USERMANUAL
OSMOSE HOBBY 100-200 GPH
26/06/2018
© All rights reserved Les Équipements d’Érablière CDL inc.
CDLMapleSugaringEquipmentInc.1
ThankyouforpurchasingaCDLHobbyreverseosmosissystem.Thisdocumentwillhelpyoumakethemostofyourproduct.
CDLMapleSugaringEquipmentInc.2
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
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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.
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Valvelocations
Drainvalve
Linefilter
Feedpump
Recirculationpump
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V5Membrane
drainvalve#1
V9Collectordrain
valve
V10Feedpumpdrainvalve
V6Membrane
drainvalve#2
V7Recirculationpumpdrain
valveV8Collectordrain
valve
V1Air
evacuationvalve
V2Concentratesamplingvalve
V3Filtratesampling
valve
V4Concentratevalve
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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
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mustbeused,itmustbeatleast12AWG.Anextensioncordthatistoolongorthathastoohighofagaugemayoverloadthemotors.Overloadingmaycausethemotorstooverheatandbreak.
220Vversion:Themachinemustbepluggedintoa220Vsingle-phaseoutlet.
PlumbingThesystemcontainsan8-footsuctionline.Donotextendthisline.Ifitisextended,thepumpmayrundryfortoolonguponstarting,whichmaydamageinternalparts.Topreventbubblesfromforminginthefeedpump,donotplacethepumpmorethan1mabovethebottomofthetank.
1mmaximum
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Amountoffiltrateneeded:600litres(160US
Batchconcentration(sparging)
Amountoffiltrateneeded:
600litres(160USgallons)
Standardconcentration
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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
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BeforeremovingmembranesfromtheROsystem,removeanyliquidremaininginthehousingsusingthedrainvalves.Next,unscrewthecollarsandremovebothcoversatthesametime.Donotunscrewtheconcentratetube.Laythesystemflatandremovethemembranes.Donotuseplierstoremovethemembraneviathefiltratetube!Thismaydamagethetube,causingsugartorunintothefiltrate.
Removethetwocollarsandgentlyremovethecapsusingaflatscrewdriver
Donotusepliersonthefiltratetube
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Pre-filtercartridgeUnscrewthepre-filterhousingandinserta10”5micronfilter(#6682101).Ifyouhavetrouble,usethetooldesignedforthispurpose.Puttheringbackinplacetocloseeverythingandensurethatthedrainplugisproperlyinplace.*Makesurethecartridgeisplacedcorrectlyinthepre-filter.
Unscrewthisringtoaccessthepre-filtercartridge
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Dailyoperations
Installationof5micronpre-filter
De-icing
Concentration
Desugaring*Within5minutesofconcentration
Rinsing
Soapwash*Putpre-filtercartridgeinsoap
Rinsing
Closing
Asneededthroughouttheday
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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
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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.
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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
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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.
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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
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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
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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
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Membraneserial#:
Date Pressure Filtrateflowresult
Temperature Resultcorrectedto13°C
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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.