................................................................ 2-42.4.1 Operator information.................................................................................................................... 2-5

2.4.2 Guarantee / warranty................................................................................................................... 2-6

2.4.3 Technical documentation............................................................................................................. 2-6

2.5 Warnings .................................................................................................................................... 2-72.5.1 Basic warnings ............................................................................................................................ 2-7

2.5.2 Electric hazards ........................................................................................................................... 2-7

2.5.3 Chemical hazards........................................................................................................................ 2-7

2.5.4 Biological hazards ....................................................................................................................... 2-8

2.6 Addresses .................................................................................................................................. 2-9

3 Component overview

3.1 Components of the water pretreatment system ..................................................................... 3-13.1.1 Water pretreatment component overview / STANDARD........................................................ 3-23.1.2 Water pretreatment component overview / BASIC................................................................. 3-3

4 Feed water inlet unit4.1 Component overview – wall-mounted prefiltration unit ........................................................ 4-14.1.1 Prefiltration unit 1‘‘, 1 1/4‘‘, 1 1/2‘‘ ................................................................................................ 4-2

4.2 Installation.................................................................................................................................. 4-34.2.1 Installation / start-up requirements .............................................................................................. 4-3

4.2.2 Data reporting.............................................................................................................................. 4-3

4.3 Specifications ............................................................................................................................ 4-44.3.1 Specifications / data sheet........................................................................................................... 4-4

4.3.2 Operating conditions.................................................................................................................... 4-5

4.3.3 Configuration options................................................................................................................... 4-5

4.4 Maintenance............................................................................................................................... 4-6


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iv Fresenius Medical Care Service Manual SM-EN 1/03.11

4.5 Functional description .............................................................................................................. 4-74.5.1 Design of components................................................................................................................. 4-7

4.5.1.1 Water inlet unit ............................................................................................................. 4-7

4.5.2 Component function..................................................................................................................... 4-7

4.5.2.1 Stop valve..................................................................................................................... 4-7

4.5.2.2 Water meter - optional.................................................................................................. 4-74.5.2.3 Backwashable prefilter 105 µm .................................................................................... 4-7

4.5.2.4 Solenoid valve.............................................................................................................. 4-8

4.5.2.5 Pipe disconnector ......................................................................................................... 4-9

4.5.3 Prefiltration rack with particle filter (optional) ............................................................................. 4-10

4.5.4 Component description.............................................................................................................. 4-10

4.6 Options ..................................................................................................................................... 4-114.6.1 Prefiltration rack with particle filter (option)................................................................................ 4-11

4.6.2 Pressure reducer - optional ....................................................................................................... 4-11

4.6.3 Configuration options (feed water tank)..................................................................................... 4-11

5 Booster pump

5.1 Booster pump assembly CRN5-8 component overview ........................................................ 5-1


5.2.2 Important start-up information...................................................................................................... 5-2

5.2.2.1 Booster pump assembly connection ............................................................................ 5-2

5.2.2.2 Connection to the domestic water supply network....................................................... 5-3

5.2.2.5 Overview of electrical connections ............................................................................... 5-9

5.2.3 Data reporting ............................................................................................................................ 5-13

5.3 Specifications .......................................................................................................................... 5-145.3.1 Specifications / data sheet......................................................................................................... 5-145.3.1.1 Performance characteristics....................................................................................... 5-14

5.3.1.2 Volumetric capacity - diagram .................................................................................... 5-15

5.3.2 Operating conditions.................................................................................................................. 5-15

5.4 Maintenance ............................................................................................................................. 5-16

5.5 Error messages........................................................................................................................ 5-175.5.1 Malfunctions, causes and correction ......................................................................................... 5-17

5.6 Functional description ............................................................................................................ 5-185.6.1 Design of components............................................................................................................... 5-18


5.6.2.1 Control unit ................................................................................................................. 5-185.6.2.2 Base load and peak load pump.................................................................................. 5-19

5.6.2.3 Alternating pressure situations ................................................................................... 5-19

5.6.2.4 Run-dry protection...................................................................................................... 5-19

5.6.2.5 Tank operation ........................................................................................................... 5-19

5.6.2.6 Automatic turnoff ........................................................................................................ 5-19

5.6.3 Functional description................................................................................................................ 5-20

5.6.3.1 Setting the system to the Standby mode.................................................................... 5-20

5.6.3.2 Selector switch functions............................................................................................ 5-20


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Fresenius Medical Care Service Manual SM-EN 1/03.11 v

6 Pumps

6.1 Pump CM5-5 – component overview ....................................................................................... 6-1

6.2 Installation.................................................................................................................................. 6-2

6.2.1 Installation / start-up requirements .............................................................................................. 6-26.2.2 Important start-up information ..................................................................................................... 6-2

6.2.3 Data reporting.............................................................................................................................. 6-2

6.3 Specifications ............................................................................................................................ 6-36.3.1 Specifications / data sheet (CM5-5) ............................................................................................ 6-3


6.4 Maintenance............................................................................................................................... 6-4

6.5 Error messages on pumps ....................................................................................................... 6-56.5.1 Visual indication on CM5-5.......................................................................................................... 6-5

6.5.1.1 Alarm messages overview ........................................................................................... 6-5

6.5.2 Pump malfunctions overview....................................................................................................... 6-6


7 Media filters (sand filters / Birm filters)

7.1 Component overview – sand filters S140, S200, S300, S400 ................................................ 7-1

7.2 Component overview – Birm filters B140, B200, B300, B400 ................................................ 7-2

7.3 Installation of the media filters (sand / Birm).......................................................................... 7-37.3.1 Installation / start-up requirements .............................................................................................. 7-3

7.3.2 Important start-up information ..................................................................................................... 7-47.3.2.1 Start-up of the sand filters / Birm filters ........................................................................ 7-4

7.3.2.2 Valve heads and drain restrictor ................................................................................... 7-5

7.3.2.3 Valves in the control head............................................................................................ 7-9

7.3.3 Programming the control for sand filters / Birm filters................................................................ 7-11

7.3.3.1 Control / display ......................................................................................................... 7-11

7.3.3.2 Control / control elements .......................................................................................... 7-11

7.3.3.3 Control / programming................................................................................................ 7-11

7.3.4 Data reporting............................................................................................................................ 7-23

7.3.5 Use of Birm for improved water quality..................................................................................... 7-24

7.3.5.1 Removal of iron using "Birm" as filter media in the sand filter .................................... 7-24

7.3.5.2 Alarm limits for water substances............................................................................... 7-24

7.3.6 Birm filter settings ...................................................................................................................... 7-26

7.3.6.1 Weekly / semi-weekly backwash................................................................................ 7-26


7.4 Specifications .......................................................................................................................... 7-297.4.1 Specifications / sand filter data sheet........................................................................................ 7-29

7.4.2 Specifications / Birm filter data sheet ........................................................................................ 7-30


7.5 Maintenance............................................................................................................................. 7-32

7.6 Error messages ....................................................................................................................... 7-337.6.1 Sand filter / Birm filter malfunctions overview............................................................................ 7-33

7.7 Functional description ............................................................................................................ 7-34

7.7.1 Design of components............................................................................................................... 7-34


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vi Fresenius Medical Care Service Manual SM-EN 1/03.11


7.7.2.1 Backwash ................................................................................................................... 7-34

7.7.2.2 Flow velocities............................................................................................................ 7-35

7.7.2.3 Feed water bypass..................................................................................................... 7-35

7.7.2.4 Efficiency .................................................................................................................... 7-35

8 Particle filter (Big Blue) 20"

8.1 Component overview – particle filter ....................................................................................... 8-1


8.2.2 Data reporting .............................................................................................................................. 8-2

8.3 Specifications ............................................................................................................................ 8-38.3.1 Specifications / data sheet........................................................................................................... 8-3


8.3.2.1 Particle filter selection table.......................................................................................... 8-3

8.4 Maintenance ............................................................................................................................... 8-4


8.5.2 Component description................................................................................................................ 8-5

9 Softener

9.1 Component overview – softener E080(B), E150(B), E225-T, E300, E400 Magnum .............. 9-1

9.2 Modification of the softener settings in case of high brine concentrations in combinationwith Kinetico-Autorol retrofit kits............................................................................................. 9-3

9.2.1 Settings for CP 216...................................................................................................................... 9-3

9.2.2 Settings for CP 213...................................................................................................................... 9-3

9.2.3 Settings for CP 210...................................................................................................................... 9-4


9.4 Display and operating elements............................................................................................... 9-69.4.1 Display during operation .............................................................................................................. 9-6

9.4.2 Programming the control unit....................................................................................................... 9-7

9.4.2.1 Control / display............................................................................................................ 9-7

9.4.2.2 Programming the control .............................................................................................. 9-79.4.3 Important start-up information.................................................................................................... 9-13

9.4.3.1 Softener start-up procedure ....................................................................................... 9-14

9.4.4 Start-up procedure for E080(B),/ E150(B), E225-T, E300, E400............................................... 9-16

9.4.4.3 Brine tank ................................................................................................................... 9-22

9.4.4.5 Triplex operation E225-T............................................................................................ 9-23

9.4.4.6 Alternating or parallel operation ................................................................................. 9-24

9.4.5 Data reporting ............................................................................................................................ 9-44

9.5 Specifications .......................................................................................................................... 9-459.5.1 Specifications / data sheet......................................................................................................... 9-46

9.5.2 Restrictor inserts depending on pressure range........................................................................ 9-47

9.5.3 Softener capacities .................................................................................................................... 9-48



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Fresenius Medical Care Service Manual SM-EN 1/03.11 vii

9.5.4.1 Softener selection table.............................................................................................. 9-49

9.5.4.2 Triplex softener (E225-T) ........................................................................................... 9-50

9.5.5 Removal of iron and manganese using a softener .................................................................... 9-50

9.6 Maintenance............................................................................................................................. 9-51

9.7 Error messages ....................................................................................................................... 9-529.7.1 Softener malfunctions overview................................................................................................. 9-52

9.8 Functional description ............................................................................................................ 9-559.8.1 Design of components............................................................................................................... 9-55


9.8.3 Functional description Triplex operation E225-T....................................................................... 9-56

10 Activated carbon filter

10.1 Component overview – A050, A100, A150, A300, A400 ....................................................... 10-1

10.2 Installation................................................................................................................................ 10-210.2.1 Installation / start-up requirements ............................................................................................ 10-2

10.2.2 Important start-up information ................................................................................................... 10-3

10.2.3 Start-up of the activated carbon filter ......................................................................................... 10-4

10.2.3.1 Valve heads and drain restrictor ................................................................................. 10-4

10.2.3.3 Control unit design ..................................................................................................... 10-8

10.2.4 Programming the control unit .................................................................................................. 10-10

10.2.4.1 Control / display ....................................................................................................... 10-10

10.2.4.2 Control / operating elements .................................................................................... 10-10

10.2.4.3 Control unit ............................................................................................................... 10-11

10.2.5 Data reporting.......................................................................................................................... 10-21

10.3 Specifications ........................................................................................................................ 10-2210.3.1 Specifications / data sheet....................................................................................................... 10-2210.3.2 Operating conditions................................................................................................................ 10-24

10.3.2.1 Activated carbon filter (Single) selection table ......................................................... 10-25

10.3.2.2 Activated carbon filter (double) selection table......................................................... 10-25

10.4 Maintenance........................................................................................................................... 10-27

10.5 Error messages ..................................................................................................................... 10-2810.5.1 Activated carbon filter malfunctions overview.......................................................................... 10-28

10.6 Functional description .......................................................................................................... 10-2910.6.1 Design of components............................................................................................................. 10-29

10.6.2 Component description............................................................................................................ 10-29

11 USER RELEVANT – Operational data acquisition / maintenance

11.1 Operational data acquisition / daily report............................................................................ 11-2

11.2 System handling instructions report – water pretreatment ................................................ 11-5

11.3 Maintenance............................................................................................................................. 11-911.3.1 Maintenance intervals for water pretreatment components....................................................... 11-9

11.3.1.1 Feed water inlet unit ................................................................................................... 11-9

11.3.1.2 Sand filter ................................................................................................................... 11-9

11.3.1.3 Particle filter ............................................................................................................... 11-9

11.3.1.4 Softener .................................................................................................................... 11-10


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11.3.1.5 Activated carbon filter ............................................................................................... 11-11

11.3.1.6 Water leakage indicator ............................................................................................ 11-11

12 SERVICE RELEVANT – Reports12.1 Operational qualification......................................................................................................... 12-112.1.1 Start-up report............................................................................................................................ 12-1

12.1.2 Water pretreatment settings reports .......................................................................................... 12-6

12.1.3 Coarse filter and booster pump assembly settings report ......................................................... 12-6

12.1.4 Sand filter settings report........................................................................................................... 12-8

12.1.5 Activated carbon filter settings report ...................................................................................... 12-10

12.1.6 Softener settings report ........................................................................................................... 12-12

12.2 Maintenance ........................................................................................................................... 12-1412.2.1 Important information on maintenance procedures ................................................................. 12-14

12.2.2 Accessories and supplies for maintenance procedures .......................................................... 12-15

12.2.3 Maintenance report.................................................................................................................. 12-15

12.3 Tools and test equipment ..................................................................................................... 12-1912.3.1 Test equipment ........................................................................................................................ 12-19

13 Definitions

13.1 Definitions and terms .............................................................................................................. 13-1

13.2 Abbreviations........................................................................................................................... 13-1

13.3 Symbols.................................................................................................................................... 13-1

14 Appendix


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Chapter 1: Index

Fresenius Medical Care Service Manual SM-EN 1/03.11 1-1

1 Index

A Abbreviations 13-1 Activated carbon filter 10-1

Activated carbon filter

malfunctions overview 10-28

Activated carbon filter settings

report 12-10

Addresses 2-9

Alternating or parallel operation 9-24

Appendix 11-1, 12-1

B

Basic warnings 2-7

Biological hazards 2-8

Booster pump 5-1

Brief description 2-4

C

Chemical hazards 2-7

Coarse filter and booster pumpassembly settings report 12-6

D

Definitions and terms 13-1

Disclaimer of liability 2-6

Duties of the responsible

organization 2-5

E

Electric hazards 2-7Error messages on pumps 6-5

F

Feed water bypass 7-35

Feed water inlet unit 4-1

G

Guarantee / warranty 2-6

IImportance of the instructions 2-2Important information 2-1

Improved water quality 7-24

M

Maintenance intervals 11-9

Maintenance report 12-15

Manual regeneration 9-14

Manually starting the regeneration

9-21Media filters (sand filters / Birm

filters) 7-1

N

Note, significance 2-3

Notes 2-3

O

Operational data acquisition / daily

report 11-2Operational qualification 12-1

Operator information 2-5

Operator responsibility 2-6

P

Particle filter (Big Blue) 20" 8-1

Preface 2-1

Prefiltration rack with particle filter 4-10

Prefiltration unit 4-2

Pressure reducer 4-11

Pump malfunctions overview 6-6

Pumps 6-1

S

Sand filter malfunctions overview 7-33

Sand filter selection table 7-25,7-31

Sand filter settings report 12-8

Selection table activated carbon

filter (double) 10-25

Selection table activated carbon

filter (Single) 10-25

Softener 9-1

Softener capacities 9-48

Softener malfunctions overview 9-52

Softener selection table 9-49

Softener settings in case of high

brine concentration 9-3

Softener settings report 12-12Start-up report 12-1

Symbols 13-1

System handling instructions

report – Water pre-treatment 11-5

T

Target group 2-5

Technical documentation 2-6

Tip, significance 2-3

W

Warnings 2-7

Warnings, significance 2-3

Water pretreatment / BASIC 3-3

Water pretreatment / STANDARD 3-2

Water pretreatment component

overview 3-2, 3-3

Water pretreatment settings

reports 12-6


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Chapter 1: Index

1-2 Fresenius Medical Care Service Manual SM-EN 1/03.11


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Chapter 2: Important information


2 Important information

2.1 Preface

2.1.1 Structure of the Service Manual

This Service Manual contains a number of individual components or

overall concepts that are not products of Fresenius Medical Care

Deutschland GmbH.

Due to the standardization of documents, the structure for standardized

Service Manuals was applied to list the contents for service technicians

in their usual workflow.

Each component is therefore described in this Service Manual as an

individual device using the general structure.

When applying the master structure, empty chapters were omitted if the

chapter contents were not applicable.


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2.2 How to use the Service Manual

Identification The document can be identified by the following information on the titlepage and on the labels, if any:

– Edition of the document – Part number of the technical document

Page identification The page identification 1-3, for example, refers to Chapter 1, page 3.

Editorial information The editorial information 1/01.05, for example, refers to: 1st edition,January 2005.

Organization of thechapters

To facilitate the use of documents from Fresenius Medical Care, the

organization of the chapters has been standardized in all manuals.

There may therefore be chapters within this document without any

content. Chapters without content are identified.

Illustrations The illustrations used in the documents (e.g. screens, photos, etc.) maydiffer from the original if this does not have any influence on the

function.

Importance of theinstructions

This document is part of the accompanying documents and is an

essential part of the device. It includes information necessary for use,

programming and start-up of the device.

This document must be studied carefully before attempting to operate

the device.

Before the responsible organization may begin operating the device,

the individual responsible for the operation must have been instructed

by the manufacturer on how to use the device and must be thoroughlyfamiliar with the contents of the document.

The device may only be operated by individuals certificated to have

been instructed on the proper operation and handling of the system.

Changes Changes to the technical document will be released as new editions orsupplements. In general, this manual is subject to change without

notice.

Reproduction Reproduction, even in parts, only with written approval.


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2.3 Notes

2.3.1 Significance of the warnings

2.3.2 Significance of the note

2.3.3 Significance of the tip

Warning

Advises the operator that failure to observe this information can result

in personal injury.

Warning

Advises the operator that failure to observe this information can cause

damage to the equipment.

Note

Information alerting the operator to the fact that failure to follow the

steps as specified may result in the specific function not being executed

correctly, not being executed at all, or not producing the desired effect.

Tip

Information providing useful tips for easy handling.


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2.4 Brief description

Design BASIC /STANDARD

Components The water pretreatment may consist of the following individualcomponents

– Feed water inlet unit (single components A-F)

– Booster pump

– Media filter (sand filter / Birm filter)

– Particle filter (Big Blue)

– Softener

– Activated carbon filter

If necessary, additional modules can be connected upstream ordownstream for improved quality.

The water pretreatment components must be installed in a dry, dust-

free room. The responsible organization must ensure that the design

specifications of the pretreatment components comply with the

requirements of the other components used. This applies especially to

the following system components such as reverse osmosis system,

permeate ring main and dialysis systems.

As the complete system consists of separate, individual systems, the

responsible organization is responsible for the complete system.


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2.4.1 Operator information

Target group The water pretreatment may only be installed, operated and used byindividuals with the appropriate training, knowledge and experience.

Assembly, extensions, adjustments, modifications or repairs may onlybe carried out by the manufacturer or persons authorized by him.

Duties of the responsibleorganization

The responsible organization assumes the following responsibilities:

– Compliance with the national or local installation, operation, use and

maintenance regulations

– Compliance with the accident prevention regulations

– Correct and safe condition of the water pretreatment.

– Permanent availability of accompanying documents.

The water pretreatment consists of components designed to improve

the permeate conductivity and is extended with additional componentsto a complete water treatment system for use in a dialysis unit by the

responsible organization.

The water pretreatment must be installed in a dry room not reserved for

medical use. The staff call should also be connected. The responsible

organization must ensure that the technical adjustments of water

pretreatment match the requirements of the other components and that

they make up the complete system.

This applies especially to the following system components such as:

– Rooms with outlets and drains for the installation of the water

pretreatment

– Leakage protection systems

– Sampling site in the soft water supply line

– Sampling sites in the ring main system

– Alert systems for malfunctions (alarms)

– Operational organization

The components of the water pretreatment must be easily accessible

from all sides. The responsible organization must ensure that its

operators have been trained.

Operators of the water pretreatment, the reverse osmosis system and

the dialysis systems must have received instructions on how to operatethe system.

The responsible organization should inform the local water supplier of

the dialysis operation and insist on early provision of data regarding

water composition, availability etc.. This measure does not relieve the

responsible organization of its obligation to regularly check the feed

water composition.

Samples for microbial testing must therefore be collected from the

system and from the individual parts of the system in accordance with

the applicable regulations.


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As the water supply system consists of a series of smaller systems, the

responsible organization is responsible for the complete water supply

system.

Operator responsibility When entering parameters, the following must be observed:

– The parameters entered must be verified by the operator, i.e. the

operator must check that the values entered are correct. If the

verification reveals a deviation between the desired parameters and

the parameters displayed, the setting must be corrected before

activating the function.

– The actual values displayed must be compared with the desired

values specified.

Disclaimer of liability Should the responsible organization wish to use other consumablesand accessories than those listed in the accompanying documents, the

responsibility to ensure the correct function of the device lies exclusively

with the responsible organization. The applicable legal regulations mustbe complied with (e.g. in Germany the Medical Device Directive, MDD

and the MPBetreibV = German regulation for the operation of medical

products).

The manufacturer does not assume any responsibility or liability for

personal injury or other damage and excludes any warranty for damage

to the components of the water pretreatment resulting from the use of

non-approved or unsuitable consumables or accessories.

2.4.2 Guarantee / warranty

Guarantee The extent of the guarantee is stipulated in the respective purchaseorders.

Warranty The purchaser's warranty rights are governed by the applicable legalregulations.

Proper function of the water pretreatment components is guaranteed for

the period specified in the sale contract.

Any use of the device which is not in accordance with its intended use

will void any liability and warranty.

2.4.3 Technical documentation

On request, descriptions and other documents are made available by

the manufacturer. These are intended to support trained personnel of

the responsible organization in servicing and repairing the device.


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2.5 Warnings

2.5.1 Basic warnings

2.5.2 Electric hazards

,

2.5.3 Chemical hazards

Warning

The design of the water pretreatment components must comply with

the requirements of the Fresenius Installation Guideline (IGL)

Warning

Danger to life caused by electrical voltage.

Touching live parts will cause an electric shock.

– Before opening electrical devices, disconnect the power plug.

Actuating the ON/OFF switch stops operation of electrical devices,

but does not disconnect the system from the supply voltage!

Warning

The national standards and regulations must be observed when

connecting the system to the power supply system.

Warning

Use of protective equipments

Rubber gloves (acrylonnitril latex, cotton-lined) should be worn to avoid

contact of chemicals or disinfectant with the skin.

When working with acidic substances:

Wear goggles! Observe the safety precautions of the concentratedsubstance used!

In the event of contact with acid:

Eye: Immediately flush with gently flowing water for 15 minutes.

Skin: Use soap under flowing water for neutralization.

Ingestion: Do not induce vomiting, but have the person affected drink

plenty of still water. Seek medical advice.


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2.5.4 Biological hazards

Warning

The system may only be disinfected after previous consultation with the

manufacturer of the system or by personnel authorized by the

manufacturer.

Warning

Risk of infection

Observe the applicable local laws and regulations concerning handling

of potentially infectious material.


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2.6 Addresses

Please address any inquiries to:

Manufacturer Fresenius Medical Care AG & Co. KGaAD-61346 Bad Homburg

Germany

Phone: + 49 (0)6172 609-0

www.fmc-ag.com

Internationalservice

Fresenius Medical Care

Deutschland GmbH

Service Support International

Hafenstraße 9

D-97424 Schweinfurt

Germany

Phone: +49 (0)9721 678-333 (Hotline)Fax: +49 (0)9721 678-130

Localservice


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Chapter 3: Component overview


3 Component overview

3.1 Components of the water pretreatment system

The following pages show the two overviews of the BASIC and

STANDARD water pretreatment system.


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3.1.1 Water pretreatment component overview / STANDARD

F e e d w a t e r i n l e t u n i t

P r e f i l t r a t i o n – R a c k w i t h p a r t i c l e f i l t e r ( o p t i o n a l )

B i r m f

i l t e r

B o o s t e r p u m p

P a r t i c

l e f i l t e r B i g B l u e , 5 µ m (

2 0 “ )

S o f t e n e r

A

c t i v a t e d c a r b o n f i l t e r

A S t o p v a l v e

B W a t e r m e t e r ( o p t i o n a l )

C B a c k w a s h a b l e p r e f i l t e r 1 0 5 µ m

D S o l e n o i d v a l v e

E P i p e d i s c o n n e c t o r

F P r e s s u r e r e d u c e r

B 1 4 0

B 2 0 0

B 3 0 0

B 4 0 0

E 0 8 0

E 1 5 0

E 2 2 5 - T

E 3 0 0

E 4 0 0

A

0 5 0

A

1 0 0

A

1 5 0

A

3 0 0

A

4 0 0

S o f t w a t e r m o n i t o r i n g u n i t / A q u a S O F T

P a r t i c l e f i l t e

r B i g B l u e , 5 µ m (

2 0 “ )

F e e d w a t e r t a n k

T u b i n g

M e d i a f i l t e r

S a n d f i l t e r

S 1 4 0

S 2 0 0

S 3 0 0

S 4 0 0


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3.1.2 Water pretreatment component overview / BASIC

F e e d w a t e r i n l e t u n i t

P r e f i l t r a t i o n – R a c k w i t h p a r t i c l e f i l t e r ( o p t i o n a l )

B o o s t e r p u m p

S o f t e n e r

A

c t i v a t e d c a r b o n f i l t e r

A S t o p v a l v e

B W a t e r m e t e r ( o p t i o n a l )

C B a c k w a s h a b l e p r e f i l t e r 1 0 5 µ m

D S o l e n o i d v a l v e

E P i p e d i s c o n n e c t o r

F P r e s s u r e r e d u c e r

E 0 8 0

E 1 5 0

E 2 2 5 - T

E 3 0 0

E 4 0 0

A

0 5 0

A

1 0 0

A

1 5 0

A

3 0 0

A

4 0 0

S o f t w a t e r m o n i t o r i n g u n i t / A q u a S O F T

P a r t i c l e f i l t e

r B i g B l u e , 5 µ m (

2 0 “ )

F e e

d w a t e r t a n k

T u b i n g

B i r m f

i l t e r

B 1 4 0

B 2 0 0

B 3 0 0

B 4 0 0

M e d i a f i l t e r

S a n d f i l t e r

S 1 4 0

S 2 0 0

S 3 0 0

S 4 0 0


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25/230

Chapter 4: Feed water inlet unit


4 Feed water inlet unit

4.1 Component overview – wall-mounted prefiltration unit

Part number: Complete assembly – description

F00002261 BASIC Feed water inlet unit 1 1/4" (Inline operation)

F00001403 BASIC Feed water inlet unit 1" (Tank operation)

POS Description

A Stop valve

B Backwashable prefilter (105 µm)

C Solenoid valve

Note:

An additional leakage detector (6328611), which switches the solenoid valve, must be implemented.

D Pipe disconnector (Inline operation)

B C DA BA C

TANK OPERATIONINLINE OPERATION


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4.1.1 Prefiltration unit 1‘‘, 1 1/4‘‘, 1 1/2‘‘


F00001116 Prefiltration unit complete 1"

F00001117 Prefiltration unit complete 1 1/4“

F00001118 Prefiltration unit complete 1 1/2“

POS Description

A Stop valve

B Backwashable prefilter

C Solenoid valve (24 V)

D Pipe disconnector

E Particle filter (Big Blue) (5 µm); 20“

F Drain kit

G Duplex softener (option)

H Electronics unit

I Leakage sensor

F

B

E

G

A

C D

H

I


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4.2 Installation

4.2.1 Installation / start-up requirements

General information

4.2.2 Data reporting

Note

Start-up of the system must be performed by a trained technician. The

wiring must be adapted to fit the respective field of application.

Note

Prior to its start-up, check the system for damage caused during

transport. If there are signs of damage to the electric components, donot turn the system on.

Note

Reports for the items of the operational qualification listed beloware available as master copies in chapter 12:

– Start-up

– Setting

– Maintenance


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4.3 Specifications

4.3.1 Specifications / data sheet

Rated output of RO system Tank operation Inline operation Rack operation

Feed water path

Type, size

1 “ 1 1/4 “ 1 1/2 “

Rated flow 1.5m³/h

25 L/min

2.9 m³/h

48 L/min

5.8 m³/h

97 L/min

Peak performance during softener regenera-

tion

2.4 m³/h

40 L/min

4 m³/h

67 L/min

7.8 m³/h

130 L/min

Weight

Weight without rack 12kg empty;

~17 kg; operation

17kg empty;

~21 kg; operation

22kg empty

~27 kg; operation

Operating weight approx. Weight

~42 kg

Weight

~46 kg

Weight

~52 kg

Operating data

Kv 2.2 m³/h 2.5 m³/h 6.0 m³/h

Maximum pressure 8.0 bar 8.0 bar 6.8 bar

Ambient temperature 1–45 °C 1–45 °C 1–45 °C

Water temperature 1-36 °C 1-36 °C 1-36 °C

Voltage supply 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Floor space

Prefiltration rack

(HxWxD in mm)

1700 x 1200 x 800 1700 x 1400 x 800 1700 x 1500 x 800

Connections

Inlet and outlet 1 1/4 “

External thread

1 1/4 “

External thread

1 1/4 “

External thread


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4.3.2 Operating conditions

For information regarding the operating conditions refer to the latest

edition of the Installation Guideline (IGL).

4.3.3 Configuration options

Possible configurations:

– Configuration with AquaSOFT (see chapter 10)

– Automatic backwash function

– Timer


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4.4 Maintenance

Note

The information given below is summarized for all waterpretreatment components in Chapter 14 (Appendix).:

– Important information on maintenance procedures

– Accessories and supplies

– Test report - maintenance

– Overview / maintenance intervals for water pretreatment

components

– Explanations for the test report


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4.5 Functional description

4.5.1 Design of components

4.5.1.1 Water inlet unit

Standard configuration

The standard configuration of a feed water inlet path consists of the stop

valve, a backwashable prefilter, a solenoid valve, a pipe disconnectorand a drain connector.

4.5.2 Component function

4.5.2.1 Stop valve

The function of the stop valve is to stop the water supply for servicing to

perform maintenance procedures. The stop valve is provided with a

sampling port for the collection of feed water samples.

4.5.2.2 Water meter - optional

An optional water meter can be installed to document the water

consumption.

4.5.2.3 Backwashable prefilter 105 µm

The backwashable prefilter is installed in the feed water path upstream

of the solenoid valve to prevent contamination and therefore an early

failure of the solenoid valve.

Water inlet unit

Components:

A) Stop valve

B) Water meter (optional)

C) Backwashable prefilter (105 µm)

D) Solenoid valve

E) Pipe disconnector

F) Pressure reducer (optional)

F) Drain


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In its standard version, the backwashable prefilter has 105 µm filterinserts. As an option this prefilter can also be designed with a 50 µm filter insert.

As the first filter in the complete water pretreatment system, this insert

is usually exposed to a high concentration of particles. Regual

backwashing of the filter during non-dialysis hours must therefore be

ensured to prevent early pressure drops. This can either be done

manually (by turning the rotary pin 180° clockwise) or with the automatic

backwashing feature.

The automatic backwashing feature is available as an option. It should

always be used in combination with a timer to be able to define a fixed

backwash time.

4.5.2.4 Solenoid valve

Function The feed water inlet solenoid valve is used to disconnect the watersupply in case of a leakage. In case of rack installation it is activated bya single-station leakage detection or in case of wall-mounted installation

by a leakage detector.

Usage as tank fill valve In combination with a feed water tank, the feed water inlet solenoidvalve is also used as a tank fill valve. In this case, the solenoid valve is

controlled by a float switch which is supplied with the feed water tank.

Manual opening If necessary, the solenoid valve can be opened manually.

In case of a power failure push the lever in and turn it by 90°. In this po-sition it is automatically locked and the valve is permanently open.

Water supply is therefore still ensured even without power supply.

If the solenoid valve is manually bypassed, the room

must never be left unattended.Otherwise the valve must be left in its original position.

Normal condition

(original position)

Valve open

(manually bypassed)

Note

Without power supply, leakage monitoring is not active.

After dialysis hours, the valve should be closed again by unlocking to

stop the water supply in case of leakage.


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4.5.2.5 Pipe disconnector

If the inlet pressure drops, the pipe disconnector ensures a

disconnection from the system (DIN EN 1717) as requested by the

Drinking Water Decree if there is a risk of back-contamination.


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4.5.3 Prefiltration rack with particle filter (optional)

4.5.4 Component description

Stop valve (see chapter 4.5.2.1 , page 4-7)

Backwashable prefilter (see chapter 4.5.2.3 , page 4-7)

Solenoid valve (see chapter 4.5.2.4 , page 4-8)

Pipe disconnector (see chapter 4.5.2.5 , page 4-9)

Particle filter (Big Blue)5 µm

see chapter 8 (particle filter)

Drain kit The drain kit is used to direct the draining water to the drain in thebuilding.

Duplex softener (option) see chapter 9 (Softener)

Electronics unit The electronics unit supplies the connected components with electricalvoltage.

Leakage sensor The leakage sensor detects (inadvertent) water leakage. In this case,the connected valve is closed. An audible alarm and a red LED indicator

signal a leakage alarm.

Prefiltration rack with particle filter (optional)

Components:

– Stop valve

– Backwashable prefilter

– Solenoid valve (24 V)

– Pipe disconnector

– Particle filter (Big Blue) (5 µm); 20“

– Drain kit

– Duplex softener (option)

– Electronics unit

– Leakage sensor


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4.6 Options

4.6.1 Prefiltration rack with particle filter (option)

4.6.2 Pressure reducer - optional

An optional pressure reducer can be installed in the feed water path. Its

function is to avoid pressure peaks and thus to limit the system load. A

pressure reducer is recommended if the static pressure at the user

points exceeds 5 bar .

The installation of a pressure reducer is recommended in case of

variations in pressure caused be pressure increases / domestic water

supply system. As an option, a domestic water station can be used

instead of a backwashable prefilter. It includes the backwashable

prefilter and a pressure reducer unit.

4.6.3 Configuration options (feed water tank)

If a feed water tank is installed, it will have the requested system

disconnection. In this case the installation of a pipe disconnector is not

required.


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Chapter 5: Booster pump


5 Booster pump

5.1 Booster pump assembly CRN5-8 component overview


F00001935 Booster pump assembly (vertical pumps CRN5-8)

POS Description

A Connection to water supply(Possible on both sides. The connection which is not used must be provided with a cap nut)

B1 Pump 1 (vertical pump CRN5-8)

B2 Pump 2 (vertical pump CRN5-8)

C Control unit

D Pressurizer vessel

W2

A

B1

D

C


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5.2 Installation

5.2.1 Installation / start-up requirements

General information

5.2.2 Important start-up information

5.2.2.1 Booster pump assembly connection

The suction line can be connected either on the right or on the outer

left of the booster pump assembly. In case of tank operation it is

recommended to connect two suction tubes in parallel to avoid

pressure drops in the suction line.

The pressure port is located in the center and can be connected

using a tubing or a pipe for a fixed connection. A high-pressure

tubing is included in the accessories package of the system.

After connection to the water supply, both pumps must be ventilated

by opening the vent screws.

Note

Start-up of the system must be performed by a trained technician. The

wiring must be adapted to fit the respective field of application.

Note

Prior to its start-up, check the system for damage caused during

transport. If there are signs of damage to the electric components, donot turn the system on.

Booster pump assembly (CRN5-8)

The pumps must be ventilated prior to start-up of the switching unit.


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5.2.2.2 Connection to the domestic water supply network

Positioning the pressure switch

The pressure switch installed at the water inlet ensures protection

against running dry. Upon delivery, the pressure switch is set to 1 bar.

It is recommended to retain this setting. If the pressure in the water inlet

drops below 1 bar, the booster pump assembly will be stopped. If this

dynamic minimum pressure is not reached, it is recommended to use a

feed water tank.

Pressure switch installation position

Note

If a pipe separator or a pressure reducer is installed on the outlet side

of the booster pump, the pressure sensor must always be installed after

these components. For the installation, remove the screw-type adapter

in the outlet block and integrate it after the pipe disconnector.

State upon delivery: Dismounting the adapter

State upon delivery: When the system is supplied, the pressuresensor is installed with an adapter at the pump outlet, this adapter

must be removed and must be installed after the pressure reducer

and the pipe separator.

The pressure sensor is installed on the outlet side after the pressure

reducer and the pipe separator.

Pressure switch installation position and connection (run-dry protection)

Pressure switch installation position (run-dry protection)


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Booster pump assembly with pump switching

Pressure switch installation position and connection

Pressure switch installation position (after pipe separator and

pressure reducer)


Electrical connection of the pressure switch for the run-dry protection


Electrical connection of the pressure sensor


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Verification / setting of the pressure switch

Connection of the pressure switch

Pressure switch connection

Connection 1: white

Connection 2: brown

Pressure sensor connection

Pressure sensor connection Connection 1: brown

Connection 2: white

Reference point on the scale

Locate the reference point.


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Rotate the selector fully counter-clockwise.

The selector must first be rotated fully counter-clockwise.

Adjust the selector to the reference point.

Rotate the selector approx. ¼ of a turn clockwise until the figure "1"

is above the reference point.

Adjust the selector to the reference point.

Adjust the scale reference point.

The pressure switch is now set to 1 bar. This means the operatingpressure of the pump is 1 bar.

Due to the pressure switch's hysteresis, the switch-off pressure is

slightly below 1 bar (approx. 0.5 bar).


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5.2.2.3 Connection to a feed water tank

Note

In case of tank operation, the tank must be provided with a float switchwhich will open a contact if the tank is empty. This contact is connected

in the pump inlet instead of the pressure switch.

Tank connection

The inlet of the booster pump assembly is directly connected to the

outlet of the tank using the pump connection set no. 6319211.

The suction line can be connected either on the right or on the outer

left of the booster pump assembly.

In case of tank operation it is recommended to connect two suction

tubes in parallel to avoid pressure drops in the suction line. The pressure port is located in the center and can be connected

using a tubing or a pipe for a fixed connection. A high-pressure tubing

with a length of x cm is included in the accessories package of the

system.

The pressure sensor is connected directly to the pump outlet.

The inlet pressure switch on the water inlet side of the pump is not

used during tank operation. In its place the float switch (see

illustration) must be wired in. This must be done during installation.


A float switch which is installed in the feed water tank ensures run-

dry protection.

The brown and white conductor must be connected.


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Installation position of the pressure sensor on the pump outlet (state

upon delivery)

Electrical connection of the pressure sensor in the switching cabinet.


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5.2.2.4 Power supply

A 400 V; 3 N ~; 50 Hz; 16 A three-phase current connection is required

to supply the pump switching unit with voltage.

Connection of a leakage detector

The floating contact of a leakage detection system can be connected to

the booster pressure assembly. The contact must be closed if there is

no leakage and must open if a leakage occurs.

It is recommended to use the insert of the leakage detecting system. It

can be connected directly to the pump control (see illustration )

5.2.2.5 Overview of electrical connections

Connection option for a leakage detection system (jumper must be removed)

Remove the jumper and connect the line to the floating contacts of

the leakage detector.

Note

When the system is supplied, positions 1 to 6 are wired.

Positions 7 and 8 must be adjusted by the technician depending on

the respective situation (feed water tank or direct operation).


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POS Connections

1 Pump 1

2 Pump 2

3 Power cable

4 Temperature switch 1

5 Temperature switch 2

6 Pressure sensor

7 Connection for run-dry protection (pressure switch or float switch)

8 Connection option for the floating contact (e.g. leakage detector)

1 2 3 4 5 6

7

8


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5.2.2.6 Settings on the booster pump assembly (CRN5-8)

Should the booster pump assembly not operate as desired when it is

supplied, the setting of the pressure level and of the delay times can be

checked and changed.

Pressure levels

Pressuretype

Description

Pmin Operating pressure for base load and peak load pump (0-10 bar):

Pmin is set to the pressure at which the pump is to start.

Pmax1 Cutoff pressure level for the peak load pump (difference to Pmin), (0-4 bar):

If this pressure is achieved at parallel operation, the peak load pump is turned off. Pmax1 should

be set to a value between Pmin and Pmax2.

Pmax2 Cutoff pressure level for the base load pump (difference to Pmax1), (0-2 bar):

If this pressure is reached during operation of one pump, this pump is switched off. Pmax2

should be set to approx. 0.5 bar below the pump's nominal pressure.

Caution:If a pressure reducer was installed downstream of the booster pump assembly, the pressure

reducer should be set to 6 bar minimum as the pressure on the pressure sensor can otherwise

never reach the cutoff pressure.

Note

The settings of max1 and Pmax

2 are difference values which add to the

lower pressure set.


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Calculation example

Setting Pmin: 3 bar

Setting Pmax1: 2 bar

Setting Pmax2: 1 bar

This means Operating pressure level (Pmin) = 3 bar

Cutoff pressure level for peak load pump (Pmax1) = 5 bar

Cutoff pressure level for base load pump (Pmax

2) = 6 bar

Delay times

T = Over-run (0–2 min):

Minimum operation time of the pump to prevent permanent start and

stop of the pump. Default setting: 2 minutes. When set to "0 minutes",the minimum operation time is approx. 30 seconds.

T = run-dry delay (0–2 min):

time after which die pumps are turned off in case the pump runs dry.

Default setting: 0 minutes.

When set to "0 minutes", the delay time is approx. 10 seconds.

Motor protection

Potentiometers P1 and P2 are set to the nominal current of the motor.

Motor protection setting (nominal current of

pump 1 and pump 2)

Setting Pmax2: Cutoff pressure level for base

load pump (difference to Pmax1)

Setting Pmax1: Cutoff pressure for peak loadpump (difference to Pmin)

Setting Pmin: Operating pressure for baseload and peak load pump

Minimum operation time setting

Water alarm delay time setting


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5.2.3 Data reporting

Note

Documentation of the settings in the Settings report

As part of the Operational Qualification, the settings must be

documented in the Settings reports upon start-up.

Note

Reports for the items of the operational qualification listed beloware available as master copies in chapter 12:

– Start-up

– Setting

– Maintenance


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5.3 Specifications

5.3.1 Specifications / data sheet

5.3.1.1 Performance characteristics

Parameter Function / specifications

Usage Pressure increase

Component Booster pump assembly

Type CRN5-8

Connection 1 1/4", external thread

Sealing material Shaft seal carbon silicide, o-ring EPDM

Installation position Vertical

Operating current 2.5 kW / kVA

Power supply 380–400 V; 3N~ 50 Hz; 16A

Operating pressure, adjustable 1–6 bar (preset to x bar)

Switch-off pressure 1–6 bar (preset to x bar)

Pressure, minimum 2.2 bar (in case of tank operation)

Pressure, maximum 6.5 bar

Water temperature, minimum 1 °C

Water temperature, maximum 40 °C

Flow rate 5.7 m³/h at 3.8 bar (at a nominal pumping head of 37.8m)

Ambient temperature, max. 40°C

Parameter Function / specifications

Electrical connection 380–400 V 3N~ 50 Hz

Power consumption 2.5 kW / kVA

Operating pressure Adjustable 1–6 bar (preset to x bar)

Cutoff pressure Adjustable 1–6 bar (preset to x bar)

Dimensions (width/ height/depth) Width / height / depth 101 cm / 92 cm / 45 cm


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5.3.1.2 Volumetric capacity - diagram

5.3.2 Operating conditions

For information regarding the operating conditions refer to the latest

edition of the Installation Guideline (IGL).

(one pump active) (two pumps active)

Delivery volume

P u m p i n g h e a d


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5.4 Maintenance

Note

The information given below is summarized for all waterpretreatment components in Chapter 14 (Appendix):

– Important information on maintenance procedures

– Accessories and supplies

– Test report – maintenance

– Overview / maintenance intervals for water pretreatment

components

– Explanations for the test report


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5.5 Error messages

5.5.1 Malfunctions, causes and correction

Setting the system to the Standby mode

Components:

A) Operating mode selector switch

B) Operation / malfunction indicator (pump 1 and pump 2)

C) Run-dry / leakage indicator

D) Main power switch

Selection Description

Green LED flashing. The motor protection has operated. No automatic confirmation aftercorrection of the problem.

Possible causes:

– Motor current too high.

– The motor temperature is too high, possible defective pressure

sensor causing permanent operation and overheating of the pump.

Confirmation:

Set the operating mode selector switch to "OFF" and then back to

"ON" again. If necessary, allow the motor to cool down first.

Red LED illuminated System was turned off due to lack of water or leakage. Automaticconfirmation after correction of the problem.

B

D

C

A


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5.6 Functional description

5.6.1 Design of components

5.6.2 Component description

The booster pump assembly (CRN5-8) is an assembly which is ready

for connection in accordance with the requirements for the minimum

flow pressure with normal centrifugal suction pumps.

The booster pump assembly in conjunction with the two vertical pumpsprovides increased operational safety of a water treatment system from

Fresenius Medical Care.

The booster pump assembly is used for the alternating control of two

booster pumps. Automatic switching ensures uniform distribution of

stress on both connected pumps and prevents damage to the pump

caused by prolonged idle times when it is not in use. To increase the

efficiency, the second pump will be turned on additionally in peak

situations.

The booster pump assembly is intended for the pressure increase in the

feed water section of the water pretreatment system. It can be used

both for increasing the pressure downstream of a feed water tank andfor direct connection to the feed water line.

5.6.2.1 Control unit

The electronic control of the booster pump assembly controls and

monitors the two connected pumps.

Booster pump assembly (CRN5-8)

Components:

A) Feed water connection

B1) Pump 1 (vertical pump CRN5-8)

B2) Pump 2 (vertical pump CRN5-8)

C) Control unit

D) Pressurizer vessel

B2

D

C

A

B1


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5.6.2.2 Base load and peak load pump

The control differentiates between a base load and peak load pump. If

water requirements are low, only the base load pump will deliver, if

water requirements rise the peak load pump will also be switched on.

This concept has the advantage that the pumps are always operated intheir optimum performance range. This contributes to a high efficiency

of the complete system. The base load and the peak load pump will be

activated alternating after each restart. This ensures uniform wear of

both pumps.

5.6.2.3 Alternating pressure situations

If the system is not in operation and the pressure in the system drops

below the start-up pressure level (Pmin), the base load pump will start.

If the pressure drops again to the start-up pressure (Pmin) caused by

an increasing water demand, the peak load pump will also be started.If, with decreasing water demand, the pressure in the system rises

above the pressure level (Pmax 1), the peak load pump will be stopped.

If water consumption stops, the pressure will rise above the pressure

level (Pmax 2) and the basic load pump will be stopped.

5.6.2.4 Run-dry protection

The adjustable pressure switch at the booster pump assembly inlet

protects the system against running dry and ensures a minimum

pressure of 1 bar at the booster pump inlet.

If the pressure at the inlet drops below 1 bar, first the peak load pumpwill stop. If the pressure at the inlet remains below 1 bar after this pump

stop, the base load pump will also be stopped.

5.6.2.5 Tank operation

When operated with a tank, a float switch will be connected instead of

the pressure to ensure protection against running dry.

5.6.2.6 Automatic turnoff

The water temperature is also monitored; if the temperature exceeds

60 °C, e.g. by a defect of the control unit and a constantly running pump

without water consumption, the respective pump will be stopped.


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5.6.3 Functional description

5.6.3.1 Setting the system to the Standby mode

5.6.3.2 Selector switch functions

Setting the system to the Standby mode

Components:

A) Operating mode selector switch

B) Operation / malfunction indicator (pump 1 and pump 2)

C) Run-dry/leakage indicator

D) Main power switch

After turning on the main power switch and after selection of

automatic 1 + 2 (position as in illustration), the operating modeswitch is used to set the system to the Standby mode.

Functions of the selector switch

Components:

A) Test mode pump 2

B) Off

A) Test mode pump 1

D) Automatic mode pump 1

E) Automatic mode pumps 1 + 2

D) Automatic mode pump 2


Automatic mode pump 1 Only pump 1 runs in the automatic mode (e.g. if pump 2 is defective).

Automatic mode pumps 1+2 Both pumps run in the automatic mode. Depending on the consumptionvolume the pumps are started and stopped (default setting). The green

LED of the active pump is constantly illuminated to indicate operation.

Automatic mode pump 2 Only pump 2 runs in the automatic mode (e.g. if pump 1 is defective).

B

D

C

A

B

ED

A

F

C


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Test mode pump 1 Pump 1 runs irrespective of the prevailing pressures and safetyfunctions. The test mode will be automatically stopped after approx. 1.5

minutes.

Test mode pump 2 Pump 2 runs irrespective of the prevailing pressures and safetyfunctions. The test mode will be automatically stopped after approx. 1.5

minutes.

Off Both pumps are off.



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Manual Servicio Pretratamiento

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