Manual Servicio Pretratamiento

Pretreatment Components
BASIC / STANDARD
Service Manual
Edition: 1/03.11
Part no.: 636 210 1
Fresenius Medical Care
Table of contents
1
Index
Important information
2.1
2.1.1
Preface........................................................................................................................................ 2-1
Structure of the Service Manual .................................................................................................. 2-1
2.2
How to use the Service Manual................................................................................................ 2-2
2.3
2.3.1
2.3.2
2.3.3
Notes........................................................................................................................................... 2-3
Significance of the warnings........................................................................................................ 2-3
Significance of the note ............................................................................................................... 2-3
Significance of the tip .................................................................................................................. 2-3
2.4
2.4.1
2.4.2
2.4.3
Brief description ........................................................................................................................ 2-4

Operator information.................................................................................................................... 2-5
Guarantee / warranty................................................................................................................... 2-6
Technical documentation............................................................................................................. 2-6
2.5
2.5.1
2.5.2
2.5.3
2.5.4
Warnings .................................................................................................................................... 2-7

Basic warnings ............................................................................................................................ 2-7
Electric hazards ........................................................................................................................... 2-7
Chemical hazards........................................................................................................................ 2-7
Biological hazards ....................................................................................................................... 2-8
2.6
Addresses .................................................................................................................................. 2-9
Component overview
3.1
3.1.1
3.1.2
Components of the water pretreatment system ..................................................................... 3-1

Water pretreatment component overview / STANDARD........................................................ 3-2
Water pretreatment component overview / BASIC................................................................. 3-3
Feed water inlet unit

4.1
4.1.1
Component overview wall-mounted prefiltration unit ........................................................ 4-1

Prefiltration unit 1, 1 1/4, 1 1/2................................................................................................ 4-2
4.2
4.2.1
4.2.2
Installation.................................................................................................................................. 4-3
Installation / start-up requirements .............................................................................................. 4-3
Data reporting.............................................................................................................................. 4-3
4.3
4.3.1
4.3.2
4.3.3
Specifications ............................................................................................................................ 4-4

Specifications / data sheet........................................................................................................... 4-4
Operating conditions.................................................................................................................... 4-5
Configuration options................................................................................................................... 4-5
4.4
Maintenance............................................................................................................................... 4-6
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4.5
4.5.1
4.5.3
4.5.4
Functional description .............................................................................................................. 4-7

Design of components ................................................................................................................. 4-7
4.5.1.1 Water inlet unit ............................................................................................................. 4-7
Component function..................................................................................................................... 4-7
4.5.2.1 Stop valve..................................................................................................................... 4-7
4.5.2.2 Water meter - optional.................................................................................................. 4-7
4.5.2.3 Backwashable prefilter 105 m .................................................................................... 4-7
4.5.2.4 Solenoid valve .............................................................................................................. 4-8
4.5.2.5 Pipe disconnector ......................................................................................................... 4-9
Prefiltration rack with particle filter (optional) ............................................................................. 4-10
Component description.............................................................................................................. 4-10
4.6
4.6.1
4.6.2
4.6.3
Options ..................................................................................................................................... 4-11

Prefiltration rack with particle filter (option)................................................................................ 4-11
Pressure reducer - optional ....................................................................................................... 4-11
Configuration options (feed water tank)..................................................................................... 4-11
4.5.2
Booster pump
5.1
Booster pump assembly CRN5-8 component overview ........................................................ 5-1
5.2
5.2.1
5.2.2
Installation.................................................................................................................................. 5-2
Important start-up information...................................................................................................... 5-2
5.2.2.1 Booster pump assembly connection ............................................................................ 5-2
5.2.2.2 Connection to the domestic water supply network ....................................................... 5-3
5.2.2.5 Overview of electrical connections ............................................................................... 5-9
Data reporting ............................................................................................................................ 5-13
5.2.3
5.3
5.3.1
5.3.2
Specifications .......................................................................................................................... 5-14

Specifications / data sheet......................................................................................................... 5-14
5.3.1.1 Performance characteristics ....................................................................................... 5-14
5.3.1.2 Volumetric capacity - diagram .................................................................................... 5-15
Operating conditions.................................................................................................................. 5-15
5.4
Maintenance ............................................................................................................................. 5-16
5.5
5.5.1
Error messages........................................................................................................................ 5-17

Malfunctions, causes and correction ......................................................................................... 5-17
5.6
5.6.1
5.6.2
Functional description ............................................................................................................ 5-18

Design of components ............................................................................................................... 5-18
5.6.2.1 Control unit ................................................................................................................. 5-18
5.6.2.2 Base load and peak load pump.................................................................................. 5-19
5.6.2.3 Alternating pressure situations ................................................................................... 5-19
5.6.2.4 Run-dry protection ...................................................................................................... 5-19
5.6.2.5 Tank operation ........................................................................................................... 5-19
5.6.2.6 Automatic turnoff ........................................................................................................ 5-19
Functional description................................................................................................................ 5-20
5.6.3.1 Setting the system to the Standby mode.................................................................... 5-20
5.6.3.2 Selector switch functions............................................................................................ 5-20
5.6.3
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Pumps
6.1
Pump CM5-5 component overview ....................................................................................... 6-1
6.2
6.2.1
6.2.2
6.2.3
Installation.................................................................................................................................. 6-2
Important start-up information ..................................................................................................... 6-2
Data reporting.............................................................................................................................. 6-2
6.3
6.3.1
6.3.2
Specifications ............................................................................................................................ 6-3

Specifications / data sheet (CM5-5) ............................................................................................ 6-3
6.4
Maintenance............................................................................................................................... 6-4
6.5
6.5.1
6.5.2
Error messages on pumps ....................................................................................................... 6-5

Visual indication on CM5-5.......................................................................................................... 6-5
6.5.1.1 Alarm messages overview ........................................................................................... 6-5
Pump malfunctions overview....................................................................................................... 6-6
6.6
6.6.1

Design of components................................................................................................................. 6-7
Media filters (sand filters / Birm filters)

7.1
Component overview sand filters S140, S200, S300, S400 ................................................ 7-1
7.2
Component overview Birm filters B140, B200, B300, B400................................................ 7-2
7.3
7.3.1
7.3.2
7.3.7
Installation of the media filters (sand / Birm).......................................................................... 7-3

Important start-up information ..................................................................................................... 7-4
7.3.2.1 Start-up of the sand filters / Birm filters ........................................................................ 7-4
7.3.2.2 Valve heads and drain restrictor................................................................................... 7-5
7.3.2.3 Valves in the control head ............................................................................................ 7-9
Programming the control for sand filters / Birm filters................................................................ 7-11
7.3.3.1 Control / display ......................................................................................................... 7-11
7.3.3.2 Control / control elements .......................................................................................... 7-11
7.3.3.3 Control / programming................................................................................................ 7-11
Data reporting............................................................................................................................ 7-23
Use of Birm for improved water quality..................................................................................... 7-24
7.3.5.1 Removal of iron using "Birm" as filter media in the sand filter.................................... 7-24
7.3.5.2 Alarm limits for water substances............................................................................... 7-24
Birm filter settings ...................................................................................................................... 7-26
7.3.6.1 Weekly / semi-weekly backwash................................................................................ 7-26
7.4
7.4.1
7.4.2
7.4.3
Specifications .......................................................................................................................... 7-29

Specifications / sand filter data sheet ........................................................................................ 7-29
Specifications / Birm filter data sheet ........................................................................................ 7-30
7.5
Maintenance............................................................................................................................. 7-32
7.6
7.6.1
Error messages ....................................................................................................................... 7-33

Sand filter / Birm filter malfunctions overview............................................................................ 7-33
7.7
7.7.1

Design of components............................................................................................................... 7-34
7.3.3
7.3.4
7.3.5
7.3.6
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7.7.2
Particle filter (Big Blue) 20"

8.1
Component overview particle filter....................................................................................... 8-1
8.2
8.2.1
8.2.2
Installation.................................................................................................................................. 8-2
Data reporting .............................................................................................................................. 8-2
8.3
8.3.1
8.3.2
Specifications ............................................................................................................................ 8-3

Specifications / data sheet........................................................................................................... 8-3
8.3.2.1 Particle filter selection table.......................................................................................... 8-3
8.4
Maintenance ............................................................................................................................... 8-4
8.5
8.5.1
8.5.2

Design of components ................................................................................................................. 8-5
Component description................................................................................................................ 8-5
Softener
9.1
Component overview softener E080(B), E150(B), E225-T, E300, E400 Magnum .............. 9-1
9.2
9.2.1
9.2.2
9.2.3
Modification of the softener settings in case of high brine concentrations in combination

with Kinetico-Autorol retrofit kits............................................................................................. 9-3
Settings for CP 216...................................................................................................................... 9-3
Settings for CP 213...................................................................................................................... 9-3
Settings for CP 210...................................................................................................................... 9-4
9.3
9.3.1
Installation.................................................................................................................................. 9-5
9.4
9.4.1
9.4.2
9.4.5
Display and operating elements............................................................................................... 9-6

Display during operation .............................................................................................................. 9-6
Programming the control unit....................................................................................................... 9-7
9.4.2.1 Control / display............................................................................................................ 9-7
9.4.2.2 Programming the control .............................................................................................. 9-7
Important start-up information.................................................................................................... 9-13
9.4.3.1 Softener start-up procedure ....................................................................................... 9-14
Start-up procedure for E080(B),/ E150(B), E225-T, E300, E400............................................... 9-16
9.4.4.3 Brine tank ................................................................................................................... 9-22
9.4.4.5 Triplex operation E225-T............................................................................................ 9-23
9.4.4.6 Alternating or parallel operation ................................................................................. 9-24
Data reporting ............................................................................................................................ 9-44
9.5
9.5.1
9.5.2
9.5.3
9.5.4
Specifications .......................................................................................................................... 9-45

Specifications / data sheet......................................................................................................... 9-46
Restrictor inserts depending on pressure range........................................................................ 9-47
Softener capacities .................................................................................................................... 9-48
9.4.3
9.4.4
vi

7.7.2.1 Backwash ................................................................................................................... 7-34
7.7.2.2 Flow velocities ............................................................................................................ 7-35
7.7.2.3 Feed water bypass ..................................................................................................... 7-35
7.7.2.4 Efficiency .................................................................................................................... 7-35
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9.5.5
9.5.4.1 Softener selection table.............................................................................................. 9-49

9.5.4.2 Triplex softener (E225-T) ........................................................................................... 9-50
Removal of iron and manganese using a softener .................................................................... 9-50
9.6
Maintenance............................................................................................................................. 9-51
9.7
9.7.1
Error messages ....................................................................................................................... 9-52

Softener malfunctions overview................................................................................................. 9-52
9.8
9.8.1
9.8.2
9.8.3

Design of components............................................................................................................... 9-55
Functional description Triplex operation E225-T ....................................................................... 9-56
10 Activated carbon filter

10.1
Component overview A050, A100, A150, A300, A400 ....................................................... 10-1
10.2
10.2.1
10.2.2
10.2.3
Installation................................................................................................................................ 10-2
Installation / start-up requirements ............................................................................................ 10-2
Important start-up information ................................................................................................... 10-3
Start-up of the activated carbon filter......................................................................................... 10-4
10.2.3.1 Valve heads and drain restrictor................................................................................. 10-4
10.2.3.3 Control unit design ..................................................................................................... 10-8
Programming the control unit .................................................................................................. 10-10
10.2.4.1 Control / display ....................................................................................................... 10-10
10.2.4.2 Control / operating elements .................................................................................... 10-10
10.2.4.3 Control unit ............................................................................................................... 10-11
Data reporting.......................................................................................................................... 10-21
10.2.4
10.2.5
10.3
10.3.1
10.3.2
Specifications ........................................................................................................................ 10-22

Specifications / data sheet....................................................................................................... 10-22
Operating conditions................................................................................................................ 10-24
10.3.2.1 Activated carbon filter (Single) selection table ......................................................... 10-25
10.3.2.2 Activated carbon filter (double) selection table......................................................... 10-25
10.4
Maintenance........................................................................................................................... 10-27
10.5
10.5.1
Error messages ..................................................................................................................... 10-28

Activated carbon filter malfunctions overview.......................................................................... 10-28
10.6
10.6.1
10.6.2
Functional description .......................................................................................................... 10-29

Design of components............................................................................................................. 10-29
Component description............................................................................................................ 10-29
11 USER RELEVANT Operational data acquisition / maintenance

11.1
Operational data acquisition / daily report............................................................................ 11-2
11.2
System handling instructions report water pretreatment ................................................ 11-5
11.3
11.3.1
Maintenance............................................................................................................................. 11-9
Maintenance intervals for water pretreatment components....................................................... 11-9
11.3.1.1 Feed water inlet unit ................................................................................................... 11-9
11.3.1.2 Sand filter ................................................................................................................... 11-9
11.3.1.3 Particle filter ............................................................................................................... 11-9
11.3.1.4 Softener.................................................................................................................... 11-10
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11.3.1.5 Activated carbon filter ............................................................................................... 11-11

11.3.1.6 Water leakage indicator............................................................................................ 11-11
12 SERVICE RELEVANT Reports

12.1
12.1.1
12.1.2
12.1.3
12.1.4
12.1.5
12.1.6
Operational qualification......................................................................................................... 12-1

Start-up report............................................................................................................................ 12-1
Water pretreatment settings reports .......................................................................................... 12-6
Coarse filter and booster pump assembly settings report ......................................................... 12-6
Sand filter settings report........................................................................................................... 12-8
Activated carbon filter settings report ...................................................................................... 12-10
Softener settings report ........................................................................................................... 12-12
12.2
12.2.1
12.2.2
12.2.3
Maintenance ........................................................................................................................... 12-14

Important information on maintenance procedures ................................................................. 12-14
Accessories and supplies for maintenance procedures .......................................................... 12-15
Maintenance report.................................................................................................................. 12-15
12.3
12.3.1
Tools and test equipment ..................................................................................................... 12-19

Test equipment ........................................................................................................................ 12-19
13 Definitions
13.1
Definitions and terms .............................................................................................................. 13-1
13.2
Abbreviations........................................................................................................................... 13-1
13.3
Symbols.................................................................................................................................... 13-1
14 Appendix
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Chapter 1: Index
Index
Abbreviations 13-1
Importance of the instructions 2-2
Activated carbon filter 10-1
Important information 2-1
Activated carbon filter

malfunctions overview 10-28
Improved water quality 7-24
Activated carbon filter settings

report 12-10
Addresses 2-9
Alternating or parallel operation
9-24
Maintenance intervals 11-9

Maintenance report 12-15
Softener selection table 9-49
Manual regeneration 9-14
Softener settings in case of high

brine concentration 9-3
Basic warnings 2-7

Biological hazards 2-8
Note, significance 2-3
Brief description 2-4
Softener settings report 12-12

Start-up report 12-1
Symbols 13-1
System handling instructions
report Water pre-treatment 11-5
Booster pump 5-1
Softener 9-1
Softener capacities 9-48
Media filters (sand filters / Birm

filters) 7-1
Selection table activated carbon

filter (Single) 10-25
Softener malfunctions overview

9-52
Manually starting the regeneration

9-21
Appendix 11-1, 12-1
Selection table activated carbon

filter (double) 10-25
Notes 2-3
T
Target group 2-5
Technical documentation 2-6
Chemical hazards 2-7

Coarse filter and booster pump
assembly settings report 12-6
Operational data acquisition / daily

report 11-2
Operational qualification 12-1
Operator information 2-5
Warnings 2-7
Operator responsibility 2-6
Warnings, significance 2-3
Definitions and terms 13-1

Disclaimer of liability 2-6
Water pretreatment / BASIC 3-3
Duties of the responsible

organization 2-5
Tip, significance 2-3
Particle filter (Big Blue) 20" 8-1

Preface 2-1
Prefiltration rack with particle filter

4-10
Electric hazards 2-7
Prefiltration unit 4-2
Error messages on pumps 6-5
Pressure reducer 4-11
Pumps 6-1
Water pretreatment / STANDARD

3-2
Water pretreatment component
overview 3-2, 3-3
Water pretreatment settings
reports 12-6
Pump malfunctions overview 6-6
Feed water bypass 7-35

Feed water inlet unit 4-1
Sand filter malfunctions overview

7-33
Guarantee / warranty 2-6
Sand filter selection table 7-25,

7-31
Sand filter settings report 12-8
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Chapter 1: Index
1-2
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Chapter 2: Important information
Important information
2.1
Preface
2.1.1
Structure of the Service Manual

This Service Manual contains a number of individual components or
overall concepts that are not products of Fresenius Medical Care
Deutschland GmbH.
Due to the standardization of documents, the structure for standardized
Service Manuals was applied to list the contents for service technicians
in their usual workflow.
Each component is therefore described in this Service Manual as an
individual device using the general structure.
When applying the master structure, empty chapters were omitted if the
chapter contents were not applicable.
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2-1
2.2
How to use the Service Manual

Identification
The document can be identified by the following information on the title

page and on the labels, if any:
Edition of the document
Part number of the technical document
Page identification
The page identification 1-3, for example, refers to Chapter 1, page 3.
Editorial information
The editorial information 1/01.05, for example, refers to: 1st edition,
January 2005.
Organization of the
chapters
To facilitate the use of documents from Fresenius Medical Care, the

organization of the chapters has been standardized in all manuals.
There may therefore be chapters within this document without any
content. Chapters without content are identified.
Illustrations
The illustrations used in the documents (e.g. screens, photos, etc.) may
differ from the original if this does not have any influence on the
function.
Importance of the
instructions
This document is part of the accompanying documents and is an

essential part of the device. It includes information necessary for use,
programming and start-up of the device.
This document must be studied carefully before attempting to operate
the device.
Before the responsible organization may begin operating the device,
the individual responsible for the operation must have been instructed
by the manufacturer on how to use the device and must be thoroughly
familiar with the contents of the document.
The device may only be operated by individuals certificated to have
been instructed on the proper operation and handling of the system.
2-2
Changes
Changes to the technical document will be released as new editions or

supplements. In general, this manual is subject to change without
notice.
Reproduction
Reproduction, even in parts, only with written approval.
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2.3
Notes
2.3.1
Significance of the warnings
Warning
Advises the operator that failure to observe this information can result
in personal injury.
Warning
Advises the operator that failure to observe this information can cause
damage to the equipment.
2.3.2
Significance of the note
Note
Information alerting the operator to the fact that failure to follow the
steps as specified may result in the specific function not being executed
correctly, not being executed at all, or not producing the desired effect.
2.3.3
Significance of the tip
Tip
Information providing useful tips for easy handling.
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2-3
2.4
Brief description
Design BASIC /
STANDARD
Components
The water pretreatment may consist of the following individual

components
Feed water inlet unit (single components A-F)
Booster pump
Media filter (sand filter / Birm filter)
Particle filter (Big Blue)
Softener
If necessary, additional modules can be connected upstream or
downstream for improved quality.
The water pretreatment components must be installed in a dry, dustfree room. The responsible organization must ensure that the design
specifications of the pretreatment components comply with the
requirements of the other components used. This applies especially to
the following system components such as reverse osmosis system,
permeate ring main and dialysis systems.
As the complete system consists of separate, individual systems, the
responsible organization is responsible for the complete system.
2-4
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2.4.1
Operator information
Target group
The water pretreatment may only be installed, operated and used by

individuals with the appropriate training, knowledge and experience.
Assembly, extensions, adjustments, modifications or repairs may only
be carried out by the manufacturer or persons authorized by him.
Duties of the responsible

organization
The responsible organization assumes the following responsibilities:

Compliance with the national or local installation, operation, use and
maintenance regulations
Compliance with the accident prevention regulations
Correct and safe condition of the water pretreatment.
Permanent availability of accompanying documents.
The water pretreatment consists of components designed to improve
the permeate conductivity and is extended with additional components
to a complete water treatment system for use in a dialysis unit by the
responsible organization.
The water pretreatment must be installed in a dry room not reserved for
medical use. The staff call should also be connected. The responsible
organization must ensure that the technical adjustments of water
pretreatment match the requirements of the other components and that
they make up the complete system.
This applies especially to the following system components such as:
Rooms with outlets and drains for the installation of the water
pretreatment
Leakage protection systems
Sampling site in the soft water supply line
Sampling sites in the ring main system
Alert systems for malfunctions (alarms)
Operational organization
The components of the water pretreatment must be easily accessible
from all sides. The responsible organization must ensure that its
operators have been trained.
Operators of the water pretreatment, the reverse osmosis system and
the dialysis systems must have received instructions on how to operate
the system.
The responsible organization should inform the local water supplier of
the dialysis operation and insist on early provision of data regarding
water composition, availability etc.. This measure does not relieve the
responsible organization of its obligation to regularly check the feed
water composition.
Samples for microbial testing must therefore be collected from the
system and from the individual parts of the system in accordance with
the applicable regulations.
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As the water supply system consists of a series of smaller systems, the

responsible organization is responsible for the complete water supply
system.
Operator responsibility
When entering parameters, the following must be observed:

The parameters entered must be verified by the operator, i.e. the
operator must check that the values entered are correct. If the
verification reveals a deviation between the desired parameters and
the parameters displayed, the setting must be corrected before
activating the function.
The actual values displayed must be compared with the desired
values specified.
Disclaimer of liability
Should the responsible organization wish to use other consumables

and accessories than those listed in the accompanying documents, the
responsibility to ensure the correct function of the device lies exclusively
with the responsible organization. The applicable legal regulations must
be complied with (e.g. in Germany the Medical Device Directive, MDD
and the MPBetreibV = German regulation for the operation of medical
products).
The manufacturer does not assume any responsibility or liability for
personal injury or other damage and excludes any warranty for damage
to the components of the water pretreatment resulting from the use of
non-approved or unsuitable consumables or accessories.
2.4.2
Guarantee / warranty
Guarantee
The extent of the guarantee is stipulated in the respective purchase

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

regulations.
Proper function of the water pretreatment components is guaranteed for
the period specified in the sale contract.
Any use of the device which is not in accordance with its intended use
will void any liability and warranty.
2.4.3
Technical documentation
On request, descriptions and other documents are made available by
the manufacturer. These are intended to support trained personnel of
the responsible organization in servicing and repairing the device.
2-6
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2.5
Warnings
2.5.1
Basic warnings
Warning
The design of the water pretreatment components must comply with
the requirements of the Fresenius Installation Guideline (IGL)
2.5.2
Electric hazards
Warning
Danger to life caused by electrical voltage.
Touching live parts will cause an electric shock.
Before opening electrical devices, disconnect the power plug.
Actuating the ON/OFF switch stops operation of electrical devices,
but does not disconnect the system from the supply voltage!
Warning
The national standards and regulations must be observed when
connecting the system to the power supply system.
2.5.3
Chemical hazards
Warning
Use of protective equipments
Rubber gloves (acrylonnitril latex, cotton-lined) should be worn to avoid
contact of chemicals or disinfectant with the skin.
When working with acidic substances:
Wear goggles! Observe the safety precautions of the concentrated
substance used!
In the event of contact with acid:
Eye: Immediately flush with gently flowing water for 15 minutes.
Skin: Use soap under flowing water for neutralization.
Ingestion: Do not induce vomiting, but have the person affected drink
plenty of still water. Seek medical advice.
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Warning
The system may only be disinfected after previous consultation with the
manufacturer of the system or by personnel authorized by the
manufacturer.
2.5.4
Biological hazards
Warning
Risk of infection
Observe the applicable local laws and regulations concerning handling
of potentially infectious material.
2-8
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2.6
Addresses
Please address any inquiries to:
Manufacturer
Fresenius Medical Care AG & Co. KGaA

D-61346 Bad Homburg
Germany
Phone: + 49 (0)6172 609-0
www.fmc-ag.com
International
service

Deutschland GmbH
Service Support International
Hafenstrae 9
D-97424 Schweinfurt
Germany
Phone: +49 (0)9721 678-333 (Hotline)
Fax: +49 (0)9721 678-130
Local
service
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2-10
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Chapter 3: Component overview
Component overview
3.1
Components of the water pretreatment system

The following pages show the two overviews of the BASIC and
STANDARD water pretreatment system.
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3-1
3-2
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Soft water monitoring unit / AquaSOFT
Prefiltration Rack with particle filter (optional)
A050
A100
A150
A300
A400
E080
E150
E225-T
E300
E400
Birm filter
B140
B200
B300
B400
Booster pump
Particle filter Big Blue, 5 m (20)
Sand filter
S140
S200
S300
S400
Media filter
Tubing
A Stop valve
B Water meter (optional)
C Backwashable prefilter 105 m
D Solenoid valve
E Pipe disconnector
F Pressure reducer
Feed water tank
3.1.1
Softener
Water pretreatment component overview / STANDARD
1/03.11
Service Manual
SM-EN
1/03.11
Soft water monitoring unit / AquaSOFT
Prefiltration Rack with particle filter (optional)
A050
A100
A150
A300
A400
E080
E150
E225-T
E300
E400
Sand filter
S140
S200
S300
S400
Birm filter
B140
B200
B300
B400
Media filter
A Stop valve
B Water meter (optional)
C Backwashable prefilter 105 m
D Solenoid valve
E Pipe disconnector
F Pressure reducer
Feed water tank
Booster pump
Tubing
3.1.2
Softener
Water pretreatment component overview / BASIC
3-3
3-4
Service Manual
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1/03.11
Chapter 4: Feed water inlet unit
4.1
Component overview wall-mounted prefiltration unit
Part number:
Complete assembly description
F00002261
BASIC Feed water inlet unit 1 1/4" (Inline operation)
F00001403
BASIC Feed water inlet unit 1" (Tank operation)
INLINE OPERATION
POS
Description
Stop valve
Backwashable prefilter (105 m)
Solenoid valve
TANK OPERATION
Note:
An additional leakage detector (6328611), which switches the solenoid valve, must be implemented.
D
Pipe disconnector (Inline operation)
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4-1
4.1.1
Prefiltration unit 1, 1 1/4, 1 1/2
Part number:
F00001116
Prefiltration unit complete 1"
F00001117
Prefiltration unit complete 1 1/4
F00001118
Prefiltration unit complete 1 1/2
POS
Description
Stop valve
Backwashable prefilter
Solenoid valve (24 V)
Pipe disconnector
Particle filter (Big Blue) (5 m); 20
Drain kit
Duplex softener (option)
Electronics unit
Leakage sensor
4-2
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1/03.11
4.2
Installation
4.2.1
Installation / start-up requirements
General information
Note
Start-up of the system must be performed by a trained technician. The
wiring must be adapted to fit the respective field of application.
Note
Prior to its start-up, check the system for damage caused during
transport. If there are signs of damage to the electric components, do
not turn the system on.
4.2.2
Data reporting
Note
Reports for the items of the operational qualification listed below
are available as master copies in chapter 12:
Start-up
Setting
Maintenance
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4-3
4.3
Specifications
4.3.1
Specifications / data sheet
Rated output of RO system

Feed water path
Type, size
Tank operation
Inline operation
Rack operation
1 1/4
1 1/2
Rated flow
1.5m/h
25 L/min
2.9 m/h
48 L/min
5.8 m/h
97 L/min
Peak performance during softener regeneration
2.4 m/h
40 L/min
4 m/h
67 L/min
7.8 m/h
130 L/min
12kg empty;
17kg empty;
22kg empty
~17 kg; operation
~21 kg; operation
~27 kg; operation
Weight
~42 kg
Weight
~46 kg
Weight
~52 kg
Kv
2.2 m/h
2.5 m/h
6.0 m/h
Maximum pressure
8.0 bar
8.0 bar
6.8 bar
Ambient temperature
145 C
145 C
145 C
Water temperature
1-36 C
1-36 C
1-36 C
230 V 50 Hz
230 V 50 Hz
230 V 50 Hz
1700 x 1200 x 800
1700 x 1400 x 800
1700 x 1500 x 800
1 1/4
External thread
1 1/4
External thread
1 1/4
External thread
Weight
Weight without rack
Operating weight approx.
Operating data
Voltage supply
Floor space
Prefiltration rack
(HxWxD in mm)
Connections
Inlet and outlet
4-4
Service Manual
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1/03.11
4.3.2
Operating conditions
For information regarding the operating conditions refer to the latest
edition of the Installation Guideline (IGL).
4.3.3
Configuration options
Possible configurations:
Configuration with AquaSOFT (see chapter 10)
Automatic backwash function
Timer
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4-5
4.4
Maintenance
Note
The information given below is summarized for all water
pretreatment components in Chapter 14 (Appendix).:
Important information on maintenance procedures
Accessories and supplies
Test report - maintenance
Overview / maintenance intervals for water pretreatment
components
Explanations for the test report
4-6
Service Manual
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4.5
Functional description
4.5.1
Design of components
4.5.1.1
Water inlet unit
Water inlet unit

Components:
A) Stop valve
B) Water meter (optional)
C) Backwashable prefilter (105 m)
D) Solenoid valve
E) Pipe disconnector
F) Pressure reducer (optional)
F) Drain
Standard configuration
The standard configuration of a feed water inlet path consists of the stop
valve, a backwashable prefilter, a solenoid valve, a pipe disconnector
and a drain connector.
4.5.2
Component function
4.5.2.1
Stop valve
The function of the stop valve is to stop the water supply for servicing to
perform maintenance procedures. The stop valve is provided with a
sampling port for the collection of feed water samples.
4.5.2.2
Water meter - optional

An optional water meter can be installed to document the water
consumption.
4.5.2.3
Backwashable prefilter 105 m

The backwashable prefilter is installed in the feed water path upstream
of the solenoid valve to prevent contamination and therefore an early
failure of the solenoid valve.
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4-7
In its standard version, the backwashable prefilter has 105 m filter

inserts. As an option this prefilter can also be designed with a 50 m
filter insert.
As the first filter in the complete water pretreatment system, this insert
is usually exposed to a high concentration of particles. Regual
backwashing of the filter during non-dialysis hours must therefore be
ensured to prevent early pressure drops. This can either be done
manually (by turning the rotary pin 180 clockwise) or with the automatic
backwashing feature.
The automatic backwashing feature is available as an option. It should
always be used in combination with a timer to be able to define a fixed
backwash time.
4.5.2.4
Solenoid valve
Function
The feed water inlet solenoid valve is used to disconnect the water
supply in case of a leakage. In case of rack installation it is activated by
a single-station leakage detection or in case of wall-mounted installation
by a leakage detector.
Usage as tank fill valve
In combination with a feed water tank, the feed water inlet solenoid
valve is also used as a tank fill valve. In this case, the solenoid valve is
controlled by a float switch which is supplied with the feed water tank.
Manual opening
If necessary, the solenoid valve can be opened manually.

If the solenoid valve is manually bypassed, the room
must never be left unattended.
Otherwise the valve must be left in its original position.
Normal condition
(original position)
Valve open
(manually bypassed)
In case of a power failure push the lever in and turn it by 90. In this position it is automatically locked and the valve is permanently open.
Water supply is therefore still ensured even without power supply.
Note
Without power supply, leakage monitoring is not active.
After dialysis hours, the valve should be closed again by unlocking to
stop the water supply in case of leakage.
4-8
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4.5.2.5
Pipe disconnector
If the inlet pressure drops, the pipe disconnector ensures a
disconnection from the system (DIN EN 1717) as requested by the
Drinking Water Decree if there is a risk of back-contamination.
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4-9
4.5.3
Prefiltration rack with particle filter (optional)
Prefiltration rack with particle filter (optional)

Components:
Stop valve
Solenoid valve (24 V)
Pipe disconnector
Particle filter (Big Blue) (5 m); 20
Drain kit
Electronics unit
Leakage sensor
4.5.4
4-10
Component description
Stop valve
(see chapter 4.5.2.1 , page 4-7)
Solenoid valve
Pipe disconnector
Particle filter (Big Blue)

5 m
see chapter 8 (particle filter)
Drain kit
The drain kit is used to direct the draining water to the drain in the
building.
see chapter 9 (Softener)
Electronics unit
The electronics unit supplies the connected components with electrical

voltage.
Leakage sensor
The leakage sensor detects (inadvertent) water leakage. In this case,

the connected valve is closed. An audible alarm and a red LED indicator
signal a leakage alarm.
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4.6
Options
4.6.1
Prefiltration rack with particle filter (option)
4.6.2
Pressure reducer - optional

An optional pressure reducer can be installed in the feed water path. Its
function is to avoid pressure peaks and thus to limit the system load. A
pressure reducer is recommended if the static pressure at the user
points exceeds 5 bar.
The installation of a pressure reducer is recommended in case of
variations in pressure caused be pressure increases / domestic water
supply system. As an option, a domestic water station can be used
instead of a backwashable prefilter. It includes the backwashable
prefilter and a pressure reducer unit.
4.6.3
Configuration options (feed water tank)

If a feed water tank is installed, it will have the requested system
disconnection. In this case the installation of a pipe disconnector is not
required.
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4-11
4-12
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Chapter 5: Booster pump
Booster pump
5.1
Booster pump assembly CRN5-8 component overview
Part number:
F00001935
Booster pump assembly (vertical pumps CRN5-8)
B1
W2
D
A
POS
Description
Connection to water supply

(Possible on both sides. The connection which is not used must be provided with a cap nut)
B1
Pump 1 (vertical pump CRN5-8)
B2
Pump 2 (vertical pump CRN5-8)
Control unit
Pressurizer vessel
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1/03.11
5-1
5.2
Installation
5.2.1
General information
Note
Note
5.2.2
Important start-up information
Booster pump assembly (CRN5-8)

The pumps must be ventilated prior to start-up of the switching unit.
5.2.2.1
Booster pump assembly connection

The suction line can be connected either on the right or on the outer
left of the booster pump assembly. In case of tank operation it is
recommended to connect two suction tubes in parallel to avoid
pressure drops in the suction line.
The pressure port is located in the center and can be connected
using a tubing or a pipe for a fixed connection. A high-pressure
tubing is included in the accessories package of the system.
After connection to the water supply, both pumps must be ventilated
by opening the vent screws.
5-2
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5.2.2.2
Connection to the domestic water supply network
Positioning the pressure switch
Note
If a pipe separator or a pressure reducer is installed on the outlet side
of the booster pump, the pressure sensor must always be installed after
these components. For the installation, remove the screw-type adapter
in the outlet block and integrate it after the pipe disconnector.
The pressure switch installed at the water inlet ensures protection
against running dry. Upon delivery, the pressure switch is set to 1 bar.
It is recommended to retain this setting. If the pressure in the water inlet
drops below 1 bar, the booster pump assembly will be stopped. If this
dynamic minimum pressure is not reached, it is recommended to use a
feed water tank.
State upon delivery: Dismounting the adapter
State upon delivery: When the system is supplied, the pressure
sensor is installed with an adapter at the pump outlet, this adapter
must be removed and must be installed after the pressure reducer
and the pipe separator.
The pressure sensor is installed on the outlet side after the pressure
reducer and the pipe separator.
Pressure switch installation position
Pressure switch installation position and connection (run-dry protection)

Pressure switch installation position (run-dry protection)
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5-3
Pressure switch installation position and connection

Pressure switch installation position (after pipe separator and
pressure reducer)
Booster pump assembly with pump switching

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

Electrical connection of the pressure sensor
5-4
Service Manual
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1/03.11
Connection of the pressure switch

Pressure switch connection
Connection 1: white
Connection 2: brown
Pressure sensor connection

Pressure sensor connection
Connection 1: brown
Connection 2: white
Verification / setting of the pressure switch
Reference point on the scale

Locate the reference point.
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5-5
Rotate the selector fully counter-clockwise.

The selector must first be rotated fully counter-clockwise.
Adjust the selector to the reference point.

Rotate the selector approx. of a turn clockwise until the figure "1"
is above the reference point.
Adjust the selector to the reference point.

Adjust the scale reference point.
The pressure switch is now set to 1 bar. This means the operating
pressure of the pump is 1 bar.
Due to the pressure switch's hysteresis, the switch-off pressure is
slightly below 1 bar (approx. 0.5 bar).
5-6
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5.2.2.3
Connection to a feed water tank
Note
In case of tank operation, the tank must be provided with a float switch
which will open a contact if the tank is empty. This contact is connected
in the pump inlet instead of the pressure switch.
Tank connection
The inlet of the booster pump assembly is directly connected to the
outlet of the tank using the pump connection set no. 6319211.
The suction line can be connected either on the right or on the outer
left of the booster pump assembly.
In case of tank operation it is recommended to connect two suction
tubes in parallel to avoid pressure drops in the suction line.
The pressure port is located in the center and can be connected
using a tubing or a pipe for a fixed connection. A high-pressure tubing
with a length of x cm is included in the accessories package of the
system.
The pressure sensor is connected directly to the pump outlet.
The inlet pressure switch on the water inlet side of the pump is not
used during tank operation. In its place the float switch (see
illustration) must be wired in. This must be done during installation.

A float switch which is installed in the feed water tank ensures rundry protection.
The brown and white conductor must be connected.
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5-7

Installation position of the pressure sensor on the pump outlet (state
upon delivery)
Electrical connection of the pressure sensor in the switching cabinet.
5-8
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5.2.2.4
Power supply
A 400 V; 3 N ~; 50 Hz; 16 A three-phase current connection is required
to supply the pump switching unit with voltage.
Connection of a leakage detector

The floating contact of a leakage detection system can be connected to
the booster pressure assembly. The contact must be closed if there is
no leakage and must open if a leakage occurs.
It is recommended to use the insert of the leakage detecting system. It
can be connected directly to the pump control (see illustration )
Connection option for a leakage detection system (jumper must be removed)

Remove the jumper and connect the line to the floating contacts of
the leakage detector.
5.2.2.5
Overview of electrical connections
Note
When the system is supplied, positions 1 to 6 are wired.
Positions 7 and 8 must be adjusted by the technician depending on
the respective situation (feed water tank or direct operation).
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5-9
POS
Connections
Pump 1
Pump 2
Power cable
Temperature switch 1
Temperature switch 2
Pressure sensor
Connection for run-dry protection (pressure switch or float switch)
Connection option for the floating contact (e.g. leakage detector)
5-10
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5.2.2.6
Settings on the booster pump assembly (CRN5-8)

Should the booster pump assembly not operate as desired when it is
supplied, the setting of the pressure level and of the delay times can be
checked and changed.
Pressure levels
Pressure
type
Description
Pmin
Operating pressure for base load and peak load pump (0-10 bar):
Pmin is set to the pressure at which the pump is to start.
Pmax1
Cutoff pressure level for the peak load pump (difference to Pmin), (0-4 bar):
If this pressure is achieved at parallel operation, the peak load pump is turned off. Pmax1 should
be set to a value between Pmin and Pmax2.
Pmax2
Cutoff pressure level for the base load pump (difference to Pmax1), (0-2 bar):
If this pressure is reached during operation of one pump, this pump is switched off. Pmax2
should be set to approx. 0.5 bar below the pump's nominal pressure.
Caution:
If a pressure reducer was installed downstream of the booster pump assembly, the pressure
reducer should be set to 6 bar minimum as the pressure on the pressure sensor can otherwise
never reach the cutoff pressure.
Note
The settings of max1 and Pmax2 are difference values which add to the
lower pressure set.
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5-11
Calculation example
Setting Pmin: 3 bar
Setting Pmax1: 2 bar
Setting Pmax2: 1 bar
This means
Operating pressure level (Pmin) = 3 bar

Cutoff pressure level for peak load pump (Pmax1) = 5 bar
Cutoff pressure level for base load pump (Pmax2) = 6 bar
Delay times
T = Over-run (02 min):
Minimum operation time of the pump to prevent permanent start and
stop of the pump. Default setting: 2 minutes. When set to "0 minutes",
the minimum operation time is approx. 30 seconds.
T = run-dry delay (02 min):
time after which die pumps are turned off in case the pump runs dry.
Default setting: 0 minutes.
When set to "0 minutes", the delay time is approx. 10 seconds.
Motor protection
Potentiometers P1 and P2 are set to the nominal current of the motor.
Motor protection setting (nominal current of
pump 1 and pump 2)
Setting Pmax2: Cutoff pressure level for base
load pump (difference to Pmax1)
Setting Pmax1: Cutoff pressure for peak load
pump (difference to Pmin)
Setting Pmin: Operating pressure for base
load and peak load pump
Minimum operation time setting

Water alarm delay time setting
5-12
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5.2.3
Data reporting
Note
Documentation of the settings in the Settings report
As part of the Operational Qualification, the settings must be
documented in the Settings reports upon start-up.
Note
Start-up
Setting
Maintenance
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5-13
5.3
Specifications
5.3.1
Parameter
Function / specifications
Usage
Pressure increase
Component
Booster pump assembly
Type
CRN5-8
Connection
1 1/4", external thread
Sealing material
Shaft seal carbon silicide, o-ring EPDM
Installation position
Vertical
Operating current
2.5 kW / kVA
Power supply
380400 V; 3N~ 50 Hz; 16A
Operating pressure, adjustable
16 bar (preset to x bar)
Switch-off pressure
16 bar (preset to x bar)
Pressure, minimum
2.2 bar (in case of tank operation)
Pressure, maximum
6.5 bar
Water temperature, minimum
1 C
Water temperature, maximum
40 C
Flow rate
5.7 m/h at 3.8 bar (at a nominal pumping head of 37.8m)
Ambient temperature, max. 40C
5.3.1.1
Performance characteristics
Parameter
Electrical connection
380400 V 3N~ 50 Hz
Power consumption
2.5 kW / kVA
Operating pressure
Adjustable 16 bar (preset to x bar)
Cutoff pressure
Adjustable 16 bar (preset to x bar)
Dimensions (width/ height/depth)
Width / height / depth 101 cm / 92 cm / 45 cm
5-14
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5.3.1.2
Volumetric capacity - diagram
(two pumps active)
Pumping head
(one pump active)
Delivery volume
5.3.2
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5-15
5.4
Maintenance
Note
pretreatment components in Chapter 14 (Appendix):
Test report maintenance
components
5-16
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5.5
Error messages
5.5.1
Malfunctions, causes and correction
Setting the system to the Standby mode

Components:
A) Operating mode selector switch
A
B
C
B) Operation / malfunction indicator (pump 1 and pump 2)

C) Run-dry / leakage indicator
D) Main power switch
Selection
Description
Green LED flashing.
The motor protection has operated. No automatic confirmation after

correction of the problem.
Possible causes:
Motor current too high.
The motor temperature is too high, possible defective pressure
sensor causing permanent operation and overheating of the pump.
Confirmation:
Set the operating mode selector switch to "OFF" and then back to
"ON" again. If necessary, allow the motor to cool down first.
Red LED illuminated
System was turned off due to lack of water or leakage. Automatic

confirmation after correction of the problem.
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5-17
5.6
5.6.1

Components:
C
B1
B2
A) Feed water connection

B1) Pump 1 (vertical pump CRN5-8)
B2) Pump 2 (vertical pump CRN5-8)
C) Control unit
5.6.2
D) Pressurizer vessel
The booster pump assembly (CRN5-8) is an assembly which is ready
for connection in accordance with the requirements for the minimum
flow pressure with normal centrifugal suction pumps.
The booster pump assembly in conjunction with the two vertical pumps
provides increased operational safety of a water treatment system from
Fresenius Medical Care.
The booster pump assembly is used for the alternating control of two
booster pumps. Automatic switching ensures uniform distribution of
stress on both connected pumps and prevents damage to the pump
caused by prolonged idle times when it is not in use. To increase the
efficiency, the second pump will be turned on additionally in peak
situations.
The booster pump assembly is intended for the pressure increase in the
feed water section of the water pretreatment system. It can be used
both for increasing the pressure downstream of a feed water tank and
for direct connection to the feed water line.
5.6.2.1
Control unit
The electronic control of the booster pump assembly controls and
monitors the two connected pumps.
5-18
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5.6.2.2
Base load and peak load pump

The control differentiates between a base load and peak load pump. If
water requirements are low, only the base load pump will deliver, if
water requirements rise the peak load pump will also be switched on.
This concept has the advantage that the pumps are always operated in
their optimum performance range. This contributes to a high efficiency
of the complete system. The base load and the peak load pump will be
activated alternating after each restart. This ensures uniform wear of
both pumps.
5.6.2.3
Alternating pressure situations

If the system is not in operation and the pressure in the system drops
below the start-up pressure level (Pmin), the base load pump will start.
If the pressure drops again to the start-up pressure (Pmin) caused by
an increasing water demand, the peak load pump will also be started.
If, with decreasing water demand, the pressure in the system rises
above the pressure level (Pmax 1), the peak load pump will be stopped.
If water consumption stops, the pressure will rise above the pressure
level (Pmax 2) and the basic load pump will be stopped.
5.6.2.4
Run-dry protection
The adjustable pressure switch at the booster pump assembly inlet
protects the system against running dry and ensures a minimum
pressure of 1 bar at the booster pump inlet.
If the pressure at the inlet drops below 1 bar, first the peak load pump
will stop. If the pressure at the inlet remains below 1 bar after this pump
stop, the base load pump will also be stopped.
5.6.2.5
Tank operation
When operated with a tank, a float switch will be connected instead of
the pressure to ensure protection against running dry.
5.6.2.6
Automatic turnoff
The water temperature is also monitored; if the temperature exceeds
60 C, e.g. by a defect of the control unit and a constantly running pump
without water consumption, the respective pump will be stopped.
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5-19
5.6.3
5.6.3.1

Components:
A) Operating mode selector switch
A
B
C
D
5.6.3.2
B) Operation / malfunction indicator (pump 1 and pump 2)

C) Run-dry/leakage indicator
D) Main power switch
After turning on the main power switch and after selection of
automatic 1 + 2 (position as in illustration), the operating mode
switch is used to set the system to the Standby mode.
Selector switch functions
Functions of the selector switch

Components:
D
A) Test mode pump 2

B) Off
A) Test mode pump 1
D) Automatic mode pump 1

E) Automatic mode pumps 1 + 2
D) Automatic mode pump 2
Selection
Description
Automatic mode pump 1
Only pump 1 runs in the automatic mode (e.g. if pump 2 is defective).
Automatic mode pumps 1+2
Both pumps run in the automatic mode. Depending on the consumption

volume the pumps are started and stopped (default setting). The green
LED of the active pump is constantly illuminated to indicate operation.
Automatic mode pump 2
Only pump 2 runs in the automatic mode (e.g. if pump 1 is defective).
5-20
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Selection
Description
Test mode pump 1
Pump 1 runs irrespective of the prevailing pressures and safety

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

functions. The test mode will be automatically stopped after approx. 1.5
minutes.
Off
Both pumps are off.
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5-21
5-22
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Chapter 6: Pumps
Pumps
6.1
Pump CM5-5 component overview
Part number:
F00002253
Booster pump (CM5-5)
631 248 1
Pressure Manager PM122 (2.2 bar) for CM5-5
POS
Description
Connection to water supply
Stop valve at feed water inlet (optional)
Booster pump CM5-5
Power connection - not illustrated
Pressure Manager PM1 (optional)
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6-1
Chapter 6: Pumps
6.2
Installation
6.2.1
General information
Note
Note
6.2.2
Pump CM5-5
The pumps must be ventilated prior to start-up of the switching unit.
6.2.3
Data reporting
Note
Start-up
Setting
Maintenance
6-2
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Chapter 6: Pumps
6.3
Specifications
6.3.1
Specifications / data sheet (CM5-5)
Parameter
Component / use
Booster pump / pressure increase
Type
CM5-5
Connection
Rp 1 suction side
Rp 1 delivery side
Material
Stainless steel
Sealing material
FKM
Installation position
Horizontal
Other components
Pressure control
Leakage sensor
Check valve
Operating current
0.9 kW
Power supply
230 V 16 A grounded mains plug
Pressure, minimum
1 bar
Pressure, maximum
6 bar
Water temperature, minimum
0 C
Water temperature, maximum
40 C
Flow rate
6 m at 3 bar
Ambient temperature, max. 55C
6.3.2
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6-3
Chapter 6: Pumps
6.4
Maintenance
Note
pretreatment components in Chapter 14 (Appendix).:
components
6-4
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Chapter 6: Pumps
6.5
Error messages on pumps
6.5.1
Visual indication on CM5-5
6.5.1.1
Alarm messages overview
Pressure-Manager PM1-22 (for CM5-5)

1. Power on / The green indicator lights as soon as the power supply
is connected.
2. Pump on / The green indicator is On when the pump is running.
3. Alarm / The red indicator is On or flashing when the pump was
turned off due to a failure. See overview.
4. [Reset] / This key is used to reset error messages and to activate
/deactivate the "switching operation" function.
Indicator
Alarm
Possible cause
The Alarm
indicator is On.
Running dry
The pump was running without water.
The Alarm
indicator is
flashing.
Switching operation exceeded
The pump has exceeded the admissible

number of times for switching on and off.
Note:
Only indicated of the if the "switching
operation" function is activated.
Service Manual
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1/03.11
6-5
Chapter 6: Pumps
6.5.2
Pump malfunctions overview
Indication
Possible cause
Action required
The green Power on

indicator is not lit.
The fuses of the electrical installation have

blown / have tripped.
Replace the fuses / switch on again. If

the new fuses blow or trip again, check
the electrical connection.
The ground fault interrupter or the voltagecontrolled circuit breaker has tripped.
Switch the circuit breaker on again.
No power supply.
Have the electrical installation checked

by an electronics specialist.
The pressure control unit is defective.
Repair or replace the pressure control

unit.
The power supply to the pump after the

pressure control unit is interrupted.
Check the plug and the cable

connections. Check if the circuit breaker
installed in the pump has tripped.
The motor protection switch has tripped

due to overload.
Check if the motor / the pump is blocked.
The pump is defective.
Repair or replace the pump.

unit.
The pump fails to start

when water is
removed. The Pump
on indicator is Off.
Level difference between the pressure

control unit and the user point to high.
Adjust the installation or select a

pressure control unit with a higher
operating pressure.

unit.
Frequent switching on
and off.
Leakage in the tubing.
Check and repair the tubing.
Check valve leaking.
Clean or replace the check valve.
A valve next to the outlet nozzle of PM 1

has been closed..
Open the valve.
The pump is not able to deliver the

required pumping height.
Replace the pump.
The pressure control unit installed has an

operating pressure that is too high.
Select a pressure control unit with a

lower operating pressure.

unit.
The check valve is blocked in "open"

position.
Clean or replace the check valve.
The green Power on

indicator is On, but the
pump fails to start.
The pump fails to

switch off.
6-6
Service Manual
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1/03.11
Chapter 6: Pumps
6.6
6.6.1
Pump (CM5-5)
Components:
Water supply with stop valve at feed water inlet (optional)
Pump
Power supply
Pressure control
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1/03.11
6-7
Chapter 6: Pumps
6-8
Service Manual
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1/03.11
Chapter 7: Media filters (sand filters / Birm filters)
Media filters (sand filters / Birm filters)
7.1
Component overview sand filters S140, S200, S300, S400
Part number:
F00001842
Sand filter S140
F00001843
Sand filter S200
F00001328
Sand filter S300
F00001329
Sand filter S400
A
B
C
D
E
F
G
H
POS
Description
Outlet block with sampling port and tube connection
Control head
Upper sieve
Riser tube
Filter bed
Tank
Gravel bed
Lower sieve
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7-1
7.2
Component overview Birm filters B140, B200, B300, B400
Part number:
F00002451
Birm filter B140
F00002452
Birm filter B200
F00002453
Birm filter B300
F00002454
Birm filter B400
A
B
C
D
E
F
G
H
POS
Description
Control head
Upper sieve
Riser tube
Filter bed
Tank
Gravel bed
Lower sieve
7-2
Service Manual
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1/03.11
7.3
Installation of the media filters (sand / Birm)
7.3.1
General information
Note
Note
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1/03.11
7-3
7.3.2
Sand filters S140, S200, S300, S400

Birm filters B140, B200, B300, B400
Note
The sand filters / Birm filters must be ventilated upon start-up.
The filter must be filled with the filter material supplied prior to startup. After filling, the filter vessels should be filled completely with
water using the immersion tube. This will facilitate ventilation at startup.
7.3.2.1
Start-up of the sand filters / Birm filters

When the filter has been set up and the control has been
programmed the system must be carefully ventilated and rinsed.
Before this is done, it must be checked that all lines and equipment
upstream of the filter have been thoroughly rinsed. To rinse the filter,
the outlet adapter of the filter must be removed and discarded to the
drain. The water inlet valve must be opened slowly and only partly.
Watch the removal of air until water exits.
When water exists, the tank is thoroughly ventilated during the
backwash phase C1 by the start of a regeneration.
When all air has been removed, the remaining phases are all
skipped after a short rinse by briefly and simultaneously pressing
+ . When ventilation is complete, the water inlet valve can be fully
opened.
Rinsing should be followed by a manual regeneration to check the
drain. In addition, the dynamic pressure of the water supply should
be briefly checked.
When the tank has been rinsed sufficiently, i.e. it has been rinsed
with 5 times the bed volume, the filter outlet can be re-mounted. The
complete water pretreatment system must now be briefly rinsed and
can then be connected to the reverse osmosis system.
The programmed values must be documented in the start-up
report.
7-4
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1/03.11
7.3.2.2
Valve heads and drain restrictor

The drains for all filters must be designed as free drains using the lines
supplied and ensuring that the distances are as short as possible. The
drains are restricted to reduce the flows in the outlet.
S140/ S200
S300 / S400
Sieve for servo flows

Drain restrictor
Drain
Drain
Sand filter TYPE
S140 / B140
S200 / B200
S300 / B300
S400 / B400
Drain rate
~45 L/min
~2000 L/h
~45 L/min
~2000 L/h
~90 L/min
~5400 L/h
~90 L/min
~5400 L/h
Sand filter and Birm filter

restrictor (D)
none
none
10 mm
10 mm
Restrictor for fine-grain

ceramic filter medium*
(D)
6 mm
6 mm
6.5 mm
6.5 mm
Sand filter design
* applies to fine-grain ceramic filter material

Additional restrictor
A reduced drain restrictor is only required for fine-grain ceramic filter

media.
On the S140/200 a small additional restrictor with 6 mm is used in
the drain connection .
When using the S400, a 6.5mm restrictor must be installed.
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7-5
Servo drain line
The large valves of the S300/400 must be provided with a servo

drain line in addition to the drain. The required line is included.
For the rinse time settings, refer to the master copies in the
appendix. These are determined specified values and should be
checked on site (see Operating phases (Service, Backwash, Fast
rinse), page 7-6).
Especially for colloid-forming particles and if no upper sieve is
installed, the backwash-time must be set so as to ensure that the
draining water is largely clear or has the same turbidity as in the
water inlet.
Operating phases (Service, Backwash, Fast rinse)

The control initiates a time-controlled backwash of the filters at defined
intervals. During the first regeneration phase, the backwash phase, the
filter bed media is lifted and separated, and rinsed.
This phase is intended to backwash all collected contaminants to the
drain.
During the following phase, the Fast rinse, the filter bed settles again
and is pre-rinsed to reduce the start-up phase of the filter in service.
The backwash phase generally lasts 5 minutes, but should be
extended depending on the quality of the feed water and the
condition of the drain water on site, until an acceptable drain water
quality is achieved.
Note
The rinse time should be selected so as to rinse for at least 2-3 tank
volumes.
The operation cycles of the filter are therefore divided into three phases:
7-6
Betrieb
Backwash
Schnelles Splen
Service
Backwash
Fast Rinse
Service Manual
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1/03.11
For the rinse time settings, refer to the master copies in the appendix.
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1/03.11
7-7
Backwash times
The backwash must be timed to occur outside the operation time of the
reverse osmosis system. The softener may also not be regenerating.
It must also be ensured that the AquaA does not supply or rinse while
the backwash is in progress, but that a regeneration of the softener,
which may have been initiated by rinsing of the AquaA, can be
completed.
2.5 hours before the backwash of the sand filter, an operation of
10 minutes in the Supply mode using the auto-start and auto-stop
function, and a rinse interval phase, which lasts at least 4 hours,
must therefore be programmed on the AquaA.
Alternatively, the programmed start-stop times and the rinse interval
phase can be used for the calculation, so that the last rinse phase
occurs approx. 2.5 hours before the backwash of the sand filter:
4 hours rinse interval
AquaA
2.5 hours interval
Softener
Sand filter
max. 110 min regeneration

Activated
7-8
Service Manual
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1/03.11
Configuration of the free flow for drains (e.g. rack)

S140/ S200
S300 / S400
7.3.2.3
Valves in the control head

The valves in the S140 / S200 are switched directly and can be opened
manually for rinsing in case of servicing. In the filter S400 with large
valve, the control activates the motor's camshaft which switches the
control valve for the actual poppet valves.
S140/ S200
Drain
S300 / S400
Drain 1
Rinse 2
Outlet
Drain 1
Inlet 4
Inlet 4 and 5
inlet
Outlet 3
Outlet 3
Rinse 2
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7-9
7.3.2.4
Control unit design

On the large valves of the S300/400 and B300 / 400, the housing unit
of the control must be secured on the valve.
This is done by removing the protective cover of the camshaft, by
pushing the spring lever on the end of the shaft outwards and pulling
the shaft a little back so that it is aligned on the front:
Then remove the housing unit from its box and push it fully onto the
rear lugs.
Then slide the shaft back to the front. This may only be done with the
arrow marks being on the top. Refit the protective cover and
reconnect the 12 V AC; 150 mA power supply unit to the control unit.
7-10
Service Manual
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1/03.11
7.3.3
Programming the control for sand filters / Birm filters
7.3.3.1
Control / display
Current display
In the picture shown it is Sunday and the filter is currently regenerating.
During operation, time and day are displayed. The day is indicated by
the triangle which moves from the left to the right.
A bar will be displayed below the date indicating the days during which
a regeneration will take place. In Europe the first day of the week is
generally the Sunday. If a regeneration is in progress, the regeneration
symbol will be displayed.
7.3.3.2
Control / control elements
Display
manual
regeneration
Reg.
Down
Save
Set
7.3.3.3
Up
Control / programming
At the start the control must be set to the correct system configuration.
When inserting the control, the following screens may be displayed:
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1/03.11
7-11
Fig. 1
Example
If 255 A is flashing, the correct system configuration can be selected

directly with the arrow key.
E.g. for S300 / 400 sand filters, 293 F must be selected.
If the correct configuration is flashing, it must be confirmed with Set
.
Fig. 1
Filter valve configuration

Setting for the following filter valves:
263 F
S140 / S200 / A050 / A100 / A150
293 F
S300 / S400 / A300 / A400
Fig. 2
Fig. 2
The control has already filed a configuration and is in progress of

aligning the shaft.
The system configuration must be entered again with a Reset (see
level 4).
7-12
Service Manual
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1/03.11
Fig. 3
Fig. 3
The display shows only dashes. In this case, there is also a stored
configuration, and the control prompts you to enter the current time and
day. This setting is lost in case of a prolonged power loss.
Here it is also recommended to enter the system configuration again
with a Reset (see level 4).
Level 1
Level 1 can only be accessed with a new control after turning power on
or with a Reset (see level 4) for entering basic data.
The arrow keys or are used to scroll, Set is used to release
the value for changing it, the arrow keys are used to change the
value, and Set is used to save the value.
LEVEL 1
Service Manual
Select valve 293 (S300/400) or 263 (S140/200) and

configuration.
Select F for filter mode.
P1
Current time
P2
Current day, identified by the arrow on the upper edge of

the display.
P3
Regeneration time
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7-13
LEVEL 1
P4
Regeneration days 0.599 = interval, days between

regenerations, selection of 0 will activate a 7-days timer:
P5
Rinse days can be activated with [ ] and [ ] or [ ];

if P4 = 0 (Europe: 1 = Sunday)
P6
Backwash time in minutes
P7
and
P8
not used
Level 2
Level 2 is also used to define basic parameters.
This level is accessed by simultaneously pressing the key Up and
Down keys + for 5 seconds.
This can only be done from the normal operation display. (Therefore if
Error 3 or Error 4 is displayed and the system configuration has not yet
been defined or verified,
immediately go to level 4 and make a reset.)
The arrow keys or are used to scroll, Set is used to release the
value for changing it, the arrow keys are used to change the value, and
Set is used to save the value.
LEVEL 2
7-14
P9
Must be set to 1 for the selection of metric units.
P10
Selection of the time display, must be set to 1 for 024 hrs.
P11
Maintenance interval in months recommended 0
P12
Time delay in seconds for remote regeneration default 60
P13
P19
not used
Service Manual
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1/03.11
Level 3 - Operating phases/times

Level 3 is used to display or define the times of the operating phases.
This level is accessed by simultaneously pressing the Set and Down
keys + for 5 seconds.
This can only be done from the normal operation display, not during a
regeneration.
LEVEL 3
C1
Backwash in minutes can be changed
C2C4
not used
C5
Fast rinse in min (can be changed)
C6C8
not used
Level 4 history
Level 4 is used to see the history.
(Possibility in H0 for a reset with the Set key for 5 seconds..
This level is accessed by simultaneously pressing the Set and Up
keys + for 5 seconds. (This can even be done during a
regeneration).
Example
LEVEL 4
H0: F
Filter display (reset by pressing the Set key for

5 seconds.)
H1: 0
(d) days since last regeneration
H2
H16
0 not used
H17: 4
(month) months since service
H18
and
H19
0 not used
Starting a regeneration
When pressing the Reg key, the Reg. symbol will be flashing. This
indicates that a delayed regeneration is due which would start at the
programmed time P3.
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7-15
If the Reg. key is pressed for 5 seconds, the Reg. symbol will be
displayed permanently and a regeneration will be started immediately.
Pressing the Set and Up keys + briefly and simultaneously, will
quickly skip a phase. This will set the remaining phase time, which
is displayed by briefly pressing the Set key , to 0.
A regeneration which has started can be skipped completely by
pressing the Set and Up keys + for 5 seconds.
7-16
Service Manual
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1/03.11
7.3.3.4
Programming table for S140 / S200 or B140 / B200 using the control Logix 762
Level 1
Return to default screen:
From each menu after 30 seconds idle phase.
Operation screen:
Indication of time and current day
Level 1
263
Valve and configuration
Filter
P1
E.g.: 9:30
Current time
P2
upper edge
Current day, days 17 (Europe: 1 = Sunday)
P3
2:00
Backwash time
P4
Regeneration days 0.599 interval, 07 days timer
P5
Rinse days
Rinse days can be activated with and or if P4=0
P6
6 / 8 (Birm 20)

(pure Birm filter, minimum 20 min)
P7
Capacity in m3
P8
Level 2
and for 5 seconds.
Blocking a value with the Reg. key
LEVEL 2
P9
Selection for metric units
P10
Selection of time display 024 h
P11
Maintenance interval in months
P12
60 seconds
Time delay for remote regeneration
P1319
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7-17
Rinse days in P5
Regeneration
Change
...
Yes / No
...
Continue
Level 3
+ for 5 seconds.
Time in minutes: S300 / S400
Manual start of backwash

Time-delayed regeneration
Short regeneration
Immediate regeneration
Regeneration after 5 seconds
Cancel regeneration
+ for 5 seconds
Skip phase
+ briefly
During a regeneration, always the remaining time of the complete
regeneration will be displayed.
Remaining time of the phase displayed with
LEVEL 3
C1
mod
Backwash 1
S140 / B140
= 6 min / 20 min
S200 / B200
= 8 min / 20 min
C2
C3
C4
C5
mod
S140 / B140 = 3 min
Fast Rinse 1
S200 / B200 = 4 min

C6/C
C8
S140 / B140 = 9 min

S200 / B200 = 12 min
7-18
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1/03.11
Level 4
and for 5 seconds
In H0 : for 5 seconds, reset for control - then Reg. for synchronization.
LEVEL 4
H0
Filter display
H1
Days since last regeneration
H6
Total consumption since reset in 1000 000 m3
H17
Months in operation
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7-19
7.3.3.5
Programming table for S140 / S200 or B140 / B200 using the control Logix 762
Level 1
Operation screen:
LEVEL 1
293
Filter
P1
e.g.: 9:30
Current time
P2
upper edge
Current day, arrow 17 (Europe: 1=Sunday)
P3
2:00
Backwash time
P4
Regeneration days 0.5 99 interval, 07 days timer
P5
Rinse days
P6
7 (Birm 20)

(pure Birm filter minimum 20 min)
P7
Capacity in m3
P8
Level 2
and for 5 seconds.
LEVEL 2
P9
P10
P11
P12
60 seconds
P1319
7-20
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1/03.11
Rinse days in P5
Regeneration
Change
...
Yes / No
...
Continue
Level 3
and for 5 seconds
Time in minutes: S300 / S400

Short regeneration
Regeneration 5 seconds
Cancel regeneration
and for 5 seconds
Skip phase
and briefly
Remaining time of the phase displayed with
LEVEL 3
C1
mod
S300 / B300
= 7 min / 20 min
Backwash 1
S400 / B400
= 9 min / 20 min
C2
C3
C4
C5
mod
S300 / B300 = 4 min.
Fast Rinse 1
S400 / B400 = 4 min

C6/C
C8
S300 / B300 = 11 min.

S400 / B400 = 13 min
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7-21
Level 4
and for 5 seconds
In H0 : 5 seconds, reset for control - then Regeneration for
synchronization.
LEVEL 4
H0
Filter display
H1
H6
H17
Months in operation
7-22
Service Manual
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1/03.11
7.3.4
Data reporting
Note
Note
Start-up
Setting
Maintenance
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1/03.11
7-23
7.3.5
Use of Birm for improved water quality
7.3.5.1
Removal of iron using "Birm" as filter media in the sand filter

Alternatively iron and manganese can be removed with Birm. The exact
amount of filter media will be determined and specified by the project
planning team.
Note
When using alternative filter media, different drain restrictors are used.
All other settings are made as specified in the settings table.
7.3.5.2
Alarm limits for water substances
Substance
Alarm limits / range
Iron content
< 4 mg/l
Manganese content
< 0.5 mg/l
Free chlorine
< 0.5 mg/l
pH range / iron removal
6.8-8.0
Iron and manganese removal
8.0-8.5
Manganese removal
8.0-9.0
If iron and manganese are not removed in the softener but in the Birm
filter, the following applies:
Note
Until the backwash 1.7 mg iron per liter of Birm can be removed from
1 m water.
If the water also contains manganese, this value is reduced to
1.2 mg per 1 m.
Based on this information the backwash interval must be calculated.
7-24
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1/03.11
7.3.5.3
Sand filter / Birm filter selection table
Reverse osmosis system rated output
SAND FILTER / BIRM FILTER TYPE

S140 / B140
S200 / B200
S300 / B300
S400 / B400
250
500
750
1000
1250
1500
1750
2000
2250
3000
4000
* at a yield of 70 %
Note
In principle, it may be said that no additional sand filter must be installed
when using a Birm filter since the Birm filter covers the sand filter's
function due to its physical characteristics.
Note
For information regarding sand and Birm layers, backwash times and
space requirements, refer to chapter Specifications / Birm filter data
sheet.
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7-25
7.3.6
Birm filter settings
Note
A reduced drain restrictor is only required for ceramic filter media.
For Birm, the backwash time is increased to at least 20 min.
The water's oxygen content must be at least 15 % of the iron content.
All other settings are made as specified in the sand filter settings
table.
7.3.6.1
Weekly / semi-weekly backwash
For 80 operating hours - weekly backwash:

For a weekly backwash, the following max. contents apply (allocation
RO system dimensions to Birm filter):
80 h
B140
Rated output*
B200
B300
B400
max. mg/l Fe (max. mg/l Fe + Mn)
250
4 (3)
500
2.1 (1.5)
750
1.4 (1)
1000
1.1 (0.8)
1250
0.8 (0.6)
1.4 (1)
1500
1.2 (0.8)
1750
1 (0.7)
2000
0.9 (0.6)
2250
0.8 (0.6)
3000
0.8 (0.6)
0.6 (0.4)
4000
0.5 (0.4)
* at 70 % yield and 80 operating hours a week (corresponding to 15 dialysis shifts of 5 h each + rinsing approx.
5 h)
7-26
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For 50 operating hours - approx. semi-weekly backwash:

For a semi-weekly backwash the following max. contents apply
(allocation RO system size to Birm filter):
50 h
B140
B200
Rated output*
B300
B400
max. mg/l Fe (max. mg/l Fe + Mn)
250
4 (4.5)
500
3.4 (2.4)
750
2.2 (1.6)
1000
1.7 (1.2)
1250
1.3 (1)
2.3 (1.6)
1500
1.9 (1.3)
1750
1.6 (1.2)
2000
1.4 (1)
2250
1.3 (0.9)
3000
0.9 (0.7)
4000
0.8 (0.6)
* at 70 % yield and 50 operating hours between the backwashes (for both tables the following applies:
Calculations with 20 % loss for 3 years of operation).
Note
Depending on the actual operating hours, the actual utilization (HD
consumption) and substances, the backwash interval must be adjusted
proportionally.
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7-27
7.3.7
7-28
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1/03.11
7.4
Specifications
7.4.1
Specifications / sand filter data sheet
Sand filter TYPE
S140
S200
S300
S400
Sand filter design

Support gravel layer
Support layer per tank
25 kg
1 bag
25 kg
1 bag
25 kg
1 bag
25 kg
1 bag
Sand bed per tank
140 liters
250 kg
10 bag
203 liters
325 kg
13 bag
203 liters
325 kg
13 bag
250 liters
400 kg
16 bag
Filter tank size
170 liters
16 x 65
41 x 162 cm
250 liters
18 x 65
47 x 165 cm
250 liters
18 x 65
47 x 165 cm
310 liters
21 x 60
56 x 172 cm
Freeboard +5 cm
45 cm
41 cm
41 cm
41 cm
Weight without water
300 kg
390 kg
400 kg
490 kg
430 kg
550 kg
560 kg
690 kg
Riser tube
Distance above upper edge
of tank
28
2025 mm
28
2025 mm
48.3
0-5 mm
48.3
0-5 mm
Backwash
Rinse volume
Approx. 450 liters
Approx. 700 liters
Approx. 990 liters
Approx. 1260 liters
Backwash flow*
45 L/min
45 L/min
90 L/min
90 L/min
Backwash time
Individually
adjustable
Individually
adjustable
Individually
adjustable
Individually
adjustable
Kv
2.5 m/h
2.8 m/h
7.3 m/h
7.5 m/h
Minimum pressure
2 bar
2 bar
2 bar
2 bar
Maximum pressure
8 bar
8 bar
6.8 bar
6.8 bar
Ambient temperature
1-40C
1-40C
1-45C
1-45C
Water temperature
1-40C
1-40C
1-36C
1-36C
Voltage supply
230 V 60/50 Hz
230 V 60/50 Hz
230 V 60/50 Hz
230 V 60/50 Hz
per power supply unit
12 V~
12 V~
12 V~
12 V~
55x72x200
55x72x200
Space requirements
Floor space
W x D x H in mm
42x60x187
50x60x192
* the values indicated are real values and depend on the prevailing conditions and the actual available pressure.
Service Manual
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7-29
7.4.2
Specifications / Birm filter data sheet
Birm filter TYPE
B140
B200
B300
B400
Birm filter design

Support gravel layer
Support layer per tank
25 kg
1 bag
25 kg
1 bag
25 kg
1 bag
25 kg
1 bag
Sand bed
Sand layer per tank
16.7 liters
25 kg
1 bag
33.5 liters
50 kg
2 bags
33.5 liters
50 kg
2 bags
50 liters
75 kg
3 bags
Birm bed
Birm layer per tank
85 liters
75 kg
3 bags
142 liters
125 kg
5 bags
142 liters
125 kg
5 bags
170 liters
150 kg
6 bags
Freeboard +5 cm
68 cm
57 cm
57 cm
60 cm
Other data: Backwash times*, space requirements, etc. identical to the sand filter specifications
* The backwash times should generally be adjusted to the local water
quality so that the water is largely clear at the end of the backwash time.
With the Birm filter, the usual minimum backwash time is 20 minutes.
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7.4.2.1
Sand filter / Birm filter selection table
Reverse osmosis system - rated

output
SAND FILTER / BIRM FILTER TYPE

S140 / B140
S200 / B200
S300 / B300
S400 / B400
250
500
750
1000
1250
1500
1750
2000
2250
3000
4000
Note
In principle, it may be said that no additional sand filter must be installed
when using a Birm filter since the Birm filter covers the sand filter's
function due to its physical characteristics.
7.4.3
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7-31
7.5
Maintenance
Note
components
7-32
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7.6
Error messages
7.6.1
Sand filter / Birm filter malfunctions overview
Error
Possible cause
Action required
Outflow outside of regeneration
Valves contaminated
Valves leaking due to worn
spring
Water pressure too low
Sieve for servo flow clogged
Rinse valves until free and

remove dirt
Replace spring
Check inlet pressure
Clean sieve for servo flow
Poor or no automated
regeneration
S300/400 sieve for servo flow

clogged.
Regeneration at the wrong time
Check time setting
Correct time setting, if

necessary.
Insufficient RO water supply due

to regeneration.
Regeneration time not offset to

RO rinse time
Set the times appropriately.
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Check the power supply

Check the shaft motor
Check the control
Replace defective components
Clean sieve for servo flow
7-33
7.7
7.7.1
Sand filter / Birm filter design

Components:
Outlet block with sample
ing port and tube connection
Control head
Upper sieve
Riser tube
Filter bed
Tank
Gravel bed
Lower sieve
7.7.2
If the feed water analysis reveals a silt density index of SDI > 3, a sand
filter must be installed to reduce suspended solids.
The sand filter removes particles from the feed water. The filter media
used is garnet which prevents suspended solids from passing through
the spacing between the media granules, which formed when the filter
was filled, at slow flow velocities. The flow velocity of the water in the
sand filter is considerably lower than in the upstream pipes or fixtures.
The water is also forced to find its way through the spacing between the
sand bed. This permits the suspended solids to settle on the sand, or
first to conglomerate before being held back in the spacings. Larger
particles settle immediately on the the surface of the filter bed.
7.7.2.1
Backwash
A sand filter must be backwashed at regular intervals to remove the
retentate. On principle, the filter effect is increased with service life of
the system (formation of a so-called filter cake). For reasons of hygiene,
it is recommended to perform a backwash once a week. If the pressure
drop has increased by 50 %, this is a criteria that a backwash should be
performed. The required frequency may therefore vary depending on
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Service Manual
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1/03.11
the water. During the backwash process, particles on the surface of the
bed, and particles in the spacings are removed and rinsed to drain.
Generally the backwash process is the better, the higher the flow
velocity. However this is restricted by the settling velocity of the filter
material, which may not be removed, and by the practical technical
constraints.
7.7.2.2
Flow velocities
In practice flow velocities around 30 m/h are used for backwashing.
Backwashing can therefore only be done outside operation times. This
can only be avoided by the connection of two sand filters in parallel. For
setting the backwash times, observe the settings in chapter 5
(backwash time).
Note
The use of Birm for iron removal in the sand filter requires that the upper
sieve be provided. The upper sieve which is supplied with the sand filter
is not required if the water contains silicate to improve the rinsing away
of conglomerated particles which have been held back.
7.7.2.3
Feed water bypass

The sand filters S300 and S400 are provided with a feed water bypass.
This ensures a reduced supply flow also during the backwash phase.
7.7.2.4
Efficiency
The efficiency of sand filters depends to a large extent on the flow rate.
The correct design of the sand filter is determined by the project
planning team.
To protect the downstream components, it is recommended to use a 20
m micro-filter in the sand filter's outlet.
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7-36
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Chapter 8: Particle filter (Big Blue) 20"
Particle filter (Big Blue) 20"
8.1
Component overview particle filter
Part number:
TYPE / description complete assembly
F00001222
Single filter Big Blue 20; 5 m
F00001223
Single filter Big Blue 20; 20 m
F00001224
Dual filter Big Blue 20; 5 m
F00001225
Dual filter Big Blue 20; 20 m
C
D
A
E
Dual version:
Single version:
POS
Description
Particle filter
Pressure gauge; inlet / outlet
Sampling port
Connector 1 1/4, external thread
Retaining plate
Drain valve
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8-1
8.2
Installation
8.2.1
General information
Note
The pressure gauges on the fine filters must be pre-assembled so that
they can be easily read from the front or from the top.
Note
electrical connection is to be adjusted to the respective installation
environment.
Note
transport. Do not put the system into operation if components are
damaged.
8.2.2
Data reporting
Note
Start-up
Setting
Maintenance
8-2
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8.3
Specifications
8.3.1
Parameter
Usage
Fine filtration
Components
Filter
Sampling port
Type
Single version / dual version
Connection
1 1/4", external thread
Nominal width
20
Material
HFPP
PVC (tubing)
Sealing material
BUNA N
Filter mesh
5 m / 20 m
Dimensions
675 x 420 (LxH)
Pressure
Maximum
Pressure drop
6.2 bar
0.5 bar
Temperature
Maximum
8.3.2
37.8 C
8.3.2.1
Particle filter selection table
2000 L/h
Permeate volume
4000 L/h
Single 5 m
Single 20 m
Dual 5 m
Dual 20 m
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8-3
8.4
Maintenance
Note
components
8-4
Service Manual
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8.5
8.5.1
Particle filter design single and dual filter

Components:
Particle filter
Sampling port
Connector 1 1/4, external thread
8.5.2
Particle filter
Particle filters are used to adsorb particles which may be released from
water treatment systems and other suspended solids still present in the
feed water.
A 20 m particle filter is connected downstream of the sand filter to
prevent filter media from entering into th supply path.
Another particle filter is installed upstream of the reverse osmosis
system. In the last stage before the system, the water is filtered with a
filtering efficiency of 5 m.
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8-5
8-6
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Chapter 9: Softener
Softener
9.1
Component overview softener E080(B), E150(B), E225-T,

E300, E400 Magnum
Part number:
F00001119
Softener E080(B) Autotrol
F00001120
Softener E150(B) Autotrol
F00001453
Softener E225-T
F00001121
Softener E300 Magnum; not filled
F00001122
Softener E400 Magnum; not filled
E080(B) / E150(B)
E225-T
B
C
D
E
F
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9-1
Chapter 9: Softener
Application example for the use of E300 Magnum / E400 Magnum:
POS
Description
Brine lines
Brine tank
Brine valve tube
Float cup
Grid plate
Brine valve
9-2
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Chapter 9: Softener
9.2
Modification of the softener settings in case of high brine

concentrations in combination with Kinetico-Autorol retrofit
kits
Softener settings in case
of high brine concentration
The following tables show the modified settings for the new softener
heads. These settings have been selected for problems with high brine
concentration.
The rinse times are extended by these times to improve rinsing out of
the brine. This ensures an optimized operation at locations with
problematic operating conditions.
9.2.1
Settings for CP 216
CP 216
9.2.2
Set point
new
C1
C2
30
30
C3
28
38
C4
C5
14
C8
T Reg.
87
106
Settings for CP 213
CP 213
Service Manual
SM-EN
Set point
new
C1
C2
17
17
C3
24
35
C4
C5
15
C8
T Reg.
62
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9-3
Chapter 9: Softener
9.2.3
Settings for CP 210
CP 210
9-4
Set point
new
C1
C2
C3
15
25
C4
C5
10
C8
T Reg.
39
56
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Chapter 9: Softener
9.3
Installation
9.3.1
General information
Note
Note
transport.
If there are signs of damage to the electric components, do not turn
the system on.
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9-5
Chapter 9: Softener
9.4
Display and operating elements
9.4.1
Display during operation
Time / day
Regeneration time
Brine volume
Capacity
Hardness
With alternating operation:

Indication of the number of the tank to be supplied (here: 1 for main)
Remaining system capacity in m with <
or alternating
Flow in L/min with faucet symbol
The following displays alternate in case of parallel operation:
Remaining system capacity of tank 1 with "1"
Remaining system capacity of tank 2 with "2"
Total flow (tanks 1+ 2), with faucet symbol.
When the system has been configured, the display will return to the
operation display from each menu after 30 seconds.
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Chapter 9: Softener
9.4.2
Programming the control unit
9.4.2.1
Control / display
Display
manual
regeneration
Reg.
Down
Save
Set
9.4.2.2
Up
Programming the control

At the start the control must be set to the correct system
configuration.
Fig. 1
Example:
If 255A is flashing, the correct system configuration can be selected

For E080 / 150 sand filters, 278 must be selected, for the 278L triplex
and for the large valves, 298A must be selected.
When the correct configuration is flashing, confirm with Set .
Fig. 1
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9-7
Chapter 9: Softener
Softener valve
configuration
Settings for the following filter valves:

278 A
E080(B) / E150(B)
278 L
E225-T
298 A
E300 / E400
Fig. 2
Fig. 2

aligning the main head (Error3) or the secondary head (Error4).
The system configuration must be entered again with a Reset (see
level4).
Fig. 3
Fig. 3
Here it is also recommended to enter the system configuration again
with a Reset (see level 4).
Level 1
or with a Reset (see level 4) for entering basic data.
For browsing use the arrow keys or , use Set to clear the
value for changing.
The value is changed with the arrow keys and set with Set .
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Chapter 9: Softener
LEVEL 1
Valve 278A (Performa) or 298A (Magnum) with configuration

A (Alternating) for 225-T: 278L
Resin volume in liters
P1
Current time
P2
Current day, identified by the arrow on the upper edge of the

display, from Sunday to Saturday.
P3
Regeneration time for E225-T: Set tanks time-delayed, e.g.

0:00, 1:30 and 3:00 hours).
P4
Regeneration days 0.5-99 = interval for forced regeneration.

Recommended: 2 days!
P5
not used
P6
Regeneration consumption in g/liters; 110 recommended
P7
Estimated capacity in kg CaCO/liter of water can be

changed
P8
Water hardness in mg CaCO/liter of water calculated from

dH *17.86 or *fH*10
Level 2
This level is accessed by simultaneously pressing the Up and Down
key + for 5 seconds.
This can only be done from the normal operation display. (Therefore if
Error3 or Error4 is displayed and the system configuration has not yet
been defined or verified, immediately go to level 4 and make a reset.)
For browsing use the arrow keys or , use Set to clear the
value for modification.
The value is changed with the arrow keys and set with Set .
LEVEL 1
Service Manual
P9
P10
Selection of the time display, must be set to 1 for 024hrs.
P11
P12
P13
Not used with twin systems - default 0 (optional salt sensor)
P14
Brine flow - refill capacity (Brine Refill) in gpm*100 (gpm =

L/min; 3.785 L/g)
P15
Brine flow - suction capacity (Draw Brine) in gpm*100
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9-9
Chapter 9: Softener
LEVEL 1
P16
Select 3, reserve type for E225-T
P17
Not used with alternating operation - for E225-T, reserve

capacity expressed in % in relation to hardness (- see above)
P18
Selection of the flow sensor for E080(B) / E150(B) /225T = 1

but for E300/E400
P19
Must be set to 1 if a valve sensor is integrated (if P18 = 3, then

K-factor)
Level 3 - operating phase times

+ keys for 5 seconds.
regeneration.
LEVEL 1
C1
Backwash in min can be changed
C2
Draw brine in min - defined in P15
C3
Slow rinse in min - can be changed (valve position same as

for draw brine)
C4
Repressurize (equals Standby for E080/150) in min - can be

changed
C5
Fast rinse in minutes can be changed
C6
C7
---
C8
Refill in min - defined in P14
Level 4 history
(Possibility in H0 for a reset with the Set key for 5 seconds).
regeneration).
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Chapter 9: Softener
Example:
LEVEL 4
Service Manual
H0: F
200
liters
Filter display (reset by pressing the

Set key for 5 seconds.)
H1: 0
H2
L/min
Current flow
H3
Water today since last regeneration
H4
Water since last regeneration
H5
2804
Consumption since reset (in 100 m)
H6
Consumption since reset in

1000 000 m
H7
3.84
Average consumption on Sundays
H8
17.4
Average consumption on Mondays
H9
22.46
Average consumption on Tuesdays
H10
21.24
Average consumption on
Wednesdays
H11
20.78
Average consumption on Thursdays
H12
18.58
Average consumption on Fridays
H13
5.36
Average consumption on Saturdays
H14
Service cycle
H15
96
L/min
Peak flow / maximum flow
H16
15:19
Fr
H17:
Months
Months since service
H18
1.234
liters
Water consumption since last

regeneration of tank 1
H19
00
liters
Water consumption since last

regeneration of tank 2
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Day and time of peak flow
9-11
Chapter 9: Softener
Starting a regeneration
When pressing the Reg. key, the Reg. symbol will be flashing. This
programmed time P3.
If Reg. is briefly pressed a second time, a factor x2 will be displayed
after the flashing Reg. symbol, indicating that both tanks will be
regenerated at the set Reg time.
displayed permanently and a regeneration will be started
immediately.
If the Reg. key is again pressed for 5 seconds immediately
thereafter, a factor x2 will be displayed after the Reg. symbol,
indicating that both tanks will immediately be regenerated one after
the other.
A regeneration which has started can be skipped by pressing the Set
and Up keys + for 5 seconds .
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Chapter 9: Softener
9.4.3
Softeners E080(B),/ E150(B), E225-T, E300, E400

The site of installation must be protected from frost and must be
level, the floor load must be sufficient for the weight of the full
softener. A floor drain is also required.
The softener must not be exposed to direct sunlight.
A 50 m particle filter and a pressure gauge for pressure monitoring
must be installed upstream of the softener.
The maximum pressure must not be exceeded; if necessary, a
pressure reducer must be installed.
E080(B) / E150(B)
The installation must be done in compliance with the local

regulations.
The overflow of the brine tank must be directed to the drain and must
also be a free flow design.
E225-T
Apply only small amounts of silicone-based FDA-approved lubricant

to seals and valves.
Tighten plastic screw-connections only by hand.
The drain must be designed as a free flow to prevent backcontamination.
To refill the brine tank use only regeneration salt tablets intended for
softening of drinking water.
When refilling salt, the salt level must always be higher than the brine
level!
E300 Magnum / E400 Magnum:
The design of the softener must ensure that the operating time of one
tank is at least the regeneration time and the time required for the
brine to develop (approx. 3 4 hours), and that regeneration takes
place at least once a day. Make absolutely sure to avoid prolonged
standby times, if necessary regeneration of both tanks must be
started manually or electrically.
Filling on site:
If the softeners are to be filled on site, use the immersion pipe to fill
the tanks completely with water after they have been filled with the
filter material and before mounting the control heads.
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9-13
Chapter 9: Softener
9.4.3.1
Softener start-up procedure

Ventilation, rinsing
When the softener has been set up and the control has been
programmed, the system must be carefully ventilated and rinsed.
upstream of the softener has been thoroughly rinsed. To rinse the
softener, the outlet of the softener must be dismounted and
discarded to the drain. The brine tank should remain empty until
rinsing and ventilation are finished. The water inlet valve must be
opened slowly and only partly. Watch the removal of air until water
exits. When using E300 / 400 softeners, the drain must now be
closed or considerably restricted.
When water exits, the tank or the vessel is not actually completely
ventilated. The air is actually completely removed with the
backwash.
Manual regeneration
When water exists, the tank is thoroughly ventilated during the

backwash phase C1 by the start of a regeneration. When all air has
been removed, the remaining phases are all skipped after a short
rinse by briefly and simultaneously pressing + . When the first
tank has been ventilated, the second tank will also be thoroughly
ventilated during the backwash phase C1 by the start of a
regeneration. The remaining phases can be skipped after a short
rinse.
After both tanks have been ventilated and if ventilation is complete,
the water inlet valve can be fully opened. During rinsing, the dynamic
pressure of the water supply should also be checked. If both tanks
are sufficiently rinsed, i.e.they have been rinsed with 5 times the bed
volume, the softener outlet can be re-mounted. The complete water
pretreatment system must now be rinsed briefly and can then be
connected to the reverse osmosis system.
Refill Phase C8
The brine tank must now be filled by starting a manual regeneration

with Reg. and fast skipping of the phases (by simultaneously
pressing + ) up to the Refill phase C8. It should now be checked
if the programmed time for the refill phase is sufficient for refilling.
(Caution: the required level applies to a brine tank filled at least up
to the brine level with salt). It would be sensible to switch on the
consumers to reach to lower operating pressure.
After the time required for the brine to develop, the first tank can be
regenerated by restarting a manual regeneration. The draw-brine
phase C2 and the slow-rinse phase (phase C3) must now be
checked during their common time to ensure that all of the brine is
drawn in and the residual brine is rinsed out again.
9-14
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Chapter 9: Softener
Please note that, although the slow-rinse phase C3 has the same effect
as the draw-brine phase C2, the system is already rinsed clear to avoid
high concentrations of brine in the standby mode.
Especially for softeners E080(B) and E150(B) it must be ensured
that any residual brine has been rinsed away at the end of C3. This
can easily be verified by taking a taste sample on the drain.
When the first regeneration is complete and the reverse osmosis
system to be supplied continues to run in the rinse mode when the
second regeneration starts, correct switching to the tanks to be
supplied and the programmed times can be checked.
Note
report.
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9-15
Chapter 9: Softener
9.4.4
Start-up procedure for E080(B),/ E150(B), E225-T, E300, E400
Preparation and ventilation

1.
The softener has been set up and the control has been
programmed using the programming table.
2.
The brine tank has been correctly positioned, has been connected
and filled with salt tablets.
The brine tank can then be filed with feed water up to the float cup
to allow the brine in the tank to develop.
3.
Caution:
The softener system must be carefully ventilated.
Close the water supply.

Dismount the outlet tubing on the particle filter and direct it to the
drain.
Slowly open the water supply.
(Important: Do not open completely!
Regeneration of the first tank

4.
Start regeneration with the

key [5 sec], the Standby tank 1 is
ventilated during the Fast Rinse phase C5.
All other phases then are skipped with the key combination + [5
sec.].
5.

key [5 sec], the Standby tank 2 is
ventilated during the Fast Rinse phase C5.
All other phases then are skipped with the key combination + [5
sec.].
6.
Rinsing of both softener tanks for approx. 10 minutes per tank.
Initiation of a manual regeneration with the

key [5 sec], switches
to the other softener tank and this tank can now also be rinsed for
10 minutes.
After rinsing, close the water supply and connect the tubing to the RO
system.
The water supply can then be fully opened.
7.

key [5 sec], the Service tank will now
be completely regenerated. No phases will be skipped and the
times can be checked.
(Important: time for the brine to develop, approx 11.5 hours)
Check that brine is drawn in during phase C2.

Check filling of brine during phase C8. When using softeners
E080(B) and E150(B), the brine tank will also be filled in the auxiliary
position C4, while the other tank is in Service, until the brine valve in
the brine tank closes.
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Chapter 9: Softener
Regeneration of the second tank

8.
The first tank is now properly regenerated.

For a manual regeneration of the second tank, it is necessary to
wait until the brine has developed.
(Important: time for the brine to develop approx. 1,5 hours)
9.

key [5 sec], the Service tank will now
be completely regenerated.
No phase will be skipped. This permits a check of the times of the
individual phases.
10. Check the water hardness at the softener outlet and thus the
softener function.
11. If the water hardness is zero, start-up of the RO system can be
started.
Note
Start another manual regeneration during the start-up.
This causes the tanks to switch, and the second tank can be
checked for proper service.
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9-17
Chapter 9: Softener
9.4.4.1
Valve heads and drain restrictor

The drains for all softeners must be designed as free drains using
the lines supplied and ensuring that distances are as short as
possible.
The drain outlets are restricted to reduce the flows.
E080(B) / E150(B) / E225-T
E300 / E400
Drain restrictor
Connection for drain with restrictor
Softener TYPE
Drain
E080(B)
E150(B)
E225-T
E300
E400
8 -15 L/min
10 -20 L/min
10 -20 L/min
15 -30 L/min
20 -40 L/min
Restrictor hole at
4.5-6 bar
4 mm
4 mm
4 mm
Blue 5.0 mm
Red 5.5 mm
Restrictor hole at
3-4.5 bar
4 mm
4.5 mm
4.5 mm
Red 5.5 mm
Green
6.0 mm
Restrictor hole at
2-3 bar
4.5 mm
5 mm
5 mm
Green
6.0 mm
Without insert
Required drain during

backwash and fast rinse
Use the appropriate restrictors for the pressures to be reached as specified in the table.
The pressure values refer to the pressure indicated at the softener inlet.
Tip
Identification of the restrictors (for E080(B), E150(B) and E225-T):
4 mm has 1 ring
4.5 mm has 2 rings
5 mm has no ring
Restrictor hole
9-18
The restrictor hole of E300 and E400 can be adjusted on site to the
prevailing pressure. The appropriate color is installed.
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Chapter 9: Softener
Servo flow line
The large valves of the E300/E400 must be provided with a servo

drain line in addition to the drain. The required lines are included.
If the drain flow during Backwash and Fast Rinse is too high, a
smaller restrictor can be installed, if necessary. The times should
then be increased accordingly.
For the rinse time settings, refer to the report master copies in the
appendix (see chapter l, page 9-20). These are determined
specified values and should be checked on site.
Configuration of the free flow for drains (e.g. rack)

E080(B) / E150(B) / E225-T
E300 / E400
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9-19
Chapter 9: Softener
Regeneration phases for E080(B) / E150(B) / E225-T / E300 / E400
Fast Rinse
Operation
9-20
Backwash
Draw brine
Pressure
compensation
Filling with brine
Auxiliary and service position for E080(B) and E150(B) / small valve
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Chapter 9: Softener
Auxiliary and service position for E300 and E400 / large valve
Auxiliary position
Service position
The tank which was last regenerated (here always tank 1) remained in
the auxiliary position. When a regeneration is initiated, this tank is
switched from the auxiliary position to the Service position. For small
softeners this means:
Fast rinsing and Service of the tank. For large softeners this means
direct switching from the auxiliary position to the Service position.
The Triplex softener regenerates in one go, i.e. without stop at the
auxiliary position.
Starting a manual regeneration applicable for all softener types
Function
Input
Start time-delayed regeneration
key [press briefly]
Start manual regeneration
key [press for 5 seconds]
Complete regeneration. Cancel
Key combination + [press for 5 seconds]
Skip regeneration phase
Key combination + [press briefly]
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9-21
Chapter 9: Softener
9.4.4.2
Suction tube - injector

The function of the suction tube is to draw in the brine, that of the Refill
Control is filling with brine:
E080(B) / E150(B) / E225-T
Refill
control
9.4.4.3
Brine connection
E300 / E400
Suction tube
Sieve for
servo flows
Suction tube Refill

control
Brine connection
Brine tank
The brine level listed in the specification is a net value. The gross value
takes the offset of the brine valve into consideration.
Depending on the net level X, the brine valves are set to the gross
level H:
Softener TYPE
E080(B)
E150(B)
E225-T
E300
E400
Brine level, net X value
14 cm
30 cm
30 cm
35 cm
45 cm
Lower offset
4 cm
4 cm
4 cm
12.5 cm
12.5 cm
Upper offset
6 cm
6 cm
6 cm
3.5 cm
3.5 cm
Level
24 cm
40 cm
40 cm
51 cm
61 cm
9-22
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Chapter 9: Softener
9.4.4.4
Valves in control head
E080(B) / E150(B) / E225-T
E300 / E400
Inlet 3
Refill 1
Brine
Drain #1
Outlet 4
Rinse
5 and 6
Rinse #2
Outlet #3
Drain 1
Inlet 4
Inlet
#4 and #5
Drain
7.8 and 9
Outlet 3
Rinse 2
The valves in the small head are switched directly and can be opened
manually for rinsing in case of servicing.
The large control heads switch indirectly via servo valves, therefore
each time the valve closes, a small servo flow will exit the servo drain.
Rinsing clear in case of servicing can only be done indirectly. The servo
flow sieve should be regularly checked according the the local
conditions.
To permit operation of the E080(B) / E150(B) with a brine tank, a refill
will be performed in the auxiliary position. This is not required for the
E225-T as it performs a complete regeneration.
9.4.4.5
Triplex operation E225-T

In triplex operation a reserve is required as the softener tanks may all
be empty simultaneously and a tank does not start regenerating before
its minimum reserve has been reached.
The reserve to be set depends on the size of the RO system and the
prevailing hardness. The values specified in the selection table are
reference values for a standard consumption profile.
An immediate regeneration P16 =3 with a defined reserve is selected in
the control.
The E225-T is equipped with one control on each tank valve. These
controls are interconnected by a cable which they use for mutually
signalling if a regeneration can be started or not. With the exception of
the regeneration time, the controls all have the same setting.
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9-23
Chapter 9: Softener
9.4.4.6
Alternating or parallel operation

For alternating operation no reserve is required (apart from C5 and C8
requirements for small softeners) as the exhausted tank can directly
switch to the regenerated tank. The softeners are therefore preferably
operated alternating!
For parallel operation a reserve is mandatory. Selectable in the program
mode:
Flow
Soft water supply
Efficiency
high
medium
low
P16 = 0, Time-delayed regeneration with Smart Reserve (Reserve set in P17)
(see diagram above)

A regeneration will only start at the regeneration time which is set in P2.
A tank will regenerate when its remaining capacity has reached the
minimum capacity limit.
Calculation of the water consumption volume of the following day is
based on the daily average water consumption (which is stored in the
history), plus a safety reserve of 20%.
If necessary, the tanks are regenerated successively, starting with the
tank with the higher consumption. This option allows correction of the
reserve to optimize salt consumption.
P16 = 1, time-delayed regeneration with defined reserve.
(see diagram above)

Regenerations do not start before the time set in P2. A tank is
regenerated when its remaining capacity is below the critical capacity
(set in P17). If the capacity of a tank drops below the limit of 50%, this
tanks will be regenerated. The 764 control causes successive
regeneration of the two tanks, irrespective of the water volume which
will be used in the next 24 hours. This option allows improved
regeneration of highly exhausted resin.
9-24
Service Manual
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Chapter 9: Softener
P16 = 2, immediate regeneration. Defined reserve / time-delayed regeneration - smart reserve
(see diagram above)

This option combines the advantages of option 0 and option 3. It is the
most flexible regeneration option and combines the benefits of the
smart reserve (optimized salt consumption) with the ability to react to
occasional days with excessive water consumption.
P16 = 3, immediate regeneration - defined reserve
(see diagram above)

Regeneration starts as soon as the capacity of a tank is exhausted or
as soon as the capacity (tank 1 + tank 2) is below the critical capacity
(set in P17). To prevent hard water, this reserve should be set to a value
that ensures sufficient soft water while the most exhausted tank is being
regenerated.
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9-25
Chapter 9: Softener
9.4.4.7
Control unit design

On the large valves of the E300/400, the housing unit of the control must
be secured on the valve.
the shaft a little back so that it is aligned on the front.
Take the housing unit out of the carton and fit it onto the rear flaps
until it stops.
marker arrow facing up. Refit the protective cover. Then position the
flow sensor.
The control is always located on the master head. Connect the

second head to a data cable which is usually provided on the master
control. The connector plugs are protected against reverse polarity.
Their orientation can be easily seen from the safety hook. Connect
the power supply unit with its 12 VAC 150 mA output to the external
power supply and the control.
9-26
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Chapter 9: Softener
This results in the following circuit diagram:
Small figure
Triplex wiring
Wired softener (example E400)
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9-27
Chapter 9: Softener
9.4.4.8
Softener E080 programming table control Logix 764
Level 1
Operation screen:
Tank number
Flow in L/min alternating with remaining capacity in m
Brief indication of time with []
Level 1
278A
40
liters resin
P1
e.g.: 9:30
Current time
P2
upper edge
Current day, arrow Sun-Mon-Tues ...
P3
2:00
Regeneration time
P4
Regeneration days 0.599 interval
P6
110
Regeneration medium consumption in g/L and regeneration
P7
1.9
Estimated capacity in kg CaCO3 - can be changed
P8
180
Water hardness in mg/L CaCO3 (mg CaCO3 = dH x 18)
Level 2
+ for 5 seconds.
Level 2
P9
P10
P11
P12
60
seconds time delay for remote regeneration
P13
--
Salt check and chlorine processor 0=none; 1=only sensor; 2=chlorine processor and
sensor
P14
70
gpmx 100 refill capacity - Brine Refill (change standard 34 to 70)
P15
30
gpmx 100 suction capacity - (gpm = l/min; 3.785 l/g) (change standard 26 to 30)
P16
--
Reserve type (parallel operation only) 0=variable reserve and time-delayed

regeneration; 1=invariable reserve, time-delayed regeneration; 2=variable reserve;
3=invariable reserve and immediate regeneration
P17
--
Reserve % capacity (0-70 %, standard 30 %), initial average or defined reserve
9-28
Service Manual
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Chapter 9: Softener
Level 2
P18
Selection flow sensor 0=magnetic; 1=1"Autotrol; 3=given K factor; 4 given pulse

equivalent
P19
P18=3: K factor (p9=1->metric) pulse per liter or P18=4 L/pulse
Pr
Preliminary refill 0=none 1=preliminary refill
Pd
time-delayed remote regeneration 0=immediate 1=time-delayed
Level 3
+ for 5 seconds
Time in minutes

Time delayed regeneration
Short regeneration
Cancel regeneration
+ for 5 seconds
Skip phase
+ short
Indication of the remaining time of the phase by
LEVEL 3
C1
mod
Backwash1
C2
fixed
12
Draw (function of P15)
C3
mod
24
slow Rinse
C4
mod
Repressurize / Standby
C5
mod
Fast Rinse 1
C6/C
C8
fixed
Refill (function of P14)
57
Level 4
and for 5 seconds
In H0 : 5 seconds, reset for control - then Reg. for synchronization.
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9-29
Chapter 9: Softener
LEVEL 4
H0
Liters resin volume
H1
H2
Current flow
H3
Water consumption of this day in m3 since regeneration
H4
Water consumption in m3 since last regeneration
H5
Total consumption since reset in x 100 m3
H6
Consumption since reset in 1000000 m
H7
Average consumption in m3 on Sundays
H8
Average consumption in m3 on Mondays
H9
Average consumption in m3 on Tuesdays
H10
Average consumption in m3 on Wednesdays
H11
Average consumption in m3 on Thursdays
H12
Average consumption in m3 on Fridays
H13
Average consumption in m3 on Saturdays
H14
Average service phases in days
H15
Peak flow in L/min
H16
Date and time of peak flow
H17
Months in operation
H18
m3 Water consumption since last regeneration tank 1
H19
9-30
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Chapter 9: Softener
9.4.4.9
Softener E150(B) programming table control Logix 764
Level 1
Operation screen:
Tank number
Brief indication of time and []
Level 1
278A
80
liters resin
P1
e.g.: 9:30
Current time
P2
upper edge
P3
2:00
Regeneration time
P4
P6
110
P7
3.8
P8
180
Level 2
+ for 5 seconds.
Level 2
P9
P10
P11
P12
60
P13
--
sensor
P14
137
P15
40
P16
--

P17
--
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9-31
Chapter 9: Softener
Level 2
P18

equivalent
1. P19
1. Pr
1. Pd
Level 3
+ for 5 seconds
Time in minutes 0

Short regeneration
Cancel regeneration
+ for 5 seconds
Skip phase
+ short
LEVEL 3
C1
mod
Backwash1
C2
fixed
18
C3
mod
25
slow Rinse
C4
mod
C5
mod
Fast Rinse1
C6/C
C8
fixed
9-32
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Chapter 9: Softener
Level 4
and for 5 seconds
In H0 : 5 seconds: reset for control - then Reg. for synchronization.
LEVEL 4
H0
Liters resin volume
H1
H2
current flow
H3
H4
H5
H6
Total consumption since reset in 1000 000 m
H7
H8
H9
H10
H11
H12
H13
H14
H15
Peak flow in L/min
H16
H17
Months in operation
H18
H19
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9-33
Chapter 9: Softener
9.4.4.10 Softener 225-Triplex programming table - control Logix 764
Reserve
% **
Hardness [dH]
RO
system
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
1500
10
15
15
15
20
20
20
25
1750
10
10
10
15
15
15
20
20
20
25
2000
10
10
15
15
20
25
30
---
---
2250
10
15
20
20
25
25
30
30
---
---
---
---
3000
10
15
15
15
20
25
30
30
---
---
---
---
---
---
4000
10
15
20
25
30
30
---
---
---
---
---
---
---
---
---
---
rated
output*
* at a yield of 70%
** reserve to be set as reference value depends on the supply profile
Level 1
Operation indicator
Tank number
Level 1
278L
80
liters resin
P1
e.g.: 9:30
Current time
P2
upper edge
P3
00:01 / 01:30 /
3:
Regeneration time (0:01 hours and time-delayed by the regeneration period

respectively)
P4
P6
110
P7
3.8
P8
180
9-34
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Chapter 9: Softener
Level 2
+ for 5 seconds.
Level 2
P9
P10
P11
P12
60
Seconds time delay for remote regeneration
P13
--
sensor
P14
22
P15
40
P16

P17
35
P18

equivalent
P19
Pr
Pd
Level 3
+ for 5 seconds
Time in minutes 0

Short regeneration
Cancel regeneration
+ for 5 seconds
Skip phase
+ short
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9-35
Chapter 9: Softener
LEVEL 3
C1
mod
Backwash1
C2
fixed
18
C3
mod
25
slow Rinse
C4
mod
C5
mod
Fast Rinse1
C6/C
C8
fixed
30
87
Level 4
and for 5 seconds
LEVEL 4
H0
Liters resin volume
H1
H2
Current flow
H3
H4
H5
H6
H7
H8
H9
H10
H11
H12
H13
H14
H15
Peak flow in L/min
H16
9-36
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Chapter 9: Softener
LEVEL 4
H17
Months in operation
H18
H19
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9-37
Chapter 9: Softener
9.4.4.11 Programming table softener E300 - Logix 764 control
Level 1
Operation indicator
Tank number
Level 1
298A
150
liters resin
P1
e.g.: 9:30
Current time
P2
upper edge
P3
2:00
Regeneration time
P4
P6
110
P7
7.2
P8
180
Level 2
+ for 5 seconds.
Level 2
P9
P10
P11
P12
60
P13
--
sensor
P14
40
P15
55
P16
--

P17
--
9-38
Service Manual
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Chapter 9: Softener
Level 2
P18

equivalent
P19
Pr
Pd
Level 3
+ for 5 seconds
Time in minutes 0

Short regeneration
Cancel regeneration
+ for 5 seconds
Skip phase
+ short
LEVEL 3
C1
mod
Backwash1
C2
fixed
25
C3
mod
25
slow Rinse
C4
mod
C5
mod
Fast Rinse1
C6/C
C8
fixed
31
94
Level 4
and for 5 seconds
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9-39
Chapter 9: Softener
LEVEL 4
H0
Liters resin volume
H1
H2
current flow
H3
H4
H5
H6
H7
H8
H9
H10
H11
H12
H13
H14
H15
Peak flow in L/min
H16
H17
Months in operation
H18
H19
9-40
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Chapter 9: Softener
9.4.4.12 Softener E0400 programming table control Logix 764
Level 1
Operation indicator
Tank number
Level 1
298A
200
liters resin
P1
e.g.: 9:30
Current time
P2
upper edge
P3
2:00
Regeneration time
P4
P6
110
P7
9.6
P8
180
Level 2
+ for 5 seconds.
Level 2
P9
P10
P11
P12
60
P13
--
sensor
P14
45
gpmx 100 refill capacity - Brine Refill
P15
60
gpmx 100 suction capacity - (gpm = l/min; 3.785 l/g)
P16
--

P17
--
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9-41
Chapter 9: Softener
Level 2
P18

equivalent
P19
Pr
Pd
Level 3
+ for 5 seconds
Time in minutes 0

Time delay regeneration
Short regeneration
Cancel regeneration
+ for 5 seconds
Skip phase
+ short
LEVEL 3
C1
mod
10
Backwash1
C2
fixed
30
C3
mod
28
slow Rinse
C4
mod
C5
mod
Fast Rinse1
C6/C
C8
fixed
36
110
Level 4
and for 5 seconds
9-42
Service Manual
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Chapter 9: Softener
LEVEL 4
H0
Liters resin volume
H1
H2
Current flow
H3
H4
H5
H6
H7
H8
H9
H10
H11
H12
H13
H14
H15
Peak flow in L/min
H16
H17
Months in operation
H18
H19
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9-43
Chapter 9: Softener
9.4.5
Data reporting
Note
Note
Start-up
Setting
Maintenance
9-44
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1/03.11
Chapter 9: Softener
9.5
Specifications
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1/03.11
9-45
Chapter 9: Softener
9.5.1
Softener TYPE
E080(B)
E150(B)
E225-T
E300
E400
Duplex/altern.
Duplex/altern.
Triplex
Duplex/altern.
Duplex/altern.
Support gravel layer (per

tank):
12.5 kg /
0.5 bag
12.5 kg /
0.5 bag
12.5 kg /
0.5 bag
25 kg /
1 bag
25 kg /
1 bag
Amount of resin (per tank):
38 L /
1.5 bags
75 L /
3 bags
75 L /
3 bags
150 L /
6 bags
200 L /
8 bags
Capacity per tank (dH *m):
96
192
192
360
480
Resin tank size
63 liters
10 x 54
26 x 139 cm
105 liters
13 x 54
34 x 139 cm
105 liters
13 x 54
34 x 139 cm
194 liters
16 x 65
41 x 162 cm
257 liters
18 x 65
47 x 165 cm
Freeboard regenerated +5 cm
34 cm
33 cm
33 cm
30 cm
43 cm
Brine tank x H [cm]
45/57 x 90
45/57 x 90
45/57 x 112
59/67 x 115
59/67 x 115
Salt grid height
12 cm
12 cm
12 cm
38 cm
38 cm
Weight without water
130 kg
210 kg
290 kg
350 kg
450 kg
430 kg
600 kg
150 kg
800 kg
1200 kg
Regeneration volume
Approx.
320 liters
Approx.
575 liters
Approx.
575 liters
Approx.
920 liters
Approx.
1230 liters
Max. regeneration flow
20 L/min*
20 L/min*
20 L/min*
32 L/min*
32 L/min*
Salt per regeneration
4.8 kg
8.7 kg
8.7 kg
17.5 kg
23 kg
(Brine level measure)

Setting dimension: upper level
of float cup
(14 cm)
24 cm
(30 cm)
40 cm
(30 cm)
40 cm
(35 cm)
51 cm
(45 cm)
61 cm
Regeneration time
60 min*
70 min*
85 min*
90 min*
100 min*
Kv
2.2 m/h
2.5 m/h
5.5 m/h
5.5 m/h
6.0 m/h
Minimum pressure
2 bar
2 bar
2 bar
2 bar
2 bar
Maximum pressure
8 bar
8 bar
8 bar
6.8 bar
6.8 bar
Ambient temperature
1-45C
1-45C
1-45C
1-45C
1-45C
Water temperature
1-36C
1-36C
1-36C
1-36C
1-36C
Voltage supply
230 V 60/50 Hz
230 V 60/50 Hz
230 V 60/50 Hz
230 V 60/50 Hz
230 V 60/50 Hz
W x D x H in mm
see space
requirements
see space
requirements
see space
requirements
see space
requirements
see space
requirements
On pallet with prefiltration rack

W x Dx H in mm
1400 x 800 x
1750
1400 x 800 x
1750
1400 x 800 x
1750
Softener design
* the values indicated are real values and depend on the actual available pressure.
9-46
Service Manual
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Chapter 9: Softener
9.5.2
Restrictor inserts depending on pressure range
SOFTENER TYPE
E080(B)
Required drain during
backwash and fast
rinse
E150(B)
E225-T
E300
E400
815 L/min
1020 L/min
1020 L/min
1530 L/min
2040 L/min
Restrictor hole at
4.56 bar
4.0 mm
4.0 mm
4.0 mm
Blue 5.0 mm
Red 5.5 mm
at 3-4.5 bar
4.0 mm
4.5 mm
4.5 mm
Red 5.5 mm
Green 6.0 mm
at 2-3 bar
4.5 mm
5.0 mm
5.0 mm
Green 6.0 mm
Without insert
The restrictor diameters specified are given for reference and may be optimized to meet the local conditions.
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9-47
Chapter 9: Softener
9.5.3
Softener capacities
The table lists the softener capacities per tank in cubic meters of water,
depending on the hardness of the water entering the softener:
Capacity in m
SOFTENER
E080(B)
E150(B) /
E225-T
E300
E400
Hardness [dH]
Hardness in mg
CaCO/L
1.9*
3.8*
7.2*
9.6*
40
48.0
96.0
180.0
240.0
80
24.0
48.0
90.0
120.0
110
17.5
34.9
65.5
87.3
150
12.8
25.6
48.0
64.0
10
180
10.7
21.3
40.0
53.3
12
220
8.7
17.5
32.7
43.6
14
260
7.4
14.8
27.7
36.9
16
290
6.6
13.2
24.8
33.1
18
330
5.8
11.6
21.8
29.1
20
360
5.3
10.7
20.0
26.7
22
400
4.8
9.6
18.0
24.0
24
440
4.4
8.7
16.4
21.8
26
470
4.1
8.2
15.3
20.4
28
510
3.8
7.5
14.1
18.8
30
540
3.6
7.1
13.3
17.8
32
580
3.3
6.6
12.4
16.6
34
620
3.1
6.2
11.6
15.5
36
650
3.0
5.9
11.1
14.8
38
690
2.8
5.6
10.4
13.9
40
720
2.7
5.3
10.0
13.3
* Total capacity of a tank in kg CaCO3 (with 48g capacity/liter of resin) as by P7 (see report master copy)
Since the hardness frequently varies due to the water supply, a

reserve of 12dH should be entered.
9-48
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Chapter 9: Softener
9.5.4
9.5.4.1
Softener selection table
Note
The choice of softener depends on the hardness of the feed water
supply and on the required volume in L/h.
Use the softener selection table shown below.
Hardness [dH]
SOFTENER TYPE
Reverse osmosis
system - rated
output*
E080(B)
E150(B)
250
1682
3082
500
850
1682
750
634
1068
2082
1000
424
850
1682
1250
420
640
1282
1500
416
634
654
1068
1750
414
628
646
1058
6078
2000
412
424
640
850
5268
2250
422
636
846
4860
3000
416*
632
634
3646
424
(424)
634
4000
E225-T
E300
E400
() Values at a flow between 4060m/h or 1.1 - 1.7 cm/sec
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9-49
Chapter 9: Softener
9.5.4.2
Triplex softener (E225-T)

The lower minimum hardness values are based on the request that, for
microbiological reasons, a regeneration is to be effected every
24 operating hours.
If the regeneration days are appropriately programmed in the control, a
forced regeneration will be initiated to achieve lower hardness levels
however at the cost of higher resources.
Note
The set reserve of the Triplex softener must be increased when
hardness increases.
The following settings are recommended for a 23 shift supply profile.
Reserve
% **
Hardness [dH]
Reverse
osmosis
system
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
1500
10
15
15
15
20
20
20
25
1750
10
10
10
15
15
15
20
20
20
25
2000
10
10
15
15
20
25
30
---
---
2250
10
15
20
20
25
25
30
30
---
---
---
---
3000
10
15
15
15
20
25
30
30
---
---
---
---
---
---
4000
10
15
20
25
30
30
---
---
---
---
---
---
---
---
---
---
rated
output*
** reserve to be set as reference value depends on the supply profile.
9.5.5
Removal of iron and manganese using a softener

The basic hardness setting of the softener must be adjusted as follows:
Substance
Hardness to be added
Hard water
Additional hardness level per retentate proportions (mg/l)
Iron (Fe 2+)
+3 dH
Manganese (Mn2+)
+5 dH
9-50
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Chapter 9: Softener
9.6
Maintenance
Note
components
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9-51
Chapter 9: Softener
9.7
Error messages
9.7.1
Softener malfunctions overview
Problem
Possible cause
Action required
Error 1
Power supply connected but

control is unsure about the
operating position.
Pressing the Up key should

reset the control.
Error 2
The control does not match the

existing power frequency.
Disconnect the power supply unit

again and connect it again; if the
problem persists, procure the
control matching the frequency.
Error 3
Control is unsure about the

camshaft position and sets it on
the master.
Error 3 persists for a prolonged
period, and the camshaft does
not rotate.
Wait 2 minutes so the camshaft

can be trued.

period despite rotating camshaft.
The motor is not connected or its

gear does not engage, check the
component position and the
cable. If necessary, replace the
component.
The visual sensor may be
unlatched, a strong light
irradiation disturbs the sensor or
it is defective.
The control is unsure about the

camshaft position and sets it at
the secondary head.
period despite rotating camshaft.
Wait 2 minutes so the camshaft

can be trued.
Display
-- : --
The control forgot the time due to

power failure for a longer period.
Set the time again with the Set

key .
Brine tank overflow
Check set height of float cup
Error 4
Uncontrolled refill flow

Refill valve always open
Inlet valve open in C2/3 as well
Leaking brine line
Drain clogged
Check the secondary head for

error causes same as for Error 3.
In addition, check the connection
cable.
Check refill valve

Check function of inlet valve and
clean it
Clean brine valve
Check brine line
Check drain valve
Fill operation or refill operation
9-52
Valves contaminated
Valves leaking, possibly due to
worn spring

remove dirt
Replace spring
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Chapter 9: Softener
Problem
Possible cause
Action required
Hard water penetration after a

regeneration
Defective regeneration due to

lack of salt
Over-estimated capacity
Leakage at the riser tube o-ring
Check brine suction (see below)
Check salt level and dosage
Ensure specified water pressure
Incorrect brine suction
Water inlet pressure too low

Drain clogged
Injector defective or clogged
Inlet valve not closed
Refill restrictor or brine valve
clogged
Check set times
Check resin volume and

programmed volume
Check riser tube seal
Check if the drain and restrictor

are free
Clean injector and replace if
necessary
Clean valve and replace if
necessary
Check refill restrictor and brine
valve
Check brine suction time and
refill time
Check set control times
High concentration of brine
Amount of brine too high

Incorrect brine suction
Minimum pressure not reached
See problem: Brine tank

overflow
See problem: Incorrect brine
suction
Install booster pump
regeneration
Check flow indicator and sensor

S300/400 sieve for servo flow
clogged.
Compare displayed flow and flow

at reverse osmosis system
Check flow sensor for correct
placement
Clean sieve for servo flows
Check time setting
Correct if necessary
Salt consumption too high
Check brine level prior to

regeneration
Undiscovered brine bottle
overflow
Check brine settings and change

if necessary
Check program times and values
Check for "Brine tank overflow"
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9-53
Chapter 9: Softener
Problem
Possible cause
Action required
Salt consumption too low
Check brine level prior to

regeneration
Check brine settings and change

if necessary
Check program times and values
Check for "Incorrect brine
suction"
RO water shortage at
regeneration.

Check drain valve
Check softener in operating
position
Ensure specified water pressure

Insert correct drain valve
Check inlet and outlet valves
Check resin tanks for absence of
obstructions
Flow indicator incorrect
Sensor not engaged

Flow turbine contaminated
Incorrect values lodged in the
control
Check flow sensor for correct

position and function
Disassemble and clean flow
turbine
Check values set in the control
9-54
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Chapter 9: Softener
9.8
9.8.1
Softener design
Intended purpose
The softener is an indispensable component of a central water treatment
system in a dialysis unit. It replaces all components in the water causing
water hardness, such as calcium (Ca++) and magnesium (Mg++), by
sodium (Na+).
The prevailing concentrations cause the sodium ions, which are
attached to the ion exchanger resin, to be substituted by ions causing
water hardness. In the course of the operating time the capacity of the
ion exchanger resin will be exhausted which means that no more ions
will be exchanged. The exhausted resin must therefore be regenerated
to be able to use a saturated saline solution (NaCl).
To ensure that a regeneration can also be performed during dialysis
hours, a softener unit is generally a twin-tank (Duplex) or triple-tank
(Triplex) design:
While the one tank is in service, the other tank is regenerating. The two
resin tanks of a twin-tank unit are controlled by a control head. The brine
for regeneration is produced in a brine tank which is connected to the
control head and which in turn is periodically refilled with salt tablets.
The control head provides the brine tank with the amount of water
required to produce the brine. It features an integrated, adjustable float
mechanism which controls both the amount of water supplied and the
amount of brine required for regeneration.
9.8.2
The scale-forming calcium and magnesium ions in the softener
pressure tanks are replaced by sodium ions. As the capacity of the
softener is directly proportional to the amount of resin, but this amount
is limited, the resin beds must be regenerated. This is done with sodium
chloride brine. The brine or sodium-chloride solution is supplied by a
brine tank.
To ensure production of brine and softening, the salt, i.e. the salt tablets,
in the brine tank must always be above the water level. If salt is refilled
too late this may lead to high concentrations of brine or hard water.
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9-55
Chapter 9: Softener
The specified, dynamic water pressure must be present to ensure

reliable function of the softener. The system consumption and the
regeneration flow must be considered in the water flow. Insufficient
pressures may delay the regeneration and may also cause a water
alarm.
As the softeners are designed for continuous operation, at least two
tanks are used for alternating operation. The minimum capacity of one
tank must be sufficient for the regeneration time of the tank which is
regenerating. As the flow velocities must not be too high, but also not
be too low, the respective selection table is to be used to select the
softener (Softener selection table / see below).
The softener control counts the flow and initiates a volume-controlled
regeneration.
Idle times should be avoided. If the softener is not used for a longer
period, a regeneration should be initiated either manually or by a higherlevel control unit. The control unit offers the possibility to enter the local
water hardness by simply entering the hardness in milligram calcium
carbonate per liter of water.
The following applies:
mg[CaCO3] = hardness value [.dH] * 17.86 = French degrees [fH.] * 10
9.8.3
Functional description Triplex operation E225-T

In triplex operation a reserve is required as the softener tanks may all
be empty simultaneously and a tank does not start regenerating before
its minimum reserve has been reached.
The reserve to be set depends on the system capacity of the reverse
osmosis system and the prevailing hardness. An immediate
regeneration P16 =3 with a defined reserve is selected in the control.
The E225-T is equipped with one control on each tank valve. These
controls are interconnected by a cable which they use for mutually
signaling if a regeneration can be started or not. With the exception of
the regeneration time, the controls all have the same setting.
9-56
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Chapter 10: Activated carbon filter

10.1 Component overview A050, A100, A150, A300, A400
Part number:
F00001844
Activated carbon filter A050
F00001845
F00001846
F00001330
F00001331
A
B
C
D
E
F
G
H
POS
Description
Control head
Upper sieve
Riser tube
Filter bed
Tank
Gravel bed
Lower sieve
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10-1
10.2 Installation
10.2.1 Installation / start-up requirements
General information
Note
Note
10-2
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10.2.2 Important start-up information
Activated carbon filters A050, A100, A150, A300, A400

The site of installation must be protected from frost and must be
level, the floor load must be sufficient for the weight of the full
activated carbon filter.
A floor drain is also required.
Do not expose the activated carbon filter to direct sunlight.
A 50 m particle filter and a pressure gauge for pressure monitoring
must be installed upstream of the activated carbon filter.
The maximum pressure must not be exceeded, if necessary, a
pressure reducer must be installed.
The installation must be done in compliance with the local
regulations.
Apply only small amounts of silicone-based FDA-approved lubricant
to seals and valves.
Tighten plastic screw-connections only by hand.
The drain must be designed as a free flow to prevent backcontamination.
The activated carbon filter must be designed to ensure that the dwell
time per tank is sufficient to reduce the total chlorine content
downstream of a tank to a value of 0.1 mg/L. The flow in the bed
should not be below 5 m/h and should not exceed 25 m/h.
The flushing of retained particles and possible coatings achieved by
the backwash is negligible; its purpose is preventing tunnel effects in
the filter bed.
Therefore the pressure drop cannot be used as a criteria for the
backwash time, as it may rise by up to a maximum of 50 %. The
standard time interval between two backwashes is one week. This
can be adjusted to local conditions.
Long times of no use should be avoided ; this should be ensured by
rinsing the reverse osmosis system.
When filling the filters:
Both filters must be filled with the supplied filter media prior to startup; after filling, the filter tanks should be filled completely with water
by means of the immersion pipe. It facilitates ventilation at start-up.
Please observe the soaking time for activated carbon filters.
Otherwise it may cause washing out of fine carbon dust over time.
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10-3
10.2.3 Start-up of the activated carbon filter

When the filter has been set up and the control has been
programmed the system must be carefully ventilated and rinsed.
upstream of the filter has been thoroughly rinsed. To rinse the filter,
the outlet of the filter must be dismounted and discarded to the drain.
The water inlet valve must be opened slowly and only partly. Watch
the removal of air until water exits.
When water exits, the tank is thoroughly ventilated during the
backwash phase C1 by the start of a regeneration.
When all air has been removed, the remaining phases are all
skipped after a short rinse by briefly and simultaneously pressing
+ . If ventilation is complete, the water inlet valve can be fully
opened.
Rinsing should be followed by a manual regeneration to check the
drain. In addition to this, the dynamic pressure of the water supply
should also be checked.
When the tank has been rinsed sufficiently, i.e. it has been rinsed
with 5 times the bed volume, the filter outlet can be re-mounted. The
complete water pretreatment system must now be rinsed briefly and
can then be connected to the reverse osmosis system.
report.
10.2.3.1 Valve heads and drain restrictor
The drains for all filters must be designed as free drains using the lines
supplied and ensuring that paths are as short as possible. The drain
outlets are restricted to reduce the flows.
A050 / A100 / A150
A300 / A400
Sieve for servo flows

Drain restrictor
Drain
Drain
Restrictor inserts depending on pressure range:
10-4
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ACTIVATED CARBON FILTER TYPE
Required drain
during backwash
and fast rinse
Restrictor hole
A050
A100
A150
A300
A400
approx. 45 L/min
approx. 45 L/min
approx. 45 L/min
approx. 60 L/min
approx. 3600 L/h
approx. 60 L/min
approx. 3600 L/h
6 mm
6 mm
6 mm
8 mm
8 mm
Operating phases (Service, Backwash, Fast rinse)

The control initiates a time-controlled backwash of the filter at defined
intervals. During the first regeneration phase, the backwash phase, the
filter bed media is lifted and separated, and rinsed.
This phase is intended to backwash all collected contaminants to the
drain.
During the following phase, the Fast rinse, the filter bed settles again
and is pre-rinsed to reduce the start-up phase of the filter in service. The
backwash phase generally lasts 5 minutes, but should be extended
depending on the quality of the feed water and the condition of the drain
water on site, until an acceptable drain water quality is achieved.
Note
The time should be selected so as to rinse for at least 2-3 tank volumes.
The operation cycles of the filter are therefore divided into three phases:
Service
Backwash
Service
Backwash
Fast rinse
Fast Rinse
For the rinse time settings, refer to the master copies in the appendix.
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10-5
Backwash times
The backwash of sand filters must be timed to occur outside the
operation time of the reverse osmosis system.
Additionally, the softener may not regenerate during the reverse
osmosis operating time.
It must be ensured that e.g. an AquaA is not in the Supply or Rinse
mode while the sand filter is backwashed. It should be possible to fully
run a regeneration of the softener possibly initiated by rinsing of the
AquaA.
2.5hours before the backwash of the sand filter, an operation of 10
minutes in the Supply mode using the auto-start and auto-stop function,
and a rinse interval phase, which lasts at least 4 hours, should therefore
be programmed on the AquaA.
Due to the long time intervals, it is recommended not to rinse the
activated carbon filter(s) on the same day as the sand filters.
At best they can be backwashed subsequently. First the activated
carbon filter(s) and then the sand filter.
4 hours rinse interval
AquaA
2.5 hours interval
Softener
Sand filter
max. 110 min regeneration

Activated
10-6
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Configuration of the free flow for drains (e. g. rack)

A050 / A100
S300 / S400
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10-7
10.2.3.2 Valves in control head

The valves in the A050150 are switched directly and can be opened
manually for rinsing in case of servicing.
When filters A300 / A400 with large valve are used, activates the
camshaft via the motor. The camshaft switches the control valves for
the actual disk valves.
A050A150
Drain
A300 / A400
Drain 1
Rinse 2
Outlet
Outlet 3
Drain 1
Inlet 4
Inlet 4 and 5
Inlet
Outlet 3
Rinse 2
10.2.3.3 Control unit design

On the large valves of the A300 / 400, the housing unit of the control
must be secured on the valve.
the shaft a little back so that it is aligned on the front.
Then remove the housing unit from its box and push it fully onto the
rear lugs.
10-8
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1/03.11
arrow marks being on the top.
Refit the protective cover and reconnect the 12 V/AC 150 mA power
supply unit to the control unit.
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10-9
10.2.4 Programming the control unit

10.2.4.1 Control / display
During operation, time and day are displayed. The day is identified by
the triangle that moves from left to right.
A bar will be displayed below the date indicating the days during which
a regeneration will take place. In Europe the first day of the week is
generally the Sunday. If a regeneration is in progress, the regeneration
symbol will be displayed.
Current display:
In the picture shown it is Sunday and the filter is currently regenerating.
10.2.4.2 Control / operating elements
Display
manual
regeneration
Reg.
Down
Save
Set
10-10
Up
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10.2.4.3 Control unit

At the start the control must be set to the correct system configuration.
Fig. 1
Example
If 255 A is flashing, the correct system configuration can be selected

E.g. for sand filter S300 / 400 293 F must be selected. When the correct
configuration is flashing, confirm with Set .
Fig. 1
Filter valve configuration

Settings for the following filter valves:
263 F
S140, S200, A050, A100, A150
293 F
S300, S400, A300, A400
Fig. 2
Fig. 2

aligning the shaft. The system configuration must be entered again with
a Reset (see level 4).
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10-11
Fig. 3
Fig. 3
Here, it is also recommended to enter the system configuration again
with a reset (see level 4).
Level 1
or with a Reset (see level 4). Basic data is entered in this level.
LEVEL 1
Select valve 293 (S300/400) or 263 (S140/200) and configuration
Select F for filter mode.
P1
Current time
P2
Current day defined by arrow at upper display edge from Sunday to

Saturday.
P3
Regeneration time
10-12
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LEVEL 1
P4
Regeneration days 0.599 = interval, days between regenerations,

selection of 0 will activate a 7-days timer:
P5
Rinse days can be activated with [ ] and [ ] or [ ];

if P4 = 0 (Europe: 1 = Sunday)
P6
P7 and P8
not used
Level 2
This level is accessed by simultaneously pressing the Up and Down
This can only be done from the normal operation display. (Therefore
if Error3 or Error4 is displayed and the system configuration has not
yet been defined or verified, immediately go to level 4 and make a
reset.)
LEVEL 2
P9
P10
Selection of the time display, must be set to 1 for 024 hrs.
P11
P12
P13P19
not used
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10-13
Level 3 - operating phase times

regeneration.
LEVEL 3
C1
Backwash in min can be changed
C2C4
not used
C5
Fast rinse in min can be changed
C6C8
not used
Level 4 history
(Possibility in H0 for a reset with the Set key for 5 seconds).
regeneration.)
Example:
LEVEL 4
H0: F
Filter display (reset by pressing the Set key for 5 seconds.)
H1: 0
d days since last regeneration
H2H16
0 not used
H17: 4
months since service
H18 and H19
0 not used
10-14
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Start regeneration
When pressing the Reg. key, the Reg. symbol will be flashing. This
programmed time P3.
displayed permanently and a regeneration will be started
immediately.
A regeneration which has started,can be skipped by pressing the Set
and Up keys + for 5 seconds.
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10-15
10.2.4.4 Activated carbon filter A050, 100, 150 programming table - control Logix 762
Level 1
Operation indicator
Level 1
263
Filter
P1
e.g.: 9:30
Current time
P2
upper edge
Current day, arrow 1-7 (Europe: 1=Sunday)
P3
2:00
Backwash time
P4
Regeneration days 0.5 - 99 interval, 0-7 days timer
P5
Rinse days
P6
5 / 8 / 12
P7
Capacity in m3
P8
Level 2
and for 5 seconds.
LEVEL 2
P9
P10
P11
P12
60 seconds
P1319
10-16
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Rinse days in P5
Regeneration
Change
...
Yes / No
...
Continue
Level 3
+ for 5 seconds
Time in minutes: A300 / A400

Short regeneration
Cancel regeneration
+ for 5 seconds
Skip phase
+ short
Display of the remaining time of the phase with
LEVEL 3
C1
mod
A50 = 5 min
A100 = 8 min
Backwash 1
A150 = 12 min
C2
C3
C4
C5
mod
A50 = 3 min
A100 = 4 min
Fast Rinse 1
A150 = 5 min
C6/C
C8
A50 = 8 min
A100 = 12 min
A150 = 17 min
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10-17
Level 4
and for 5 seconds
In H0 : 5 seconds, reset for control - then Reg. for synchronization.
LEVEL 4
H0
Filter display
H1
H17
Months in operation
10-18
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10.2.4.5 Activated carbon filter A300 / 400 programming table - control Logix 762
Level 1
Operation indicator
LEVEL 1
293
Filter
P1
e.g.: 9:30
Current time
P2
upper edge
Current day, arrow 1-7 (Europe: 1=Sunday)
P3
2:00
Backwash time
P4
P5
Rinse days
P6
8 / 10
P7
Capacity in m3
P8
Level 2
and for 5 seconds.
LEVEL 2
P9
P10
P11
P12
60 seconds
time delay for remote regeneration
P1319
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10-19
Rinse days in P5
Regeneration
Change
...
Yes / No
...
Continue
Level 3
and for 5 seconds
Time in minutes: A300 / A400

Short regeneration
Cancel regeneration
and for 5 seconds
Skip phase
+ briefly
Display of the remaining time of the phase with
LEVEL 3
C1
mod
A300 = 8 min
Backwash 1
A400 = 10 min
C2
C3
C4
C5
mod
A300 = 4 min
Fast Rinse 1
A400 = 6 min
C6/C
C8
A300 = 12 min
A400 = 16 min
10-20
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Level 4
and for 5 seconds
In H0 : 5 seconds, reset for control - then Regeneration for
synchronization.
LEVEL 4
H0
Filter display
H1
H6
H17
Months in operation
10.2.5 Data reporting
Note
Note
Start-up
Setting
Maintenance
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10-21
10.3 Specifications
10.3.1 Specifications / data sheet
Softener TYPE
A050
A100
A150
A300
A400
Support gravel layer (per tank):
25 kg /
1 bag
25 kg /
1 bag
25 kg /
1 bag
25 kg /
1 bag
25 kg /
1 bag
Amount of activated carbon (per

tank):
50 L /
25 kg /
1 bag
100 L /
50 kg /
2 bags
150 L /
75 kg /
3 bags
200 L /
102 kg /
4 bags
250 L /
128 kg /
5 bags
Filter tank size
105 liters
13 x 54
34 x 140 cm
170 liters
16x65"
41x162 cm
250 liters
18x65"
47 x 165 cm
250 liters
18x65"
47 x 165 cm
310 liters
21 x 60
55 x 172 cm
Freeboard +5 cm
55 cm
69 cm
70 cm
43 cm
40 cm
Weight (not filled)
70 kg
100 kg
155 kg
190 kg
220 kg
Weight (filled)
170 kg
290 kg
400 kg
430 kg
540 kg
Riser tube
distance above upper edge of
tank
28
2025 mm
28
2025 mm
28
2025 mm
48.3
0-5 mm
48.3
0-5 mm
Rinse volume
Approx.
350 liters
Approx.
500 liters
Approx.
750 liters
Approx.
720 liters
Approx.
960 liters
Backwash flow*
45 L/min*
45 L/min*
45 L/min*
60 L/min*
60 L/min*
Backwash time
15/20/25 min
15/20/25 min
15/20/25 min
Individually
adjustable
Individually
adjustable
Kv
2.7 m/h
2.8 m/h
3.0 m/h
6.1 m/h
6.5 m/h
Minimum pressure
2 bar
2 bar
2 bar
2 bar
2 bar
Maximum pressure
6 bar
6 bar
6 bar
6.8 bar
6.8 bar
Ambient temperature
1-40C
1-40C
1-40C
1-45C
1-45C
Water temperature
1-40C
1-40C
1-40C
1-36C
1-36C
Voltage supply
230 V
60/50 Hz
230 V
60/50 Hz
230 V
60/50 Hz
230 V
60/50 Hz
230 V
60/50 Hz
Per power supply unit
12 V~
12 V~
12 V~
12 V~
12 V~
Filter design
10-22
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Softener TYPE
A050
A100
A150
A300
A400
35x60x160
42x60x187
50x60x192
55x72x200
55x72x200
Floor space
W x D x H in mm
* the values indicated are real values and depend on the actual conditions and available pressure (values given in brackets
are theoretical limits for flow velocities of 15-20 m/h)
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10-23
10.3.2 Operating conditions

10-24
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10.3.2.1 Activated carbon filter (Single) selection table
Dwell time in min

Activated carbon
filter size
A050
A100
A150
A300
A400
System capacity (L/h)
250
8 (minimum)
500
4 (minimum)
8 (minimum)
750
6 (minimum)
8 (minimum)
1000
4 (minimum)
6 (minimum)
1250
3 (minimum)
5 (minimum)
8 (minimum)
1500
4 (minimum)
6 (minimum)
8 (minimum)
1750
4 (minimum)
6 (minimum)
7 (minimum)
2000
3 (minimum)
5 (minimum)
6 (minimum)
2250
3 (minimum)
4 (minimum)
5 (minimum)
3 (minimum)
4 (minimum)
3000
4000
3 (minimum)
10.3.2.2 Activated carbon filter (double) selection table
Dwell time in min

Size
Activated carbon
filter
A050
A100
A150
A300
A400
System capacity (L/h)
250
16 (minimum)
500
8 (minimum)
16 (minimum)
750
12 (minimum)
16 (minimum)
1000
8 (minimum)
12 (minimum)
1250
6 (minimum)
10 (minimum)
16 (minimum)
1500
8 (minimum)
12 (minimum)
16 (minimum)
1750
8 (minimum)
12 (minimum)
14 (minimum)
2000
6 (minimum)
10 (minimum)
12 (minimum)
Service Manual
SM-EN
1/03.11
10-25
Dwell time in min

2250
6 (minimum)
3000
8 (minimum)
10 (minimum)
6 (minimum)
8 (minimum)
4000
10-26
6 (minimum)
Service Manual
SM-EN
1/03.11
10.4 Maintenance
Note
Maintenance intervals / overview for components of the water
pretreatment
Service Manual
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1/03.11
10-27
10.5 Error messages

10.5.1 Activated carbon filter malfunctions overview
Problem
Possible cause
Action required
Outflow outside of regeneration
Valves contaminated
Valves leaking due to worn
spring
Sieve for servo flows clogged

remove dirt
Replace spring
Check inlet pressure
regeneration

Check time setting
Correct if necessary
RO water shortage due to

regeneration.
Regeneration time not offset to

RO rinsing time
Set the times appropriately
10-28
Check the control

A300/400 sieve for servo flow
clogged.
Service Manual
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1/03.11
10.6 Functional description

10.6.1 Design of components
Activated carbon filter design

Components:
Control head
Upper sieve
Riser tube
Filter bed
Tank
Gravel bed
Lower sieve
10.6.2 Component description

The flow velocity of the water starts to decrease in direction of the
activated carbon filter. The water is also forced to find its way through
the spacing between the activated carbon bed.
Substances in the water attach to the large surface, 300-1200m per
gram, of the activated carbon which is extremely porous. As only
suspended particles and possible layers, but not the adsorbed
substances, can be removed by backwashing, the activated carbon
must be replaced after a certain time.
Service Manual
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1/03.11
10-29
To permit economic operation, two tanks are connected in series and

loading and exhaustion of the first tank are monitored by regular checks.
When the limit of a total chlorine content of 0.1 mg/L has been reached
after collecting a sample after the first tank, this tank will be filled with
new activated carbon and will be returned to operation as the second
tank in the flow.
A flexible tubing eliminates the need to change its position.
10-30
Service Manual
SM-EN
1/03.11
Chapter 11: USER RELEVANT Operational data acquisition / maintenance
11 USER RELEVANT Operational data

acquisition / maintenance
Service Manual
SM-EN
1/03.11
11-1
11.1 Operational data acquisition / daily report

The following page shows the operational data acquisition report (daily
report) for the water pre-treatment system.
11-2
Service Manual
SM-EN
1/03.11
OPERATIONAL DATA ACQUISITION
DAILY REPORT
Water pretreatment
Site of installation
_____________________________________________________
Address
_____________________________________________________
ZIP code
_____________________________________________________
Place
_____________________________________________________
Responsible technician:
Phone:
GENERAL NOTES
Monitoring of the operating parameters is indispensable to ensure a safe and continuous operation of the reverse osmosis unit.
Meticulous recording of the data is also an absolute requirement for potential warranty claims. If values deviate, inform the
technical service to be able to take appropriate action before a malfunction occurs.
International
service

Deutschland GmbH
Service Support International
Hafenstrae 9
D-97424 Schweinfurt
Germany
Phone: +49 (0)9721 678-333 (Hotline)
Fax: +49 (0)9721 678-130
Local
service
Service Manual
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1/03.11
11-3
OPERATIONAL DATA ACQUISITION /

DAILY REPORT
Year:_______ Calendar week:_______
Water pretreatment
Procedure
Alarm
limit
Weekday
Entries (operator)
Unit
Mon
Tue
Wed
Thu
Fri
Sat
Sun
__:__
__:__
__:__
__:__
__:__
__:__
__:__
______
______
______
______
______
______
______
---
<1 dH
(green)
Time
Coarse filter
Backwashed
Pressure
---
36
bar
Salt
refilled
Soft water sample
checked
Chlorine content with activated carbon filter (optional) installed

measured
< 0.1
mg/L
Pressure of 20 m prefilter with sand filter (optional)* installed

measured
(at the filter input)
---
measured
(at the filter
output)
---
-----------
-----------
-----------
-----------
-----------
-----------
-----------
-----------
-----------
-----------
-----------
-----------
-----------
-----------
bar
bar
* The difference between the inlet and outlet pressure of the prefilter must not exceed 1 bar.
Pressure of 20 m prefilter with sand filter (optional)* installed
measured
(upstream)
---
measured
(downstream)
---
bar
-----------
-----------
-----------
-----------
-----------
-----------
----------bar
-----------
-----------
-----------
-----------
-----------
-----------
-----------
* The difference between the inlet and outlet pressure of the prefilter must not exceed 1 bar.
Initials
11-4
Service Manual
SM-EN
1/03.11
11.2 System handling instructions report water pretreatment

The following page shows the System handling instructions report for
the Water pre-treatment.
Service Manual
SM-EN
1/03.11
11-5
SYSTEM HANDLING INSTRUCTIONS

REPORT
Water pretreatment
Place where instructions

were given
Customer:
Address:
Zip code / place:
Phone:
Fax:
Person(s) assigned by the responsible organization;

Operator
Others
Instructions
Feed water inlet (incl. shut-off option)
Coarse filter
Booster pump
Sand filter
Pipe disconnector
Softener
Particle filter / replacement interval: every 3 months
Leakage monitoring system
11-6
Service Manual
SM-EN
1/03.11
Comments:
Service Manual
SM-EN
1/03.11
11-7
Instructor:
Date, signature
Participant:
Date, signature
11-8
Service Manual
SM-EN
1/03.11
11.3 Maintenance
11.3.1 Maintenance intervals for water pretreatment components
Note
The manufacturer recommends to perform the following
maintenance procedures within the specified intervals.
11.3.1.1 Feed water inlet unit
Component
Check / maintenance
Daily (if no automated backwash), in case of pressure

loss, initiate backwash
Solenoid valve
Monthly
Press the test key (black) on the single place leakage
socket while the water is running: The valve closes.
Pipe disconnector
Visual inspection every 6 months
Pressure reducer
Annually for design with sieve, clean sieve insert and

replace, if necessary (every 13 years)
Leakage sensor
Monthly
Test of position alarm: Turn the sensor upside down, red
LED illuminated.
11.3.1.2 Sand filter
Component
Check / maintenance
Check drain for free outflow
Annually
Check time
Annually and after a prolonged power failure
S300/400 Servo flow clean sieve
Depending on water quality
11.3.1.3 Particle filter
Component
Check / maintenance
Filter insert
Daily check of the difference pressure (as specified by

operational data acquisition report / daily report).
At least every 3 months
Filtration unit
Visual check for leakage after filter replacement
Service Manual
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1/03.11
11-9
Particle filter
A / drain valve
Interrupt water supply.
Drain the water by means of the drain valve.
Use the filter wrench to unscrew the housing.
Replace the filter.
Screw on the housing with the new filter medium.
Turn the system on.
11.3.1.4 Softener
Component
Check / maintenance
Refill salt -
Daily, as required
The salt must always be above the maximum

brine level
Clean the brine tank and brine valve
Annually as required
Annually, as required
Check time
E300/400 Servo flow clean sieve
11-10
Service Manual
SM-EN
1/03.11
11.3.1.5 Activated carbon filter
Component
Check / maintenance
Measure the residual chlorine concentration
Daily after the first activated carbon tank (as specified by

the operational data acquisition report / daily report)
Check time
E300/400 Servo flow clean sieve
Depending on water quality
11.3.1.6 Water leakage indicator
Component
Check / maintenance
Interval
Water detector with probe 230V
Monthly
631 916 1)
Functional check: Moisten the

contacts (or establish conductive
contact connection). Audible alarm;
valve closes
Single-place leakage from the water

pretreatment rack
(without separate part number)
Press the test key and check if the

valve closes properly (valve function is
checked).
Monthly
Moisten or connect the contacts and

verify if the leakage detector reacts
(audible alarm / valve closes).
Service Manual
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1/03.11
11-11
11-12
Service Manual
SM-EN
1/03.11
Chapter 12: SERVICE RELEVANT Reports
12 SERVICE RELEVANT Reports

12.1 Operational qualification
12.1.1 Start-up report
The following page shows the Start-up report for the Water
pretreatment.
Service Manual
SM-EN
1/03.11
12-1
START-UP REPORT
Water pretreatment
Technician's name:
System type including options / software:

Version:
Customer/customer no.:
Serial no.:
Inventory no.:
Service report number:
Operating hours:
Equipment code:
No.
Description
Reading
Measured value
(display)
1 Visual inspection and preparation
1.1
Components show no signs of transport damage
1.2
Labels and inscriptions
1.3
Water supply correctly connected
1.4
Connection of all tubes has been checked and, if

necessary, connections have been retightened.
1.5
The power cable shows no signs of damage.
2 Default settings
2.1
Outlet line (drain) connected.
2.2
Connection to the brine valve checked for tightness
2.3
Salt refilled
2.4
Floor drain installed
12-2
Service Manual
SM-EN
1/03.11
No.
Description
Reading
Measured value
(display)
2.5
Softener setting (see Settings report):

measured feed water hardness
2.6
Ventilate softener (follow the softener operation

manual)
2.7
- Manual regeneration performed as specified (see

chapter 9.4.3.1 , page 9-14)
2.8
Soft water sample hardness: 0 dH
2.9
Fine filter inserted
2.10
Pressure, dynamic after softener > 1.5 bar
________dH
3 Permeate ring main

3.1
Flow diagram available
Yes
No
3.2
New installation
Yes
No
3.3
Serial number
___________________
3.4
Material
___________________
3.5
Length of the ring main
4 Functional test
4.1
Solenoid valve:
Trigger the water leakage indicator - valve closes and
an alarm is generated.
4.2
Pipe disconnector:
Close the stop valve and start a backwash on the
coarse filter; the pipe disconnector disconnects.
4.3
Backwashable coarse filter:

Timer programmed, time set correctly.
Perform a backwash.
Service Manual
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1/03.11
12-3
No.
Description
Reading
Measured value
(display)
4.4
Sand filter:
Installed
Yes
No
If installed, set time and perform a backwash
OK
Rinse interval set

Mon, Tue, Wed, Thu, Fri, Sat, Sun
Caution:
The rinse interval must not coincide with the activated
carbon filter's rinse times!
4.5
OK
Activated carbon filter:
Installed
Yes
No
If installed, set time and perform a backwash
OK
Rinse interval set

Caution:
The rinse interval must not coincide with the sand
filter's rinse times!
4.6
4.7
OK
Booster pump:
Installed
Yes
No
If installed, no leakage and no running noise
OK
SDI test (measured upstream of reverse osmosis

system):
Desired: SDI < 3
SDI:___________________
SDI Feed water
SDI:___________________
SDI after the sand filter (if installed):
SDI:___________________
SDI after the fine filters
Comments:
Date:
12-4
Signature:
Stamp:
Service Manual
SM-EN
1/03.11
The system has been released for its intended use.

Yes
No
Date of
next inspection
Comments:
Date:
Signature:
Service Manual
SM-EN
Stamp:
1/03.11
12-5
12.1.2 Water pretreatment settings reports

12.1.3 Coarse filter and booster pump assembly settings report
The following pages show the master copy for the setting reports for
coarse filters and the booster pump assembly.
12-6
Service Manual
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1/03.11
SETTINGS REPORT
COARSE FILTER TIMER
BOOSTER PUMP ASSEMBLY (CRN5-8)
Water pretreatment
Technician's name:
Customer/customer no.:
System type including option(s) /

software version:
Serial no.:
Inventory no.:
Service report number:
Operating hours:
Equipment code:
Component
Setting
Standard
Every day
04:00
Pressure switch: _______bar
1 bar
Float switch
---
Pmin
Operating pressure:_______bar
0-10 bar
P1max
Cutoff pressure for peak load pump ________bar
Coarse filter timer

Weekday
Time
_________ h. / min.

Run-dry protection
0-4 bar
P2max
Cutoff pressure for

base load pump ________bar
Service Manual
SM-EN
1/03.11
0-2 bar
12-7
12.1.4 Sand filter settings report

The following pages show the master copy for the settings report for the
sand filter.
12-8
Service Manual
SM-EN
1/03.11
SAND FILTER SETTINGS REPORT

Level 1
Filter
P1
Current time
P2
P3
Backwash time
P4
P5
P6
P7
- - --
P8
- - --
Capacity in m3
Level 2
P9
P10
P11
P12
P1319
- - --
Rinse days in P5
Regeneration
Change
...
Yes / No
...
Continue
Level 3
C1
mod
Backwash 1
C2
C3
C4
C5
mod
Fast Rinse 1
C6/C
C8
Service Manual
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1/03.11
12-9
12.1.5 Activated carbon filter settings report

The following pages show the master copy for the settings report for the
activated carbon filter.
12-10
Service Manual
SM-EN
1/03.11
ACTIVATED CARBON FILTER SETTINGS REPORT

Level 1
Filter
P1
Current time
P2
P3
Backwash time
P4
P5
P6
P7
- - --
P8
- - --
Capacity in m3
Level 2
P9
P10
P11
P12
P1319
- - --
Rinse days in P5
Regeneration
Change
...
Yes / No
...
Continue
Level 3
C1
mod
Backwash 1
C2
C3
C4
C5
mod
Fast Rinse 1
C6/C
C8
Service Manual
SM-EN
1/03.11
12-11
12.1.6 Softener settings report

The following pages show the master copy for the Settings report for the
softener.
12-12
Service Manual
SM-EN
1/03.11
SOFTENER SETTINGS REPORT

Level 1
Lliters of resin
P1
Current time
P2
Current day, arrow Sun-Mon-Tues...
P3
Regeneration time
P4
P6
Regeneration medium consumption in g/l and regeneration
P7
P8
Level 2
P19
P18=3: K factor (p9=1->metric) pulse per liter or P18=4 l/pulse
Pr
Pd
Time-delayed remote regeneration 0=immediate 1=time-delayed
Level 3
C1
Backwash1
C2
C3
slow Rinse
C4
C5
Fast Rinse 1
C6/C
C8
Service Manual
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1/03.11
12-13
12.2 Maintenance
12.2.1 Important information on maintenance procedures
Checks
This chapter includes the required maintenance procedures (MA).

The maintenance procedures (MA) are a recommendation of the
manufacturer. The maintenance procedures must be carried out every
2 years (24 months) and ensure troublefree operation.
Tester's qualification
The checks must be performed by the technical service of

Fresenius Medical Care or a person authorized by them.
The checks may only be performed by persons qualified to properly
perform the specified checks owing to their educational background,
training, knowledge and experience. Furthermore, the persons
performing the checks must not be bound by any directives when
performing this activity.
Test equipment and

accessories
The activities described in this technical document require the

availability of the necessary technical test equipment and accessories.
Specifications
Observe the information on the specifications.
Precautions
Before turning power on, repair any visible damage.

Prior to opening the system and when working on the open system, the
following precautions have to be observed:
Protect the components against ingress of fluids.
Do not touch live parts.
Disconnect and connect all jacks, connectors and components only
when the device is turned off.
ESD precautions
12-14
When repairing the system and when replacing spare parts, observe
the applicable ESD precautions.
Service Manual
SM-EN
1/03.11
12.2.2 Accessories and supplies for maintenance procedures
Note
The required accessories and supplies are listed in the electronic
Spare Parts Catalog eSPC.
Note
The required replacement intervals are specified in the maintenance
report.
12.2.3 Maintenance report

The following page shows the Maintenance report for the Water
pretreatment.
Service Manual
SM-EN
1/03.11
12-15
MAINTENANCE REPORT
Water pretreatment
Manufacturer:
Date:
Technician's name:
System:
Technician:
Intervals (every 24 months):
The following inspections must be carried out at no greater than 24 months' intervals.
MA
No.
Description
Desired value / function
1 Water pretreatment - visual inspections

MA
1.1
Labels and inscriptions.
Are present and legible.
MA
1.2
Mechanical condition of
components.
Permits further safe use.
MA
1.3
Damage or contamination.
Not detectable.
MA
1.4
Power cable.
No signs of damage.
Moisten water sensor; valve closes, audible alarm
Close the stop valve and start a backwash on the

coarse filter; the pipe disconnector disconnects.
(Green cap is visible)
Perform a backwash.
2 Water sensor
MA
2.1
Water sensor.
3 Pipe disconnector
MA
3.1
Functional test.
4 Backwashable particle filter

MA
4.1
Backwash.
5 Booster pump
MA
5.1
Leakage.
No leakage.
MA
5.2
Running noise
No running noise.
12-16
Service Manual
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1/03.11
MA
No.
Description
Desired value / function
6 Sand filter
MA
6.1
Backwash and times
Backwash performed and times checked.
MA
6.2
Time
Corresponds to the current time.
MA
6.3
SDI test.
Specified: SDI < 3
MA
6.4
Replacement interval sand
Specified: every 4 years.

MA
7.1
Backwash and times
Backwash performed and times checked.
MA
7.2
Time.
Corresponds to the current time.
MA
7.3
Residual chlorine concentration on

the outlet (chlorine strip test)
Collect a sample:
Chlorine: ______________________ mg/L

Specified: free chlorine < 0.1 mg/L.
MA
7.4
Replacement interval activated

carbon
Specified: every 4 years.
8 Softener
MA
8.1
Hard water sample.
Hardness: ______________________ dH
MA
8.2
Check hardness setting.
Hardness setting checked.
MA
8.3
Soft water sample
Hardness: 0 dH
MA
8.4
Brine valve.
Check and clean if necessary.
MA
8.5
Brine tank
Drain and clean the brine tank.
MA
8.6
Regeneration control and volume

flow:
Manual regeneration initiated and times checked.
Initiate manual regeneration and

check set times and level in the
brine tank.
in C4/C8 - completely filled
in C4 - completely aspirated
Check flushing in C3 (taste test if

necessary)
MA
8.7
Compare flow on softener display

and flow of RO system.
Values OK?
MA
8.8
Replacement interval softener

resin
Desired: every 8 years
6 Particle filter
MA
9.1
Filter element.
Replace filter element.
MA
9.1
SDI test.
Desired: SDI < 3
Service Manual
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1/03.11
12-17
The system has been released for its intended use.
Yes
No
Comments:
Date:
12-18
Signature:
Stamp:
Service Manual
SM-EN
1/03.11
12.3 Tools and test equipment

12.3.1 Test equipment
HMED case set complete with electronic

pressure gauge
Part no.: M30 770 1
COND 3210 (part no.: 630 635 1)

- without RS232
or
COND 3310 (part no.: 630 634 1)
- with RS232
Case set complete with CD temperature
meter
ESC Service kit, complete

Part no.: 630 387 1
Analog test set TKA29 for system separator

Part no.: 634 566 1
Service Manual
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1/03.11
12-19
Flow meter for reverse osmosis systems

Part no.: 634 465 1
Visocolor HE Chlor test kit

Part no.: 631 688 1
Test kit for determination of the water

hardness
Type: Visocolor ECO
Part no.: 635 091 1
Filter HWP 47 mm, 0.45 m

Part no.: 631 391 1
SDI silt density index measuring device

Part no.: 631 811 1
12-20
Service Manual
SM-EN
1/03.11
Chapter 13: Definitions
13 Definitions
13.1 Definitions and terms
Dialysate
The exchange fluid used in dialysis.
13.2 Abbreviations
Fig.
Figure (diagram)
13.3 Symbols
See component documentation.
Service Manual
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1/03.11
13-1
Chapter 13: Definitions
13-2
Service Manual
SM-EN
1/03.11
Chapter 14: Appendix
14 Appendix
Note
Reports required as master copies for use by operators and service
technicians are to be found in Chapter 11 (user relevant) and
Chapter 12 (service relevant).
Service Manual
SM-EN
1/03.11
14-1
Chapter 14: Appendix
14-2
Service Manual
SM-EN
1/03.11

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Pretreatment Components

Fresenius Medical Care

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

Brief description ........................................................................................................................ 2-4

Warnings .................................................................................................................................... 2-7

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

Components of the water pretreatment system ..................................................................... 3-1

Feed water inlet unit

Component overview wall-mounted prefiltration unit ........................................................ 4-1

Specifications ............................................................................................................................ 4-4

Fresenius Medical Care

Functional description .............................................................................................................. 4-7

Options ..................................................................................................................................... 4-11

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

Specifications .......................................................................................................................... 5-14

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

Error messages........................................................................................................................ 5-17

Functional description ............................................................................................................ 5-18

Fresenius Medical Care

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

Specifications ............................................................................................................................ 6-3

Error messages on pumps ....................................................................................................... 6-5

Functional description .............................................................................................................. 6-7

Media filters (sand filters / Birm filters)

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

Installation of the media filters (sand / Birm).......................................................................... 7-3

Specifications .......................................................................................................................... 7-29

Error messages ....................................................................................................................... 7-33

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

Fresenius Medical Care

Particle filter (Big Blue) 20"

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

Specifications ............................................................................................................................ 8-3

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

Functional description .............................................................................................................. 8-5

Modification of the softener settings in case of high brine concentrations in combination

Display and operating elements............................................................................................... 9-6

Specifications .......................................................................................................................... 9-45

Component description.............................................................................................................. 7-34

Fresenius Medical Care

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

Error messages ....................................................................................................................... 9-52

Functional description ............................................................................................................ 9-55

10 Activated carbon filter

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

Specifications ........................................................................................................................ 10-22

Error messages ..................................................................................................................... 10-28

Functional description .......................................................................................................... 10-29

11 USER RELEVANT Operational data acquisition / maintenance

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

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

Fresenius Medical Care

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

12 SERVICE RELEVANT Reports

Operational qualification......................................................................................................... 12-1

Maintenance ........................................................................................................................... 12-14

Tools and test equipment ..................................................................................................... 12-19

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