Millipore Water Filtration Instructions

AFS®-8 AFS®-8D AFS®-16 AFS®-16D

User Manual

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D ii

Notice

The information in this document is subject to change without notice and should not be construed as a commitment by Millipore Corporation. Millipore Corporation assumes no responsibility for any errors that might appear in this document. This manual is believed to be complete and accurate at the time of publication. In no event shall Millipore Corporation be liable for incidental or consequential damages in connection with or arising from the use of this manual.

We manufacture and sell water purification systems designed to produce pure or ultrapure water with specific characteristics (mS/cm, T, TOC, CFU/ml, Eu/ml, etc...) when it leaves the water purification system provided that the systems are fed with water quality within specifications, and properly maintained as required by the supplier.

We do not warrant these systems for any specific applications. It is up to the end user to determine if the quality of the water produced by our systems matches his expectations, fits with norms / legal requirements and to bear responsibility resulting from the usage of the water

Copyright

Copyright © 2003, all rights reserved, Millipore Corporation. Documentation : PF08616 (Rev 2 - 11/05) CD-ROM : PF08884 (Rev 2 - 11/05) Manufacturer: Millipore S.A.S., 67120 Molsheim, France

Trademarks

Millipore is a registered trademark of Millipore Corporation. AFS, Millipak, Millex and Q-Gard are registered trademarks of Millipore Corporation. Progard and RoClean are trademarks of Millipore Corporation. Teflon is a registered trademark of E.I. du Pont de Nemours & Co. All other trademarks are trademarks of their respective manufacturer.

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D iii

Warranty

Millipore Corporation («Millipore») warrants the products manufactured by it against defects in materials and workmanship when used in accordance with the applicable instructions for a period of one year from the date of shipment of the products. MILLIPORE MAKES NO OTHER WARRANTY, EXPRESSED OR IMPLIED. THERE IS NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

The warranty provided herein and the data, specification and descriptions of Millipore products appearing in Millipore’s published catalogues and product literature may not be altered except by express written agreement signed by an officer of Millipore. Representations, oral or written, which are inconsistent with this warranty or such publications are not authorized and if given, should not be relied upon.

In the event of a breach of the foregoing warranty, Millipore’s sole obligation shall be to repair or replace, at its option, any product or part thereof that proves defective in materials or workmanship within the warranty period, provided the customer notifies Millipore promptly of any such defect. The exclusive remedy provided herein shall not be deemed to have failed of its essential purpose so long as Millipore is willing to repair or replace any nonconforming Millipore product or part. Millipore shall not be liable for consequential damages resulting from economic loss or property damages sustained by a customer from the use of its products.

However, in some states the purchaser may have rights under state law in addition to those provided by this warranty.

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D iv

DECLARATION OF CONFORMITY

EUROPEAN UNION EC DIRECTIVES

Directive 89/336/CEE

Directive 73/23/CEE

AFS® 8-8D-16-16D

♦ The system mentioned above is manufactured in Millipore SAS - 67120 Molsheim - FRANCE -facilities whose quality management system is approved by an accredited registering body to the ISO9001 Quality System Standards.

♦ We certify that these Lab Water Systems are designed and manufactured in application of the following European Council directives :

- 89/336/CEE relating to Electromagnetic compatibility

- 73/23/CEE relating to electrical equipment designed for use within certain voltage limits

♦ Standards to which conformity is declared as applicable are the following :

- EN 55022 Class B: 1998: Limits and method of radio-disturbance characteristics of information technology equipments

- EN 50082-1: 1997: Electromagnetic compatibility: generic immunity standard

- EN 61000-3-2 Edition 1995/ A1 and A2 EDITION 1998/ A14 Edition 2000: Limits for harmonic current emissions (equipment input current up to and including 16A per phase)

- EN 61000-3-3 Edition 1995: Limitation of voltage fluctuation and flicker in low-voltage supply systems for equipment with rated current of 16 A.

- EN 61010-1: 1993 /A2: 1995: Safety requirements for electrical equipment for measurement, control and laboratory use.

Guy REYMANN

Quality Assurance Manager

Millipore SAS

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D v

Directive 2002/96 EC: For European users only

The symbol “crossed bin” on a product or its packaging indicates that the product should not be treated like household waste when discarded. Instead the product should be disposed of at a location that handles discarded electric or electronic equipment.

Proper disposal of equipment containing electric or electronic components will help to reduce pollution effects to the environment or to human health. Proper recycling of these products helps in environmental preservation and helps to protect natural resources. For more information about recycling of products containing electric or electronic components, please contact your local recycling representative or organisation.

TABLE OF CONTENTS

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D vi

CHAPTER 1 INTRODUCTION .............................................................................1 1-1 USING THIS MANUAL ................................................................................................................. 1 1-2 GENERAL INFORMATION............................................................................................................. 2 1-3 FLOW SCHEMATIC .................................................................................................................... 2 1-4 OPERATING PRINCIPLE ................................................................................................................ 3 1-5 SPECIFICATIONS....................................................................................................................... 3

Electrical specifications .................................................................................................................. 3 Water connections ....................................................................................................................... 3 Feed water requirements * ............................................................................................................. 4 Environmental Specifications ........................................................................................................... 4 Product Water Quality and Product Water Flowrate Specifications ......................................................... 4 Dissolved Gas Based Upon the Measured Oxygen (O2) Content (AFS-8D and AFS-16D) ........................... 5 Dimensions and Weight ................................................................................................................ 5

1-6 CONTACTING MILLIPORE ............................................................................................................ 6 Internet and Email ......................................................................................................................... 6 Manufacturing Site........................................................................................................................ 6

CHAPTER 2 OPERATION ..................................................................................7 2-1 USING THE SOFTWARE ............................................................................................................... 7

OPERATE / STANDBY Button ......................................................................................................... 7 MEASURE Button .......................................................................................................................... 8

Measurements when in FILLING TANK or TANK FULL mode ................................................................................ 8 Measurements in PRODUCTION mode (Water is being sent to the analyzer).......................................................... 8

CLEANING Button........................................................................................................................ 8 MENU Button .............................................................................................................................. 9

CHAPTER 3 MAINTENANCE............................................................................11 3-1 INSTALLATION AND REPLACEMENT OF CONSUMABLES .........................................................................11

Progard Pretreatment Pack .............................................................................................................11 Q-Gard A Cartridge................................................................................................................... 12 Bacteria Filter............................................................................................................................. 13

Millipak ................................................................................................................................................... 13 Simfilter .................................................................................................................................................... 13

Installing the Millex Tank Vent Filter on the 10 Liter tank ...................................................................... 14 Cleaning of the Screen filter.......................................................................................................... 15

3-2 ROUTINE MAINTENANCE.......................................................................................................... 15 Chlorine Sanitization of the reverse osmosis cartridge ........................................................................ 15 pH cleaning of the reverse osmosis cartridge ................................................................................... 16

TABLE OF CONTENTS

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D vii

CHAPTER 4 TROUBLESHOOTING......................................................................17

CHAPTER 5 ORDERING INFORMATION..............................................................21 REFERENCE INFORMATION FOR AFS SYSTEMS:............................................................................................21

CHAPTER 6 APPENDIXES ................................................................................22 APPENDIX A INSTALLATION ...............................................................................................................22

Unpacking .................................................................................................................................22 Installation of the system................................................................................................................23

Installing the elbow connectors......................................................................................................................23 Connection of the Inlet (Feed) Tubing .............................................................................................................23 Connection of the Reject Tubing ....................................................................................................................23 Connections between the AFS and the 10 Liter tank..........................................................................................23 Overflow Tubing ........................................................................................................................................24 Connection of the Tank Level Switch to the AFS................................................................................................24 Connection of the electrical power to the AFS..................................................................................................24 Fixing the Emergency Kit Tubing ....................................................................................................................25 Bench mounting the AFS and 10 Liter tank ......................................................................................................25 Wall Mounting the AFS and 10-Liter Tank ......................................................................................................26 Connection between the AFS and the analyzer ................................................................................................26 Installing the Simfilter ...................................................................................................................................27 Installing the Millex Vent Filter onto the 10 Liter tank ..........................................................................................27

Starting the System for the First Time ................................................................................................28 APPENDIX B EMERGENCY KIT PROCEDURE.............................................................................................30 APPENDIX C ADJUSTING THE VACUUM LEVEL (AFS-8D AND 16D SYSTEMS ONLY) ..............................................31 APPENDIX D DAILY MAINTENANCE LOG SHEETS.......................................................................................33 APPENDIX E MONITORING BACTERIA LEVELS IN WATER ..............................................................................36 INDEX .........................................................................................................................................37

INTRODUCTION

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 1

Chapter 1 INTRODUCTION

1-1 USING THIS MANUAL This manual is for the Analyzer Feed System 8 and 16 (AFS® 8, 8D, 16, 16D). AFS will be used to refer to the AFS – 8, AFS – 8D, AFS – 16, and AFS – 16D system unless specified in the text. Please review the manual before using the system. The INSTALLATION section is located in Appendix A. Since the INSTALLATION section is normally used only one time, this will provide quicker access to the Operating and Troubleshooting sections in the future. There are locations in the text which refer the user to certain Figures. These are located at the end of the manual.

These “warning” symbols are placed at certain points of the manual to draw your attention to actions where a risk of damage to the system or possible personal injury can occur.

Safety Symbols found in this manual or on the Water System Cabinet:

Symbol What it means

This HAZARD symbol is used to refer to instructions in this manual that need to be done safely and carefully.

This ATTENTION symbol is used to refer to instructions in this manual that need to be done carefully.

This DANGER sticker is used to refer to a position on the AFS System Cabinet or inside of it that could be hazardous.

This ELECTRICAL GROUND sticker is used to refer to a position on the AFS System Cabinet or inside where an electrical ground connection is made.

This ELECTRICAL DANGER sticker is used to refer to a position on the AFS System Cabinet or inside where an electrical danger could exist.

!

INTRODUCTION

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 2

1-2 GENERAL INFORMATION The AFS is a water purification system that produces NCCLS Type I Product Water directly from potable tap water. These parameters are listed in the table below. The system combines Reverse Osmosis (RO) and Ion Exchange technology to accomplish this. The product water then feeds the analyzer directly, without any extra user interaction. A flow schematic is shown in the following section.

The AFS system is designed to produce NCCLS Type I quality water. NCCLS Type I water guidelines are as follows:

Parameter NCCLS/CAP Specification for Type I Water

Maximum Bacterial Content ≤ 10 CFU/ml *

Minimum Resistivity 10 MΩ-cm **

Maximum Silicate Level ≤ 0.05 mg/L

Particulate Matter 0.22 micron filter

Organic Contaminants Activated carbon*** or Reverse Osmosis or Distillation

pH Not Specified

* CFU/ml = Colony Forming Units per ml ** MΩ.cm = Megohm.cm compensated to 25 °C *** Not required by CAP NCCLS stands for the National Committee for Clinical Laboratory Standards CAP stands for the College of American Pathologists

1-3 FLOW SCHEMATIC A simplified flow diagram is shown below for the AFS System.

TAPWATER

PROGARDPRETREATMENT

PACK

ROPUMP

DISTRIBUTIONPUMP

QGARD ACARTRIDGE

BACTERIAFILTER

PRODUCTWATER

RO

RO REJECT

10 LTANK

DEGASSER(AFS-8D & 16D)

INTRODUCTION

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 3

1-4 OPERATING PRINCIPLE Potable tap water enters the Progard 3 Pretreatment Pack. The Progard 3 is used to prevent mineral scaling, organic fouling and chlorine oxidation of the Reverse Osmosis (RO) cartridge. The Progard 3 is a consumable item. The RO Pump is used to boost the tap water pressure. This will create more permeate flow from the RO cartridge. The RO cartridge removes a large percentage of ions from the tap water. In addition, a large percentage of bacteria and organic material is removed by the RO cartridge. The RO has a waste (reject) stream which is directed to drain. All ions, bacteria and organic material removed by the RO are directed to the waste stream. The permeate flow from the RO is stored temporarily in the 10 Liter (L) Tank.

When AFS Product Water is sent to the analyzer, the water pressure in the tubing between the AFS and the analyzer will decrease. A pressure switch located inside the AFS will sense the drop in pressure and turn on the Distribution Pump. This pump is used to send water from the 10 L tank through the Q-Gard A Cartridge, Degasser, and the Bacteria Filter. The Q-Gard A Cartridge contains ion exchange resin and other purification media which remove trace ions and trace organic molecules from the water stored in the 10 L Tank. The Q-Gard A Cartridge is a consumable item. The Degasser is an item that removes trapped gas found in the product water. The Bacteria Filter is a consumable item that removes bacteria and any particles larger than 0.05 µm in the Product Water.

NOTE: Millipore water systems are designed to stay in operation mode and will perform best as such. The systems should be placed in Standby mode or switched off ONLY for maintenance or repairs.

1-5 SPECIFICATIONS ELECTRICAL SPECIFICATIONS

100 ± 10% VAC 50/60 Hz main fuse: 2.0 Amp T (Time Lag) (5x20mm) Power: 70 VA

120 ± 10% VAC 60 Hz main fuse: 2.0 Amp T (5x20mm) Power: 70 VA

230 ± 10% VAC 50/60 Hz main fuse: 1.0 Amp T (5x20mm) Power: 70 VA

Internal Fuses (All Systems): 1.0 Amp T (5x20mm) (All Internal Fuses must be replaced by authorized Millipore personnel only)

The electrical source must be located within 1 meter (m.) from the system. The electrical source must also be earth grounded.

WATER CONNECTIONS Feed water connection (Customer Must Supply Connection To This Fitting) Feed water tubing Reject tubing - Maximum height of Reject tubing Product water tubing Product Line Drain Valve tubing Emergency Kit tubing Drain capacity

1/2 inch Female National Pipe Thread (FNPT) 8 millimeters (mm) outer diameter (OD), length: 2 meters (m) maximum (6.5 ft. (feet)) 8 mm OD, length: 4 m. maximum (13 ft.) Cannot exceed 1 m (3 ft.) above system 6 mm OD, length: 2.0 m. maximum (6.5 ft.) 6 mm OD, lentgh: 2.0 m. maximum (6.5 ft.) 8 mm OD, length: 2.5 m. maximum (8 ft.) 120 liters per hour (LPH)

INTRODUCTION

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 4

FEED WATER REQUIREMENTS *

Minimum pressure and flowrate 1.5 bar (22 psi) at 120 LPH ** Maximum feed water pressure 3.0 bar (50 psi) Conductivity < 2000 µs/cm Temperature 2 - 35 °C (35.6 - 95 °F) pH 4 - 10 Fouling Index (SDI) < 5 Total chlorine ≤ 1.0 ppm without PrePak < 3 ppm with PrePak

* The pretreatment pack (Progard 3) has been developed to be fed with potable water meeting the specifications above. Additional pretreatment or pre-filtration may be necessary when these levels are exceeded or due to specific local water characteristics. Call Your Local Millipore Office for additional information.

** Call Your Local Millipore Office if the Tap water pressure is below 1.5 bar (22 psi) at 120 LPH

ENVIRONMENTAL SPECIFICATIONS

Indoor Use Only

Storage Temperature 5 °C < T < 40 °C

Operating Temperature 5 °C < T < 40 °C

Relative Humidity Should not exceed 80% for temperatures below 31 °C Should stay within 50% to 80% between 31 °C and 40 °C.

Altitude < 3000 metres

Installation Category II

Pollution Degree 2

PRODUCT WATER QUALITY AND PRODUCT WATER FLOWRATE SPECIFICATIONS

Ionic rejection

Typ. - Min.

Rejection Of

Particles

Rejection of micro-

organisms

Rejection Of

Organics Silica

Maximum Bacterial Content

Resistivity

97 % - 94 % > 99 % > 99 % > 99 % for MW > 100

> 99 % rejection

≤ 0.05 mg/L ≤ 10 CFU/ml >10 MΩ-cm

@ 25° C

INTRODUCTION

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 5

The specifications shown above are dependent on the maintenance and operating status of the RO membrane.

Reject Flow Rate 7 °C < T < 30 °C

Peak Dispensing rate of Product Water (to atmosphere)

Maximum Product Pressure

AFS 8(D) – 20 LPH

AFS 16(D) – 25 LPH Up to 0.6 Liters per minute for 18 minutes AFS 8D, 16D – 1 bar (15 psi)

AFS 8, 16 – 2 bar (30 psi)

DISSOLVED GAS BASED UPON THE MEASURED OXYGEN (O2) CONTENT (AFS-8D AND

AFS-16D) Adjustable down to approximately 3 parts per million (ppm).

DIMENSIONS AND WEIGHT Height Width Depth Dry Weight Operating Weight (Filled with water)

455 mm (18 in) 255 mm (10 in.) 500 mm (19.7 in.) 15 kg (33 lbs) and 1.1 kg (2.4 lbs) for the tank 19 kg (41 lbs) and 11.1 kg (24.5 lbs) for the tank

INTRODUCTION

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 6

1-6 CONTACTING MILLIPORE INTERNET AND EMAIL

The Millipore Internet Site can be used to find addresses, telephone/fax numbers, and other information.

Internet Site Address: www.millipore.com

www.millipore.com/techservice

MANUFACTURING SITE Millipore SAS

67120 Molsheim

FRANCE

OPERATION

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 7

Chapter 2 OPERATION

2-1 USING THE SOFTWARE The keypad (Figure 1, A) allows you to interface with the system. Changing the software modes, reviewing the system’s performance, and initiating maintenance procedures can be done via the keypad. The results of your actions can be seen on the display (Figure 1, B) located directly above the keypad.

OPERATE / STANDBY BUTTON Hold the OPERATE / STANDBY button down for 2 seconds. The display will show the changes from one operating mode to another (see the descriptions of these operating modes below).

STANDBY: This operating mode is displayed when the system is not operating any of the internal components. Normally this operating mode is used when starting a maintenance procedure. The system performs an automatic flush of the RO cartridge every 6 hours (all operating modes). The flush mode rinses the RO to remove anything that has built up on the membrane surface. No water will be sent to the analyzer when the system is in this mode.

FILLING TANK: This operating mode is displayed when the 10 Liter tank is being filled with RO water. If the analyzer requires water, the distribution pump will send the water to the analyzer as needed.

TANK FULL: This operating mode is displayed when the 10 Liter Tank is full of RO permeate water. If the analyzer requires water, the distribution pump will send the water to the analyzer as needed.

PRODUCTION: This operating mode is displayed when water is being sent from the AFS to the analyzer. The AFS switches automatically to PRODUCTION mode if the system is in TANK FULL or in FILLING TANK mode.

The Resistivity of the product water is shown in the bottom left corner of the display. The displayed resistivity is temperature compensated to 25 °C. The actual temperature of the product water is displayed in the bottom right corner of the display.

You can get product water from the AFS for a maximum of 18 continuous minutes. This is a software feature which prevents the Distribution Pump from running dry. The Distribution Pump will stop after 18 minutes of continuous use. DISP. TIME OVER (Dispensing Time Over) will alternate with PRESS OPERATE in the display. You must change the system into STANDBY mode in order to reset the timer. (Hold down the OPERATE/STANDBY button for two seconds). After the timer is reset, the AFS should be changed to FILLING TANK or TANK FULL mode so that water can be sent to the analyzer if needed.

DISP TIME OVER will reset automatically as soon as the tank is full.

If you use a tank greater than 10 liters, contact your local Millipore office.

S T A N D B Y

F I L L I N G T A NK

>1 0 M Ω c m 2 1 . 3 ° C

T A N K F U L L

>1 0 M Ω c m 2 1 . 3 ° C

P R OD U C T I O N

>1 0 M Ω c m 2 1 . 3 ° C

P R OD U C T I O N

D I S P . T I M E OV E R

OPERATE MEASURE CLEANING MENUSTANDBY

OPERATION

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 8

MEASURE BUTTON The Measure Button allows you to see various water quality related parameters.

MEASUREMENTS WHEN IN FILLING TANK OR TANK FULL MODE Various measurements are made when the Tank is being filled with permeate water from the RO membrane.

Reminder: The permeate from the RO membrane is not the final product water.

Press the MEASURE button

The top line of the display will show the pressure of the water that is going into the RO cartridge. This pressure results from the RO Pump increasing the tap water pressure. The bottom line of the display shows the ionic percent rejection of the RO membrane. This is determined using the feedwater conductivity and permeate conductivity values. The RO ionic % rejection represents the percentage of ions that are rejected by the RO membrane and then sent to the drain.

Press the MEASURE button again

The top line of the display shows the pressure of the water that is going into the RO cartridge. The electrical conductivity of the RO feed water is shown on the bottom line of the display.


The top line of the display shows the pressure of the water that is going into the RO cartridge. The electrical conductivity of the RO permeate water is shown on the bottom line of the display.


The system returns to FILLING TANK or TANK FULL mode.

MEASUREMENTS IN PRODUCTION MODE (WATER IS BEING SENT TO THE ANALYZER) The Resistivity Value (compensated to 25 °C) and the Temperature of the Product Water are displayed at all times when in PRODUCTION mode.

(See Measurements when in FILLING TANK or TANK FULL mode)

CLEANING BUTTON The Cleaning button is used to initiate either the Chlorine Sanitization cycle or the pH Cleaning cycle. A complete description of both cycles can be found in the Maintenance Section of this manual.

R O P R E S : 4 . 0 b a r

R O F E E D : 9 5 2 µ S

R O P R E S : 4 . 0 b a r

P E R M E A T E : 2 0 . 1 µ S

R O P R E S : 4 . 0 b a r

R E J E C T I ON: 9 7 . 9 %

F I L L I N G T A NK

>1 0 M Ω c m 2 1 . 3 ° C



OPERATION

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 9

MENU BUTTON The Menu Button can be used to access various Customer Menus (example: changing the displayed language). Hold down the MENU button for 2 seconds to access the Customer Menu. The Customer Menu can be accessed in any Operating Mode

PAK LIFE

The first screen shows the number of days remaining before the Progard 3 Pretreatment Pack needs to be exchanged. The number of days remaining is calculated by both a day-by-day timer and a measurement of water usage by the system. The number of days will count down (decrease).

When a new Progard 3 Pretreatment Pack is installed, the display will show NO DATA for seven days. This message is necessary so the system can determine an accurate rate of water usage.

Press the MENU Button. This scrolls the display over to the OPTIONS portion of the Customer Menu.

LANGUAGE

This gives you the option to change the language seen on the display. The Arrow Buttons (MEASURE or CLEANING) can be used to scroll between various languages. The languages that can be chosen include English, Français (French), Deutsch (German), Italiano (Italian), Español (Spanish), and Japanese.

Press the OPERATE / STANDBY Keypad Button to scroll down to the next choice in the OPTIONS selection.

EXTERNAL ALARM

An external alarm (buzzer, light, etc.) can be connected to the AFS system. When an Alarm or Service message is shown on the display, the system will send either a 100/120/230 volt signal to an external alarm connected to the system. The voltage of the signal depends upon the voltage supplied to the system.

Use the Arrow Buttons (MEASURE or CLEANING) to activate (ON) or deactivate (OFF) the External Alarm.


PRESSURE UNITS

You can change the units that are displayed for the pressure measurement when the system is in operation. Use the Arrow Buttons (MEASURE or CLEANING) to choose between bar, psi or kPa.


S E R V I C E : L I F E T I M E

P A K L I F E 2 5 DA Y S

S E R V I C E : OP T I ON S

L A NGUA G E E NG L I S H

S E R V I C E : O P T I ON S

E X T . A L A R M : OF F


P A K L I F E NO DA T A

S E R V I C E : OP T I O N S

P R E S . UN I T : b a r


OPERATE STANDBY

OPERATE STANDBY

OPERATE STANDBY

MENU

OPERATION

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 10

RESISTIVITY OR CONDUCTIVITY DISPLAY

This option changes the displayed units during PRODUCTION mode. These units include resistivity (MΩ.cm) or conductivity (µS/cm). Use the Arrow Keypad Buttons (Measure and Cleaning) to choose between MΩ.cm or µS/cm.

NOTE: When you scroll to the following menu option, you will have 10 seconds before the software automatically starts the System Rinse. In order to prevent this from happening, press the MENU again before the end of 10 seconds.

Press the MENU Keypad Button to scroll over to the next menu option.

SYSTEM RINSE

The System Rinse starts automatically after a 10 second delay. If you want to start a 240 minute System Rinse, wait 10 seconds when this display is shown.

If you accidentally start a System Rinse and want to cancel it, call Your Local Millipore Office for assistance.

The purpose of the System Rinse is to rinse the preservatives in the RO membrane. The 10 Liter Tank will not fill during the 240 minutes of the System Rinse.

NOTE: Poor water quality could result if a new RO cartridge is not rinsed for the required time.

Press the MENU Keypad Button to scroll over to the next menu option.

PRINTER

It is possible to print out various information about the AFS Water System. A cable is necessary to connect between the AFS and a printer. The cable is not supplied with the AFS. Call Your Local Millipore Office for further information regarding the cable and use of the printer function.

Press the MENU Keypad Button to exit the Customer Menu.

STANDBY, FILLING TANK, TANK FULL, or PRODUCTION mode should be shown on the display.

S E R V I C E : F UNC T I ON

S Y S T E M R I N S E

S E R V I C E : OP T I ON S

P R OD . UN I T : M Ω c m

MENU

MENU

MENU

MAINTENANCE

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 11

Chapter 3 MAINTENANCE

3-1 INSTALLATION AND REPLACEMENT OF CONSUMABLES The following table is a quick reference for when the consumables (packs, cartridges, and filters) should be exchanged. Whenever a service or alarm LED is lit, see the Troubleshooting section for a detailed description of the problem and possible solutions. The procedures for replacing the packs and filters are described after the table. See "Ordering Information" for the correct catalogue numbers.

Consumable names When to change the Consumables (See Troubleshooting Section for more information if the system is producing Low Flow)

Progard Pretreatment Pack

Replace the Progard when the message "EXCHANGE PROGARD" is shown on the display. Also replace the Progard if the system has been turned off for more than 48 hours. System should be powered on and in STANDBY mode when the Progard is replaced.

Bacteria Filter

Replace the Simfilter or Millipak when the Progard is exchanged (See above)

Millex® Vent Filter

Replace the Millex when the Progard is exchanged (See above)

Q-Gard A Cartridge

Replace the Q-Gard A Cartridge when the system displays "EXCHANGE CARTRIDGE" message. Replace it only after opening the manual Product Line Drain Valve and draining any water that may have stayed stagnant in the cartridge.

PROGARD PRETREATMENT PACK 1. (For the first installation of the system, remove the protective plugs from where the Progard 3

will connect to the system.)

The system should be turned on and in STANDBY mode when replacing the pack.

Place the system into STANDBY mode by holding the OPERATE / STANDBY button down for 2 seconds. The STANDBY display flashes to indicate depressurization of the system.

2. Open the front blue door by pressing on the 2 latches on the right side and pulling the door open (Figure 2, B).

3. Pull out the used Progard (Figure 2, C).

4. Remove the two protective caps from the new Progard. Wet the two O-rings on the new Progard with water.

5. Insert the Progard into the system. Push it in as far as it will go.

6. Close the door. It is necessary to fully snap the latches (Figure 2, B) shut to hold the Progard inside. You should here both latches "click" shut.

7. Press the OPERATE / STANDBY button to change the system into FILLING TANK or TANK FULL mode. The system may initially display PRODUCTION until the pressure rises.

MAINTENANCE

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 12

Q-GARD A CARTRIDGE (See Figure 2)

What you will need: Q-Gard A Cartridge, at least 5 liters of water in the Tank (approximately half the Tank).

1. Make sure the AFS system is in STANDBY mode. Wait for the STANDBY display to stop flashing if necessary.

2. Open the Product Line Drain Valve (Figure 4) and release any pressure in the distribution tubing.

3. Close the Product Line Drain Valve.

4. If there is a Q-Gard A installed, wait until the STANDBY display stops flashing - lift the pack adapter cover (E) to the top position - remove the metal locking clip - pull out the Q-Gard A Cartridge

5. Remove the protective caps from the new Q-Gard A Cartridge (D), and wet the pack o-rings using a few drops of purified water.

6. Slide the pack onto the metal guide pin (F). - Lift up the pack slightly in order to push the bottom of the pack into the slot at the bottom of the system. - Push the pack completely onto the pack adapter. The metal guide pin (D) should be visible now.

7. Lock the pack in place with the metal locking clip on the end of the metal guide pin (F).

8. Lower the adapter cover (E) over the newly installed Q-Gard A Cartridge.


10. With the tubing from the Product Line Drain Valve secure in the drain, open the Product Line Drain Valve to change the system into PRODUCTION mode.

11. Allow approximately 5 Liters of water (half of the Tank) to pass through the Q-Gard A Cartridge in order to rinse the ion exchange resin correctly.

MAINTENANCE

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 13

BACTERIA FILTER MILLIPAK

The Millipak should be changed at the same time as the Progard 3. The Millipak can be used immediately after installation.

1. Make sure the AFS system is in STANDBY mode. Wait for the STANDBY display to stop flashing if necessary.

2. Remove the O-ring used to affix the Millipak to the bracket. Unscrew the fittings on both ends of the Millipak.

3. Screw the Millipak (clear side up) into the top and bottom connectors and finger-tighten the connections. Secure the Millipak on the bracket using the O-ring. Discard the old Millipak.


5. With the tubing from the Product Line Drain Valve secure in the drain, open the Product Line Drain Valve to change the system into PRODUCTION mode.

6. Verify that there are no visible leaks after the Millipak fills. Vent the Millipak after filling.

SIMFILTER Quick DisconnectFitting attached tothe Analyzer

Fitting

Tubing from AFSSIMFILTER

The Simfilter should be changed at the same time as the Progard 3. The Simfilter can be used immediately after installation.

1. Locate the Quick Disconnect Fitting which is normally connected to the analyzer. Separate the fitting by pushing down on the metal piece and pulling the fitting apart. If a Quick Disconnect fitting is not used, remove the tubing connected to the fitting on the analyzer.

2. Unscrew the metal nut and remove the tubing from the Quick Disconnect fitting. Screw the nut back on the fitting so it does not get misplaced.

3. Connected directly onto the Simfilter is a fitting. Unscrew the nut and remove the tubing coming from the AFS. Discard the Simfilter, including the attached fitting. The new Simfilter comes with a fitting and tubing already attached.

4. The new Simfilter can be installed at this time. Unscrew the nut from the fitting and place the nut on the tubing coming from the AFS.

5. Push the tubing onto the fitting on the Simfilter. Screw the nut back onto the fitting to secure the tubing.

6. Connect the tubing on the other side of the Simfilter to the fitting connected to the analyzer. If this fitting is the Quick Disconnect fitting coming with the system, follow the instructions below:

1. Unscrew the nut on the Quick Disconnect fitting

2. Slide the nut onto the tubing from the Simfilter

3. Push the tubing onto the fitting

4. Tighten the nut onto the fitting so that the tubing is locked into place

5. Reconnect the Quick Disconnect fitting to the analyzer

MAINTENANCE

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 14

INSTALLING THE MILLEX TANK VENT FILTER ON THE 10 LITER TANK (Only on the systems without aeration kit)

The Millex Tank Vent Filter should be replaced at the same time as the Progard 3 and the Bacteria Filter.

1. Unscrew and remove the lid of the 10 Liter tank. Remove the used Millex Tank Vent Filter and discard.

2. Place the vent filter onto the lid so that the writing can be seen after it is installed. The filter can only fit securely onto the cap one way.

MAINTENANCE

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 15

CLEANING OF THE SCREEN FILTER If possible, the screen filter should be cleaned each time the Progard 3 is replaced.

Cleaning the screen filter will allow a better flowrate to reach the system. It also aides in preventing any large foreign particles from causing damage to the system. The screen filter is in the 1/2 inch FNPT fitting connected to the feed water valve. This is the valve which supplies water to the system.

1. Put system into STANDBY mode. Hold the OPERATE / STANDBY button down for two seconds if you are in one of the operating modes

2. Close the feed water valve.

3. Disconnect the tubing from the fitting connected to the feed water.

4. Unscrew the fitting from the 1/2 inch FNPT fitting connected to the feed water. Locate the screen filter.

5. Clean the screen filter to remove any particles that were trapped by the filter. This can be done by running water through it in the opposite direction as normal.

6. Reconnect the tubing to the feed water. More Teflon® tape may be needed on the 1/2 inch MNPT fitting to prevent leaks.

7. Open the feed water valve.

3-2 ROUTINE MAINTENANCE CHLORINE SANITIZATION OF THE REVERSE OSMOSIS CARTRIDGE

A chlorine sanitization should be performed when the message "START AUTOCLEAN" appears on the display. The yellow service light also flashes.

1. Place the system in STANDBY mode by holding the OPERATE / STANDBY button down for 2 seconds. The STANDBY display flashes to indicate the depressurization of the system.

2. Once the STANDBY display stops flashing, unscrew the sanitization port plug (Figure 1, C) and put a chlorine tablet in.

3. Replace the sanitization port plug. Hand tighten only.

4. Start the cleaning cycle as follows:

Hold the CLEANING button down for two seconds. The chlorine cleaning cycle starts after a 10 second delay. The remaining time of the cleaning cycle is displayed.

NOTE: During the cleaning cycle, water can be drawn from the 10 Liter tank to feed the analyzer. The cleaning cycle is 15 minutes. At the end of this cycle the system automatically changes to FILLING TANK or TANK FULL mode

C l 2 C L E A N 1 4 mn


MAINTENANCE

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 16

PH CLEANING OF THE REVERSE OSMOSIS CARTRIDGE A pH cleaning should be performed as needed. If the % ionic rejection drops several points or if the flow rate coming from the AFS has decreased, a pH cleaning of the RO could renew the cartridge.

• Use the RoClean™-A (acid) once a month or when necessary when the feedwater entering the AFS has a high level of hardness. A high level of hardness is defined as > 150 ppm Calcium / Magnesium and > 30 ppm Alkalinity

• Use the RoClean -B (base) once a month or when necessary in order to remove organic buildup on the membrane. It is recommended to use the RoClean -B if the Fouling index of the feedwater is greater than 5.

1. Place the system in STANDBY mode by holding the OPERATE / STANDBY button down for 2 seconds. The STANDBY display flashes to indicate depressurization of the system.

2. Once the STANDBY display stops flashing, unscrew the sanitization port plug (Figure 1, C) and add the RoClean -A or RoClean -B cleaning pouch.

3. Screw the sanitization port plug back in place.

4. Start the additional cleaning cycle as follows:

Hold the CLEANING button down for 2 sec.

Press once on CLEANING to display the pH Cleaning mode.

The pH cleaning cycle will start after a 10 second delay. The remaining time of the cleaning cycle is displayed.

NOTE: During the pH cleaning cycle, water can be drawn from the 10 Liter tank to feed the analyzer. The pH cleaning cycle is 90 minutes. At the end of this cycle the system automatically changes to FILLING TANK mode or TANK FULL mode.

p H C L E A N

C l 2 C L E A N


TROUBLESHOOTING

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 17

Chapter 4 TROUBLESHOOTING

WHAT’S WRONG ? WHAT CAUSED THIS ? HOW TO FIX IT

Display is empty. Green Power LED is off.

Power Switch turned off. Power Cord not plugged in. No source of electrical power. Blown fuse on water system.

Check power switch on back of system. Check that power cord is plugged in. Check the source of electrical power. Replace fuse on the back of the system.

Low Water Flow from system. Water flow to analyzer is < 500 ml/min.

System is not in PRODUCTION mode. 10 L tank is empty of water. Tubing to/from the Tank is kinked. Q-Gard A Cartridge is not full of water (recently installed). Simfilter is partially clogged Millipak is airlocked Millipak is clogged and will not allow water through it. Distribution Pump voltage low or pump is not operating.

System will change into PRODUCTION mode when the analyzer starts to draw water and the system was in FILLING TANK or TANK FULL mode. Check water level in 10 l reservoir. Check all external tubing. When tank is full, put the system into PRODUCTION mode by opening the Product Line Drain Valve between the system and the analyzer. Allow water to fill the Q-Gard A Cartridge. Open the Product Line Drain Valve to see it there is a lot of flow going to drain. If there is, then the Simfilter is clogged and should be replaced. Locate the air vent valve on the top side (clear side) of the MilliPak. Open this slowly, but do not remove it from the MilliPak. Allow any air on the clear side of the MilliPak to be vented out. Measure water flow and without Millipak installed. Change Millipak and air vent out. Blown Motor fuse or Voltage setting is too low on Interface PC Board – Call Your Local Millipore Office. If the solutions above have been tried without any success, call Your Local Millipore Office and follow the instructions on how to use the EMERGENCY KIT if water is needed.

TROUBLESHOOTING

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 18


No aeration of 10 Liter tank

No aeration pump installed Filter is clogged

Order AerationPump if desired Water can not pass through the Millex membrane. Remove the Millex filter, allow the pump to run for 30 seconds without the filter to force out any trapped water. Install a new Millex

Vacuum Pressure is not high enough or is fluctuating

The system has not been used in a long time The Vacuum Regulator needs to be adjusted

Open the Product Line Drain Valve and put the system into PRODUCTION for several minutes Go to Appendix C, To Increase the Vacuum Level

REJECTION < S.P. is displayed. The red Alarm LED is flashing. The system continues to operate.

The RO cartridge % ionic rejection is below a pre-specified setpoint in the software (normally 90%). This condition has to exist for 3-6 minutes for the alarm to be displayed.

Clean the RO cartridge with an Acid or Base Cleaner (RoClean -A or RoClean -B) depending upon feedwater. Check RO % rejection setpoint in software – Call Your Local Millipore Office.

PRODUCT < S.P. is displayed. The Red Alarm LED is flashing. The system continues to operate.

Resistivity of the AFS Product water is below a pre-specified setpoint in the software. This occurs when the resistivity (compensated to 25 °C) is below the resistivity setpoint for at least four times of a duration of 5 seconds or more.

Open the Product Line Drain Valve between the AFS and the analyzer. Allow some water to rinse the Q-Gard A Cartridge and go to drain. If the procedure above does not increase the Resistivity, replace Q-Gard A Cartridge – ion exchange resin is exhausted.

PAK NOT IN PLACE is displayed. The red Alarm LED is flashing. The system has stopped operating.

A microswitch which detects the Progard 3 presence is not fully closed.

Install the Progard 3 Pretreatment Pack again. Check for the proper function of the Progard microswitch

TROUBLESHOOTING

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 19


LOW PRESSURE is displayed. The red Alarm LED is flashing. The system has stopped operating.

The system pressure sensor has measured less then 0.5 bar (7 psi) for more then 20 seconds.

No water is reaching the pressure sensor or water pressure on pressure sensor is < 0.5 bar for 10 seconds. Verify that the feed water is reaching the system. Perform the action below and then Call Your Local Millipore Office. Action 1 - Go to STANDBY mode. Press MEASURE. Record highest displayed pressure. Action 2 - Turn off, then on power. Locate RO reject tubing. While system is in FLUSH mode, determine RO reject flow to drain. Record this value.

EXCHANGE PROGARD is displayed. The yellow Service LED is flashing. The system continues to operate.

The system has determined that the Progard has processed a predetermined volume of water and/or the timer for the Progard has reached 0 Days.

Replace the Progard using the instructions found in the Maintenance Section of this manual. It is highly recommended to replace the Simfilter and Millex vent filter at the same time.

START AUTOCLEAN is displayed. The yellow Service LED is flashing. The system continues to operate.

The AUTOCLEAN message is displayed automatically when the timer has reached 0 days.

Perform a chlorine sanitization of the RO membrane. Use the instructions for ‘Cleaning the RO Membrane’ in the Maintenance section of this manual.

CHECK PUMP is displayed. The yellow Service LED is flashing. The system continues to operate.

The system has determined that the pump pressure is not high enough at a particular temperature.

Call Your Local Millipore Office.

ERROR 6 is displayed. The red Alarm LED is flashing. The system continues to operate.

The measured water temperature is < 0 °C. This is indicative of a sensor error. This error takes 3-6 minutes to become activated.



The measured water temperature is > 45 °C. This error takes 3-6 minutes to become activated.

Check / lower the feedwater temperature. Call Your Local Millipore Office.

TROUBLESHOOTING

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 20



The resistivity of the product water is below a predetermined value in the software. This value is much lower than the Resistivity Setpoint. This is indicative of a sensor problem. This error occurs after 3-6 minutes of system operation.

Turn off / on the system power. Return to PRODUCTION mode. If the problem occurs again in 3-6 minutes, then Call Your Local Millipore Office.


The measured resistivity is > 25 MΩ-cm at 25 °C. This is indicative of a sensor problem.



There was a problem writing data to the electronic memory of the system.

Turn off/on the power. Put the system into PRODUCTION by opening the Product Line Drain Valve for 5-10 minutes, then go to STANDBY mode. If the error returns, then call Your Local Millipore Office.

ORDERING INFORMATION

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 21

Chapter 5 ORDERING INFORMATION

REFERENCE INFORMATION FOR AFS SYSTEMS:

Description Catalogue Number

Progard 3, Millipak 100, and Millex filter CPAFS8PRM

Progard 3 Pre-treatment Pack , 1/pk PR0G00003

Q-Gard A Polishing Cartridge, 1/pk CP2ALLRES

Simfilter Bacteria Filter and Millex Vent Filter, 1 of each/pk HFBCTFAFS

Millipak100 0.22 um final filter MPGL10ZW1

PrePaK 1 Pretreatment Pack 2/box PRPK00001

Reverse Osmosis (RO) Cartridge (without housing) CDRC60201

Chlorine tablets (Quantity: 45) ZWCL01F50

ROCLEAN -A: Acid Cleaning Pouch ZWACID012

ROCLEAN -B: Base Cleaning Pouch ZWBASE012

Accessories

Pack Support (2 tube, 2 gauges) ZFPACKSP2

System Floor Stand ZAF3STAND

Wall Mounting Bracket for AFS SYSTFIX01

Millipak Mounting Kit (included with AFS-8D/16D) MPKMNTKIT

Aeration Kit 120V (included with AFS-8D/16D) ZAFS6AKIT

Aeration Kit 230V (included with AFS-8D/16D) ZAFS5AKIT

Printer Cable PRNTCBL01

F A Z S

Voltage/Frequency 5 = 230 V/50 Hz 6 = 120 V/60 Hz 7 = 100 V/50-60 Hz

0

Type of System 08 = AFS-8(D) 16 = AFS-16(D)

Degassing Option 0 = No Degasser D = Degasser Installed

APPENDIXES

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 22

Chapter 6 APPENDIXES

APPENDIX A INSTALLATION UNPACKING

The AFS is shipped as several different items within one box. A check list of these items is shown below to use as a reference while unpacking the box. Please note that the Q-Gard A Cartridge, the Progard Pretreatment Pack, and the Bacteria Filter are not supplied with the system. These must be ordered separately. See Figure 5 in the back of the manual for visual identification

Present

Present Yes No (A) Water purification system (B) Power cord (C) Operating manual (D) 8 mm OD Feed and Reject water tubing (6 meters) (E) 6 mm OD Product water tubing (2 meters) 6 mm OD Product Line Drain Valve reject tubing (2 meters) (F) 10 Liter Tank (with connections already attached) (G) Pressure Regulator (H) Bag of fittings for connection of system Use the checklist included in the bag of fittings to make sure all items were shipped and

are accounted for.

(I) Q-Gard A Cartridge (ordered separately) (J) Progard Pretreatment Pack (ordered separately) (K) Millex Vent Filter (L) Simfilter (ordered separately) or Millipak (ordered separately) (M) Millipak Mounting Kit (only with AFS 8D and 16D systems) (N) Bacteria Samplers Aeration Pump (only with AFS 8D and 16D systems) Aeration Tubing Kit (only with AFS 8D and 16D systems) Plastic Drain Connector (Airgap) (only with AFS 8D and 16D systems)

Observed by ______________ _____________________ ____________________ Name Signature Date

Verified by ________________ _____________________ ____________________ Name Signature Date

APPENDIXES

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 23

INSTALLATION OF THE SYSTEM The AFS system can be placed on a bench or fixed to a wall. The instructions vary slightly depending

upon where the system will be placed. However the system must be located within 2 meters of the analyzer and within 2 meters of the feedwater source.

INSTALLING THE ELBOW CONNECTORS (See Figure 3)

1. Remove the protective plugs located on the back of the AFS by pressing on the collar (A) and pulling the plugs out (B). The five plugs that should be removed are the FEED 1 (H), PRODUCT 2 (K), DRAIN 3 (I), IN 4 (M) and OUT 5 (J).

2. Insert the appropriate sized elbow connectors into these five connections. There are two 8 mm OD and three 6 mm OD elbow connectors.

CONNECTION OF THE INLET (FEED) TUBING 1. Close the valve that will supply feed water to the system. (Valve ending in 1/2 inch Male National Pipe

Thread (MNPT) connection is not included with system).

2. Remove the clear plastic cap located on the end of the 8mm OD tubing supplied. You will need enough tubing to connect the system to the Pressure Regulator and then to the feed water valve or fitting (no more than 2 meters total). Connect the tubing to the 1/2" Female NPT fitting (Figure 5, D). Cut the tubing to the desired length to go to the Pressure Regulator.

3. Connect the tubing to the Pressure Regulator. Cut another piece of tubing to connect from the Pressure Regulator to the system.

4. Connect the tubing at the opposite end of the pressure regulator into FEED 1 (Figure 3, H) by inserting it firmly in the elbow fitting. Verify that the connection is secure by pulling on the tubing. It should not come loose if pulled.

5. Connect the tubing to the feed water supply. The feed water valve or fitting should terminate in a 1/2 inch MNPT fitting. Apply some White tape (supplied with the system) to the 1/2 inch MNPT fitting. This will create a good seal and help prevent leaks. Screw the 1/2 inch FNPT fitting (attached to the feed water tubing) onto this 1/2 inch MNPT valve or fitting.

CONNECTION OF THE REJECT TUBING 1. With the remaining 8 mm OD tubing supplied, cut to the desired length (< 4 meters) in order to connect the RO

reject to the drain.

2. Connect the reject tubing to DRAIN 3 (Figure 3, I) located on the back of the system. Insert the tubing firmly into the elbow fitting in that location.

3. The other end of the tubing should be placed securely in a drain capable of 120 LPH.

CONNECTIONS BETWEEN THE AFS AND THE 10 LITER TANK 1. Decide where the system and tank will be located (on the wall or on a flat surface).

If the system is to be bench or wall mounted, proceed with the bench or wall installation at this time (Go to Bench Mounting, or Wall Mounting). Continue with the installation from this point after the system is in place.

!

APPENDIXES

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 24

A

B

2. Cut and connect a piece of 6mm tubing to connect from “IN 4” (Figure 3, M) on the back of the system to the fitting on the top of the tank. Cut and connect a piece of 6mm tubing to connect from “OUT 5” (Figure 3, J) to either of the fittings on the bottom of the tank.

Use as much tubing as necessary to connect the tank to the system without having a kink in the tubing. A kink (or bend) in the tubing would restrict the flow to and from the system and tank. Cut the tubing to the appropriate size.

OVERFLOW TUBING 1. Push the double fitting (Tubing side) onto the stem fitting on the top of the tank (Figure 1, F).

If the Aeration Pump is connected to the 10 Liter tank:

Connect the clear tubing to the double fitting (Barbed side). Connect the other end of the tubing to the plastic drain connector (Air gap). The Air Gap needs to placed over or in a drain.

If the Aeration Pump is NOT connected to the 10 Liter tank:

Connect the clear tubing with the check valve attached to the double fitting (Barbed side)

Connect the loop of clear tubing to the other side of the check valve.

Use as much tubing as necessary to connect to the drain

CONNECTION OF THE TANK LEVEL SWITCH TO THE AFS 1. Verify that the tank level switch is secure in the top of the 10-liter tank. (A)

2. Insert the phono jack of the level switch into the port at the back of the system. This is the port located next to the power switch. (B).

CONNECTION OF THE ELECTRICAL POWER TO THE AFS This system is equipped with an electrical cord having a grounding wire with an appropriate grounding plug. The plug must be plugged into an outlet that is properly installed and grounded.

1. Connect the power cord (Figure 5, B) to the back of the AFS (Figure 1, D). Connect the other end of the power cord to an earth grounded power source.

!

APPENDIXES

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 25

FIXING THE EMERGENCY KIT TUBING The Emergency Kit tubing is the union fitting connected to a reducing fitting. It is to be attached next to the Inlet tubing using the white clips that come with the system. The tubing is to be used only if the system is not able to produce water.

1. Using the white clips supplied with the system, connect the Emergency Kit tubing to the feed water tubing.

See Emergency Kit for how to connect the kit to the system if water is needed and for the proper usage of the kit.

BENCH MOUNTING THE AFS AND 10 LITER TANK The AFS can be placed on a bench, provided that the bench can support the weight of the tank and the system when both are filled with water.

1. After the water connections have been made, the system and the tank can then be fixed together using the 2 nuts, bolts, and washers coming with the system.

2. Place a washer on one of the bolts. Push the bolt through one of the two holes on the mounting bracket of the 10 Liter tank.

3. Screw one of the nuts onto the end of the bolt so that it barely rests on the end of the bolt. Do not fully tighten the nut at this time. The result should look similar to the photo on the right.

4. Repeat the same procedure for the other nut, bolt and washer on the other hole on the mounting bracket of the 10 Liter tank.

5. Align the 2 nuts to the corresponding mounting holes on the back of the AFS system. Push the nut into the mounting hole and then slide it upwards. It is easier to insert the nut into the mounting hole of the system if the tank is angled slightly (See the photo above for the location of one of the mounting holes on the AFS).

6. With access on the side of the system, use your finger to hold the nut in place. Hand tighten the bolt as much as possible while holding the nut with your finger. Tighten the nut and bolt on the other side of the system.

7. Further tighten the bolts by using the 6 sided hex wrench coming with the system.

APPENDIXES

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 26

WALL MOUNTING THE AFS AND 10-LITER TANK If the system is to be wall mounted, verify that the wall is able to support the operating weight of the system and the tank. Do not mount the tank lower than the system. The system and the tank must be mounted to the wall separately.

CALL YOUR LOCAL MILLIPORE OFFICE FOR MORE DETAILS IF NECESSARY

1. Using the appropriate screws for your wall surface, mount the wall bracket for the AFS system according to the instructions that come with SYSTFIX01 (Wall Mounting Bracket). This bracket must be ordered separately. Make certain to leave enough space to mount the 10 Liter tank next to the system.

2. Use the appropriate screws to attach the 10 Liter tank to your wall surface. Use all four mounting holes on the mounting bracket of the tank. When mounting the 10 Liter tank to the wall, make sure that the tubing connected to the tank will be able to reach the fittings on the back of the AFS system. Remember that when the tubing is connected, there can not be any kinks (bends) in the tubing. The result of a kink is that the flow of water will be restricted to and from the tank.

3. Return to step number 2 in the section Connections between the AFS and the 10-Liter tank. Continue with the installation.

CONNECTION BETWEEN THE AFS AND THE ANALYZER (If you are using a Millipak, follow the instructions that come with the Millipak Mounting Kit) (See Figure 4)

It is highly recommended to place the system within 2 meters of the analyzer.

One piece of 6 mm tubing is used to connect the AFS to the Product Line Drain Valve Tee and then continue to the Simfilter.

The Simfilter is connected to the analyzer.

The other 6 mm piece connects the Product Line Drain Valve to the drain.

1. Insert the end of one of the pieces into the elbow fitting on the back of the AFS labelled PRODUCT 2 (Figure 3, K).

2. Cut the tubing to the desired length to connect the system to the Product Line Drain Valve Tee. Remember that the remaining tubing from this piece will be used to connect from the Product Line Drain Valve Tee to the Simfilter. Push the tubing onto the fitting.

3. With the remaining 6 mm tubing, cut to the desired length in order to go from the Product Line Drain Valve Tee to the Bacteria Filter. Push the tubing onto the fitting.

4. Push the tubing from the other 6 mm piece onto the fitting on the Product Line Drain Valve. After cutting to the desired length, secure the other end of the tubing into the drain.

APPENDIXES

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 27

INSTALLING THE SIMFILTER Quick DisconnectFitting attached tothe Analyzer

Fitting

Tubing from AFSSIMFILTER

1. Unscrew the nut from the fitting on the Simfilter and place the nut on the tubing coming from the Product Line

Drain Valve Tee.

2. Push the tubing onto the fitting (If necessary, use sandpaper to hold the tubing). Screw the nut back onto the fitting to keep the tubing secure.

3. Connect the tubing attached to the other side of the Simfilter to the fitting connected to the analyzer. If this fitting is the Quick Disconnect fitting coming with the system, follow the directions below:

1. Unscrew the nut on the Quick Disconnect fitting

2. Slide the nut onto the tubing from the Simfilter

3. Push the tubing onto the fitting

4. Tighten the nut onto the fitting so that the tubing is secured

5. Connect the Quick Disconnect fitting to the analyzer

INSTALLING THE MILLEX VENT FILTER ONTO THE 10 LITER TANK The Millex Vent Filter should be replaced at the same time as the Progard and the Bacteria Filter.

1. Unscrew and remove the lid of the 10 Liter tank.

2. Place the vent filter onto the lid so that the writing can be seen after it is installed. The filter can only fit securely onto the cap one way.

APPENDIXES

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 28

STARTING THE SYSTEM FOR THE FIRST TIME Before starting the system, verify that all of these steps have been completed:

Yes No

(1) System is in the desired location (wall mounted or bench mounted) (2) Power cord is connected (3) Inlet tubing is connected securely

- Inlet tubing is connected to a feed water source - Regulator is installed before the system - The other end of the Inlet tubing is connected to the system at INLET 1 on the back of

the system

(4) Reject tubing is connected securely - Reject tubing is connected securely to the drain - The other end of the reject tubing is connected to DRAIN 3 on the back of the system

(5) The tubing between the system (IN 4( and (OUT 5) to the 10 Liter tank is securely in place. Make sure there are no kinks in the tubing

(6) The tubing between the system (PRODUCT 2) and the analyzer is connected - This includes the Product Line Drain Valve Tee and Simfilter

(7) Overflow tubing is connected from the 10 Liter tank to the drain (8) Tank Level Switch is connected to the AFS system from the 10 Liter tank to the system (9) The Emergency Kit tubing is in place attached next to the Inlet tubing (10) Millex Vent Filter is in place on the lid of the 10 Liter tank

After the system is installed and mounted, the system startup procedure can be started.

1. Install the Progard Pretreatment Pack (See Maintenance, Installation and Replacement of Packs, Progard Pretreatment Pack.

2. Open the feed water valve.

3. Switch on power to the system by moving switch (Figure 3, L) to position I

The first display will show you the type of system (AFS8) as well as the serial number of your system. This is displayed for 10 seconds.

Display of operating mode (FLUSH and STANDBY alternating)

A F S 8 V 1 . 0 1

S R . N ° F 0 A N5 6 8 A 5 C

F L U S H

APPENDIXES

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 29

S Y S T . R I N S E : 2 4 0 m n

S T A ND B Y

System rinsing required (Duration: 4 hours)

Reminder: SYSTEM RINSE will remove the preservatives in the RO cartridge. Poor quality water could result if the RO cartridge is not rinsed.

Hold the MENU button down for 2 seconds

Press the MENU button twice and you will see this display

The system rinse will begin after a 10 second delay. The remaining time of the system rinse is shown in the display.

After the SYSTEM RINSE is completed, the system automatically goes into STANDBY mode.

4. Install the Q-Gard A Cartridge (See Maintenance, Installation and Replacement of Packs, Q-Gard A Cartridge).


P A K L I F E : 5 5 DA Y S


S E R V I C E : F UNC T I ON

S Y S T E M R I NS E

APPENDIXES

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 30

APPENDIX B EMERGENCY KIT PROCEDURE Use the Emergency Kit only after the suggestions in the Troubleshooting Section have been tried with no effect. Call your Local Millipore Office and proceed with the Emergency Kit procedure.

The Emergency Kit Tubing should be attached to the feedwater line.

What you will need before you continue: New Q-Gard A Cartridge, Emergency Kit

1. After it has been confirmed that the system is not producing water, make sure the system displays STANDBY.

2. Turn off the power to the system. The emergency kit is to be used only with the power off.

3. Close the feed water valve.

4. Disconnect the tubing attached to “FEED 1 (Figure 3, H)” on the back of the system.

5. Connect the tubing from the pressure regulator into the union fitting on the Emergency Kit Tubing.

6. Disconnect the tubing attached to “OUT 5” (Figure 3, J). Be warned that if there is water in the reservoir, it could spill out.

7. Push the tubing from the other side of the Emergency Kit Tubing into "OUT 5" (Figure 3, J)

8. Open the Product Line Drain Valve (See Drawing Below)

9. Leave the Product Line Drain Valve open.

10. Install a new Q-Gard A Cartridge.

11. Open the Feed water valve. After the Q-Gard A Cartridge is filled, water should be seen going through to the drain through the open Product Line Drain Valve. Decrease the pressure going to the system using the Pressure Regulator attached to the tubing before the Emergency Kit Tubing. The correct setting is 1.5 bar.

12. Allow water to flow through the Q-Gard A Cartridge to the drain for 10 minutes. This will rinse the resin in the Q-Gard A Cartridge and prepare it for use.

13. Close the Product Line Drain Valve (See Drawing Below) after 10 minutes.

14. The system is now ready for use. The analyzer can draw water now.

The feed water valve should be closed when the analyzer will not need water for a long period of time (weekends, overnight, etc.).

OPERATE/STANDBY MESURE CLEANINGMENU

Power

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Alarme

ANALYZER1

PRODUCT LINEDRAIN VALVE(CLOSED POSITION)

EMERGENCYKIT

FEED WATER

OUT 5

APPENDIXES

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 31

APPENDIX C ADJUSTING THE VACUUM LEVEL (AFS-8D AND 16D SYSTEMS ONLY)

The vacuum level is normally set in manufacturing from 10 to 12 inches of Mercury.

A

B

To adjust the vacuum level, use the following procedures:

To increase the vacuum level :

Verify that the tank is at least half full.

Place the AFS in PRODUCTION mode by opening the Product Line Drain Valve (located between the AFS and the analyzer). Allow the system to run for at least 3 minutes.

Using a screw driver, slowly turn the vacuum adjustment screw clockwise (A in the figure above).

CAUTION: To prevent regulator damage do not force or over-turn adjustment screw.

The vacuum gauge (B in the figure above) will indicate the level of vacuum during adjustment.

To decrease the vacuum level;

Verify that the tank is at least half full.

Place the system in STANDBY mode.

Open the Product Line Drain Valve.

Remove the Q-Gard A Cartridge. This will reduce the vacuum level when in STANDBY mode. (The Product Line Drain Valve must be located below the system in order to reduce the vacuum to zero)

APPENDIXES

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 32

Using a screw driver, turn the adjustment screw counter clockwise a few complete turns (A in the figure above).

CAUTION: To prevent regulator damage do not force or over-turn the adjustment screw.

Re-install the Q-Gard A Cartridge and close the door.

Place the AFS in PRODUCTION mode by opening the Product Line Drain Valve (located between the AFS and the analyzer). Allow the system to run for at least 3 minutes.

Wait for RINSING mode to finish if necessary.

Allow a few minutes for the vacuum level to stabilize. The vacuum gauge (B in the figure above) will indicate the level of vacuum during adjustment.

APPENDIXES

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 33

APPENDIX D DAILY MAINTENANCE LOG SHEETS Attached is a maintenance log sheet for you to monitor daily AFS parameters. It is important for inspection, accreditation, and troubleshooting purposes that you complete this log.

Photocopy the sheet, then record the following information:

The date you complete maintenance procedures (such as cleaning or sanitizing the RO cartridge or changing the Progard, Q-Gard A, Millex Vent Filter, or Bacteria Filter).

Control panel display readings (i.e., product quality, temperature, feed and permeate conductivity and percent rejection of the RO cartridge).

Bacteria counts.

APPENDIXES

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 34

AFS-8(D) & 16(D) Daily Maintenance Log - System Readings

System Model & Serial Number ____________________________ Month / Year ______________

Check in the PRODUCT Mode

Date

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

This is a master copy. Please make Photocopies. REV. 9/01

AFS Daily Maintenance Log

APPENDIXES

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 35

AFS-8(D) & 16(D) Daily Maintenance Log - System Readings

System Model & Serial Number ____________________________ Month / Year ______________

Check in the PRODUCT Mode

Date

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

This is a master copy. Please make Photocopies. REV. 9/01

AFS Daily Maintenance Log

APPENDIXES

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 36

APPENDIX E MONITORING BACTERIA LEVELS IN WATER Sample According to NCCLS/CAP Guidelines

To meet NCCLS requirements for the specification of bacteria count, periodic testing is recommended. Each laboratory has to establish a guideline on how often they need to do a bacteria count. NCCLS recommends that a bacteria culture be done weekly. Refer to NCCLS document C3-A3, volume 17/No. 18. NCCLS recommends the use of the Heterotrophic sampler count (HPC). NCCLS document C3-A3 Volume 11 No. 13.

How to Use the Millipore HPC™ Total Count Sampler

Millipore’s HPC Total Count Sampler meets NCCLS guidelines. To use the sampler, follow these steps:

1. Remove the sampler paddle from the bag. Write the date, type, and sampling site on the outside case.

2. Sanitize the sampling port: Working from the inside out, wash the port with a 10% bleach solution.

3. Open the sampling port on the AFS product line and let it run for at least one minute.

4. Pour a sample into the sampler case up to the 18 mL line. Insert the sampler firmly into its case.

CAUTION: Wet the membrane uniformly but do not shake the sampler case.

5. Carefully lay the sampler, membrane down, on a flat surface. Wait 30 seconds while the sample filters through the membrane.

6. Remove the paddle from the sampler case. Shake off any excess liquid from the paddle with a firm snap of your wrist. Empty the case and reinsert the paddle.

CAUTION: Make sure the sampler has an air-tight seal to prevent drying during incubation.

7. Incubate the sampler at 25°C ± 1°C for 48-72 hours. Total incubation time must be at least 48 hours.

8. Remove the sampler from the incubator and the paddle from the sampler case. Examine the filter surface on the paddle with either an illuminated stereoscopic microscope (10x to 20x) or an illuminated magnifier (≥5x).

9. Record the results as cfu/mL.

AFS®-8 - AFS®-8D - AFS®-16 - AFS®-16D 37

INDEX

10 Liter tank, 7, 10, 14, 15, 16, 18, 22, 23, 24, 25, 26, 27, 28

CHECK PUMP, 19 CLEANING, 9, 15, 16 Conductivity, 4, 8, 10, 33 DRAIN, 3, 8, 11, 12, 13, 17, 18, 19, 20, 22, 23,

28, 30, 31, 32 ERROR, 19, 20 EXCHANGE PROGARD, 11, 19 EXTERNAL ALARM, 9 FEED, 1, 3, 4, 8, 15, 16, 18, 19, 22, 23, 25, 28,

30, 33 FILLING TANK, 7, 8, 10, 11, 12, 13, 15, 16, 17 Language, 9 LOW PRESSURE, 19 Maintenance, 5, 7, 8, 11, 15, 19, 28, 29, 33 MEASURE, 9, 19 MENU, 9, 10, 29 Millipak, 13, 26 NCCLS, 2, 36 PAK NOT IN PLACE, 18 pH, 2, 4, 8, 16

Pressure, 3, 4, 5, 8, 9, 11, 12, 13, 18, 19, 22, 23, 30

Printer, 10, 21 PRODUCT < S.P., 18 PRODUCTION, 7, 8, 10, 11, 12, 13, 17, 18, 20,

31, 32 Progard, 3, 4, 9, 11, 13, 14, 15, 18, 19, 21, 22,

27, 28, 33 Pump, 3, 7, 8, 17, 18, 19, 22, 24 Q-Gard A, 3, 11, 12, 17, 18, 21, 22, 29, 30,

31, 32 REJECTION < S.P., 18 Resistivity, 2, 4, 7, 8, 10, 18, 20 RINSING, 32 RO, 2, 3, 5, 7, 8, 10, 16, 18, 19, 21, 23, 29,

33 Screen filter, 15 Simfilter, 11, 13, 17, 19, 21, 22, 26, 27, 28 STANDBY, 7, 9, 10, 11, 12, 13, 15, 16, 19, 20,

28, 29, 30, 31 START AUTOCLEAN, 15, 19 SYSTEM RINSE, 10, 29 TANK FULL, 7, 10, 11, 12, 13, 15, 16, 17

OPERATE/STANDBY MEASURE

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FIGURE 1

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FIGURE 2


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FIGURE 5

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MANUAL

MILLIPOREMILLIPORE

(Orderedseparately)

SIMFILTER


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Millipore Water Filtration Instructions