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Leader

 

Evaporator

 

Springtech

 

EXTREME

 

6

 

Reverse

 

Osmosis

 

System

 

Manual

      

Page:

 

4

 

 

INTRODUCTION

 

A

 

Leader

 

Evaporator

 

Springtech

 

EXTREME

 

Reverse

 

Osmosis

 

system

 

is

 

designed

 

to

 

significantly

 

improve

 

the

 

producer’s

 

productivity

 

by

 

generating

 

high

 

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

 

6

 

are:

 

 

Easy

 

accessibility

 

to

 

pumps

 

and

 

membranes

 

 

Stainless

 

steel

 

frame,

 

membrane

 

housings,

 

pumps

 

and

 

pump

 

housings

 

 

Fast

 

wash

 

cycle

 

 

With

 

reasonable

 

sap

 

–

 

the

 

ability

 

to

 

generate

 

high

 

brix

 

concentrate

 

with

 

a

 

single

 

pass

 

 

Flow

 

meters

 

for

 

the

 

permeate

 

of

 

each

 

vessel

 

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,

 

in

 

a

 

pure

 

form,

 

through

 

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

 

Reverse

 

Flow

 

Concentrate

 

Cycle

 

–

 

Concentrate

 

cycle

 

in

 

which

 

the

 

flow

 

through

 

the

 

system

 

is

 

reversed

 

allowing

 

more

 

even

 

use

 

of

 

the

 

membranes

 

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

 

Chemical

 

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

 

Recirculation

 

Loop

 

–

 

Process

 

of

 

recirculating

 

output

 

from

 

the

 

concentrate

 

cycle

 

to

 

the

 

raw

 

sap

 

tank,

 

increasing

 

the

 

concentration

 

of

 

the

 

sap

 

in

 

the

 

tank

 

Содержание Springtech EXTREME 6

Страница 1: ...Leader Evaporator Co Inc 49 Jonergin Drive Swanton VT 05488 Tel 802 868 5444 www leaderevaporator com EXTREME 6 Reverse Osmosis System...

Страница 2: ...OWER REQUIREMENTS 12 GENERAL CONNECTION LAYOUT 13 Simple 3 Tank RO Diagram 13 STRAINER TO VALVE V6 CONNECTION 14 VESSEL PUMP PRE FILTER CANISTER AND WASH TANK DRAINS 14 V3 V4 AND V19 CONNECTIONS 17 V1...

Страница 3: ...Rod Clamped Membranes 42 Installation 43 Steps for Installa on of Brine Seal Clamped Membranes 43 Steps For Installa on of Threaded Rod Clamped Membranes 45 Common Steps for Installation 47 DAILY 48...

Страница 4: ...ap 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...

Страница 5: ...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...

Страница 6: ...d 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 ATTACHM...

Страница 7: ...re Pump Second stage of pressurizing the system required to process the sap through the membranes Recirculation Pumps Recirculates liquid within the vessel to which they are attached Feed Pump Feed Pu...

Страница 8: ...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...

Страница 9: ...ough V1 and V2 Valves V1 controls the pressure to the membranes It is opened way when starting then adjusted to reach the pressure wanted Close V1 to raise the pressure in the system V2 controls the f...

Страница 10: ...Wash Tank to Feed Pump V18 2 Way HANDLE POINTED HORIZONTAL No Flow HANDLE POINTED DOWN Membranes to Valve V19 V19 3 Way HANDLE POINTED HORIZONTAL Membranes to Wash Tank HANDLE POINTING VERTICAL Membra...

Страница 11: ...ION PHOTO ITEM LEADER ORDER DESCRIPTION PHOTO Membrane Preservative 1 lb 70001 RO Soap 5 Lbs 69992 Citric Acid 1 lb 70008 Glycol 1 gal 70009 20 Cartridge Filter 70012 Food Grade Grease 55095 Digital R...

Страница 12: ...ly it will need to have adequate ventilation during operations to prevent overheating The dimensions of the main system unit are Width 34 Length 109 Height 70 A minimum of two feet around the system i...

Страница 13: ...he 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 y...

Страница 14: ...When installing make the connection from the strainer to valve V6 Y Strainer Reducing adapter Vessel Pump Pre Filter Canister And Wash Tank Drains The drains are located 1 under each pressure vessel...

Страница 15: ...under the feed pump 1 under the pressure pump 1 under recirculation pump 2 Recirculation pump 1 will drain through the pressure pump drain Recirculation pump 3 will drain through recirculation pump 2...

Страница 16: ...inless steel ball valve To setup the drain you will need items not included 1 1 Stainless Steel band clamps 1 piece of 1 hose long to connect to the drain adapter and to reach the collection point 2 T...

Страница 17: ...e onto the 1 C style quick coupler 4 Position the stainless steel band clamp s over the hose on the coupler and tighten the band clamp s 5 Secure the other end of the hose to the drain connection 6 Co...

Страница 18: ...the hose 3 Slide the hose onto a 1 C style quick coupler 4 Position the stainless steel band clamp s over the hose on the adapter and tighten the band clamp s 5 Secure the other end of the hose to the...

Страница 19: ...NOTE Breakers are not shown in the correct position BREAKER ID CIRCUIT START POSITION CB1 Feed Pump ON CB2 Pressure Pump OFF CB3 Recirculation Pump OFF CB4 Recirculation Pump OFF CB5 Recirculation Pu...

Страница 20: ...2 for the data sheet format The following data is recorded Date date the information is collected Activity Concentration cycle enter a C or Test enter a T Sap the sugar concentration of the raw sap Co...

Страница 21: ...the end of each days use whichever comes first Rinse Run after the Desugar cycle Wash Chemical wash after a rinse A chemical wash should be run after 6 hours of concentrating OR at the end of every da...

Страница 22: ...r Data Sheet and write it in the field labelled Machine Serial 4 In the field labelled Vessel Location fill in the location of the vessel to be tracked Vessels are numbered from the bottom of the syst...

Страница 23: ...nchmark rates If the measured difference see the calculation below is 15 or more then further cleaning will be necessary See the flow chart on page 24 To calculate the difference to the benchmark do t...

Страница 24: ...Leader Evaporator Springtech EXTREME 6 Reverse Osmosis System Manual Page 24...

Страница 25: ...n minimum way then adjust Open minimum way then adjust Open Fully Open Fully V3 Handle Points Horizontal Handle Points Horizontal Handle Points Vertical Handle Points Vertical V4 Handle Points Vertica...

Страница 26: ...w to set the V1 and V2 valves 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 un...

Страница 27: ...Leader Evaporator Springtech EXTREME 6 Reverse Osmosis System Manual Page 27 Standard Concentrate Output Sap Recirculation Loop...

Страница 28: ...en a minimum of way to start then adjust to the desired concentration level of flow V3 Horizontal Left V4 Vertical Up V18 Horizontal Left V19 With V3 and V4 in the concentrate setting V19 should have...

Страница 29: ...e top of the strainer installed before valve V6 until all the air is released from the system Close the bleed valve 4 When the machine has started adjust V1 and V2 to produce the desired conditions De...

Страница 30: ...ter part of Desugar with lower sugar being rinsed out 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 c...

Страница 31: ...lose the bleed valve 5 Check the concentrate sugar level approximately every 5 minutes The Desugar cycle should be run until the concentrate sugar is 1 to 2 Rinse Cycle In this cycle permeate is run t...

Страница 32: ...l Page 32 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 Vertical Up V4 Horizontal Lef...

Страница 33: ...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...

Страница 34: ...drain posi on 3 At the completion of the rinse cycle add R O soap LEADER Order 69992 to the wash tank and mix Mix alkaline R O soap with the liquid in the wash tank until the required pH is reached T...

Страница 35: ...al Page 35 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 completely WD Horizontal valve is closed At...

Страница 36: ...sed from the system Close the bleed valve 6 If the system does not start due to a LOW PRESSURE ALARM partially close valve V18 until an operating pressure of 50 80psi is reached and run the remainder...

Страница 37: ...as follows 1 Open the lower drain of the filter housing and allow the liquid to drain from the housing The draining process can be hastened by opening the upper drain also 2 Loosen the eye nuts and r...

Страница 38: ...e bottom of the cup should fit into the hole in the filter 8 Place the compression plate over the threaded rod and lower onto the cup and spring assemblies lining one assembly up in each hole 9 Secure...

Страница 39: ...sh position 3 Set valves V3 and V4 in a rinse cycle position 4 Open the drain of the membrane housing to be changed Allow the membrane to drain until empty 5 Disconnect the permeate line quick coupler...

Страница 40: ...he end of the membrane housing to the body of the membrane housing 10 Remove membrane housing cap from the membrane Determine the style of securing mechanism used to hold the membranes together There...

Страница 41: ...Slide the mated membranes out of the pressure vessel 2 Remove the alignment coupling from the left end of the membrane assembly 3 Place the membrane assembly on a clean solid surface upright with the...

Страница 42: ...mbrane on a solid clean surface 6 Remove the membrane coupler and the clamp halves from each of the membranes Steps for Removal Of Threaded Rod Clamped Membranes 1 Slide the mated membranes out of the...

Страница 43: ...eaded rods Turn the remaining nuts until they are approximately to lower than their original position 6 Remove the spacer ring from the top of the bottom membrane then remove the membrane coupler 7 Re...

Страница 44: ...of the membrane 4 Insert the clamp assembly half into the groove at the top portion of the membrane with the bolts pointed up 5 Using a marker mark the outside edge of the clamp end of each membrane...

Страница 45: ...ngs on the alignment couplings used on both ends of the membranes Lightly lubricate the O rings with permeate or non chlorinated well or spring water Ensure the alignment coupling is in place in the u...

Страница 46: ...sembly Inspect the O rings on the membrane coupler and replace if necessary Lubricate the O rings of the coupler with permeate or non chlorinated well or spring water then insert the coupler into the...

Страница 47: ...emained in place in the pressure vessel 9 Slide the assembled membranes into the membrane housing Ensure the membrane goes all the way into the housing with the membrane coupling at the left end of th...

Страница 48: ...coupler 7 Follow the instructions for the Beginning of Season Startup see page 49 Daily Each day it is recommended the following be done 1 Remove clean and reinstall the strainer in the Y strainer 2...

Страница 49: ...EM lubricant NOTE Lubricate the bearings ONLY at the interval specified Over lubrication will cause the bearings to fail MOTOR FUNCTION HP Bearing Location Lubrication Interval hrs Lubrication Amount...

Страница 50: ...us alkaline soap wash cycle continue to the next step Acid Soak Cycle c If the difference is 15 of less continue with Step 4 3 Do an acid soak cycle see page 34 allow the machine to soak for 1 to 7 da...

Страница 51: ...feed lines 2 Replace prefilters 3 Open the control box by turning the latches on the right side of the panel then opening the door carefully to the left 4 Turn off the pressure and recirculation pump...

Страница 52: ...ER Order 69992 to the wash tank and mix Mix alkaline R O soap with the liquid in the wash tank until the required pH is reached To determine the required pH refer to the Machine Serial Number Data She...

Страница 53: ...Pre Filters need changing System needs to be bled No liquid coming from storage Check the positions of all valves Low rate found during permeability test Suspected bacteria buildup Rewash system with...

Страница 54: ...Leader Evaporator Springtech EXTREME 6 Reverse Osmosis System Manual Page 54 ATTACHMENT 1 ELECTRICAL SCHEMATIC...

Страница 55: ...Leader Evaporator Springtech EXTREME 6 Reverse Osmosis System Manual Page 55...

Страница 56: ...PERMEATE 2 PERMEATE 3 CONCENTRATE TEMPERATURE FEED PUMP MEMBRANE WATER REMOVAL GPH PROCESSED SUGAR CONCENTRATION FLOW gpm PRESSURE psi SUGAR CONCENTRATION FLOW gpm PRESSURE psi ATTACHMENT 2 OPERATION...

Страница 57: ...Leader Evaporator Springtech EXTREME 6 Reverse Osmosis System Manual Page 57 ATTACHMENT 3 PERMEABILITY TEST SHEET...

Страница 58: ...nufacturer 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 repla...

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