Extreme 1 Reverse Osmosis Manual NEW
Contents
1. reading from the top of the stainless steel float in the permeate flow meter e Concentrate Flow gallons per minute of concentration from the system reading from the top of the Stainless steel float in the concentrate flow meter e Temperature reading from temperature gauge on the control panel of the system F e Feed Pressure reading from the pressure gauge on the control panel of the system psi e Membrane Pressure reading from the pressure gauge on the control panel of the system psi e Water Removal percent of water removed from incoming sap calculated as follows PERMEATE FLOW Permeate Flow as read from the meter TOTAL FLOW Add Permeate Flow and Concentrate Flow together o Divide PERMEATE FLOW by TOTAL FLOW and multiply the result by 100 o Record this number as the Water Removal O e GPH Processed gallons per hour being processed by the system calculated as follows o TOTAL FLOW Add Permeate Flow and Concentrate Flow together o Multiply Total Flow by 60 and record the resulting number as the GPH Processed Cycles and Timing The Springtech EXTREME 1 has 4 defined cycles Concentrate Desugar Rinse and Wash The following table outlines recommended intervals CYCLE INTERVAL Run 1 to 12 hours dependent on sap quality Run at the end of every Concentrate cycle or at the end of each day Run after the Desugar cycle Wash Chemical wash after a rinse A chemical wash should be run after 12 hours o2. Position breakers CB1 CB2 and CB3 to the ON position Close the control box cover and refasten the latches Run a rinse cycle see page 28 until a minimum of 300 US gallons of water have been processed Near the end of the rinse cycle turn valve V19 down and fill the wash tank 2 3 full Return valve V19 to its original position Run a hot water wash see page 31 Repeat the rinse cycle see page 28 again filling the wash tank as specified then add R O soap LEADER Order 69992 to the wash tank and mix Add R O soap until a pH of 11 is reached Run an alkaline wash cycle see page 31 Perform a rinse cycle see page 28 using a minimum of 300 US gallons of water Drain the wash tank using valve WD horizontal left then reposition the valve for recirculation vertical up Perform a permeability test see page 20 a Compare the results to the results of the test when the system was new If the results are not acceptable contact LEADER EVAPORATOR or your local Distributor Dealer for assistance b Record the results if acceptable and use these results as the reference for test for the season Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 41 TROUBLESHOOTING CHART The following conditions may occur during operations CONDITION CAUSE ACTION Feed pump does not start when No power Verify power is ON at the source START button is pressed Feed pump starts but system does Low Pressure not con
3. AWG Orange D 0 10 W13 e 24Vdc Com 16 AWG Purple Sy 120 Others Default 11 24Vde PLC CPU ji Ge l we Comd we O 12 o_o GND WwW e START INIT START Green e OC c3 es XI Y1 QUTIH 13 Te X2 IN2 2 OUT2 mee R Pressure Alarm STOP Red rr on Y3 OUT3 gt 14 H Fa H ps Y4 OUT4 wi oS C2 0 Re High Temperature Alarm e oo IT eg AC 3 Y6 OUT6 D 9 d 10 XT7 1N7 SES R Motor Failure E X8 IN8 PA 16 High Temperature Alarm 17 e W18 M1 e L wig PLC Relay Out Leader Evaporator Co Inc M2 49 Jonergin Drive w20 Swanton VT 05488 19 o 802 868 5444 M3 AA SEET Extreme 1 sch et 1 0 M We d o eegen with optional expansion pump ue opt or jump 2 21247 Date 4 24 2015 Rev 3 By SM Size A Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 43 ATTACHMENT 2 OPERATIONS DATA LOGSHEET Water Removal permeate flow permeate 1 flow concentrate flow 100 GPH Processed permeate flow concentrate flow 60 SPRINGTECH EXTREME 1 OPERATIONS DATA AO A AA E AO SUGAR psp Ge ee eS dee A AAA A A SPA PRESSURE ps eme DATE E A ee ee ee eee eee SUGAR ee E E _ A A A FLOW fepma eme mitt eng wm o DATE AAA SETA A SUGAR AAA A AA A EA AA AAA row gem mme 1 eme PRESSURE pa mmm wm Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System
4. E we a gt a o W d D eet He A gy S LU ae f AZ a Leader Evaporator Manufacturer s Warranty For Springtech Extreme Reverse Osmosis Machines Leader Evaporator Co Inc warranties our Springtech Extreme line of Reverse Osmosis Machines against any manufacturer defects for a period of two years from the date of purchase This warranty is at the discretion of the manufacturer Leader Evaporator Co Inc to be replaced or repaired as necessary All replaced parts become the manufacturer s property Leader Evaporator Co Inc shall not be held responsible for any damage or injury arising from negligence abuse improper handling or installation Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 47
5. Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 8 _ Alarm Reset Alarms 0 Control Panel Bass Fe l Start button when pressed starts the system pumps in sequence The Alarm reset button is a master reset for all the alarms and will stop the machine when pressed The Temperature Meter indicates the temperature of the liquid flowing through the system Low pressure Alarm indicates the pressure is too low in the system to start the pressure pump This alarm can be part of normal operations The machine will shut down when the indicator light is activated High Temperature Alarm indicates the Wash cycle has completed This alarm is part of normal operations The machine will shut down when the alarm light is on Motor Failure Alarm is due a motor contactor tripping Contact Leader Evaporator View from Front of System Flow Meters The Concentrate Meter indicates the liquid flow from the concentrate side of the pressure vessel in gallons per minute The Permeate Meter indicates the permeate flow from the membrane in gallons per minute Vx V1 and V2 Valves PSI RU e V1 controls the pressure to the membranes It is opened Y way when starting then adjusted to reach the pressure wanted Close V1 to raise the pressure in the system View from Front of System V2 controls the flow from the concentrate side of the membranes It is opened way when starting then adjusted to
6. Manual BI Quick Start Guide 1 Quick Coupler C Qty 3 LEADER ORDER DESCRIPTION PHOTO Membrane RO Soap 5 Lbs 69992 Preservative Seng 1 Ib Sech Citric Acid 1 Glycol 1 gal 70009 Ib wi 20 Food Grade 55095 Cartridge Grease Filter 12 Sap Long 2 59006 Hydrometer Diameter Test Cup Digital Sap 61073 Refractomet Refractometer 2 to 20 GPM O to 10 GPM Flow Meter H How Meter pH Meter pH Meter 61060P Sales Replacement E EA Probe Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 11 SETUP NOTES e All materials used should be approved for potable water No copper should be used e When installing plumbing for the system factor in the system may need to be moved for such items as maintenance It is recommended the connections be made with fittings such as quick disconnects e All feed piping to the Springtech system must be at least as large as the feed on the system itself 1 is recommended e Allinstallations must meet applicable governmental regulations Area Required The space to be used should be capable of preventing the RO system from freezing Additionally it will need to have adequate ventilation during operations to prevent overheating The dimensions of the unit are e Width 28 e Length 48 e Height 77 A minimum of two feet around the system is recommended You must also be able to obtain an additional area in order to r
7. Manual YEAR 2015 Page 44 E ee eee ee eee eee EE E OS SUGAR a CONCENTRATION CONCENTRATE FLOW gpm PERMEATE AE OOO a A PRESSURE psi DATE SUGAR CONCENTRATION CONCENTRATE Ge e AAA e EE ee o rollo oo EEN A mA AOS PRESSURE psi DATE SUGAR CONCENTRATION CONCENTRATE EE EE O EOS e E HE AS LAA AO PRESSURE BSI ee IO ee WATER REMOVAL EN DATE MARE RE EE WEE RE EE GE WE SUGAR E O AA A A THESE A OS A A OA Sere LL A gt lo o ee ee eee ES PR ear O A WATER REMOVAL AL A O Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 45 E ee eee ee eee eee EE E OS SUGAR a CONCENTRATION CONCENTRATE FLOW gpm PERMEATE AE OOO a A PRESSURE psi DATE SUGAR CONCENTRATION CONCENTRATE Ge e AAA e EE ee o rollo oo EEN A mA AOS PRESSURE psi DATE SUGAR CONCENTRATION CONCENTRATE EE EE O EOS e E HE AS LAA AO PRESSURE BSI ee IO ee WATER REMOVAL EN DATE MARE RE EE WEE RE EE GE WE SUGAR E O AA A A THESE A OS A A OA Sere LL A gt lo o ee ee eee ES PR ear O A WATER REMOVAL AL A O Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 46 ATTACHMENT 3 WARRANTY INFORMATION Leader Evaporator Co Inc 49 Jonergin Drive Swanton VI 05488 Tel 802 868 5444 Fax 802 868 5445 www leaderevaporator com Lag D E mae ee eg en yn Be p DEM y R ay 4 IE f
8. Rinse Cycle Valve Settings also available on the Quick Start Guide 1 Position the valves as follows V1 Open the valve completely V2 Open the valve completely V3 The flow indicator should be DOWN Valve is open for recirculation within the system V4 The flow indicator should be DOWN Valve is open for recirculation within the system Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 29 V6 The handle should be toward the pump housing Input from the liquid source selector should be from the permeate tank V18 Handle should be parallel to the pipe Valve is open V19 Handle should be vertical down Valve is open to drain WD The flow indicator should be up 2 Press the START button on the control panel Within 30 seconds all pumps should start some air purge may be required 3 Run the Rinse cycle until a minimum of 300 US gallons of stored permeate has been used If the Rinse is to be followed by a Wash cycle at the end of the rinse fill the wash tank approximate full by turning the V19 valve horizontally right NOTE If the machine shuts down due to low pressure and the feed line has been bled check the prefilters If the prefilters are dirty replace and retry the rinse cycle If the prefilters appear clean or are new and the problem continues partially close valve V18 until an operating pressure of 50 80 psi is reached and run
9. Season Shutdown and Storage If permeate is not available to perform the rinse and wash cycles stated in the following procedure obtain the necessary volume of water using non chlorinated well or spring water Do a rinse cycle see page 28 alkaline soap wash see page 31 rinse cycle see page 28 2 Doan acid soak cycle see page 31 allowing the system to soak for 1 to 7 days starting the system once per day and allowing it to run to the auto stop temperature at 118 F 3 Do a rinse cycle see page 28 intensive alkaline soap wash see page 31 rinse cycle see page 28 Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 39 10 11 Perform a permeability test see page 20 If the test result shows a difference of greater than 15 to the benchmark repeat the process starting with Step 2 Drain the wash tank valve WD then close the drain In the wash tank mix a 13 US gallons of permeate b 2 US gallons of glycol c 1Tablespoons of membrane preservative Set the system valves for a wash cycle see page 30 and run the system for 15 minutes Drain the wash tank Empty then reinstall the prefilter housings Drain the pumps then close all drains Maintain a temperature minimum of 40 F to 50 F in the area where the system is stored Do not allow the system to freeze Drain and clean all storage tanks Cover them in order to keep dirt and pests out NOTE If permeate is not available
10. clamp over the coupler NOTE For demonstration purposes the picture does not show the hose fully slid onto the quick coupler 6 Pull the metal latches on the quick coupler out to the sides perpendicular to the body of the quick coupler then slide the open end of the coupler over the F style coupler on valve V6 7 Raise the metal latches on the quick coupler back to the side of the C quick coupler while pressing the couplers together WD Connection The WD valve is to be setup so the connection can be easily disconnected and reconnected as necessary It is the connection from the wash tank to drain The following is the recommended connection detail Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 14 1 Teflon tape a 1 F style quick coupler Thread the F style quick coupler into valve WD under the wash tank and slightly behind the control panel Tighten the coupler Obtain a length of 1 braided hose that will connect to the drain Slide a 1 stainless steel band clamp over one end of the hose Slide the hose onto a 1 Y C style quick coupler and tighten the clamp over the coupler Pull the metal latches on the quick coupler out to the sides perpendicular to the body of the quick coupler then slide the open end of the coupler over the F style coupler on valve WD Pull the metal latches on the quick coupler back to the side of the C quick coupler while press
11. for cleaning use non chlorinated well or spring water Beginning of Season Startup As permeate will not be available to perform the rinse and wash cycles stated in the following procedure obtain the necessary volume of water using non chlorinated well or spring water CB1 CB2 CB3 5 6 7 8 a 10 11 BREAKER ID Connect the reverse osmosis system to the concentrate permeate and feed lines Replace prefilters Open the control box by unfastening the latches buckles of the left side then opening the door carefully to the right Turn off the pressure and recirculation pump breakers FeedPump ON Close the control box cover and refasten the latches buckles Ensure your source valves water or permeate are open to feed the system Position the valves for the rinse cycle see page 28 Press the START button to start the feed pump Run the feed pump until most of the bubbles are gone from the flow meters located on the front of the system This will take 3 to 4 minutes Not all the bubbles can be removed Press the STOP button to stop the feed pump Check all fittings hoses connections and parts of the system for leaks Repair as necessary Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 40 12 13 14 15 16 17 18 19 20 21 Open the control box by unfastening the latches buckles of the left side then opening the door carefully to the right
12. the remainder of the cycle Wash Cycle There are three different wash cycles A hot water wash which can be run when good clear sap was processed and the flows are still good An alkaline soap wash is done to remove bacteria from the system Generally alkali washes alone are used where the sap quality is poor and flow rates recover to normal after the wash An acid soak and wash is done to remove mineral deposits from the system Generally the acid soak is used where sap quality is good and the system does not recover flow rates after the alkaline soap wash Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 30 Hot Water Wash 1 Perform a rinse cycle see page 28 using a minimum of 300 US gallons of permeate stored for system rinsing 2 Toward the end of the rinse cycle turn valve V19 toward the wash tank feed position This will direct the flow of permeate to the wash tank When the wash tank is full return V19 to the drain position 3 Set the valves as listed below 4 Start and run the system until it shuts down automatically The system will shut down when the temperature reaches 118 F 5 Perform a Rinse cycle see page 28 using a minimum of 300 US gallons of stored permeate water NOTE If the machine shuts down due to low pressure check the prefilters If the prefilters are dirty replace and retry the wash cycle If the prefilters appear clean or are new and the problem continues partially
13. the desired concentration level Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 9 View from Left Side of System Flow Control Valves These valves control the flow of liquid through the system V3 Permeate flow V4 Concentrate flow V6 Feed flow V18 Cleaning or Concentrate flow V19 Drain or Wash Tank SET VALVE TYPE POSITION LIQUID FROM TO SET POSITION LIQUID FROM TO HANDLE HANDLE V3 POINTING Membrane to Permeate out UP POINTING Membrane to Valve V19 DOWN HANDLE HANDLE POINTING Membrane to Concentrate out POINTING Membrane to Valve V19 UP DOWN TOWARD PUMP WASH TANK PIPE HANDLE POINTING Membrane to Valve V19 HORIZONTAL HANDLE POINTING Membrane to Wash Tank HORIZONTAL HANDLE POINTING Drain Wash Tank HORIZONTAL HANDLE POINTING No Flow UP HANDLE POINTING Membrane to Drain DOWN HANDLE POINTING Recirculation to feed pump UP HANDLE HANDLE POINTING lo External to Feed Pump TOWARD Wash Tank to Feed Pump Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 10 The Leader Springtech EXTREME Reverse Osmosis system consists of the following parts Included Equipment LEADER LEADER ORDER DESCRIPTION PHOTO ORDER DESCRIPTION PHOTO Springtech 700018 gt f Strainer Y 1 4 EXTREME 1 AE modified with gd el bleeder valve Springtech Springtech EXTREME 1 EXTREME 1 User
14. to be setup so the connections can be easily disconnected and reconnected as necessary The following is the recommended connection detail In order to assemble the connections you will need braided hose and clamps sold separately e 3 Cstyle Quick Couplers supplied e 3 minimum 1 Stainless Steel Band clamps e 1 ID braided food grade hose with length to make the connections for the Permeate and Concentrate tank The connection to the drain can be made with flexible hose Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 16 V19 Connection To Drain V3 Connection To Permeate Storage Permeate 4 Storage Concentrate Storage Cut 1 ID flexible hose to reach from the valve V19 to the drain connection Place at least one 1 stainless steel band clamp over one end of the hose Slide the hose onto the 1 C style quick coupler Position the stainless steel band clamp s over the hose on the coupler and tighten the band clamp s Secure the other end of the hose to the drain connection Connect the quick couplers by opening the latches on the C style coupler position the metal latch arms out perpendicular to the body of the coupler then sliding the C coupler onto the F coupler Pull the metal latch arms back down to the sides of the C coupler Cut 1 ID braided hose to length from valve V3 to the fill connection for the permeate tank Place at least one
15. 1 stainless steel band clamp over one end of the hose Slide the hose onto a 1 C style quick coupler Position the stainless steel band clamp s over the hose on the adapter and tighten the band clamps Secure the other end of the hoses to the tank fill connection Connect the quick couplers by opening the latch on the C style coupler position the metal latch arms out perpendicular to the body of the coupler then sliding the C coupler onto the F coupler Pull the metal latch arms back up to the sides of the C coupler Cut 1 ID braided hose to length from valve V4 to the fill connection for the concentrate tank Place at least one 1 stainless steel band clamp over one end of the hose Slide the hose onto a 1 C style quick coupler Position the stainless steel band clamp s over the hose on the adapter and tighten the band clamps Secure the other end of the hoses to the tank fill connection Connect the quick couplers by opening the latch on the C style coupler position the metal latch arms out perpendicular to the body of the coupler then sliding the C coupler onto the F coupler Pull the metal latch arms back up to the sides of the C coupler Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 17 OPERATION When starting the Reverse Osmosis unit there is a sequence in which the pumps will activate Pressing the START button will first activate the feed pump In normal o
16. SHKaAR Swans OH EXTREME 1 Reverse Osmosis System Contents INIRODUCHON VE 4 TO Fe OF OPERATION ets notaria 4 IR dn EE 4 RI gei gel geg Elte LEE 5 EQUIPMENT DESCRIPTION RE 6 POAT VICW EE 6 REI TEE 7 FS i OND EE 7 Neit 7 Hee EE del inte Pressure e nl EE 8 Pretilter Assembly ana Wash Tania 8 A A o PR A Ea Pee ne eee ere ee 8 Being e PAIS EE 9 lege 9 VINO EE 9 FO tete ge 10 included Sto TT d ai emeeanetaarre trie teria omen En ta Tien rth EE 11 Optional Setup Equipment Parts and SUppliesS E 11 HE 12 PAGO o O A A a A a E A ar A A 12 POWer e Ten TEE 12 GenerarConnection Layout EE 12 SIMPLE 3 TANK R O DIAGRAM EE 13 A Ee 14 A o 14 EEN 14 VESSEl ANG PUMP RT EE 15 Me ME MES a o a A A A 16 VIS Connecuon TO Dial iia 17 Va Connection To Rermeate Oratorio cai 17 V4 Connection To Concentrate OFIC ARA A Ad 17 OPERA NON DEE 18 Startup Of System WI Lts OF NO FICO E 18 Mba System Cleaning A sd 18 Data Ree al 19 Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 2 REH et 19 Buet De KEE 20 Biel gen e EE ER Adiustine Vi and ee e E 22 San leh OF GSC ninan nd teat aaater a g ch haute hetecu taut tea ass sasctmaiaotaneccsuemn S 23 Concentrate Cde a N a a A r N 23 W re 26 PRINS PCY EE 28 WAS Ti CV CVC ad 30 AOE WV ter WY EN 31 A E 31 Intensive Alkaline SOA Wasi od 31 AGA SOAK aiee eer 31 KE CR Ka D Le GE 33 Pipe EU 33 Membrane Removal and Installation viccccissssscsscce
17. ave no flow Direct V19 to the wash tank as a precaution WD The flow indicator should be up 2 Press the START button on the control panel Within 30 seconds all pumps should start If the system does not continue to run due to a low Pressure Alarm repeat Step 2 up to 2 additional times The STOP ALARM RESET button will need to be pressed after each time 4 If the system does not start on the third try bleed the system To bleed the system open the valve on the top of the strainer installed before valve V6 until all the air is released from the system Close the bleed valve 5 When the machine has started adjust V1 and V2 to produce the desired conditions Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 25 Desugar Cycle In this cycle the permeate is run in a concentrate cycle to flush accumulated sugar from the membrane Dependent on the operation the Desugar process may be done in one of the following ways e Flushing liquid for the full cycle is run to the concentrate tank e Flushing liquid for the full cycle is run to the sap tank e Flushing liquid for the part of the cycle with the highest concentration of sugar is run to the concentrate tank then the remainder is run to the sap tank Flush Liquid Running To Concentrate Tank first part of Desugar with higher sugar being rinsed out Optional 3 Way Valve for Recirculation and Desugar Concentrate Tank EZ amis N Pressure Sa
18. close valve V18 until an operating pressure of 50 80 psi is reached and run the remainder of the cycle Alkaline Soap Wash 1 Perform a rinse cycle see page 28 using a minimum of 300 US gallons of permeate stored for system rinsing 2 Toward the end of the rinse cycle turn valve V19 toward the wash tank feed position This will direct the flow of permeate to the wash tank When the wash tank is full return V19 to the drain position 3 Atthe completion of the rinse cycle add R O soap LEADER Order 69992 to the wash tank and mix Add R O soap until a pH of 11 is reached NOTE This applies to FILMTEC E8 membranes For other membranes consult with a LEADER sales person or a local distributor dealer 4 Set the valves as listed below 5 Start and run the system until it shuts down automatically The system will shut down when the temperature reaches 118 F NOTE If the machine shuts down due to low pressure check the prefilters If the prefilters are dirty replace and retry the wash cycle If the prefilters appear clean or are new and the problem continues partially close valve V18 until an operating pressure of 50 80 psi is reached and run the remainder of the cycle Perform a Rinse cycle see page 28 using a minimum of 300 US gallons of stored permeate water 7 Drain the wash tank The drain valve is located under the wash tank Turn the flow indicator to the left Intensive Alkaline Soap Wash 1 Follow the directions
19. d assembly Concentrate 7 Permeate Tube Permeate Sap Concentrate The drawing above represents the flow of liquid through a membrane in the system The membrane is housed in a pressure vessel not shown Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 5 EQUIPMENT DESCRIPTION The LEADER EVAPORATOR Springtech EXTREME Reverse Osmosis System is designed to offer maximum concentration to cost performance Through optimizing of pumps and membranes the reverse osmosis systems deliver greater flow potential to the user The LEADER EVAPORATOR Springtech EXTREME Reverse Osmosis system is designed and built using the same principles of superior quality applied to our evaporators The LEADER EVAPORATOR Springtech EXTREME Reverse Osmosis System is covered by a manufacturer s warranty See ATTACHMENT 3 NOTES 1 Pictures sketches and drawings presented in this document are not to scale 2 Directions right and left will be as facing the front of the system Front View Flow Meters Pressure Gauge lt I K I A v Prefilters Power Control Panel Feed Pump Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 6 Rear View V3 V4 V18 v19 Pressure h ee Wash Tank Wash Tank Drain WD Recirculation Pressure Pump Pump Feed Pump Provides liquid to the system and Feed Pump M1 1 HP is t
20. e cycle see page 28 using a minimum of 300 US gallons of permeate from the permeate storage tank 8 Doa permeability test see page 20 If the test is good continue the rinse cycle with any additional permeate MAINTENANCE Pre Filters When the feed pump pressure drops below 20 psi the prefilters may need to be changed The procedure to change the prefilters is as follows NOTE there are two filter housings mounted side by side Change each one separately Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 33 1 Loosen and remove the lower portion of the filter housing 2 Empty the liquid from the housing 3 Remove the filter from the housing 4 Wipe the O rings of the top of the assembly then apply a light coating of food grade grease such as LEADER order 64436 WT e Filter Alignment I Projection 5 Rinse out the housing Insert a new filter into the housing aligning one of the open ends over the alignment projection 6 Bring the lower filter housing with the filter installed up to the underside of the top of the filter housing on the system Carefully align Underside of the Top of the Filter Housing Alignment Projection the open top of the filter with the alignment a projection in the top of the filter housing Thread the bottom of the housing onto the top of the housing and securely hand tighten Leader Evaporator Springtech EXTREME 1 Reverse Osmo
21. e vm em wm em vm em mew eee e wm e ee owe YES Less than 15 difference from benchmark flow Intensive Alkali Soap Wash check pH every15 minutes adding soap as necessary to maintain pH Alkali Soap Wash Rinse Permeability Citric Acid Soak minimum 8 hours YES Less than 15 difference from benchmark flow Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 21 Flow Valve Information The following is a table illustrating the type of valve being used and where fluid flows when the valves are in certain positions NOTE Flow as stated only occurs when all valves are set for the proper cycles SET VALVE TYPE POSITION LIQUID FROM TO 8 SET POSITION LIQUID FROM TO HANDLE HANDLE V3 3 Way POINTING Membrane to Permeate out POINTING Membrane to Valve V19 UP DOWN HANDLE HANDLE V4 POINTING Membrane to Concentrate out POINTING Membrane to Valve V19 UP DOWN HANDLE POINTING External to Feed Pump TOWARD Wash Tank to Feed Pump HANDLE POINTING TOWARD PUMP WASH TANK PIPE HANDLE HANDLE POINTING No Flow POINTING Membrane to Valve V19 UP HORIZONTAL HANDLE HANDLE POINTING Membrane to Drain POINTING Membrane to Wash Tank DOWN RIGHT HANDLE HANDLE WD POINTING Recirculation to feed pump POINTING Drain Wash Tank UP HORIZONTAL The following is a summary table of the system cycles and the related valve settings for the cycle s
22. ecessary the four 4 O rings of the membrane plug Lightly lubricate the O rings with food grade grease then slide the plug into the membrane Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 36 2 Insert the membrane into the housing with the plug end down Ensure the membrane goes all the way into the vessel with the membrane plug seated in the housing lt E A Membrane O ring Brine Seal 3 Check the O rings on the alignment coupler replace if damaged Lightly lubricate the O rings if necessary with food grade grease then insert the coupling into the end of the membrane Lubricate the membrane O ring brine seal with food grade grease 4 Inspect the O rings of the cap and replace if damaged Lubricate the O rings with food grade grease if necessary 5 Place the cap on the housing aligning the two connections and the holes in the cap and the housing 6 Secure the cap to the housing with the nuts and bolts removed earlier 7 Invert the housing and place it into the hole in the system frame while aligning the connections on the housing with those of the recirculation pump Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 37 8 Place the securing strap around the housing and loosely tighten the nuts and bolts to hold it in place 9 Finish aligning the recirculation pump connections then slide the rubber coupler over the membrane housing
23. emove membranes and pump assemblies The room should have adequate drainage The walls ceiling and floor should be easy to clean Power Requirements The system requires 220V 1 Phase 38 amps All electrical work should be done by a licensed electrician and meet all local codes See ATTACHMENT 1 for the wiring schematic MOTOR ID MOTOR FUNCTION SIZE HP NAMEPLATE AMPERAGE General Connection Layout The following illustrates a generalized layout for connections with the Springtech EXTREME RO System The first drawing shows tank connections to the system The second drawing shows an arrangement of valves to connect the incoming liquid to the system Dependent on the location other arrangements are likely It is beyond the scope of this document to recommend the best layout for all situations It is recommended you contact your LEADER EVAPORATOR sales person or your local Distributor Dealer for assistance in deciding the correct tanks and layout for your needs Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 12 SIMPLE 3 TANK R O DIAGRAM To Evaporator Concentrate Storage Permeate Storage 1 3 Way Valve Liquid Source Selector Sap Storage Springtech EXTREME RO System Liquid Source Selector Sap Concentrate Permeate 1 1 2 3 Way Valve EN K 1 1 2 3 Way Valve T X 1 1 2 Ball Valve To 1 1 2 T Strainer before Valve V6 on System Valves should be i
24. f concentrating or at the end of every day NOTE If only a few hundred gallons of sap was run and the machine is to be cleaned run a hot water wash The following cycles always need to be run in sequence when used e Desugar Rinse e Desugar Rinse Alkaline Soap Wash Rinse also called Alkaline Soap Wash cycle e Desugar Rinse Alkaline Soap Wash Rinse Acid Soak Rinse Alkaline Soap Wash Rinse also called Chemical Wash cycle Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 19 Permeability Test The permeability test is used to monitor the performance of the system It is based on comparing the results of a benchmark test taken when the system is new or at the start of anew season The permeate flow rate is the basis for the results of the test Performing the permeability test for benchmarking 1 Perform a rinse see page 28 then fill the wash tank full of permeate by moving valve V19 to the horizontal left position Set the valves in the wash cycle position see page 30 Close valve V18 Run the system until the temperature reaches 55 F a E HS Adjust the membrane pressure to 200 psi using valves V1 and V2 NOTE If the starting temperature is higher than 55 F the same results can be obtained at 70 F and 150psi operating pressure Record the flow rates from the permeate flow meter and from the concentrate meter 7 Multiply the permeate flow rate by 60 t
25. for the Alkaline Soap Wash 2 Check the pH of the wash solution every 15 minutes Maintain the pH by adding soap Acid Soak 1 Perform an alkaline Soap wash as listed above 2 At the end of the rinse cycle following the wash turn valve V19 toward the wash tank feed position Run until the wash tank is approximately full return V19 to the drain position 3 Add cup of citric acid to the wash tank and mix 4 Runa wash cycle The system will shut down when the temperature reaches 118 F 5 Shut off the system and allow the acid solution to soak for 8 to 24 hours 6 Drain the wash tank 7 Performa rinse cycle see page 28 using a minimum of 300 US gallons of stored permeate water 8 Perform an alkaline soap wash as detailed above 9 Drain the wash tank 10 Perform a rinse cycle see page 28 using a minimum of 300 US gallons of stored permeate water Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 31 Permeate Tank Optional 3 Way Valve for l a Recirculation and Desugar Pre Filter Recirculation Pressure Sap Source Tank A K 5 Y Strainer Ka PEN V6 Pressure fs Flow Meter Membrane E ME Sap Flow E Permeate Flow GE Concentrate Flow Concentrate Flow Pressure Relief QE Wash Solution Flow Wash Cycle Valve Settings also available on the Quick Start Guide 1 Position the valves as follows V1 Open the valve completely V2 Open the valve complete
26. gtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 23 Standard Concentrate Output Permeate Tank Optional 3 Way Valve for Recirculation and Desugar SE i Concentrate Tank E Z I Recirculation N Pressure Membrane Y Strainer Ka V6 Pressure Pump e Flow Meter Mu Sap Flow EJ Permeate Flow NA Concentrate Flow MA Concentrate Flow Pressure Relief Sap Concentration Loop Optional 3 Way Valve for Recirculation and Desugar Concentrate Tank HH Recirculation Pump N Pressure Sap Source Tank Pressure Pump eS Flow Meter Mu Sap Flow EJ Permeate Flow WA Concentrate Flow ua Concentrate Flow Pressure Relief Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 24 Concentrate Cycle Valve Settings also available on the Quick Start Guide 1 Position the valves as follows V1 Open Y way to start then adjust to the desired maximum pressure Do NOT Exceed 550 psi V2 Open a minimum of way to start then adjust to the desired concentration level or flow V3 The flow indicator should be UP V4 The flow indicator should be UP V6 The handle should be toward the pump housing Input from the liquid source selector should be from the raw sap or previously concentrated sap V18 Valve handle is vertical up Valve is closed V19 With V3 and V4 in the concentrate setting V19 should h
27. he first stage of pressurizing the system w i H A ei 0 3 K Fea K A D La Ed lt lt be d st A Mad G O View from Left Side of System Pressure Gauges Feed pump pressure is read after the prefilters Feed Pump Pressure Membrane pressure is read after the last membrane WARNING DO NOT ALLOW THE OPERATING PRESSURE TO EXCEED 550 psi Membrane Pressure Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 7 Pressure Recirculation and Pressure Pumps ei Pump Motor T M2 5 HP Pressure Pump Second stage of pressurizing the system required to process the sap through the membranes Recirculation Pump Recirculates liquid within the vessel to which they are attached Recirculation St H View from Rear of Pump Motor p SE H A System M3 1 5 HP Pressure Pump Assembly Recirculation Pump Assembly Prefilter Assembly and Wash Tank Prefilter assembly requires 2 20 cartridge filters Wash tank is used to mix the chemical solution for cleaning the system Prefilter Assembly X2 8 i gt gem i iew from Rear of System _ __ a Sampling Ports Concentrate port is used to sample the liquid concentrate to determine the sugar percentage The Permeate port is used to sample the permeate from the membrane to determine if it is allowing sugar to pass through Concentrate Port Permeate Port View from Front of System Leader
28. ing the couplers together The membrane housing drain is located under the housing It is a quick disconnect The feed pump drain is a stainless steel plug located on the front of the pump housing at the bottom of the tee where the temperature sensor is mounted Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 15 The recirculation and pressure pump drains are Recirculation Pump Drain de provided with a stainless steel ball valve It is recommended the drains be setup to collect the liquid The connections on the system for the drain will need items sold separately e 2 PVC adapters e 2 Stainless Steel band clamps e 2 pieces of hose long enough to connect to the drain adapter and to reach the collection point An additional drain the wash tank overflow drain can be connected using a 1 combo elbow adapter items sold separately Install drain connections as follows 1 Teflon tape the Y PVC adapter 2 Thread the PVC adapter into the stainless steel ball valve 3 Cut Y ID braided hose to length to reach from the ball valve to the point where you will be collecting the liquid Place a Y stainless steel band clamp over one end of the hose Slide the hose onto the PVC adapter Position the stainless steel band clamp over the hose on the adapter and tighten the band clamp V3 V4 and V19 Connections V3 V4 and V19 valves are
29. l Wash Cycle Process of chemical washing the membranes by recirculating a solution through the reverse osmosis system Dependent on requirement chemical maybe be alkali or acid Permeability Test Test to determine the performance of the membranes against a benchmark Sap Concentration Loop Process of recirculating output from the concentrate cycle to the raw sap tank increasing the concentration of the sap in the tank Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 4 Description of Membrane Permeate Tube Perforated Permeate Permeate Carrier Membrane Sap Membrane Plug The basic units of the reverse osmosis membrane are described in the cross section drawing Attached to the permeate tube is a membrane unit consisting of a permeate carrier between two membranes There are a number of these membrane units attached around the outside of the permeate tube Between each of the membrane units is a spacer through which the sap and concentrate can flow The permeate tube is perforated so the permeate can be collected from the membrane unit At each unit as the sap is pressurized the permeate can flow through the membrane and be carried to the permeate tube The concentrate cannot penetrate the membrane and is pushed out the membrane assembly The membrane units are wound around the permeate tube and an outside support structure is placed around the woun
30. lons of water from the permeate tank While this cycle is running check all fittings piping connections and hoses for leaks Repair as necessary 3 Atthe end of the rinse cycle change the position of valve V19 so the liquid flow is directed to the wash tank When the wash tank is approximately full return V19 to the drain position 4 Mix alkaline R O soap with the liquid in the wash tank until a pH of 11 is reached Note this is for FILMTEC E8 membranes If other membranes are being used consult with a Leader Sales person or a local Distributor Dealer 5 Set the valves for and run an alkaline wash cycle see page 31 allowing the system to run until the automatic temperature shutdown at 118 F Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 18 6 Set the valves for and run a rinse cycle see page 28 using a minimum 300 US gallons of water from the permeate tank 7 Run the benchmark permeability test see page 20 Data Logging Data on the operation of the system should be recorded and kept See ATTACHMENT 2 for the data sheet format The following data is recorded e Date date the information is collected e Activity Concentration cycle enter a C or Test enter a T e Sap the sugar concentration of the raw sap e Concentrate the sugar concentration of the concentrate from the system Test results from the concentrate port e Permeate Flow gallons per minute of permeate
31. ly V3 The flow indicator should be DOWN Valve is open for recirculation V4 The flow indicator should be DOWN Valve is open for recirculation V6 The handle should be toward the wash tank line Valve is open to the wash tank Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 32 V18 Handle should be parallel to the pipe Valve is open V19 Handle should be horizontal right Valve is open to the wash tank WD The flow indicator should be up Add the soap required for the type of wash to be performed NOTE Ensure the wash tank is filled first 3 Press the START button on the control panel Within 30 seconds all pumps should start For an alkaline soap wash run the Wash cycle until the system shuts down automatically The system shutdown is based on the temperature of the liquid When the liquid reaches 118 F the system will shut down NOTE If the machine shuts down due to low pressure check the prefilters If the prefilters are dirty replace and retry the wash cycle If the prefilters appear clean or are new and the problem continues partially close valve V18 until an operating pressure of 50 80psi is reached and run the remainder of the cycle 5 Press the STOP ALARM RESET button to reset the alarm 6 Open the wash tank drain valve to drain the wash tank When the wash tank is empty return the drain valve to the recirculation position 7 Run a rins
32. n the R O room for ease of operation Additional valves and tanks may be required depending upon installation Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 13 Strainer Connections Plumbing from the supply tanks is recommended to be 1 ID The strainer is not mounted to the system It will need to be mounted by the user The connection can be made as follows 1 Identify the flow direction through the strainer There is an arrow on top of the strainer which shows the direction of flow The input side pushes the liquid through the strainer prior to it going into the system Additionally when mounting the strainer the spigot should be on top as it will need to be opened to bleed air from the system 2 Install a valve before the Y strainer so the strainer can be removed and cleaned V6 Connection The V6 valve is to be setup so the connection can be easily disconnected and reconnected as necessary The following is the recommended connection detail 1 Teflon tape a 1 F style quick coupler 2 Thread the F style quick coupler into valve V6 Tighten the coupler NOTE Secure valve V6 so as not to break it when tightening the coupler 3 Obtain a length of 1 braided hose that will connect to the strainer output on the incoming liquid source 4 Slide a 1 Y stainless steel band clamp over one end of the hose 5 Slide the hose onto a 1 C style quick coupler and tighten the
33. o give a US gallons per hour rate This number will be the rate benchmark rate for comparison to past and future testing Record this number in the data log with Activity TA A permeability test should be performed after each wash cycle The test is performed as described above for steps 2 through 6 Compare the flow rate obtained in the test with previous benchmark rates If the flow rate is less than the benchmark rate by 15 or more then further cleaning will be necessary See the flow chart on page 21 To calculate the difference to the benchmark do the following calculation 1 Current Measured GPM Benchmark GPM X 100 Note concerning the chart if the sap is of good quality high clarity with no visible suspended material and the performance of the system cannot be returned to the benchmark level with alkaline soap chemical wash it will need an acid soak Acid soak will help remove mineral deposits If the sap is of poor quality and bacteria is responsible for overall poor performance the alkaline soap wash should remove the problem NOTE This applies to FILMTEC E8 membranes Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 20 ConcentrateCyde K 1 to 12 hours or end of day Less Than 1 hour Desugar Rinse Alkali Soap Wash Hot Water Wash Rinse Bes Permeability Test Liew eww ew www ew wm ww eww ww ew wm wm ww ww wm Paw wm ewe em wm e vm vm we
34. ough the membrane while the concentrated solution remains outside the membrane and is concentrated For the sugar maker this means water permeate is removed from the sap and a sap with a higher sugar level concentrate is produced for the evaporation process Terms Semi permeable Membrane Unit consisting of multi layers of spacers and membranes Pre Filter Unit Designed to remove suspended solids from the sap incoming to the reverse osmosis system Feed Pump The initial pump designed to supply the reverse osmosis unit with sap and maintain pressure in the system Pressure Pump The pump designed to provide the pressure needed to force the sap through the reverse osmosis membrane Pressure Vessel The containment unit for the semi permeable membrane Permeate Purified water removed from the maple sap during the concentrate cycle Concentrate the maple sap having a higher percentage of sugar because water permeate has been removed Permeate Holding Tank A tank designed to hold a minimum twice the hourly output of the system Concentrate Cycle Process during which water is removed from maple sap resulting in Concentrate and Permeate De Sugaring Cycle Process to reclaim sugars from the membrane during which Permeate is run through the reverse osmosis unit using Concentrate cycle valve settings Rinse Cycle Cleaning process of passing stored Permeate through the Reverse Osmosis system and out to drain Chemica
35. p Source Tank ty E 13 Pressure Pump R Flow Meter ME Sap Flow E Permeate Flow H Concentrate Flow EXA Concentrate Flow Pressure Relief Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 26 Flush Liquid Running To Sap Tank later part of Desugar with lower sugar being rinsed out Optional 3 Way Valve for Recirculation and Desugar Concentrate Tank Fo Recirculation Pump N Pressure Sap Source Tank a Pressure Pump eS Flow Meter H Sap Flow EJ Permeate Flow NA Concentrate Flow EA Concentrate Flow Pressure Relief Desugar Cycle Valve Settings also available on the Quick Start Guide 1 Position the valves as follows V1 Leave valve where it was set during the concentration cycle V2 Leave the valve where it was set during the concentration cycle V3 The flow indicator should be UP Valve is open to the Permeate tank V4 The flow indicator should be UP Valve is open to the Concentrate tank V6 The handle should be toward the pump housing Input from the liquid source selector should be from the permeate tank Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 27 V18 Valve handle is vertical up Valve is closed V19 With V3 and V4 in the concentrate setting V19 should have no flow Direct V19 to the wash tank as a precaution WD The flow indicator should be up 2 Pres
36. pecified Detail on the cycle settings is in the sections that follow CYCLE Open way then adjust Open way then adjust Open Bn Open a V2 Open minimum way then Open minimum way then Open Fully Open Fully adjust adjust Handle Pointed UP Handle Pointed UP Handle Pointed DOWN Handle Pointed DOWN Handle Pointed UP Handle Pointed UP Handle Pointed DOWN Handle Pointed DOWN THE PUMP Sap THE PUMP Permeate THE PUMP Permeate TANK PIPE HORIZONTAL open Handle Pointed RIGHT Handle Pointed RIGHT Handle Pointed DOWN Handle Pointed RIGHT Handle Pointed UP Handle Pointed UP Handle Pointed UP Handle Pointed UP HORIZONTAL Drains Closed Closed Closed Closed S NOTE During the Rinse cycle if the machine shuts down due to low pressure and the feed line has been bled or during the Wash cycle if the machine shuts down due to low pressure check the prefilters If the prefilters are dirty replace and retry the rinse wash cycle If the prefilters appear clean or are new and the problem continues partially close valve V18 until an operating pressure of 50 80 psi is reached and run the remainder of the cycle Adjusting V1 and V2 for Operations V1 sets the maximum allowable pressure and should never be completely closed The maximum pressure is 550 psi with a recommended level of 200 350 psi Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 22 V2 is adjusted for concentration output b
37. perations within 30 seconds the pressure pump will start followed by the recirculation pump During any cycle if permeate is not available use non chlorinated well or spring water Startup of System with Little or No Fluid 1 Set the system valves for a rinse cycle see page 28 2 Open the control box by unfastening the latch on the left side then opening the door carefully to the right B BREAKER ID CIRCUIT START POSITION Feed Pump PON Recirculation Pump 4 Close the control box cover and refasten the latches buckles 5 Ensure your source valves water or permeate are open to feed the system 6 Press the START button to start the feed pump 7 Run the feed pump until most of the bubbles are gone from the flow meters located on the front of the system This will take 3 to 4 minutes Not all the bubbles can be removed 8 Pressthe STOP button to stop the feed pump 9 Open the control box by unfastening the latches buckles on the left side then opening the door carefully to the right 10 Position breakers CB1 CB2 and CB3 to the ON position 11 Close the control box cover and refasten the latches 12 Proceed to the instructions for the Initial System Cleaning Initial System Cleaning To prepare the system after setup 1 Put approximately 600 US gallons of non chlorinated well or spring water into a clean permeate storage tank 2 Set the valves for and run a rinse cycle see page 28 using a minimum 300 US gal
38. pipe so that it rests between the grooves 10 Place the two clamp halves over the rubber seal and aligning the pieces with the grooves in the connector pipes Place the bolts in the clamp and tighten Check to ensure the clamp is properly seated and tightened by ensuring the two halves fit tightly together 11 Thread in and tighten the concentrate line to the connection at the top end of the housing 12 Ensure all fittings are aligned and tight then tighten the nuts and bolts on the securing strap 13 Reconnect the permeate line to the end of the membrane housing using the quick coupler 14 Follow the instructions for the Beginning of Season Startup see page 40 Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 38 Daily Each day it is recommended the following be done 1 Remove clean and reinstall the strainer in the Y strainer 2 Sample the permeate liquid from the sampling port a Purge the permeate sample line by running the system and drawing a volume of permeate from the port approximately equal to a test cup b Draw a sample for testing Test the permeate sugar level using either a refractometer or a hydrometer c Ifthe results indicate there is any sugar present there is a possible problem with the membrane O rings connector or alignment coupling Check the troubleshooting chart 3 Check all hoses piping fittings and connections for leaks Repair as necessary Run a c
39. re Pump gt e ATV Ss 5HP 230 Vac 1 Phase 23 Amps Nameplate H ojo de T2 Ke w So 6BAWG a 3 AWG e A E X y z F CONDUIT FITTINGS TO MEET A NI D e ENCLOSURE RATING CB2 M2 OL2 20A NO pe 2 Recirculation Pump 1 BONDING OF CONDUCTORS TO ne BE ji Ss 1 5HP 230 Vac 1 Phase 7 Amps Nameplate BE TIED WITH MAIN GROUND eo e HS a oO L 2 112M AL gt SH L e es a o o OWT O CB3 M3 OL3 silted aaa Din om T E ni inn OA Recirculation Pump 2 Fe EN Me gt 1 5HP 230 Vac 1 Phase 7 Amps Nameplate A ry A gt O o paz O ls O x gt j Si E 7 1 2 7 Optional extension kit RA PA DER SE Dain RRR Se Ee cria O O 2A CB4 ez gt hdi llos J ponts 230Vac 120Vac EY NENS W2 16 AWG White PLC OUT5 AM AL OL1 el ws wa 95 4 96 e Feed Pump 1A CB5 Nowa o PLC OUT6 ga e SE OL2 Wi 16 AWG Black J bi A 2 BL 6 Pressure Pump 10 6 PLCEXT OUT1 Al oa LAS OL3 wr Ma A e Recirculation Pump 1 2 IN ws Ars A2 OL4 i i m 95 r 96 e Recirculation Pump 2 ze kel A A Optional extension kit WINE AS ADA AAA E 8 4 1 6 Red 22 IN o 7 20 Type J Wire 23 IN BUM VET Temp Controller 5 Types Ti Liou PWR 12 i Thermocouple White 5 Out 10 o 6 r SS 24Vdc Power Supply ee as Temp Controller P j E e emp Controller rammin 7 AC ode 6 SS St P rog g W13 Int JIC 8 AC Vdc Unit E Oft HEAT e wi2 Sein 24Vdc 16
40. sis System Manual YEAR 2015 Page 34 Membrane Removal and Installation Removal 1 Stop the system by pressing the STOP button 2 Position valve V6 to the wash position 3 Set valves V3 and V4 in a rinse cycle position Recirculation Pump Clamps Recirculation Pump Seals P Ge 4 Disconnect the permeate line quick coupler from under the membrane housing Allow the vessel to drain until empty Remove the outer sections of the recirculation pump clamps by loosening and removing the nuts and bolts Under the outer clamp parts are rubber seals Slide the seals toward the recirculation pump so they are not over the membrane housing connection Loosen and remove the concentrate hose from the concentrate connection on the housing Remove the nuts and bolts securing the strap around the vessel CAUTION The housing is heavy and will now be loose Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 35 9 Remove the housing from the system and place it upside down on a solid surface ex floor CAUTION Housing is heavy 10 Remove the nuts and bolts securing the cap to the housing then remove the cap from the membrane 11 Remove the alignment coupling from the end of the membrane 12 Remove the membrane from the housing and then remove the membrane plug from the end of the membrane Note the membrane will contain liquid Installation 1 Inspect and replace if n
41. sscssnveveescsdevecnaueeveveseivenssavevevccsd deenavavsesecedbdesnssousseesesueenvscasdesecoenaevessaices 35 FRE FINO EE 35 nstala eg EEE EE EAT T E E E cad 36 Dal EE 39 TNO Cores cha Nate neat o eta ia 39 ENd Of Season SAUTCOWN and Sl ee 39 Beginning olse ason tata accua 40 TROUBLESHOOTING CHART renent n EE 42 AITACHMENTHL ELECTRICALSCHEMATI Enri iS 43 ATTACHMENT 2 OPERATIONS DATA LOG SHEE T us 44 ATTACHMENT 3 WARRANTY INFORMATION EE 47 Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 3 INTRODUCTION A Leader Evaporator Springtech EXTREME Reverse Osmosis system is designed to significantly improve the producer s productivity by generating higher sugar percentage sap Through use of high pressure the system removes water from the sap resulting in a more concentrated sugar solution entering the evaporator This in turn shortens the boil time required resulting in fuel and time savings Some of the features of the Springtech EXTREME 1 are e Easy accessibility to pumps and membranes e Stainless steel frame membrane housing pressure and recirculation pumps e Fast wash cycle e With reasonable sap the ability to generate 6 to 10 brix concentrate with a single pass e Flow meters for the permeate of each membrane and one for the system concentrate THEORY OF OPERATION In reverse osmosis through the use of special semi permeable membranes and high pressure water is forced ina pure form thr
42. sthe START button on the control panel Within 30 seconds all pumps should start If the system does not continue to run when you release the START button due to a low Pressure Alarm repeat Step 2 up to 2 additional times The STOP ALARM RESET button will need to be pressed after each time 4 Ifthe system does not start on the third try bleed the system To bleed the system open the valve on the top of the strainer installed before valve V6 until all the air is released from the system Close the bleed valve 5 Check the concentrate sugar level approximately every 5 minutes The Desugar cycle should be run until the concentrate sugar is down to at least 1 to 2 Rinse Cycle In this cycle permeate is run through the system at high volume and low pressure to rinse sugar minerals and bacteria from the R O Arinse cycle is required before and after every wash cycle At least 300 US gallons of permeate is required in a rinse following a chemical wash Desugar and rinsing the system every 4 to 6 hours can help to maintain higher performance rates Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 28 Permeate Tank Optional 3 Way Valve for Recirculation and Desugar Concentrate Tank E gt Pre Filter Recirculation 5 Y Strainer IAN V6 Pressure Pump Pressure Membrane C e Flow Meter HA Sap Flow EJ Permeate Flow MIA Concentrate Flow HA Concentrate Flow Pressure Relief
43. tinue running Low rate found during permeability Suspected bacteria buildup Rewash system with R O alkali soap test Suspected Mineral Buildup Acid wash system Sugar in the permeate Leak at alignment coupling or Replace O ring or alignment coupling membrane plug or the membrane connector Membrane deterioration Replace membrane Temperature Alarm Indicator Normal operations for wash cycle Reset alarm by pressing the STOP button Motor Failure Alarm Indicator Motor contactor has tripped Contact LEADER Technical Service Leader Evaporator Springtech EXTREME 1 Reverse Osmosis System Manual YEAR 2015 Page 42 ATTACHMENT 1 ELECTRICAL SCHEMATIC Service 230 Vac 1 Phase 75 85 opt Amps 2 Wire amp Ground f i 12 G g SI m MAIN DISCONNECT MUST BE ADDED AT INSTALLATION High Voltage _ i Note 20A r EAr r Feed Pump All control wire is 16 AWG Red ETE Kees l NA 1HP 230 Vac 1 Phase 6 Amps Nameplate unless otherwise noted D 319 DO e All terminal blocks are labeled TR TA 49 AWG e to their corresponding wire numbers o o LY oO 5 A 14 TORQUE TERMINALS TO 15lb in CB1 M1 OL1 e USE 75 C COPPER CONDUCTORS ONLY 60A FIG que A Pressu
44. y flow or sugar There are two methods of determining how to set the V1 and V2 valves e Concentrate Preferred Turn V1 to a minimum pressure and turn V2 until the desired concentration is obtained Adjust V1 until the pressure desired is reached Readjust V2 until the concentration desired is reached e Volume Preferred Turn V2 to a minimum and Turn V1 until the desired flow is reached Adjust V2 until the concentration desired is reached Readjust V1 until the desired flow is reached Sample Port Use When using the concentrate sample port run approximately 1 test cup of concentrate through in order to purge the lines Pour that cup back into the raw sap tank Draw a second cup and sample The permeate sampling port should be purged as done with the concentrate sample port The permeate through this ports should be sampled once per day Concentrate Cycle In this cycle the system inputs sap or pre concentrated sap and cycles it through the membranes resulting in a concentrated liquid concentrate and the water being removed permeate There are two output options within the Concentrate Cycle The first is to direct the concentrate to the concentrate tank The second is to direct the concentrate to the sap tank this is called the Sap Concentration Loop Valves are required between valve V4 and the concentrate tank allowing the option for concentrate to be directed to the sap tank valves sold separately Leader Evaporator Sprin
45. ycle of Desugar see page 26 Rinse see page 28 Alkaline Soap Wash see page 31 Rinse see page 28 5 Doa Permeability test see page 20 Inspect and clean storage tanks a Permeate b Concentrate c Sap Periodic 1 When the feed pump pressure drops below 20 psi the prefilters need to be changed see page 33 2 Ifa permeability test see page 20 indicates the system performance is less than 85 of the benchmarked performance a Runacycle of Rinse see page 28 Intensive Alkaline Soap Wash see page 31 checking pH 2 to 3 times and adding additional soap as necessary Rinse see page 28 and repeat the permeability test see page 20 b If necessary or at the end of the season run a cycle of Rinse see page 28 Acid Wash see page 31 Rinse see page 28 Alkaline Soap Wash see page 31 Rinse see page 28 and repeat the permeability test see page 20 3 Pump motors will need to be lubricated The following table describes the lubrication requirements NOTE The output of the grease gun will need to be measured prior to lubricating the bearings in order to ensure the proper amount of lubrication is used a All bearings require EXXON POLYREX EM lubricant Lubrication Lubrication Lubrication Lubrication Bearing Interval Amount Bearing Interval Amount MOTOR FUNCTION Location hrs ounces Location hrs ounces M2 Trresureramp 5 pumpera sso 5 non Pumpena sso 39 End Of
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