Operating Manual Reverse Osmosis Water Purifier MELAdem 55 Dear Doctor, Thank you for placing your trust in this reverse osmosis water purifier. Since 1951, MELAG has specialised in the production of sterilisation equipment for medical practice. During this period, our family-owned and operated company has succeeded in becoming a leading manufacturer of sterilisation equipment. More than 450,000 MELAG appliances worldwide testify to the exceptional quality of our sterilizers. Before using the MELAdem 55 please study this operating manual carefully. In order to ensure a long working life for your reverse osmosis water purifier and to preserve its value, please make sure that it is serviced regularly. MELAG management and personnel. Technical details are subject to modification without prior notice
CONTENTS 1 Installation... 3 2 Information on components of the system... 3 3 Placing into operation for the first time... 5 4 Connection of the MELAdem system... 6 4.1 Connection of the MELAdem system to a Cliniklav 25 autoclave... 6 4.2 Connection of the MELAdem system to an autoclave Type 25... 7 5 Maintenance instructions... 8 5.1 Replacement of the Pre-filter... 8 5.2 Replacement of the activated carbon filter... 9 5.3 Replacement of the mixed-bed resin cartridge in the ion-exchanger... 9 5.4 Quality test for the permeate... 9 6 Technical Data...10 Contents
Operating Manual MELAdem 55 1 Installation The MELAdem 55 demineralises water using the principle of reverse osmosis. Incoming water at mains pressure is passed through a semi-permeable membrane contained in a reverse-osmosis module. The mineral content of the water which permeates the membrane is reduced by approximately 95 %. The incoming water is thus split up into two parts: a demineralised permeate, and a part with increased salt concentration (concentrate), which is disposed of. In order to ensure that even poor quality mains water is purified sufficiently for the operation of medical equipment e.g. an autoclave, the permeate water from the reverse-osmosis module is also passed through an ion exchange unit. This contains an ion-exchange resin which is able to reduce any residual mineral contents of the permeate to a minimum. A storage container is provided in which the purified water can then be stored. It can be connected by a pipe directly to the autoclave. When the storage container is full, the water inlet valve closes automatically. All operations are controlled by water pressure. 2 Information on components of the system 1. Mains water supply connection 2. Pre-filter 3. Activated carbon filter 4. Ion exchanger 5. Reverse osmosis module 6. Storage container 7. Concentrate outflow pipe 1 5 to feed water intake of the 2 3 4 7 Sensor feed water Concentrate out flow pipe Illustration 1 Components of the MELAdem 55 Page 3
1: Mains water supply connection The water purifier is connected to the mains supply via a 3/4 stop tap, which is normally left on at all times. The stop tap should be fitted with a non-return valve and an air-release valve in order to prevent water flowing back into the mains supply. It should only be closed if the system is not going to be used for a period of time (see Section 5 Maintenance instructions here), or during servicing and maintenance work. We also recommend fitting a Water Stop (MELAG Art. No.: 01056), in order to prevent damage due to leaks. 2: Pre-filter A pre-filter in an exchangeable filter cartridge helps to protect the sensitive reverse-osmosis membrane. It removes suspended particles, rust and other undesirable matter from the incoming mains water. The cartridge should be exchanged at least every 6 months, or more frequently if the water supply contains particularly high levels of impurities. 3: Activated carbon filter Further protection is provided for the reverse osmosis membrane by an activated carbon filter, again in an exchangeable cartridge. The activated carbon filter is intended primarily to remove free chlorine, which would damage the reverse-osmosis membrane. The activated carbon cartridge should also be replaced every 6 months, or more often if the chlorine level of the water supply is high. 4: Ion exchanger The permeate from the reverse osmosis module flows into an ion exchanger, where it is demineralized (conductivity < 1µs). The ion exchange resin in the storage container element should be renewed when it is exhausted. 5: Reverse osmosis module The reverse osmosis module is the key element in the water purifier. It consists of a thin, wound polyamide membrane. In addition to colloids, it also holds back many organic substances such as hydrocarbons, chloro-hydrocarbons, phenols, pesticides etc. The retention capability of the reverse osmosis filter is approx. 95%. The water which has passed through the filter, known as the permeate, flows on to the ion exchanger. The residual concentrate is disposed of. 6: Water storage tank After passing through the ion exchanger, the demineralised water is led into a plastic storage container where it is stored until needed. The water storage tank is equipped with a shut-off valve that stops the water feed when the water level reaches the maximum of approx. 15 litres. When this valve is closed, the shut-off valve of the reverseosmosis unit also closes, which then stops the flow of untreated water. An electrical float switch provides a signal to the autoclave type 25 if there is not enough water in the water tank (< 3 litres). The permeate storage tank (for the output water) is directly connected to the autoclave if it is equipped for automatic water replenishment feed (see Section 4 Connection of the MELAdem system here). In such cases, the autoclave will intake demineralised water from the lower-lying water storage tank. 7: Connection of the drainage hose for used water The concentrate from the reverse osmosis is led away for disposal through the concentrate outflow pipe. If the system is connected to a Cliniklav 25 autoclave or an autoclave type 25, the drainage hose for used water is connected to the drainage hose of the autoclave itself. Page 4
Operating Manual MELAdem 55 3 Placing into operation for the first time When placing the device into operation for the first time, please proceed as follows: 1. Remove the enclosure lid from the unit: unscrew the screws, and carefully remove the enclosure lid in an upward direction. 2. Use the enclosed screws to mount the unit to a mounting bracket on the wall, or in a lower cabinet. Install the unit so that it is possible at all times to exchange the filter. 3. Place the water storage tank in the lower cabinet, or next to the unit on the floor (see Section 4 here). 4. Remove the black closure flaps from the connections on the device, and keep them in a safe place (you will need them again when you shut down the device, or move it to another place). 5. Hook up the lines as shown in the illustration and description in Section 2 here. All the connecting lines on the unit have been designated by adhesive labels. The hose connections are delivered with threaded fittings, clamping rings, and coupling rings (union nuts). Do not allow these hoses to kink (twist or curl). 6. Remove the container element from the ion exchanger. This is necessary to prevent rinse water from damaging it. 7. Open the feed for the untreated water, and check the threaded fittings to make sure that there is no leakage. 8. Disconnect the hose screw connection from the reverse osmosis unit to the internal storage tank on the latter and place the hose end in an outflow, floor drain or a bucket. 9. Unscrew the filter housing of the subsequent ion exchanger (4), remove the mixed-bed resin cartridge and screw on the empty filter housing to flush the unit. 10. Open the raw water tap and let the raw water run through the unit for ca. 20 minutes in order to free the unit from preservatives and dust residue. 11. Connect the raw water tap after flushing. 12. Unscrew the filter housing of the subsequent ion exchanger. Attention: the filter housing is full to the brim with water. 13. Pour off the water in the filter housing. Replace the mixed-bed resin cartridge in accordance with the section 5.3 and screw-on the filter housing again. 14. Screw on the house screw connection from the reverse osmosis unit to the internal storage tank to the latter 15. Open the raw water tap. Check whether the reverse osmosis unit and the hose connections are free from leaks 16. Allow the water storage tank to fill for approx. 1.5-2 hours, and check the function of its shut-off valve. When the tank is completely full, the valve in the tank and in the reverse-osmosis unit will close. This means that no concentrate will flow. 17. Do not use the contents of the first tank filling (the preservative contained in the system will pollute the first tank filling). One tank filling will take approx. 3-4 h, depending on the pressure and temperature of the untreated water. 18. Rinse the enclosure and put the container element back in its place. 19. Check the quality of the permeate with a conductivity tester. Replace the enclosure lid onto the unit. The system will now function completely automatically. Page 5
4 Connection of the MELAdem system 4.1 Connection of the MELAdem system to a Cliniklav 25 autoclave Connections seen from below Feed water 3/4 Cooling water3/4 Wastewater water purifier Wastewater Cliniclave 25 6 Wall mounted trap with double hoze nuzzle 8 Outlet stop trap 1/2 3/4 with air release and non return valve with Y- connection 9.1, 9.2, 9.3 Water stop, consisting of control unit, solenoid valve and water sensor 11 Pressure hose for water purification system 12 Pressure hose for cooling water 12.1 Connection for hose cooling water 3/4 13 Pipe for wastewater DN22 13.1 Connection for pipe waste water DN 22 Cliniklav 25 14 Pressure hose for feed water supply 14.1 Connection for Pressure hose feed water supply 15 Hose for wastewater for water purification system Illustration 2 Cliniclave 25, complete with lower cabinet and water treatment unit (view from behind) 15.1 Connection for pressure hose waste water MELAdem 55 16 Hose for feed water for storage tank 17 Water purifier (reverse osmosis system 18 Storage tank for water purification system The MELAdem 55 reverse-osmosis system can be directly connected to autoclaves that have been prepared for connection of a non-pressurized automatic water feed system. With such a configuration, the autoclave directly pulls demineralised water out of the deeper-lying water storage tank. Please follow the steps below to connect the MELAdem reverse-osmosis system to such a properly prepared autoclave: 1.Install the reverse-osmosis system as described in Section 3 Placing into operation for the first time above. 2.Use the 1/2" delivered pressure hose with 3/4" fittings to connect the suction element of the permeate storage tank to the feed-water connection of the autoclave. 3. Connect the drain hose of the water-treatment unit to the drain hose connection of the autoclave. Page 6
Operating Manual MELAdem 55 4.2 Connection of the MELAdem system to an autoclave Type 25 6 Wall mounted trap with double hoze nuzzle 8 Outlet stop trap 1/2 3/4 with air release and non return valve with Y- connection 9.1, 9.2, 9.3 Leak detector, consisting of control unit, solenoid valve and water sensor 11 Pressure hose (2 pieces) 13 Wastewater hose DN22 14 Pressure hose for feed water supply 15 Wastewater hose for water purification system 15.1 Connection for waste water hose 16 Feed water hose to storage tank 17 Water treatment unit (reverse osmosis unit) 18 Storage tank for water treatment unit 19 Sensor for feed water shortage Illustration 3 Autoclave Typ 25, complete with lower cabinet and water treatment unit (view from behind) The MELAdem 55 reverse-osmosis system can be directly connected to autoclaves that have been prepared for connection of a non-pressurized automatic water feed system. With such a configuration, the autoclave directly pulls demineralised water out of the deeper-lying water storage tank. Please follow the steps below to connect the MELAdem reverse-osmosis system to such a properly prepared autoclave: 1. Install the reverse-osmosis system as described in Section 3 Placing into operation for the first time above. 2. Use the 1/2" delivered pressure hose with 3/4" fittings to connect the suction element of the permeate storage tank to the feed-water connection of the autoclave. 3. Connect the drain hose of the water-treatment unit to the drain hose of the autoclave. Page 7
5 Maintenance instructions The following maintenance tasks should be carried out at the stated intervals in order to ensure trouble-free operation: Frequency Maintenance task Daily Check the permeate with the conductivity tester (with the Cliniklav 25 autoclave or the autoclave type 25, this will take place automatically, before every program run). Every 6 months Replace the pre-filter Every 6 months Replace the activated carbon filter As necessary (if conductivity values are poor) Renew the ion-exchange resin cartridge At regular intervals Check the tubes and threaded connections for leaks, compressions or kinks (twists or curls) Various measures are necessary before or after periods of inoperation: Period of inoperation Up to 2 weeks More than 2 weeks On resuming operation after more than 4 weeks Precautionary measures Turn off water intake Turn off water intake, empty storage container Swill out equipment and storage container, and install new prefilter, activated carbon filter and ion exchange resin 5.1 Replacement of the Pre-filter Turn off the mains water supply Unscrew the filter cylinder (a) from the head (b) Remove the filter unit (1) and place the new filter unit in the cylinder Take the sealing ring out of the cylinder (a), clean, give a slight coating of silicone and replace Screw back the cylinder by hand (do not use tools) Check that all parts sit tightly, with no leaks. Check that all parts sit tightly, with no leaks. Illustration 4 Pre-filter Page 8
Operating Manual MELAdem 55 5.2 Replacement of the activated carbon filter Turn off the mains water supply. Unscrew the filter cylinder (a) from the head (b) Remove the activated carbon filter unit (1) and place the new activated carbon unit in the cylinder (with the arrow pointing upwards!) Take the sealing ring out of the cylinder (a), clean, give a slight coating of silicone and replace Screw back the cylinder by hand (do not use tools) Check that all parts sit tightly, with no leaks. Illustration 5 Activated carbon filter NOTE! It is important to exchange the filter unit regularly in order to avoid damage to the reverse osmosis module which would shorten its operational life. 5.3 Replacement of the mixed-bed resin cartridge in the ion-exchanger When the mixed-bed resin is exhausted (inadequate water quality of the permeate) then it must be exchanged: Turn off the mains water supply and if necessary empty the storage container Unscrew the cylinder (a) from head (b) Take out the container element (1), remove the lid and pour out the exhausted resin Refill with 0.5 litre fresh resin (the contents of one package), knocking the element to compact the resin, so that the entire contents can be included Close the lid of the container element Take the sealing ring out of the cylinder (a), clean, grease slightly and replace Re-insert the resin unit with the three feet on the underside Tighten the cylinder by hand (do not use a tool) Check that all parts sit tightly, with no leaks. Illustration 6 Ion-exchanger 5.4 Quality test for the permeate The quality of the permeate must be regularly checked. The Cliniklav 25 autoclave and the type 25 autoclave have an integrated conductivity tester. In the initial operating state of the autoclave type 25, you can display the conductivity by pressing the button Water. At the Cliniklav 25 autoclave the conductivity can be displayed at any time by pressing the button. The system will automatically measure the conductivity before every program run. If the water quality is poor, the autoclave display will show the error message Water quality poor, and no program will start. The quality of the permeate should therefore be regularly tested, in order to allow prompt maintenance of the water treatment system. If the MELAdem system is not connected to the autoclave, you should regularly check the permeate with a conductivity tester. Page 9
6 Technical Data Water source Bacteriological quality Membrane Permeate output Mains water supply Drinking water TFC-bacteria resistant, wound module max. 200 litre/day (at 4.5 bar/25 C) Retention capability RO Rated retention capability approx. 95% Conductivity of purified water (permeate) Water pressure min/max. - approx. 20-30 µs/cm from 600 µs intake water - < 1 µs/cm from 600 µs intake water with ion exchanger 2 bar to 6 bar Water temperature min./max. 5 C to 35 C Water ph-value min./max. 4.0 to 10.0 Total mineral content of mains water Iron content of mains water max. 1500 mg/l max. 0.1 mg/l Yield approx. 20-25 % Pre-filter I Fine particulate filter 10, 5 µm Pre-filter II Activated carbon 10 Post-treatment Dimensions H x W x D Overall weight (with filters) Capacity, storage container Dimensions, storage container H x W x D Length of inlet / outlet pipes Ion exchanger, contents approx. 0.5 litre resin approx. 445 mm x 390 mm x 130 mm approx. 12 kg approx. 15 litre approx. 350 mm x 270 mm x 230 mm approx. 1500 mm Page 10 Rev.: 1 14/0068 55 BA_eng_doc