Nortec SynPur User Manual
Installation, Operating and Maintenance
Instructions
Conductivity Synthesizer
Model SynPur
Type LS 400
LS3400
LS3402
A WMH company
Table of Contents - Conductivity Synthesizer
1. Introduction ................................................................................................................................. 3
1.1 First Things First! ........................................................................................................................ 3
1.2 About this Technical Document .................................................................................................. 3
2. For Your Safety ........................................................................................................................... 5
2.1 Agreement on Appropriate Use .................................................................................................. 5
2.2 General Safety Information ......................................................................................................... 5
3. Product Overview ....................................................................................................................... 6
3.1 System variants .......................................................................................................................... 6
3.1.1 Basic System A ........................................................................................................................... 8
3.1.2 Basic System B ........................................................................................................................... 8
3.1.3 Conductivity Synthesizer with existing full deionization stage .................................................... 9
3.2 System description ................................................................................................................... 10
3.2.1 Functional description of the mounting rail ............................................................................... 11
3.2.2 Functional description of the SynPur ........................................................................................ 11
3.2.2.1 Display Symbols ....................................................................................................................... 14
3.3 Functional description of the Synthesizer cartridge .................................................................. 16
3.4 Functional description of the additive ....................................................................................... 17
4. Installation ................................................................................................................................. 18
4.1 Safety information concerning installation ................................................................................ 18
4.2 General placement and assembly information ......................................................................... 18
4.2.1 Support console SynPur ........................................................................................................... 19
4.2.2 Mounting rail ............................................................................................................................. 19
4.2.3 CO2 bottle .................................................................................................................................. 20
4.3 Electrical installation ................................................................................................................. 21
4.3.1 SynPur ...................................................................................................................................... 21
4.3.1.1 Linking of fault and service outputs .......................................................................................... 22
4.3.1.2 Linking to the HPS .................................................................................................................... 22
4.3.1.3 Linking to the remote fault reporting system............................................................................. 23
4.4 Material specification ................................................................................................................ 24
4.4.1 Electrical components ............................................................................................................... 24
4.4.2 Additive ..................................................................................................................................... 24
4.4.3 Pressure reducer ...................................................................................................................... 24
5. Operation .................................................................................................................................. 25
5.1 Start-up in daily operations ....................................................................................................... 25
5.2 Shutdown in daily operations .................................................................................................... 26
5.3 Checks/regular service ............................................................................................................. 27
6. Replacing components ............................................................................................................. 29
6.1 SynPur ...................................................................................................................................... 30
6.2 Synthesizer cartridge ................................................................................................................ 32
6.3 CO2 Bottle ................................................................................................................................. 33
7. Technical Data .......................................................................................................................... 34
7.1 Conductivity synthesizer SynPur .............................................................................................. 34
7.2 Synthesizing stage .................................................................................................................... 34
7.3 CO2 bottle ................................................................................................................................. 34
7.3.1.1 Gas ........................................................................................................................................... 34
7.3.1.2 Pressure reducer ...................................................................................................................... 34
8. Appendix ................................................................................................................................... 35
8.1 Spare parts ............................................................................................................................... 35
8.2 Replacement parts .................................................................................................................... 35
8.3 Accessories .............................................................................................................................. 35
8.4 Fresenius Test Certificate ......................................................................................................... 36
8.5 Statement of Conformity ........................................................................................................... 37
Created: 21.12.2006
Changed: 21.03.2007
Printed: 02.03.2009 page 2 of 37
1. Introduction
1.1 First Things First!
Thank you for choosing the DRAABE SynPur.
The SynPur was designed in accordance with the latest level of technology and
generally accepted safety standards and regulations. Nevertheless, inappropriate
use of the system can result in the risk of injury to the user and/or others, as well
as damage to property and equipment.
Therefore, to ensure safe, appropriate, and economical operation of the system, all
of the information and particularly the safety-related information in this document
should be noted and followed.
For questions that are not addressed or not adequately answered in this document,
please contact your local NORTEC representative or our service +1 613 822 0335.
Our specialists will be happy to assist you.
1.2 About this Technical Document
Limitations
The subject of this Technical Document is the DRAABE SynPur. The system
components (e.g. SynPur, mounting rail, etc.) are described only to the extent
necessary for proper operation. Since the system offers various upgrading options,
this document relates to the basic system. Depending on the application and
specified capacity, various system components are available. Because the system
serves as the preliminary stage for a DRAABE air humidification system, a higher
humidification capacity has a direct influence on the different parts of the system
described in this document. Some accessories are not absolutely essential; others
are part of the standard configuration. For additional information on accessories
and or individualized solutions, please refer to the customer-specific diagram or
contact NORTEC.
The information in this Technical Document is limited to the:
- Installation, initial startup, operation, and maintenance of the SynPur.
The Technical Document is supplemented by various separate documents (order
forms, diagrams, etc.). Where applicable, cross-references to these publications
are contained in the Technical Document.
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Changed: 21.03.2007
Printed: 02.03.2009 page 3 of 37
!
Agreement
This symbol identifies Safety and Hazard Information that could lead to personal
injury and/or property damage if it is ignored. Safety and Hazard Information is also
identified by the term ATTENTION.
This symbol identifies important information. This information is also identified by
the term IMPORTANT.
This symbol is found on the nameplates of all devices. It is intended to remind you
to read the Technical Document before handling any of the equipment. If anything
is still unclear after reading the document, please contact the Technical Customer
Support department of the manufacturer before handling the equipment in any
way.
Definitions
Untreated water:
Drinking water or tap water.
RO water:
Reverse osmosis water (or pure water) is water that has been partially
demineralized in the pure water system RO water is also necessary as a
preliminary stage for the smooth operation of the SynPur.
DI water:
Fully deionized water contains no minerals. In plants that produce deionized water,
this water can be connected to the SynPur.
DM water:
In the Synthesizer cartridge the last minerals are extracted from the RO water. This
demineralized water is conditioned in the SynPur with an additive and is suitable
for the humidification of „clean rooms,“ etc.
Additive:
The additive is a gas (carbon dioxide) used to condition the DM water to enable
humidification with DM water.
Synthesizer cartridge:
The Synthesizer cartridge contains a resin solution formulated especially for
DRAABE for the production of DM water.
Document Storage
Please keep this Technical Document readily accessible in a safe place. If the
document is ever lost, please contact NORTEC.
Languages
This Technical Document is available multiple languages. Please contact NORTEC
with related questions.
Created: 21.12.2006
Changed: 21.03.2007
Printed: 02.03.2009 page 4 of 37
2. For Your Safety
2.1 Agreement on Appropriate Use
The SynPur is intended for use exclusively as a preliminary stage for DRAABE
air humidification systems within the specified operating conditions in non-
potentially explosive environments. It is used to condition the feed water (RO or DI
water) and deliver a product that is processed further by the downstream air
humidification system. Any other use is considered inappropriate and can result in
the system becoming a hazard.
The proper use of the system includes compliance with all of the information
contained in these instructions (particularly the safety information) and strict
adherence to the specified operating conditions.
2.2 General Safety Information
- Only persons who are familiar with the product and are adequately trained
for the respective work should install and operate the SynPur. The customer is
responsible for ensuring that the technical documentation is supplemented by
internal company instructions regarding supervisory and reporting obligations,
work organization, employee qualification, etc.
- Before beginning work on components of the SynPur, the system should be
shut down properly according to Chapter 5.2 and secured against accidental
restart (controller off, water supply closed, and system depressurized).
- Compliance is required with all local safety regulations concerning:
- The use of mains-supplied electrical and electronic equipment.
- The design of water and high-pressure systems.
- All safety regulations concerning the use of pressurized gas containers,
especially those filled with carbon dioxide (CO2), should be obeyed.
- Inadequately maintained air humidification systems can pose a health hazard.
Because this system is used as a preliminary stage in an air humidification
system, the following rule applies equally to it: maintenance activities must
be performed properly in the specified intervals.
- If it can be assumed that a non-hazardous operation is no longer possible,
the SynPur must be shut down immediately and secured against
accidental restart and NORTEC should be notified. Circumstances in which
this could be the case include the following:
- Components of the system are damaged.
- The system is no longer functioning properly.
- Connections or lines are not leak-tight.
- To avoid water damage, materials that are sensitive to water should not be
stored directly under the SynPur.
- Aside from the activities described in these instructions, no other interventions
are permitted on the Conductivity Synthesizer.
- Only original accessories and replacement parts from NORTEC should be
used.
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Changed: 21.03.2007
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- Changes to the Conductivity Synthesizer are prohibited without written
approval from NORTEC.
- After changes are made to the system, NORTEC Customer Service or agents
authorized by NORTEC should perform an acceptance inspection before the
initial startup.
3. Product Overview
3.1 System variants
The Conductivity Synthesizer system is very flexible. The customer-specific
systems are oriented on the humidification demand of the downstream air
humidification system. Parts of the system depend on the performance data of the
upstream water purification system. Essentially, a distinction is made between
Basic System A, Basic System B, and the Conductivity Synthesizer in use with an
already existing deionization stage. All variants discussed below have a maximum
conditioning capacity of 400 kg/h.
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Printed: 02.03.2009 page 6 of 37
Inlet water
(raw water)
Water softener
Rinsing
120 V ~
Drain
Remote fault telemetrie
Pure Water System (PerPur)
120 V ~
Installation rail CSF
Product
HPS3202
230 V
HPS3208
208V
3~
3~
High Pressure System (HighPur)
Synthesis
cartridge
Additiv
Installation rail LS
TF 4 TF 4 TF 8.1 TF 8.1 TF 8.1
Remote fault unit
Groupe controller Unilog
Conductivity Synthesizer
GLT
120V ~
120 V ~
1
1
Potential free contact
Maintenance
Potential free contact
mal function
2
Remote fault telemetrie
HPS
2x potential free contacts
2
Figure 1: Complete air humidification system
Created: 21.12.2006
Changed: 21.03.2007
Printed: 02.03.2009 page 7 of 37
bar
b
a
r
b
a
r
b
a
r
IN OUT
Patentierte
Reinraum-Befe uchtung
Prozessorge steuerte
Demineralisi erung
Automatisiert e
Hygienefunk tionen
ModemSchnittstelle
Ausbeute 10 0%
Anbindung
Gebäudetec hnik
Ein/Aus
Produkt
Gas
Synthese wasser
Synthese -
patrone
Reinwasse r
3.1.1 Basic System A
The Basic System A consists of a mounting rail, an SynPur, a Synthesizer
cartridge, and the additive. Basic System A is shown in the figure below.
Mounting rail
Product
Infeed
Synthesizing stage Additive
Figure 2: Basic System A
3.1.2 Basic System B
The Basic System B consists of a mounting rail, an SynPur, two to four synthesizer
cartridges, and the additive. Basic System B is shown in the figure below. The
higher the humidification demand, the faster the resins in the synthesizer cartridges
are depleted. To extend the replacement intervals, up to four cartridges can be
connected in sequence. As shown in the figure, the mounting rail is connected to
the inlet of the first cartridge. The outlet of the first cartridge is connected to the
inlet of the second cartridge, etc. The outlet of the last cartridge is connected again
to the mounting rail.
SynPur
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Changed: 21.03.2007
Printed: 02.03.2009 page 8 of 37
bar
b
a
r
b
a
r
b
a
r
IN OUT IN OUT
Patentierte
Reinraum-Befeuchtung
Prozessorgesteuerte
Demineralisierung
Automatisierte
Hygienefunktionen
ModemSchnittstelle
Ausbeute 100%
Anbindung
Gebäudetechnik
Ein/Aus
Produkt
Gas
Synthesewasser
Synthesepatrone
Reinwasser
3.1.3 Conductivity Synthesizer with existing full deionization stage
SynPur
Mounting rail
Product
Infeed
Synthesizing stages Additive
Figure 3: Basic System B with two synthesizing stages
If a full deionization stage already exists in a plant for generating fully deionized
water (DI water), the DI water can be connected directly to the mounting rail. The
synthesizer cartridges are not required in this case. This system consists of a
mounting rail, an SynPur, and the additive. The connection to the synthesizer
cartridge should be jumpered on the mounting rail (see Figure 3).
Requirements of the DI water:
- Conductivity < 0.1µS
- Constant flow pressure of 2-3 bar (29-43.5 psi)
- Freedom from organic components (< 100 KBE)
Deionized water in untreated form is not suitable for use in a single-component air
humidification system. The SynPur conditions the DI water in such a way that it can
be used without reservation.
Created: 21.12.2006
Changed: 21.03.2007
Printed: 02.03.2009 page 9 of 37
bar
b
a
r
b
a
r
b
a
r
Patentierte
Reinraum-Befeuchtung
Prozessorgesteuerte
Demineralisierung
Automatisierte
Hygienefunktionen
ModemSchnittstelle
Ausbeute 100%
Anbindung
Gebäudetechnik
Ein/Aus
Produkt
Gas
Synthese-
wasser
Synthesepatrone
Reinwasser
SynPur
Mounting rail
DI water Product
Additive
Figure 4: Conductivity Synthesizer with existing DI stage
3.2 System description
The DRAABE Conductivity Synthesizer is a compact conditioning unit that provides
maximum convenience and economic efficiency. It regulates the aqueous
properties of the product. The infeed water for the downstream air humidification
system represents the product. With the DRAABE single-component nozzle
systems (such as the TurboFog system) this water is brought to an operating
pressure of 85 bar (1232 psi) by means of high-pressure pulsation. At this
pressure, special jets deliver the water into the air in the room. The humidity in the
room is increased.
Consisting of the components synthesizing stage, additive, mounting rail, and the
SynPur, the system is connected between the water purification system and the
high-pressure pulsation system (HPS).
The basic design of the system is shown in the figure (see Sections 3.1.1 and
3.1.3).
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Printed: 02.03.2009 page 10 of 37
1
2 3
4 5 6 2
7 98 10
3.2.1 Functional description of the mounting rail
The mounting rail forms the interface between the water purification system, the
Conductivity Synthesizer, and the high-pressure pulsation system (HPS). A check
valve (1) prevents backflow of the conditioned water.
The synthesizer cartridge is connected to the mounting rail with quick couplings
(3). The shut-off valves (2) enable quick replacement of the cartridge or the filter
(e.g. during maintenance activities). From the support console, the circulation of
the Conductivity Synthesizer is connected from above (7).
A filter (4) protects the downstream Conductivity Synthesizer from possible
impurities in the water. After the filtration the DI water is connected to the
Conductivity Synthesizer (9) and the product is returned to the mounting rail (10).
The DI water (5) and the product (6) can be sampled at any time over the sampling
taps (5/6).
Infeed Product
Filter 20µ
Figure 5: Mounting rail
3.2.2 Functional description of the SynPur
In certain environments (e.g. „clean rooms“, ESD-protected areas, etc.), the water
to be atomized must be free of minerals (DI water = fully demineralized water). The
SynPur has the task of removing all of the minerals from the already purified water
in order to introduce minimum quantities of CO2. The product is a specially treated
(conditioned) water that is fed to the HPS to be atomized.
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All internal processes of the SynPur are managed by a programmable logic
controller (PLC).
The function of the SynPur is explained below. The display shows the functional
status based on a stylized flow diagram and LED’s. A detailed description of the
display is found in Section 4.3.3.
Figure 6: Display of the SynPur
The SynPur is ready for operation when the supply voltage and the water supply
(with adequate water pressure) and the additive (with adequate gas pressure) are
connected. In addition, the lighted mains switch indicates that the device is turned
on.
The infeed pressure switch monitors the pressure of the water supply and shuts
the system off if the water supply malfunctions. In this case, the red LED „Fault“
lights up on the display.
Another pressure switch monitors the gas inflow. The LED „Additive“ lights up on
the display when gas is present. If the gas supply malfunctions the pressure switch
shuts the system off and the red LED „Fault“ lights up on the display. At the same
time, the LED „Additive“ turns off. Operation can be resumed after the bottle has
been replaced (for more information on replacing the bottle, see Section 6.3).
Because the resins in the synthesizer cartridges are depleted during the process of
extracting the minerals, the SynPur continuously monitors the quality of the
demineralized water. When a first threshold value is reached, the SynPur outputs a
service message indicating that the synthesizer cartridge should be replaced soon.
When the second threshold value is reached, the SynPur outputs a fault message
and the system– and therefore also the entire downstream air humidification
system – is shut off. To resume operation the synthesizer cartridge must be
replaced at this point (for more information on replacing the cartridge, see Section
6.2).
If there is no demand for humidification for an extended period, no product can be
accepted. In this case, there is a danger of germination during downtime. To avoid
this, the system should be equipped with extensive hygiene functions. The
DRAABE BioSafe System ensures a hygienically unobjectionable operation. The
SynPur directs the water cyclically from the synthesizer cartridge over a bioreactor
that disinfects the synthesizer cartridge, or the water from the cartridge, by means
of intensive UV-C radiation (it circulates). The unit responsible for this function is
referred to as the circulation.
If the circulation of the SynPur is shut off, the pump pressure and the motor current
are monitored as soon as the pump starts to run. The LED „Circulation“ lights up
on the display.
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Changed: 21.03.2007
Printed: 02.03.2009 page 12 of 37
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