mode d`emploi des concentrateurs modulaire 2000
Contents
1. Capacity model 80 160 GPH a 150 600 GPH 600 1000 GPH 114 Modular 2000 plus 10 Brix 1600 GPH Modular 2000 12 2400 3200 GPH Figure 9 Coupling table We suggest that you wash the filter every day you use your RO 11 A well lit well heated well ventilated isolated shelter for the machine should be planned in the saphouse The entrance door dimensions must be calculated according to the machine dimensions see section 5 1 The shelter should be heated prior to delivery and installation of the machine The durability of the electrical components will depend on the feeding quality Therefore it is very important to have your electrician check your installations to make sure that they comply with the local electricity code standards 2 YEARLY START UP All the following procedures can be made with spring water without Chlorine or well water as long as it is clean and does not stain Your machine has been filled with a glycol solution to prevent the membranes and other components from freezing The preparation of your system at the beginning of each season must be carried out in the following way Read the user s manual completely Call an electrician to connect the unit to an electrical source Connect the unit to the maple sap concentrate and filtrate basins Connect the filtrate pipe beneath the membrane Plug in the machine and rinse the unit following the same proc2. MODULAIRE 2000 OPERATOR S MANUAL FOR MODELS 1600 3200 GPH LEADER EVAPORATOR LTD 49 Jonergin Drive Swanton Vermont 05488 TEL 802 868 5444 www leaderevaporator com VERSION 2005 02 02 OPERATOR S MANUAL FOR A REVERSE OSMOSIS 2000 TABLE OF CONTENTS 1 MODULAIRE 2000 USER S MANUAL c ccccceceeceececceeceeeeceececcneeeeeeeeeceecaeeeeeeeeeeeeeneeeeeceeeeneneeees 5 VL INTRODUCTION WT 5 IM MM MM M 5 129r De ee ee MEM Mec iE 5 1 4 INSTALLATION sanieren 11 START UP eae wean 12 3 USER 5 GUIDE ei 13 3 1 CALCULATION OF SAP CONCENTRATION Pannen 16 3 2 MEMBRANE PERMEABILITY TEST 17 3 0 JANNUAL CEOSING PHOGEBSS ccce 18 PRESERVA ION SOLUTION See vsus to reno Ee E E een 19 3 5 ANNUALSTORAGE PROCESS ner ae 19 A MANUFACTURER WARRANTY EA 20 S EQUIPMENT DESCRIPTION unsinnig een een 21 Bil PHYSICAL DIMENSION S anne 22 23 PEREO URE E 24 54 MEMBRANE CASING an ee reelle lea ae iedis 25 35 READING zT UERSUM 26 0 ELECTRICAL BOARD nee 27 Sur DATA ee ee 28 APPENDIX 1 SERIAL EXPANSION KIT AND EXPANSION MODULE nzuauununnunnunnn
3. W O CO O Co IN O O NO O NO ER NO 8 N CO co co N co N co co O C1 Co O d co CO IN N O i OD 8 O O NO OD CO N CO C1 CO IN C1 OD CO CO N k CO i NO d RB C2 Ol G IN CO ID IO G O1 CO XJ o j O B CO gt O71 O1 O1 O1 O01 9 G NIN TN IN W JOLIN JO W no o N Go O N 9 lt N CO Co O1 gt IN iN OD O1 NO O O N C1 CO C1 NO O 00 00 co CO 19 18 9 8 5 4 D O CO CO CO co 1 354 14 1 397 Q3 O1 C O gt O CO 1 489 1 537 1 588 1 641 1 695 12 u 10 9 8 7 1 752 6 L6 EN 2 12 11 10 5 4 3 2 1 co Co CO Aes les S 218 9 MININ Co NI NO O 1 87
4. 1 p s Example 3 3 4 5 0 4 0 e 5 90 30 90 60 90 9 0 EN 1 NEN NENNEN Concentration calculation Concentration calculation rn x 5 Example 3 10 B Example 2 E Example 1 0 1 2 Concentrate Examples Permeate Example Figure 11 Data results Permeate flow Permeate flow Concentrate flow Hour flow 60 x permeate flow concentrate flow Concentration 100 x Here are three examples to facilitate your comprehension your machine treats 9 gom of permeate and you set the concentrate at 3 6 or 9 gom What will be the concentration percentage and the total flow of the machine Let us use the data sheet above NOTE GPM Gallons per minute 1 filtrate 9gpm and concentrate 3 gom Concentration 100 x 9 3 9 75 720 gallons per hour 2 filtrate 9 gom of concentrate 6 gom 16 Concentration 100 x 9 6 9 64 840 gallons per hour 3 filtrate 9 gom and concentrate 9 gom Concentration 100 x 9 9 9 50 1080 gallons per hour IT IS VERY IMPORTANT THAT YOU REMEMBER TO TAKE THIS DATA EVERY DAY YOU USE YOUR REVERSE OSMOSIS THIS WILL ENABLE YOU TO DETECT ANY OPERATIONAL DIFFICULTY 3 2 PERMEABILITY TEST OF MEMBRANES The filtration process and the membrane s performance vary depending on the type of membran
5. 3 1 938 NIN WwW O1 O1 O1 19 CO CO 00 CO O1 4 NO OO W 101 OINO N NO O co A IA I po P O S CO O O NO NO CO OO oO O DA O d CO CO CO CO CO CO CO CO O1 4 OO OO O INIO 68 66 _ 1 _34 The application formula is Corrected Flow GPH UO GPP app CONT hoop Corr desired Temp F We can take an example to illustrate the formula application with the table showed above You need to find out the flow of any unit at one temperature of 2 C 36 F for example You must take the flow value at 13 C 55 F as a base value and multiply by the correction factor value 1 4420 at this temperature Finally divide them by the correction factor value at the desired temperature Data Flow at 13 C 55 F 1600 GPH Temperature correction factor at 13 C 55 F 1 4420 and the desired temperature value 2 C 36 F So the correction factor value at this temperature is 2 0740 1600GPH 1 4420 2307 2 1112 GPH 2 0740 2 0740 Corrected Flow GPH 360 Figure 20 Correction factor sheet 37 APPENDIX 1 SERIAL EXPANSION KIT AND EXPANSION
6. 45 236 50 1 230 26 29 x34 x69 1x20 eee ee a OLTS AE118450 1 x 600 1 UD 5CV 26 AMP ZO RAL UE TZ 2 20 AE118475 1 x 600 400 1 097230 37 29 4 2 72 2 20 VOLTS AE32847 2 x 600 1000 3 CV i230 VAIN 44 AMP Bo TZ 2 20 VOLTS AE5384D75 3 x 600 1600 1200 5 CV 230 2 X 7 5CV 81 AMP 30 x73 x72 4X20 VOLTS AE5484D75 4 x 600 2000 1600 Tu 2 X 7 5CV 81 AMP 30 86 72 OLTS GETS OLTS OLTS AE7518675 E3 ds Bem 60 120 30 x73 x77 OLTS AE5286D75 2 x 800 1600 1200 5 CV 230 2 X 7 5CV 81 AMP 30 x54 x77 4X20 VOLTS AE75286D75 E3 2 x 800 1600 1200 5CV 230 2 X 7 5CV 90 120 30 73 77 4 20 VOLTS AE75286D75 E4 2 x 800 1600 1200 7 5CV 230 2 X 7 5CV 90 150 30 86 77 4 20 VOLTS AE75386T75 3 x 800 2400 1800 7 5CV 230 3 X 7 5CV 30 x73 x77 VOLTS AE75386T75 BE4 3 x 800 2400 1800 7 5CV 230 I v 120 150 30 x86 x77 6X20 VOLTS AE75486075 4 800 3200 2400 7 5 CV 1220 4 X 7 5CV 30 x86 x77 VOLTS Reverse osmosis with 2nd membrane in series to concentrate 10 brix level FT OF W x DEPTH x H FILTER SURFACE AE328475B 2 x 600 1000 L 7 3 CV 230 VOLTS 30 x54 x77 AE518418675B 1 x 1200 NE 5 CV 230 VOLTS TCV 30 x54 x77 2X20 EL x 800 AE75284286D75B 2 x 600 Ts 5CV 230 30 85 3 16 4X20 VOLTS 77 The average capacity for reverse osmosis machine is expressed in American gallons for sap concentration of 2 to 10 deg
7. 5 D24 Concentrate flowmeter This flowmeter calculates the concentrate flow The value in gallons per minute GPM is indicated on the reading panel D23 Permeate flowmeter As it comes out of the membrane the permeate is run directly through this flowmeter The flow value is indicated on the reading panel in GPM During the concentration process the liquid is directed to the permeate storage basin It is essential to know the permeate and concentrate flows to calculate the sap concentration percentage This calculation is detailed in section 3 1 CALCULATION OF THE SAP CONCENTRATION V1 Concentrate pressure regulating valve This valve controls the concentrate pressure The pressure increases as you tighten the valve and decreases as you loosen it J29 Pressure gauge membrane pressure It is this gauge which evaluates the concentrate pressure in the membrane It is possible for you to know the value of this pressure in psi simply by looking on the reading panel V31 Permeate sample valve This valve is located at the machine outlet more precisely on the manifold near the V3 and V4 valves You can know if the reverse osmosis process is performed correctly by analyzing the permeate For example if the membrane is damaged and therefore not able to retain all the sugar your permeate will be sweet V32 Concentrate sample valve Located at the machine outlet after the V4 valve this valve allows you to obtain a concentrate sam
8. INDICATOR 0 1000 PSI membrane pressure TIMER 0 60 MINUTES PERMEATE FLOWMETER CONCENTRATE FLOWMETER CONCENTRATE PRESSURE REGULATING VALVE V1 CONCENTRATE FLOW REGULATING VALVE V2 TEMPERATURE DISPLAY PRESSURE PUMP clear light FEEDING PUMP HIGH TEMPERATURE red light SELECTOR MAN STOP AUTO Figure 16 Reading panel 26 9 6 ELECTRICAL BOARD Etere SOs l koe bos Te 9 6 20 CODE QUANTITY DESCRIPTION 1 METER DIN RAIL 1 1 4 FOR ELECTRICITY 1150144 1 ELECTROD CONTROL SYRELEC PNR 220A 6 1150191 RELAY BASE 8 PINS OMRON 8 1151590 1 BARRIER TERMINAL 300V 12 TERMINALS 6 0 LONG _9 152121 1 98 BACKPLATE PAINTED FACADE 11 1150258 2 AUXILIARY CONTACT CB NO VERT TYPE 1150758 2 METERS DIN RAIL 1 1 4 FOR ELECTRICITY 151700 220 VOLTS DELAY 0 10 SECONDS OMRON Figure 17 Electrical board for 1600 gal The length varies according to the RO s capacity 21 gt gt here Many or these components as there are membranes 5 7 OPERATION DATA Your machine operation data has to be taken on every day of use These readings are essential to insure an efficient maintenance of your membranes They also help you detect operating problems immediately The readings have to be taken half an hour after the beginning of the concentration cycle Write down your observations in the following tables 1 Date date of the day you
9. L CLOSING PROCESS All of the following procedures can be made with spring water without Chlorine or well water as long as it is clean and does not stain Use as much permeate water as possible to store your machine 1 2 3 4 Rinse your machine with half the number of water gallons it can concentrate per hour Wash the machine with the amount of soap recommended and let the temperature raise up to 46 C 115 F Soap 4 ounces per membrane Rinse your machine with half the number of water gallons it can concentrate per hour Wash the machine with ACID and let the temperature raise up to 46 C 115 F The unit should soak as long as possible maximum 1 month 5 6 and 7 Do another rinse and wash soap cycle followed by another rinsing as you had done in the three first steps Do a permeability membrane test 8 Fill the washing basin just to half of its capacity with filtrate gt Concentrate the permeate at 200 PSI pressure Returning the permeate and concentrate to the washing basin To do that you must position the valves in washing soap cycle close valve V18 and adjust the pressure to 200 pounds Take down a reading of permeate flow when the temperature reaches 13 C 55 F This reading will indicate you the filtration capacity of your membrane only without imply another factor such as temperature biofilms or bacteria A permeability test at 21 C 70 F and 150 PSI will give you the same lecture
10. MODULE Figure 21 explains serial and parallel functioning The concentration percentage of the sap is shown The circles represent the recirculation pumps the rectangles represent the membranes and the arrows show the fluid course including recirculation Parallel functioning During this functioning Parallel mode the membranes concentrate the sap Serial simultaneously After going through the feeding pump all the liquid is divided according to the number of V27 valves that are open thus the number of pressure pumps in function serial functioning During this functioning 4 mode the sap is concentrated successively 8 2 2 by every membrane This option allows 29 higher concentration percentage of the sap Figure 21a Parallel functioning Figure 21b Serial functioning Expansion module Certain reverse osmosis can be provided with an expansion module which means that you can add one or more membranes accompanied by pressure pumps Those machines are already provided with a metallic support for this purpose Figure 21c Expansion module Serial expansion kit You can allow the production of a sweeter sap by adding a serial expansion kit This unit works in series with one of the machine s membranes The sap is thus concentrated two times rather than one The expansion kit can be placed beside the reverse osmosis since it is provided with a support of its own It can thus be added to machines that do not have an
11. N DATA ste acsi oo a 28 FIGURE 19 PRODUCTION SHEET FOR REVERSE OSMOSIS 35 FIGURE 20 CORRECTION FACTOR 37 FIGURE 21 SERIAL AND PARALLEL FUNCTIONING 38 FIGURE 22 SERIAL EXPANSION KIT 8 X 40 40 FIGURE 23 INSTALLATION DIAGRAM 1 22 222 220 200200020000000n0n 42 FIGURE 24 INSTALLATION DIAGRAM 2 nun nun nun ann mann nnnn 42 FIGURE 29 VALVES nee 43 Stable water basin The water passes through the membrane thus increasing the water level on the salted side YO NOsSVNO The water level also increases on the sweetened side Qo o0Ozszoo mo ZU TI ITI ZU The osmosis process is reversed when pressure is applied on the sweet salted side SAX OO SS Fig 4 Maple sap The reverse osmosis process is reproduced in the maple grove Figure I Osmosis and reverse osmosis 1 MODULAIRE 2000 USER S MANUAL CONGRATULATIONS You just acquired an Leader Evaporator reverse osmosis This proves your interest in new technologies and beautiful things In fact you have purchased a technologically advanced unit built by skilled professionals at LEADER EVAPORATOR COMPANY INC who bring many years of research to the
12. TEMPERATURE CONTROLLER Temperature 48 C 118 ELECTRICAL TESTS Dielectric test O Total Amperage Amps PROTECTION AGAINST FREEZING Density Temperature Salesman name Buyer s name Orderzi o o m Fill up in case of malfunction Our goal is to offer you an impeccable product This is why every REVERSE OSMOSIS machine is thoroughly inspected at the factory We ask that you help us improve our production methods by sending your comments to our production manager at this fax number 819 828 3408 Do not forget to send us the reverse osmosis production sheet with a description of the problems encountered and their causes We thank you in advance for your collaboration Comments Technician Date 36 Correction factor for FLUID SYSTEM 8921S membrane Machine capacity GPH corrected according to the temperature Corr T 150 300 45 1000 1600 1 000 4 1 030 140 1 061 5 1 096 1 1 126 8 1 161 1242 1987 _ 1 196 1 234 169 1870 1 272 68 1549 79 1406 51 1361 23 1317 96 1273 70 1232 44 1191 2 005 19 1151 2 074 95 1112 34 1 2 1470 101 201 302 403 470 537 672 1075 To calculate the capacity of your unit We suggest you to proceed in the following way D 1 Q O gt O N O O no AB d O O1 8 eme iN ho NO O BAIE Oo
13. TOMATIC OPERATI NG In the automatic operating mode the machine can start automatically when the sap basin is full and stop by itself when it is empty Manual adjustments have to be made first TIMER By setting the timer you choose your RO s operating duration You will find an image accompanied by a short description of the reading panel in section 5 5 The selector 11 is used for the manual and automatic operating The position of the washing timer 2 is also shown on this page 10 1 4 INSTALLATION All the Leader Evaporator modulaires concentrators are delivered with three way valves at the inlet and outlet of the machine The permeate and sap basin pipe ought to be connected to a filter figure 8 The latter must be connected to the V6 valve if this is not already done when you receive your machine The pipe diameter has to be equal to or greater than that of the filter installed on the machine see table below You must plan your connecting pipes to prevent restriction during the rinse and concentration cycles Watertightness of the feeding pipe must be checked to prevent vibrations which could cause pressure pump and membrane deterioration The table below shows the coupling dimensions Connect this end of the filter to the Figure 8 Filter Valve allowing the relief the air in the pipes Connect the sap and permeate pipe to this end This part can be unscrewed to clean the filter inside
14. V27 feeding valve of pressure pumps 10 Turn ON the switch button located over pressure switches 11 Position valves V35 on wash cycle horizontal 12 Position valves V34 on wash cycle vertical 13 Turn the switch on manual P S To fill up the wash barrel position V19 direction valve towards the barrel vertical only during the time it takes for the tank to fill up at the end of rinse cycle Soap wash 1 Position V6 inlet valve towards wash reservoir 2 Open drain valve V18 vertical 3 Position V19 direction valve vertical towards wash barrel 4 Position V3 permeate direction valve horizontal towards wash barrel 5 Position V4 concentrate direction valve horizontal towards manifold 6 Open in one turn pressure valve V1 and then open concentrate flow valve V2 all the way 7 Open V27 feeding valve of pressure pumps 8 Turn ON the switch button locate over pressure switches 9 Position valves V35 on wash cycle horizontal 10 Position valves V34 on wash cycle vertical 11 Position switch on manual mode 12 The temperature must reach 46 C 115 F 13 Proceed with rinse cycle immediately after the wash Recirculation wash 1 Turn off the faucet feeding sap reservoir 2 Turn on the faucet permeate feeding sap reservoir 3 Position V6 inlet valve towards permeate reservoir 4 Open drain valve V18 vertical 5 Position V3 permeate direction valve
15. aken when the unit was manufactured or after you first utilisation during the season You will evaluate in this way the permeability of your membrane This data will be your reference for other successive tests You are now ready to concentrate maple sap VVVVV VV VV WV 12 3 USER S GUIDE This manual was designed to help you work with your reverse osmosis All of these instructions are also printed on the front of your machine N B TO AVOID BREAKING THE UNIT MAKE SURE THAT THE PUMPS ARE FILLED WITH WATER BEFORE STARTING THE MACHINE PUMP NOTIN OPERATION If one pump is not in service you have to concentrate in parallel The valves V34 vertical and V35 horizontal must be positionned as indicated in the picture below see serial parallel Concentration all the pumps in operation 1 Turn off feeding permeate reservoir valve 2 Turn on feeding sap reservoir valve 3 Turn off drain valve V18 horizontal 4 Position concentrate three way valve V4 vertical towards concentrate reservoir 5 Position permeate direction valve V3 vertical towards permeate reservoir 6 Position inlet valve V6 in direction of sap reservoir 7 Open concentrate valves V2 8 Close pressure valves V1 9 Open V27 feeding valve of pressure pumps 10 Turn ON the switch button located over pressure switches 11 Position valves V35 on concentration cycle vertical 12 Position valves V34 on concentration cycle ho
16. collect the data 2 Sap density in Brix degrees 3 Concentrate density in Brix degrees 4 Concentrate flow measured by the concentrate flowmeter 5 Permeate flow measured by the permeate flowmeter 6 Water temperature for the water that is treated inside the reverse osmosis 7 Membrane pressure measured by the membrane pressure gauge goers Brix Flow GPM GPH 6 7 100x 4 4 5 ame ss En d ee IE 6june02 20 80 75 25 55 40 75 600 C Eo qoc qp ou Figure 18 Operation data 28 Density Brix Flow GPM GPH 4 5 6 7 100 4 4 5 60x 4 5 PERENNE p Density Brix Flow GPM Sap Conc Filtrate Conc F Degrees psi T Flow or GPH 1 2 3 4 5 6 7 100x 4 4 5 60x 4 5 Test 30 Density Brix Flow GPM GPH 4 5 6 7 100 4 4 5 60x 4 5 PERENNE p 31 Date E Brix F low GPM Lemp Pressure Concentrate Conc GPH pot 12 3 4 5 6 7 100x 4 4 5 32 Date E Brix F low GPM Lemp Pressure Concentrate Conc GPH pot 12 3 4 5 6 7 100x 4 4 5 33 Date E Brix F low GPM Lemp Pressure Concentrate Conc GPH pot 12 3 4 5 6 7 100x 4 4 5 34 Figure 19 Production sheet for reverse osmosis REVERSE OSMOSIS Membrane models Serial number Model Pump Motor a CONDUCTIVITY TEST Poesie pomene Coreene ns
17. d expansion module support There are two types of expansion kits the first is provided with a 8 x 40 membrane and the second with an 8 x 60 membrane The latter possesses a higher capacity which means it can concentrate more gallons per hour Figure 21 Serial and parallel functioning 38 Expansion kit components 1 8 1 2 x 40 envelope with 8 40 400pi ca membrane The envelope is the membrane s case 2 Recirculator support It is this support which allows the kit to be placed aside from the reverse osmosis 3 Turbo pump 3Hp 230V Since the liquid entering the kit is already pressurized enough the pump only allows the recirculation of this liquid 4 Magnetic starter This magnetic starter is set to forward the electricity from the electrical panel box to travel to the motor and turbo and execute the primary functions Stop Start 5 Inlet liquid pipe This pipe must be connected with the membrane output in the reverse osmosis 6 Concentrate pipe The concentrate pipe is set to forward the membrane concentrate to travel to the front panel via valve kit V18 7 Permeate outlet To collect the permeate you will have to install a pipe at the permeate outlet and be connected to the reverse osmosis front panel Membrane 8 x40 PVD1 for example 6 Hosealimentaire 01130205 _ Hose PVC reinforced 04210585 39 Figure 22a Expansion Kit WITH flowmeter 1 This b
18. e Figure 2a Functioning of the 1600 gal reverse osmosis Cancentrate mh Evaparatar Crain vB Fermegote Figure 2b Functioning with serial expansion kit see appendix 1 tra 4 i4 4 i 1 a 4 5 x 1 Overt JIN Me IX IX v18 E Il M J2 KT i x IN er 2 V2 d X x H bu Even if certain components appear in different quantities the functioning of the 6 1600 gal to 3200 gal reverse osmosis is the same V6 Inlet valve Three basins washing permeate and sap are connected to this three way valve located at the machine inlet The origin of the liquid entering the reverse osmosis unit is determined by the valve s position B20 Wash basin This basin located above the feeding pump stores the washing liquid The soap and recirculation washes are explained in the USER S GUIDE section Figure 3 Feeding pump P7 P7 Feeding pump All of the liquid entering your machine sap washing liquid or permeate goes through the feeding pump that gives it the impulse necessar
19. e exerted pressure on membrane sap temperature percentage of sugar in the concentrate and presence of other components such as bacteria biofilm and mineral salts Therefore it is important to maintain similar test conditions for all samplings To do so we recommend that you use the following method 1 Prepare a basin full of permeate obtained from sap concentration or from clear detritus free spring water 2 Rinse machine for 10 minutes with permeate so that only permeate remains inside 3 Fill the washing basin just to half of its capacity with filtrate 4 Concentrate the permeate at 200 PSI pressure Returning the permeate and concentrate to the washing basin To do that you must position the valves in washing soap cycle close valve V18 and adjust the pressure to 200 pounds 5 Take down a reading of permeate flow when the temperature reaches 13 C 55 F This reading will indicate you the filtration capacity of your membrane only without imply another factor such as temperature biofilms or bacteria A permeability test at 21 C 70 F and 150 PSI will give you the same lecture You can compare the permeate flow value with the one taken when the unit was manufactured 6 Compare the permeate flow value from your test no 5 to the same test made at the factory or when you operated your machine for the first time during the season You will then be able to establish the exact condition of your membrane 17 3 3 ANNUA
20. erine for one membrane 8 x 60 Of pr serve osmo Proceed in the following way 1 Valves positioned in washing soap cycle with the exception of valve V19 rinsing cycle 2 Drain the washing basin 3 Add the preservation solution 4 To reduce the solution in the basin to 4 inches bottom up Switch position in manual operation by 15 seconds period allowing in this way the starting of the priming pump without the action of the pressure pump 5 Valves position in washing soap cycle 6 Doa solution circulation for a period of 10 minutes Following the above steps drain the basin and the permeate output under the membrane housing 19 4 MANUFACTURER WARRANTY Reverse osmosis machines are guaranteed by their manufacturer against all workmanship defects for a period of two complete seasons starting on the installation date of the machine The manufacturer s responsibility regarding this warranty is limited to the repair or replacement of parts when he should consider it necessary to do so All replaced parts become the manufacturer s property Leader Evaporator Ltd shall not be held responsible for any damage or injury arising from negligence abuse improper handling or installation 20 5 EQUIPEMENT DESCRIPTION Your reverse osmosis unit includes the following components 5 1 PHYSICAL DIMENSIONS MEMBRANE CAPACTTY MEMBRANE FEEDING PRESSURE TOTAL DIMENSIONS FT OF SURF PUMP PUMP W x DEPTH x FILTER AE124
21. ess as for membrane rinsing with half the number of water gallons your unit can concentrate in an hour For example if your machine has an 8 inches membrane thus a 600 gallons per hour GPH capacity rinse it with 300 gallons of water Perform a washing without soap reaching a water temperature of 46 C 115 F Do a second rinsing cycle as soon as the washing cycle is finished Do a second washing without soap It is very important to reach the water temperature mentioned before Do another rinsing cycle as soon as the washing cycle is finished Do a third washing cycle this time adding the soap Make sure to reach a temperature of 46 C 115 F Do a final rinsing cycle with half the number of water gallons your unit can concentrate in an hour Carry out a permeability test of membranes Fill the washing basin just to half of its capacity with filtrate Concentrate the permeate at 200 PSI pressure Returning the permeate and concentrate to the washing basin To do that you must position the valves in washing soap cycle close valve V18 and adjust the pressure to 200 pounds 3 Take down a reading of permeate flow when the temperature reaches 13 C 55 F This reading will indicate you the filtration capacity of your membrane only without imply another factor such as temperature biofilms or bacteria A permeability test at 21 C 70 F and 150 PSI will give you the same lecture 4 Compare the permeate flow value with the one t
22. gt Compare the permeate flow value with the one taken when the unit was manufactured or after you first utilisation during the season You will evaluate in this way the permeability of your membrane If your membrane is clean continue on step 9 If you are not satisfied with the cleanness of your membrane you can pursue this process on step 4 or simply send back the membrane to be CLEANED at the factory Put 20 litres of permeate in the washing basin and 4 litres of glycol or glycerine Add a teaspoon of pr serve osmo and let the water flow for 15 minutes Then stop your machine and HEAT the room all year between 5 C and 10 C P S If the room is subject to FREEZING put 20 litres of glycol or glycerine for each 8 x40 membrane and 30 litres for each 8 x 60 membrane in the wash basin and let the liquid run inside the machine see annual storage with antifreeze and preservation solution 18 3 4 ANNUAL STORAGE WITH ANTIFREEZE It is possible to further insure adequate storage of your machine by storing it in a glycol and water solution and following instructions for the soap washing process Before carrying out the annual storage process you must be sure that the machine has been thoroughly cleaned 3 5 PRESERVATION SOLUTION This preservation solution will protect the machine against freezing during the winter months The below table presents you the way to proceed Glycol or glycerine for one membrane 8 x 40 Glycol or glyc
23. n under the wash basin The front drain under V19 valve must not be connected to the overflow on the back Fermeoste Entery into machine By way of v6 valve 42 Diagrams The figures 22 and 23 show possible installations for your reverse osmosis unit The installation on figure 22 allows you to wash and drain the basins while you are in concentration mode This will not be possible if you install your unit as shown on figure 23 The squares represent a top view of your basins The permeate that comes out of your machine must go back into the permeate basin and the concentrate basin feeds the evaporator On figure 22 each basin is connected to two pipes one linked to the drain and the other to the V6 valve On figure 23 a single pipe connects the basins to the V6 valve Basins You can add as many permeate and sap basins as you want That allows you to fill up a sap basin as soon as it becomes empty with permeate obtained from the concentration process Make sure that the basins are situated higher than the RO so that gravity will cause the liquids to run from the basins to the V6 valve Do not install level indicators on the pipes at the outlet of your basins This allows the air to enter the pipe system causing the machine to stop Valves On figure 22 it is suggested that you install two valves or one three way valve under your permeate and sap basins see figure 24 Make sure that your valves can be completely closed The
24. nunnunnunnunnnnunnunnunnnnnnn 38 APPENDIX 2 PIPE INSTALLATION SUGESTIONS zuauunununnunannunannunnnnunnnnunnnnunnununnununnunnnnunannunannunnnn 42 LISTE OF FIGURES FIGURE 1 OSMOSIS AND REVERSE OSMOSIS 2uu2u002u00nun0nunanunanunnnnnnnnnnunnnnnnnnnnnnnnnnnnnnnnnnnnnnn nenn 4 FIGURE 2A FUNCTIONING OF 1600 GAL REVERSE OSMOSIS eene eene nenne 6 FIGURE 2B SERIAL FUNCTIONING WITH EXPANSION KIT SEE APPENDIX 1 6 FIGURE 3 FEEDING PUMP an es 7 FIGURE 4 TEMPERATURE CONTROLLER 8 nn nnns FIGURE 5 PRE FIETER F9 ee 8 FIGURE 6 LOW PRESSURE CONTROL 11 8 FIGURE 7 MEMBRANE MS 9 FIGURE 8 FILTER ce M 11 FIGURE 9 COUPLING TABLE 5 a a ER 11 FIGURE 10 PICTOGRAM 13 FIGURE 1T DATA RESULTS ae 16 FIGURE 12 REVERSE OSMOSIS UNIT auch 22 FIGURE 13 PRE FILTER 10 MICRONS zu esses m ossa oux ca Doug se e 23 FIGURE 14 PRESSURE 24 FIGURE 15 MEMBRANE HOUSING en nie a ceto re 25 FIGURE 16 READING PANEL 252 22 24 as Ed ou iN e 26 FIGURE 17 ELECTRICAL BOARD FOR 1600 GAL Ir o bisous nd da yos 27 FIGURE OPERATIO
25. ox must be connected to some electrical source Therefore its very important to verify your installation with your electrical technician and verify the conformity with the electrical code local norms Your box must be connected with the motor pressure pump contactor in your reverse osmosis by an auxiliary contact see fig 1C This last item is normally open NO shipped to you with the kit box This last item is also supply with a contactor and time relay controller Also when the motor for the pressure pump starts the auxiliary contact will be closed connecting in this way your modular with the KIT 2 Concentrate pipe to be connected with valve V18 3 Input maple sap to be connected with the membrane output in the reverse osmosis 4 Permeate pipe to be connected with the permeate flowmeter output see fig 1B 5 Wire for the auxiliary contact The auxiliary must be installed in the contactor for the pressure pump seer fig 1 8 x40 600GPH 01260019 Flowmeter Kit 10GPM 01261011 8 x60 800GPH 01260439 Flowmeter Kit 20GPM 01261012 40 Figure 22b Expansion Kit WITHOUT flowmeter 1 This box must be connected to some electrical source Therefore its very important to verify your installation with your electrical technician and verify the conformity with the electrical code local norms Your box must be connected with the motor pressure pump contactor in your reverse o
26. ple before it is sent into the concentrate basin With this sample you will be able to note the difference made by a change of the concentrate flow on the concentration percentage and therefore you will be able to obtain the sweetness you want Concentrate basin After going through the valves flowmeters and gauges the concentrate is directed to a storage basin concentrate basin to feed the evaporator The company does not provide you with this basin V3 Permeate direction valve V4 Concentrate direction valve The direction taken by the liquid is determined by the three way valve position The black arrows indicate which ways the permeate V3 and the concentrate V4 can go V18 Drain valve There are as many drain valves as there are pressure pumps This valve is closed during the concentration process It is open while washing or rinsing V19 Direction valve This valve directs the water during washing or rinsing only V33 Check valve When a pressure pump and the membrane linked to it do not work this valve prevents the liquid from running back into the inactive components V34 Valve serial parallel V35 Valve serial parallel This are the valves that allows a configuration change between serial to parallel in your modulaire unit MANUAL OPERATING When selecting this operating mode you choose the starting time of your machine The feeding pump sill start first and then pressure pumps will start sequentially AU
27. rees brix at temperature of 55 F 21 DIMENSIONS FOR A 1600 GAL UNIT Height 77 Width 30 Depth 54 machine AEB286D75 See table of physical dimensions Pian Figure 12 Reverse osmosis unit 22 9 2 PRE FILTER A 10 microns filter is used to clear the liquid to be treated from any substance in Suspension e length 50 cm e diameter 6 5 cm Figure 13 Pre Filter 10 microns 23 5 3 PRESSURE PUMP A pressure pump is used to pressurize the liquid in order to obtain the desired filtration This pump has the following features MOTOR PRESSURE FLOW ELECTRICITY 208 230 440 and 600 volt three phase engines are available upon request Figure 14 Pressure pump 16GPM e a LIT ue il j Nu mber Description d 7 095006 SEAL RINGS NBR E 9 9500 03 INT CHAMBER t 11 095515 SPLIT CONE NUT EXE 120900 _ 12 SPLIT CONE Se 13 1050 51 IMPELLER 85 1000 90 UPTHRUST WASHER x LEN 80GPM aE Sik i Nu mber Description SN 7 2250 14 SEAL RING 8 1200 01 INTERMEDIATE BEARING 1 9 1250 05 INTERMEDIATE CHAMBER 11 120003 SPLIT CONE NUT fe 12 1200 02 SPLIT CONE 13 125003 IMPELLER AND WEAR RING 72 1200 05 IMPELLER WEAR RING J p n 80GPM 24 5 4 MEMBRANE CASING Each membrane is enclosed in a casing with the following feat
28. rizontal 13 Turn the switch on manual or auto 14 The machine will start sequentially 15 Adjust machine at required concentration with V2 valve by way of concentrate and permeate testing valves Membrane Sugar extracting 1 Turn off the sap reservoir feeding valve 2 Turn on the permeate reservoir feeding valve 3 Turn off drain valves V18 horizontal 4 Position concentrate three way valve V4 vertical towards concentrate reservoir 5 Position permeate direction valve V3 vertical towards permeate reservoir 6 Position inlet valve V6 in direction of sap reservoir 7 Open concentrate valves V2 8 Close pressure valves V1 9 Open V27 feeding valve of pressure pumps 10 Turn ON the switch button located over pressure switches 11 Position valves V35 on wash cycle horinzontal 12 Position valves V34 on wash cycle vertical 13 Turn the switch on manual 14 The machine will start sequentially 13 Rinse cycle 1 Turn off the faucet feeding sap reservoir 2 Turn on the faucet permeate feeding reservoir 3 Position V6 inlet valve towards permeate reservoir 4 Position V4 concentrate direction valve horizontal towards manifold 5 Position V3 permeate direction valve horizontal towards drain 6 Position V19 direction valve horizontal towards drain 7 Open drain valve V18 vertical 8 Open in one turn pressure valve V1 and then open concentrate flow valve V2 all the way 9 Open
29. s and membranes The switch button located on top of the grey box has to Bo turned on or else your pressure pump will not work ETC Figure 6 Pressure control C11 J10 Pressure gauge This gauge allows you to read the pressure at the filters outlet Should it drop below 12 psi 82 737kPa the machine will stop by itself P12 Pressure pump The filtered water is pressurized with the help of the pressure pump The lower part of the pump creates what is called recirculation This gives the sap the necessary speed to clean the membrane surface automatically during the sap concentration process The same thing happens to the washing liquid during the soap and recirculation washes M5 Membrane The sap is concentrated by the membranes resulting in a sweeter sap concentrate and treated water permeate The 1600 to 3200 GPH gallons per hour machines have a pressure pump for each membrane It is possible to add an expansion module like the one shown on figure 7 or a serial expansion kit to increase your reverse osmosis capacity see appendix 1 V2 Concentrate flow regulating valve As it comes out of the membrane the concentrate sets out for the reading panel reaching a flow regulating valve The flow will be measured by a flowmeter D24 You can adjust the concentration percentage by regulating the concentrate flow The sample valve V32 will allow you to determine the concentration that suits you Figure 7 Membrane
30. se valves will allow you to wash and drain a basin while you concentrate That way you will save a considerable amount of time Figure 25 Valves Two way valve Three way valve Basin Basin i on Drain RO 43 Drain WASHING AND TAKING CARE OF YOUR MEMBRANES 1 WHEN TO WASH THE MEMBRANES The filtration process and thus the membrane s performance vary depending on the type of membrane exerted pressure on membrane sap temperature percentage of sugar in the concentrate and presence of other components such as bacteria biofilm and mineral salts Therefore it is important to maintain similar test conditions in each sampling To do so we recommend that you use the following method 2 TESTING METHODS gt Fill the washing basin just to half of its capacity with filtrate gt Concentrate the permeate at 200 PSI pressure Returning the permeate and concentrate to the washing basin To do that you must position the valves in washing soap cycle close valve V18 and adjust the pressure to 200 pounds gt Take down a reading of permeate flow when the temperature reaches 13 C 55 F This reading will indicate you the filtration capacity of your membrane only without imply another factor such as temperature biofilms or bacteria A permeability test at 21 C 70 F and 150 PSI will give you the same lecture gt Compare the permeate flow value with the one taken when the unit was manufactured or after you fir
31. season To be efficient the Osmo acid soaking has to last at least 8 hours It can go on without damaging the membrane for up to one month The acid wash is carried out following the soap wash mode Reverse Osmosis operation lt A v Concentration Y Sugar removal in membrane Y Rinsing and is Recirculation Y Soap Sa diee Daily wash v Rinsing with permeate 12 hrs Y Soap wash Y Y Hinse Rinse A Y Permeability test 200 pds sq in YES NO Intensive wash cycle gt N Acid or oxydizing wash Rinse 20 min Soap wash 4 x40 8 40 8 x 60 Rinse 20 min Y Test 200 pds sq in Clean gt gt __ Membrane Soap Oxydizer Hydranautic PVD1 Dirty Filmtec NF70 BW30 Acid osmo Sani membrane membrane Er 2 Sani Oxy next day gt gt gt 45
32. smosis by an auxiliary contact see fig 2C This last item is normally open NO shipped to you with the kit box This last item is also supply with a contactor and time relay controller Also when the motor for the pressure pump starts the auxiliary contact will be closed connecting in this way your modular with the KIT 2 Concentrate pipe to be connected with valve V18 3 Input maple sap to be connected with the membrane output in the reverse osmosis 4 Permeate pipe link with the flowmeter permeate input see fig 2B between the flowmeter and membrane If needed change the flowmeter for a 20GPM capacity 5 Wire for the auxiliary contact The auxiliary must be installed in the contactor for the pressure pump seer fig 2C 8 x 40 600GPH 01260019 8 x 60 S00GPH 01260439 41 APPENDIX 2 PIPE INSTALLATION SUGGESTIONS This appendix contains ideas to help you use your RO easily and efficiently Fermeote pipe Concentrate AF VR NN Permeate or sap m Evaporator The overflow on the back is linked to the drain under the wash basin The front drain under V19 valve must not be connected to the overflow on the back Fermeate Drain Entery into machine by way of VB valve Figure 23 Installation diagram 1 Figure 24 Installation diagram 2 Fermeate pipe Concentrate Fermeate TW Evaparator The overflow on the back is linked to the drai
33. st utilisation during the season You will evaluate in this way the permeability of your membrane 3 WASHING FREQUENCY It is often difficult for the user to determine when and how to wash the membranes because the operating conditions vary according to many environmental factors We have thus established a simple and efficient method to keep your membrane clean without putting it through a lot of washes Otherwise it would wear out prematurely 4 SOAP WASH The soap wash is the key process to keeping your membrane clean This soap has been specially conceived to clean your membrane while providing the best capacity in gallons per hour longevity ratio This type of wash is efficient when the temperature reaches 43 C 110 degrees F but does not exceed 46 C 115 F because this could change its properties The recommended washing time is 30 to 45 minutes It is more important that you be sure to have the right temperature conditions and the right amount of soap increasing the soap wash time or using another soap th an sani osmo soap could destroy your membrane 5 RECIRCULATION WASH During this type of washing in recirculation mode the water contained in the permeate basin runs through the whole machine at the lowest possible pressure for 8 to 12 hours 6 ACID WASH The acid wash is a very important process to keep your membrane clean It helps getting rid of the biofilm and bacteria that develop when there are hotter periods in the
34. the pipe in a drain or a basin that can be emptied At the end of the RO wash put V4 valve in concentration position This will send the hot water from the wash into the concentrate pipe instead of the drain Repeat this procedure in rinse mode To do this operation close the valve V18 partially Sap and permeate basin valves The flow of those basins must be controlled by a valve situated under each one Figure 4 Temperature controller 58 S8 Temperature controller This controller evaluates the liquid s temperature as it penetrates the reverse osmosis The value is immediately displayed on a screen located on the reading panel The temperature must never exceed 49 Celsius 120 Fahrenheit The programming manual is available inside the reading panel LEVEL MODE SHIFT J28 Pressure Gauge This gauge measures the pressure provided at the feeding pump Its value is indicated on the reading panel V27 Pressure pump feed valve This valve permits or stops the water feed in the pressure pumps You can decide which pump will be functional since there is one valve for each pump F9 Pre filter The sap is filtered by a 10 micron cartridge This clears it from any substance in suspension Figure 5 Pre filter F9 C11 Low Pressure control This control ensures that the filters are not obstructed by dirt or micro organisms If such were the case the machine would stop by itself thus protecting the pump
35. ures e material stainless steel 01260826 0 1260119 0 1260473 0 1260019 01260439 01261011 01261012 01260023 01260732 e dimensions 125 x 20 cm ENVELOPE 5 FOR COMPLETE MEMBRANE 4 ENVELOPPE 8 1 2 40 STAINLESS STEEL ENVELOPPE 8 1 2 40 STAINLESS STEEL SERIAL EXPANSION KIT 8 X 40 600 GPH SERIAL EXPANSION KIT 8 X 60 800 GPH INCLUDES 1 MEMBRANE 8 x 40 or 8 x 60 ENVELOPE 8 5 x 40 or 8 5 x 60 stainless steel 1 SUPPORT TURBO PUMP 3 stainless steel MAGNETIC STARTER OPTIONS FLOWMETER KIT 10 GPM FLOWMETER KIT 20 GPM EXPANSION MODULE 8 X 40 FOR RO INCLUDES MEMBRANE 8 40 ENVELOPE 8 5 x 40 STAINLESS STEEL FILTER ENVELOPE COUPLING KIT EXPANSION MODULE 8 X 60 FOR RO INCLUDES MEMBRANE 8 x 60 ENVELOPE 8 5 x 60 STAINLESS STEEL FILTER HOUSING B These modules are made for EXP ANSIONABLE separ ators T he fl owmeters pressure gauges etc are not included KS SEE APPENDIX ON SERIAL EXPANSION KITS AND EXPANSION MODULES Figure 15 Membrane housing 25 5 5 READING PANEL The reading panels were designed to meet your needs They include the following items as standard equipment CODE 01090021 1 01090013 1 011501552 01260117 3 01260098 4 01260422 5 01260422 6 01151198 7 01150709 8 01153371 9 01150706 10 01153355 11 DESCRIPTION PRESSURE INDICATOR 0 300 PSI pre filters and feeding pump PRESSURE
36. use of reverse osmosis in maple syrup production 1 1 INTRODUCTION Reverse osmosis is a process by which a solution s natural tendency to scatter its components uniformly is reversed It occurs in the reverse osmosis because an applied pressure forces the water through a semi permeable membrane The water that does not pass through the membrane is left with all the sugar and thus called the concentrate 1 2 BACKGROUND The reverse osmosis process has been observed and studied for more than 250 years Father Nolet a French scientist carried out experiments on the osmosis phenomenon around 1748 The scientists have realized long ago that this process could be reversed and that many applications could flow from this research The principle of reverse osmosis has been applied to the desalination of water since the beginning of 1960 1 3 OPERATION How does it work This is probably the first question that came to your mind as you opened this manual The sap provided by maple trees is a solution containing mostly water 96 to 98 2 to 3 sugar and small quantities of mineral salts proteins and other elements such as aroma Sap is the solution in which you will increase the amount of sugar in relation to the quantity of water This will be done by extracting the water from the maple tree sap This separation process will give a more concentrated sap solution concentrate and the portion of water which has been subtracted from the sap permeat
37. vertical towards permeate reservoir 6 Position V4 concentrate direction valve horizontal towards manifold 7 Open in one turn pressure valve V1 and then open concentrate flow valve V2 all the way 8 Open V27 feeding valve of pressure pumps 9 Turn ON the switch button located over pressure switches 10 Position valves V35 on wash cycle horizontal 11 Position valves V34 on wash cycle vertical 12 Position switch on manual mode 13 Proceed with rinse cycle immediately after the wash 14 SERIAL PARALLEL PUMP NOT IN OPERATION If one pump is not in service you have to concentrate in parallel The valves V34 vertical and V35 horizontal must be positionned as indicated in the picture below see serial parallel SERIAL Concentration Place the direction valves V34 horizontal position and V35 vertical position as indicated in the picture below In this position the membrane s unit will work in serial concentration PARALLEL Wash Rinse Sugar extracting Place the direction valves V34 vertical position and V35 horizontal position as indicated in the picture below In this way the membrane s unit will work en parallel Figure 10 Pictogram 15 3 1 CALCULATION OF SAP CONCENTRATION The concentration percentage is calculated in terms of the permeate and concentrate flows Operation data Conc Flow GPH re i 6 7 100x 4 4 5 60x 4 5 720 C 1080
38. y to pursue its way inside the reverse osmosis Sap and permeate basins The sap basin contains the maple tree sap The permeate basin is filled with the water extracted from the sap during the concentration procedure We recommend that the sap and permeate basins be connected with a common feeding pipe connected directly to the inlet valve V6 of your machine We also recommend that the permeate basin be able to contain at least twice the modulaire s capacity It is preferable to place the maple sap and permeate basins in such a way that gravity will cause the liquids to run By doing this you will not have to provide your machine with an additional pump pushing the fluids up to the V6 valve Please note that the sap and permeate basins are not supplied by the company Sap and permeate pipes Return lines have to be installed up to the permeate and concentrate basins These lines must be emptied Here is a suggestion that will help you proceed Place the V19 valve in rinse position V3 and V4 valves half way between two positions at a 45 degree angle The V6 valve must be in soap washing position This will send all liquid in the pipes to the drain You must be able to get these lines out of the basins so that the liquid contained in those basins is not drained during the process By following the paragraph below it will be possible to wash the sugar residues from the concentration pipe Here is a way of doing it First of all make sure to install
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