user osmose hobby manual 100-200 gph...cdl maple sugaring equipment inc. 11 membrane installation...

USERMANUAL

OSMOSE HOBBY 100-200 GPH

26/06/2018

© All rights reserved Les Équipements d’Érablière CDL inc.

CDLMapleSugaringEquipmentInc.1

ThankyouforpurchasingaCDLHobbyreverseosmosissystem.Thisdocumentwillhelpyoumakethemostofyourproduct.


TableofcontentsProductdiagram..............................................................................................................................3

Valvelocations............................................................................................................................4

Definitions.......................................................................................................................................6

Safety..............................................................................................................................................6

Inspection........................................................................................................................................6

Installation.......................................................................................................................................6

Electrical......................................................................................................................................6

Plumbing.....................................................................................................................................7

Membraneinstallation..............................................................................................................11

Pre-filtercartridge.....................................................................................................................13

Dailyoperations............................................................................................................................14

De-icing.....................................................................................................................................15

Concentration............................................................................................................................15

Desugaring.................................................................................................................................16

Rinsing.......................................................................................................................................16

Washing.....................................................................................................................................16

Closing.......................................................................................................................................16

Procedurefollowingapoweroutage........................................................................................16

Draining.........................................................................................................................................17

Maintenance.................................................................................................................................17

Start-of-seasonprocedure............................................................................................................17

End-of-seasonprocedure..............................................................................................................18

Tips................................................................................................................................................18

Troubleshootingchart...................................................................................................................19

PWPtest........................................................................................................................................20

Potentialsavings...........................................................................................................................23

Warranty.......................................................................................................................................23


Productdiagram

Washtankoption#OSHO-A00007

19L/5USgal.

ConcentratecontrolvalveV4

Filtrateflowmeter

Concentrateflowmeter

Temperaturecontrol

Linefilter

Electricalpanel

ConcentratesamplingvalveV2

FiltratesamplingvalveV3

Stopbutton

Startbutton

“On”light

Filtrateoutput

Pre-filter

Weight:185lb/84kg

Size:27x26x67in.


Valvelocations

Drainvalve

Linefilter

Feedpump

Recirculationpump


V5Membrane

drainvalve#1

V9Collectordrain

valve

V10Feedpumpdrainvalve

V6Membrane

drainvalve#2

V7Recirculationpumpdrain

valveV8Collectordrain

valve

V1Air

evacuationvalve

V2Concentratesamplingvalve

V3Filtratesampling

valve

V4Concentratevalve


DefinitionsSap:Liquidthatcomesfromamapletree.Generally,thiswatercontainsaround2%sugarandmineralsalts.

Filtrate:Purewaterthatnolongercontainssugar.Itiscreatedwhenitrunsthroughamembraneinthereverseosmosis(RO)system.Itisusedtowashthemachine.

Concentrate:SugarwaterobtainedaftersaphasrunthroughtheROsystem,removingthepurewater.

Feedpump:Pumpthatusespressuretopushthesapthroughthemembranes.

Recirculationpump:Pumpthatrecirculatessapthroughthemembranehousingstopreventthemembranesfrombecomingclogged.

Linefilter:Filterattheentranceofthefeedpumpthatpreventsdebrisfromenteringthepump.

Pre-filter:Filterthatsitsbeforethemembranesandpreventsdebrisfromenteringthesystemandtherecirculationpump.

Concentratevalve:Valvethatcontrolstheflowoftheconcentrateexitingthesystem.

Flowmeter:Toolusedtomeasuretheflow.ReadsinUSgallons/minuteandlitres/minute.

SafetyIt is important to read this document before using the reverse osmosis system. It containsinformationonhowtousethesystemsafely.Misusecanbedangerousfortheuserbecauseofthesystem’sworkingpressure.

InspectionPerformaquickvisualinspectiononceyoureceivethesystemtocheckforbreaksoranomalies.Inspectitagainbeforeeachuse.

InstallationEnsurethattheROsystemisinstalledaccordingtotherequirementsbelow.Theproduct’slifespanmaybeshortenedifitsinstallationdoesnotfollowCDL’srecommendations.

Electrical110Vversion:Themachinemustbepluggedintoa110Vsingle-phaseoutlet.*Itisimportanttoputa20Acircuitbreakerandensurethewire’sgaugeissufficient.Ifanextensioncord


mustbeused,itmustbeatleast12AWG.Anextensioncordthatistoolongorthathastoohighofagaugemayoverloadthemotors.Overloadingmaycausethemotorstooverheatandbreak.

220Vversion:Themachinemustbepluggedintoa220Vsingle-phaseoutlet.

PlumbingThesystemcontainsan8-footsuctionline.Donotextendthisline.Ifitisextended,thepumpmayrundryfortoolonguponstarting,whichmaydamageinternalparts.Topreventbubblesfromforminginthefeedpump,donotplacethepumpmorethan1mabovethebottomofthetank.

1mmaximum


Amountoffiltrateneeded:600litres(160US

Batchconcentration(sparging)

Amountoffiltrateneeded:

600litres(160USgallons)

Standardconcentration


MembraneinstallationWhenusingnewmembranesintheROsystem,thesestepsmustbefollowedinorder:Rinse,soapwash,rinse.Ifthesestepsarenotfollowed,themembranes’performanceandlifespanmaybeaffected.EnsurethattheU-cupsareinstalledaccordingtothediagram.Addfood-gradegreasetothegasketsandU-cups.Oncethemembranesareinplace,rotatethemslightlyinthehousingtoensureeverythingisworkingproperly.*Note:donotusetoomuchgrease.Excessgreasemayplugporesinthemembrane.

NoU-cup

Mem

bran

e#1

NoU-cup

Mem

bran

e#2

Mem

bran

e#1

Mem

bran

e#2


BeforeremovingmembranesfromtheROsystem,removeanyliquidremaininginthehousingsusingthedrainvalves.Next,unscrewthecollarsandremovebothcoversatthesametime.Donotunscrewtheconcentratetube.Laythesystemflatandremovethemembranes.Donotuseplierstoremovethemembraneviathefiltratetube!Thismaydamagethetube,causingsugartorunintothefiltrate.

Removethetwocollarsandgentlyremovethecapsusingaflatscrewdriver

Donotusepliersonthefiltratetube


Pre-filtercartridgeUnscrewthepre-filterhousingandinserta10”5micronfilter(#6682101).Ifyouhavetrouble,usethetooldesignedforthispurpose.Puttheringbackinplacetocloseeverythingandensurethatthedrainplugisproperlyinplace.*Makesurethecartridgeisplacedcorrectlyinthepre-filter.

Unscrewthisringtoaccessthepre-filtercartridge


Dailyoperations

Installationof5micronpre-filter

De-icing

Concentration

Desugaring*Within5minutesofconcentration

Rinsing

Soapwash*Putpre-filtercartridgeinsoap

Rinsing

Closing

Asneededthroughouttheday


De-icingIftheROsystemisusedafterbeingexposedtofreezingconditions,itmustbede-icedbeforeuse.Todoso,useahotairguntoheattheouterstainlesssteelsurfaceofthefeedandrecirculationpump.Youmayalsousetowelssoakedinveryhotwater.Ifyouchoosethismethod,wrapthetowelsaroundthestainlesssteelpartsofthepumpsandleavethemforseveralminutestoensurethatnoiceremainsinthepump.Soakthetowelsinmorehotwaterasneeded.*Becarefulnottooverheatneartherecirculationpump,whichhasgaskets.Additionally,donotusepropanetorchesbecausethehigherheatmaymeltthepumpgaskets.

Concentration

1) Closealldrainvalvesandbothsamplingvalves:V1–V3andV5–V10.2) Attachthelinefilterreceptacle,whichislocatedattheentranceofthefeedpump.3) Installthepre-filter.*Ideally,useacartridgeotherthantheoneusedinwashing.Attachtheplugbelowthepre-filter.4) Ensurethatthebluefeedhoseisconnectedtothepump.5) OpenconcentratevalveV4fully.6) PlugtheROsystemintoa110V20Aor220Voutlet(dependingonsystemmodel).7) Placethebluesuctionhoseintothesaptank.8) Placethefiltrateandconcentratehosesintotheappropriatetank(s).9) Pressandholdthegreen“start”buttonandgraduallycloseconcentratevalveV4usingthehandleuntilthepressure

contactinitiates.Therecirculationpumpwillthenturnon.Letitrunatlowpressureuntilthereisnomoreairintheflowmeters.

10) Graduallyadjusttheconcentratevalveuntiltheconcentrateandfiltratehavethesameflow.11) Regularlycheckoperationsettings.12) Onceconcentrationhasended,graduallydecreasethepressurewiththeconcentratevalveuntiltheROsystem

automaticallystops.*Note:Donotwaituntilthesystemrunsoutofsap,asthepumpsmayrundryfortoolongbeforestopping.*Neverconcentratetomorethan8degreesBrix.

Partstode-ice

Watchoutforthegaskets


Desugaring1) Placethefiltrateandfeedhoseinthefiltratetank.Theconcentratehosemustremaininthe

concentratetank.2) Startthesystemtobeginthedesugaringcycle(step9oftheconcentrationcycle).3) Takesamplesofconcentrateatregularintervals,untiltheconcentrationisat0.5degreesBrix.4) Stopthesystem.

Rinsing1) Placethefeedhoseinthepermeatetank.Placetheconcentrateandfiltratehoseoverthedrain.2) Startthesystem(step9oftheconcentrationcycle).Adjustthepressureto60psi.Aminimumof

300L/80USgallonsoffiltratemustbeusedpermembrane.3) Stopthesystemoncetherecommendedwaterlevelhasbeenreached.

Washing1) Exchangethepre-filtercartridgeforonededicatedexclusivelytowashing.2) Placetheconcentrateandfiltratehosesinthewashtank(removetheblueplugandinsertboth

hosesintothehole).3) Attachthewashtankhosetothefeedpumpentrance.4) Fillthewashtankwithfiltratethathasbeenheatedto40°Candaddtherequiredamountof

soap.Followthemanufacturer’srecommendationsfortheamountofsoaptouse(pH).5) OpenthetankvalveandstarttheROsystem.6) Adjustthepressureto60psiandwashincyclesuntilthesystemstops.Thewashcyclewillendat

43°C/109.4°F.7) Performthefinalrinsewithalloftheremainingfiltrate.

Closing1) Drainallliquidfromthewashtank.2) Removethepre-filtercartridgeandunscrewthecapfromthebottomofthehousing.3) OpendrainandconcentrationvalvesV1–V10.4) Disconnectthesuctionhoseanddrainthewaterinside.5) Detachthelinefilterreceptacleattheentranceofthefeedpumptoremoveresidualwater.6) Pressandholdthegreen“start”buttonfor2seconds.Thiswillevacuatethewaterremaining

insidethefeedpump.7) Repeatstep6twice,tensecondsapart.8) UnplugtheROsystem.

ProcedurefollowingapoweroutageIftheROsystemhasstoppedafterapoweroutage,makesurenoicehasformedinsidethepumps.Next,followtherinseprocedurebeforerestartingconcentration.


DrainingItisimportanttodraintheROsystemassoonasyouarefinishedusingit.Thiswillpreventicefrombuildingupifthesystemisstoredinanareathatissubjecttofreezingconditions.OpendrainandconcentratevalvesV1–V10toremoveanyliquidremaininginthesystem.

MaintenanceThelinefiltermustbecleanedbeforeeachuse.Blockagesinthefiltercanrestrictpumpinput,causingbubblestoform.Thiscausesprematurewearandashortenedlifespanforthepump.Thepre-filtercartridgemustbechangedoncethereisa50psidifferencebetweenthetwogauges.

Start-of-seasonprocedureBeforeconcentratingthefirstsapharvestoftheyear,youmustfollowthesesteps:

1. Insertanewpre-filtercartridge.2. Installthemembranesintheseparator.PayattentiontothedirectionoftheU-cups.3. Rinsewithpotablewaterthatdoesnotcontainironormanganese.4. Performasoapwash.5. Rinse.

Oncethesestepsarefinished,youmaybeginconcentration.

Changethepre-filtercartridgeoncethereisa50psipressure

Unscrewthefiltertoclean


End-of-seasonprocedureAttheendoftheseason,itisrecommendedtoperformthefollowingproceduresinorderbeforestoringthesystemanditsmembranes:soapwash,rinse,citricacidwash,rinse,soapwash,rinse.Usethefollowingprocedureforthecitricacidwash:

1) Exchangethepre-filtercartridgeforonededicatedexclusivelytowashing.2) Placetheconcentrateandfiltratehosesinthewashtank(removetheblueplugandinsertboth

hosesintothehole).3) Attachthewashtankhosetothefeedpumpentrance.4) Fillthewashtankwithfiltratethathasbeenheatedto40°Candaddacupofpowderedcitric

acid.5) OpenthetankvalveandstarttheROsystem.6) Adjustthepressureto60psiandwashincyclesuntilthesystemstops.Thewashcyclewillendat

43°C/109.4°F.

Oncethewashesarefinished,storethemembranesinthesystemorstoragecanisters.Ifthemembranesarestoredinacanisterorhermeticallysealedbag,usestoragesolutionCDL#80000.RemovetheU-cupsanduseatablespoonofsolutionforacanisterfulloffiltrate.Todoso,laytheseparatorflat(restingonthehandles)andremovethemembranes.Thiswillpreventanyliquidremaininginthecanistersfromreachingthesystem’smotors.Ifthemembranesarestoredinthesystem,fillthefiltratemachinewith2litresoffood-gradepropyleneglycol#88020.Leavethemembranesinthissolutionandensurethatthefeed,filtrateandconcentratehosesareplugged.Airmustnotenterthesystem.Neverstorethemembranesinthesystemwithstoragesolution#80000(sodiummetabisulfite).Thissolutionwearsdownthecanistercoversandgaskets.Keepthemembranesandsolutionawayfromfreezingconditions.

TipsHereareafewtipstohelpyourROsystemrunefficientlyandincreaseyouryield:

• Performrinseandwashcyclesaftereachuse.• Duringthewashcycle,reachthestoptemperatureof43°C/109.4°F.Washingismore

effectiveatthistemperature.• Usedifferentpre-filtercartridgesforwashingandconcentration.• Donotletthemembranessitinmaplewaterformorethan5minutes.Bacteriainthe

sapmayplugthesurfaceofthemembrane.• Ifwaterotherthanfiltrateisusedforrinsing,makesurethewaterdoesnotcontainiron

ormanganese.• Theend-of-seasonprocedurewillhelpextendthelifespanofthemembranes.


TroubleshootingchartThischartdescribesseveralminorissuestheoperatormayencounterduringtheseason.Ifaproblemarises,refertothistabletofindasolution.Iftheproblempersists,contactourtechnicalservice.

Problem Cause Solution

Thesystemisnotstarting • Itisnotpluggedin• Afusemayhaveburntout

• Checkthebreakersintheelectricalpanel

• Checkthefuses

Therecirculationpumpisnotstarting

• Themembranepressureisnothighenough

• Sapisnotreachingthesystem

• Airisenteringthesystem• Thepressureswitchisnot

workingproperly• ThepumpbuttonisnotON

• Graduallyturntheconcentratevalvewhenstarting

• Makesurethesuctionhoseisnotblockedandthatitisbelowthesaplevel

• Checkthefeedhose• Ensurethatthereisnoice

blockingthepressureswitch

• PresstheONbuttonontherecirculationpump

Thefiltrateflowisdecreasing • Themembranesareplugged

• Thesap’sBrixistoohigh

• Performawashcycle• Stopthesystemifit

exceeds8degreesBrix

Thefeedpumpismakingastrangenoise

• Thelinefilterisplugged• Airisenteringthesystem• Thesuctionstraineris

plugged• Sapisnotreachingthe

pump

• Cleanthelinefilter• Makesurethesuction

strainerisnotblocked• Makesurethesuctionhose

isnotblocked• Makesurethesuctionhose

isconnectedproperlyThewashcycleisnotendingonitsown

• Thetemperatureisbelow43°C

• Preheatthefiltrateto40°C

Waterisnotexitingthesamplingvalves

Thefiltrateandconcentratehosesaretoolow

• Placethehoseshigherthantheflowmeters


PWPtestThePWP(PureWaterPermeability)testshowshowwellamembraneisperforming.ThisnumberallowsyoutocalculateyieldlossesinthemembranethroughouttheseasonbycomparingittotheoriginalPEPnumber.TheinitialPEPnumbershouldbetakenafterthefirst20hoursofuse.Acorrectionfactorwillbeusedbecausefiltrateflowvariesdependingonsaptemperature.Thevalueswillthereforebebalancedsotheycanbecalculatedasthoughthesapwasat13°C).

Howtocalculate

1. Startthesysteminrinsemodeusingfiltrate.2. Adjusttheconcentratevalveuntilthepressurereaches60psiatthemembranes.3. Oncetheflowmetershavestabilizedandtherearenomoreairbubbles,recordthe

filtrateflowmetervalue.4. Recordthewatertemperature.5. Takethefiltratevalueanddivideitbythetemperaturecorrectionfactor.

Example

InitialPWP(after20hoursofuse):

1.1GPM(filtrateflow)0.790(temperatureof5°C)

= 1.392GPM

PWPafterrinsing(PWPduringtheseason):

0.9GPM0.816(temperatureof6°C)

= 1.102GPM

Yieldlosscalculation

(initialPWP/PWPafterrinsing)InitialPWP x100 = %loss

(1.392/1.102)1.392 x100 = 20.83%yieldlossor79.17%efficiency


Decreasesinmembraneperformancearecausedbyvariationsinsapquality.Saptendstoclogmembranesmorequicklyatthebeginningandendoftheseason.Ifperformancedropsby15%ormoreduringconcentration,theproceduremustbefollowedbyawashtopreventclogging.

CorrectionfactortableTemperature°C/°F Correctionfactor

0/32 0.6721/34 0.6952/36 0.7193/37 0.7424/39 0.7665/41 0.7906/43 0.8167/45 0.8428/46 0.8669/48 0.89310/50 0.91911/52 0.94612/54 0.97313/55 114/57 1.02815/59 1.05516/61 1.08417/63 1.11218/64 1.14219/66 1.17020/68 1.221/70 1.22922/72 1.25923/73 1.28924/75 1.31925/77 1.350


Membraneserial#:

Date Pressure Filtrateflowresult

Temperature Resultcorrectedto13°C


PotentialsavingsHereisatableshowingyourpotentialsavings.Whilethesevaluesmayvaryfromonelocationtoanother,theygiveageneralideaoftheevaporationtimeyoumaysave.

Initialamountofsap:200USgal.

Evaporation:16USgal./hour

Concentration(Brix)

2 4 6 8

Amountofconcentrateto

boil

200 100 66.7 50

Amountofwaterto

evaporate(USgal.)

194 94 60.7 44

Evaporationtime(%)

100 48.5 31 22.7

WarrantyThesystemhasa1-yearwarrantyonallmanufacturingdefects.Theproductmustbeusedundernormalconditionstobecovered.Thewarrantydoesnotapplyiftheoperatorhasincreasedthemaximumoperatingpressureormadeanyothermodificationstothereverseosmosissystem.

user osmose hobby manual 100-200 gph...cdl maple sugaring equipment inc. 11 membrane installation...

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