How it works

Essential systems

Components & Software

Notice

Purpose The purpose of this document is to explain the:

• overall Flow Schematic of an Essential Water System (‘System’),
• various components,
− purpose, and
− water flow,
• various software modes and relationships to components.

Tools needed Interactive flow schematics in Flash® are available on the WW Service
Support database. They can be used to complete this document and to
understand the different system process and software modes (see Operating
Status).

Document This document has the following properties:

properties • Version: V0.3
• January 2013

Copyright  2013 MILLIPORE S.A.S. ALL RIGHTS RESERVED. THIS

DOCUMENT OR PARTS THEREOF MAY NOT BE REPRODUCED IN
ANY FORM WITHOUT THE WRITTEN PERMISSION OF THE
PUBLISHERS.

Trademarks Elix, AFS, Progard, Opticap, BioPak, Q-Gard, Millitrack and Millipak are
registered trademarks of Merck KGaA.
RiOs is trademark of Merck KGaA.
All other trademarks are trademarks of their respective manufacturers.
Table of Contents

Terminology .......................................................................................................................... 5
Reminder ........................................................................................................................ 5
Flow Schematic ..................................................................................................................... 6
Interactive files ............................................................................................................... 6
Monitoring Devices ............................................................................................................... 8
Conductivity and Resistivity Cells .................................................................................. 8
Pressure Sensor ............................................................................................................... 9
Hydraulic Devices ............................................................................................................... 10
Solenoid Valves ............................................................................................................ 10
RO Booster Pump ......................................................................................................... 11
Distribution pump ......................................................................................................... 13
Check Valves ................................................................................................................ 15
Capillary Device ........................................................................................................... 16
Flow Controller ............................................................................................................. 18
Pressure Regulator ........................................................................................................ 19
Electronic Devices ............................................................................................................... 22
Printed Circuit Board .................................................................................................... 22
RFID – Radio Frequency Identification Device ............................................................. 24
Software Package and Web Interface ................................................................................ 26
Software Package.......................................................................................................... 26
Web Interface – Installation Step .................................................................................. 31
Web Interface - Millitrack® Software ........................................................................... 33
Man Machine Interface or MMI ........................................................................................ 36
Display and keypad ....................................................................................................... 36
First installation with MMI - remarks ............................................................................ 43
Table of alarms and alerts ............................................................................................. 44
 Terminology
Reminder

Table of terms The table below lists all terms and their equivalent used in this document.

Commonly used Meaning Others

AFS 8, 16, 24 Type of AFS AFS HF, AFS UV HF,
AFS High Flow, AFS
High Flux
AFS 10E, 15E Type of AFS AFS-E UV HF, AFS
High Flow, AFS High
Flux
Capillary device Hydraulic device Capillary, capillary
tube
Divert valve Electrical device Permeate valve, 3-way
valve
EDI Electro deionization Elix, Elix module
Essential System range ACME, ACME
platform
ACME System range: project Essential range
name in R&D
Electro valve Electrical device Solenoid valve, inlet
valve, reject valve,
divert valve
RO Reverse osmosis RO membrane, RO
cartridge

Units The table below lists all units used in this document.

Units Meaning
°C degree Celsius
A Ampere
b bar
h hour
L litre
L/min Litre per minute
L/h Litre per hour
mA Milli ampere
MΩ.cm Mega ohm centimetre
min minute
psi Pound per square inch
V Volt
µS/cm Micro siemens per centimeter

ESSENTIAL How It Works Guide - Components & Software V0.3 Page 5 of 45

 Flow Schematic
Interactive files

Introduction An Essential system is made of different parts and hydraulic components put
together in such a way that the:
• Elix section purifies tap water to make Elix water which is then stored in a
tank, and
• AFS or distribution Section purifies the stored water (upon demand) to
make Product water to analyzer.

List of flow For each type of system, an animated flow schematic in Flash® format is
schematics available for better understanding the different system process.

System type Flow schematic name

AFS 8D, 16D ACME AFS D UV
AFS 8, 16, 24 ACME AFS UV HF
AFS 10E, 15E ACME AFS-E UV HF
Elix Essential 3, 5, 10, 15 ACME ELIX
Elix Essential 3, 5, 10, 15 UV ACME ELIX UV
RiOs Essential 5, 8, 16, 24 ACME RIOS

Downloading Go on the WW Service Support database, in Lab Water Products  Service

and launching Manuals. A ZIP package file contains all the flow schematics.

Step Action
1 Save the ZIP file on your hard disk drive.
2 Unzip the file .
3 Choose the system type.
Open the folder and double click on ACME.html:

4 Internet Explorer starts and displays the flow schematic.

Note: a web browser is needed to run the flow schematic (IE 8).

Continued on next page

ESSENTIAL How It Works Guide - Components & Software V0.3 Page 6 of 45

Interactive files, Continued

Example of a This is an example of the AFS 10E flow schematic.

flow schematic

Symbols The table describes the meaning of each icon used in the flow schematic.
description
Item Icon Description
2 way electro valve Electronic device used to block or to let
go the water flow.
3 way electro valve Electronic device used to block or to let
go the water flow.
Capillary device Thin tube that regulates the amount of
water to reject.
Check valve Mechanical device that controls the
direction of the water flow.
Flow controller Hydraulic device that limits the amount
of water rejected by the RO.
Pressure regulator Hydraulic device that is used to
maintain and control water pressure.

Pressure sensor Electronic device that measures the

pressure on the RO and distribution
sections.
Pump Component used to pressurize water.

Resistivity or Sensor used to measure the water

conductivity cell conductivity.
Strainer Small size filter that prevents large
particles to enter the system (inlet
strainer) or to enter the
conductivity/resistivity cells.
Thermistor or Sensor used to measure the water
temperature sensor temperature.
UV lamp 254 nm wave length ultra violet lamp
used to kill bacteria.

ESSENTIAL How It Works Guide - Components & Software V0.3 Page 7 of 45

 Monitoring Devices
Conductivity and Resistivity Cells

Purpose The Resistivity/Conductivity Cell measures the electrical conductivity of the

• feed water,
• RO Permeate water,
• Elix Product water, and
• Distribution Product water.
This indicates the amount of ions in this water by measuring its resistivity.

Principle The conductivity measurement is done by putting two electrodes in water. A

difference of electrical potential is set between these two electrodes, and the
intensity of the current that travels is measured. The conductivity of the water
is proportional to the intensity of the electrical current.

Thermistor The thermistor or temperature sensor is measuring the water temperature. The
resistivity/conductivity measurements can be compensated at 25°C for
purified water quality measurement (recommendation by United States
Pharmacopoeia as a reference temperature).

Looking inside An Elix Resistivity Cell, when opened up, looks like the photo below.

Item Description Photo

A Flow in (6 or 8 mm
D
tefen connection)
B Strainer (pore size = C
190 microns)
C O-ring A
F
D Thermistor B
E
E Side port (not used;
blocked)
F Flow out

ESSENTIAL How It Works Guide - Components & Software V0.3 Page 8 of 45

Pressure Sensor

Purpose There are one or two pressure sensors depending on the type of system. The
Pressure Sensor is used to measure the pressure of the
• RO loop, and
• Distribution loop (AFS type).

Principle Water enters in the pressure sensor housing. Its pressure is pushing on a
membrane that measures the voltage which is converted then into a pressure
value in bar, psi or kpa (depending on the unit chosen in the software).

Characteristics • Measurement range: 0-14 bar / Accuracy 0.3%

• Output signal: 0.5 - 4.5 Vdc
• Signal vs pressure: 0.2857 V/bar or 3.5 bar/V

RO pressure Using the pressure sensor, the system can

sensor • Monitor the RO pressure on the reject line of the RO section, and
• Monitor the LOW PRESSURE and display an alarm stop.

Spare part The same part number is used for both pressure sensors. Only some parts are
used for one or the other.

RO pressure sensor Distribution pressure sensor

AND

Distribution • The pressure sensor measures the distribution pressure. And then it
pressure sensor compares these measured values to start and stop set point values in order to
send water to analyzer when required.
• These set point values can be adjusted in Millitrack software depending on
the feed water pressure requirements of the analyzer. It is very important
to adjust the back pressure regulator accordingly.

AFS HF AFS D
Start distribution pressure: 0.7 bar Start distribution pressure: 0.6 bar
Stop distribution pressure: 1.3 bar Stop distribution pressure: 1.0 bar
Back pressure regulator: 2.0 bar ± 0.1 (default) No back pressure regulator
BPR adjustment range: 0.9 - 3.0 bar ± 0.1 No back pressure regulator
Start distribution pressure min: 0.3 bar Start distribution pressure min: 0.0 bar
Stop distribution pressure max: 2.0 bar Stop distribution pressure max: 2.0 bar

ESSENTIAL How It Works Guide - Components & Software V0.3 Page 9 of 45

 Hydraulic Devices
Solenoid Valves

Purpose • Solenoid Valves are used to control the water flow in different sections of
the system.
• There can be a maximum of 4 solenoid valves depending on the type of
system.

Valves Purpose
System inlet Controls the flow of the feed water entering the
system
RO Flush • Increases the RO Reject flow rate to drain in
Flush Mode
• Allows the RO pump pressure to build up in Tank
Filling Mode
RO Permeate divert Allows the flow of the
• permeate water to be sent to drain via the RO
reject tube
• permeate water to be sent to EDI module
Recirculation loop Controls the flow of the distribution water to
(AFS® D only) recirculate in the loop

Principle There are two types of valves:

2 way valve Inlet, RO flush and recirculation

3 way valve RO Permeate divert

Note: It is a normally closed 2 way valve: when powered, it becomes open.

3-way valve 3 way permeate divert valve has

• a normally closed path (or not powered): RO permeate water is sent to EDI
module (Tank Filling or Production modes).
• a normally opened path (or powered): RO permeate water is sent to drain
via the RO reject tube (like in Rinsing or Flush modes).

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RO Booster Pump

Introduction The RO booster pump increases the flow rate of the water exiting the
Internal Pressure Regulator. Since the RO Reject Solenoid Valve is closed
when the RO Pump is powered, the water flow encounters a resistance. This
builds up the water pressure after the pump. This increases the feed pressure
to the RO Membrane and causes a higher flow across it.

Principle The RO pump voltage is regulated with the feed water temperature in order to
have a constant flow rate to the EDI module.

Characteristics • Brushed motor,

• Diaphragm Pump head,
• Positive Displacement Pump (constant volume at varying discharge
pressure),
• 40 VDC, maximum 1.3 A @ 110 psi or 7.5 bar (bypass fully open).

RO pump The voltage to the RO Pump can be adjusted:

voltage • automatically (voltage changes with feed water temperature to make set
point pressure), or
• manually using “RO Pump Speed Manual Activation” and “RO Pump
Speed Adjustment”. See block “RO voltage and speed”.

RO voltage and When voltage is adjusted manually, there is a relationship between the
speed Motor% (X axis) and the applied voltage (Y axis). This relationship is shown
in the graphic below.
RO Pump Output

45
40
35
Output Voltage (V)

30
25
20
15
10
5
0
0 20 40 60 80 100
Output Reference (%)

As an example, if the RO Pump Speed was set to 90%, then the applied
voltage to the RO Pump would be 37 VDC.

Continued on next page

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RO Booster Pump, Continued

Looking inside The illustration below describes the principle of a diaphragm pump.

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Distribution pump

Principle • The distribution pump is used to send the water to an external device or an
analyzer upon request. This request is detected on pressure variations by the
pressure sensor that starts or stops the distribution pump.
• When distribution is stopped, the pump is still operating through a
recirculation process: this maintains the water quality in the distribution
loop and avoids restarting of the pump, in order to increase its lifetime.
• In idle mode, the distribution pump goes into a 5 min recirculation every
hour to refresh the water in the loop.
• For AFS degasser, the distribution pump has a vacuum side on the pump
head. This creates the vacuum for the degasser device to remove air from
the product water.

Characteristics There are two types of distribution pump and their characteristics are:

AFS HF AFS D
24 Vdc diaphragm pump 24 Vdc brushless pump
I nominal = 1.1A @ 30psi I max = 0.75A
Up to 2.2 L/min Up to 0.6 L/min
8 mm fitting connection ¼” fitting connection

Recirculation There are two types of recirculation: post-recirculation and an hourly time
based recirculation.

Type Description
Post recirculation – 10 • Initiated when analyzer stops requesting
min water.
• Duration adjustable between 0 and 30 min.
Recirculation – 5 min/hr • Initiated 5 min every hour when system is
not in distribution or post-recirculation.
• Frequency adjustable between 0 and 60 min.

Continued on next page

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Distribution pump, Continued

Start and stop • The distribution pump is controlled by the distribution pressure sensor and
set points the back pressure regulator.
• The distribution pressure sensor has two set point values that start and stop
the distribution pump upon the analyzer request.

Item Description
Distribution pressure Used for starting and stopping the distribution
sensor pump.
(Adjustable. Default Start • The start (default 0.7 bar) is based on a set
at 0.7 bar and Stop at 1.3 point value and is detected by a drop of
bar) pressure in the distribution loop.
• The stop (default 1.3 bar) is based on a set
point and is detected by an increase of
pressure in the distributing loop.
Back pressure regulator • Used to maintaining and adjusting the
(Adjustable. Default at 2 pressure in the distribution loop. This device
bar) is adjusted 0.7 bar higher than the stop set
point value.
• When analyzer requests water, the
distribution loop delivers water at 2 bar of
pressure.

Vacuum line The vacuum line is made of

Part Function
Vacuum pump Membrane pump head creates vacuum when the pump
is operating in distribution or recirculation.
Vacuum The regulator is used to mix some outside air with the
regulator vacuum. This decreases the vacuum to a desired level.
Vacuum gauge The gauge is used to display the applied vacuum level.
Degasser The degasser contains a very large amount of micro
porous hollow fibres. These fibres allow water to flow
through the inside of each fibre. The vacuum is applied
on the outside of the fibre. The dissolved gases inside
the fibres are pulled through tiny holes.

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Check Valves

Purpose • A Check Valve prevents water from entering the system in the wrong
location and bypassing various components.
• There are several check valves used in the system range:

Check valve Location Comment

1.5 psi (1/4” barbed) Manifold RO recycle loop
2.9 psi (0.2 bar) Conductivity/ Permeate conductivity,
resistivity cell Elix Resistivity cell
3 psi (1/8” barbed) Recirculation loop AFS D distribution
outlet
3” H20 (1/4” barbed) Distribution loop AFS HF distribution
outlet
3 psi (1/4” barbed) Distribution pump Tank is higher than
Polisher inlet system
6” H20 (3/8” barbed) Tank overflow Overflow tubing

Principle The check valve is made of

• a housing that can be opened,
• a spring, and
• a valve.

Looking inside A view of a check valve disassembled:

A: housing and o-ring

B: valve with a spring

ESSENTIAL How It Works Guide - Components & Software V0.3 Page 15 of 45

Capillary Device

Purpose • The Capillary Device looks like a thin tubing and regulates the amount of
RO Reject water sent to the drain when the RO Reject Solenoid Valve is
closed.
• Ions, particles, organic molecules and other impurities rejected by the RO
Cartridge need to be sent to a drain. Otherwise, these impur ities would
accumulate on the feed water surface of the RO Cartridge.
• The water flowing through the Capillary Device contains all the impurities
sent to drain.

Principle • The water flow through a Capillary Device is determined by its:

− pressure drop,
− length, and
− diameter.
• The pressure drop is 1.3 bar unless the feed water pressure is lower. The
pressure drop is the difference between the Internal Pressure Regulator and
the drain pressure (usually 0 bar).
• All capillaries have the same length. The length can not be modified.
• The Capillary Devices vary by capillary diameter.

Types There are 5 types of Capillary Devices. These are summarized below.

System Capillary ID Flow rate @1.3 bar

RiOs 5, Elix 3 0.7 mm 13 L/h
RiOs 8, Elix 5, AFS 8, AFS 8D 0.8 mm 19 L/h
RiOs 16, Elix 10, AFS 16, AFS 0.9 mm 23 L/h
10E
AFS 16D 1.0 mm 27 L/h
RiOs 24, Elix 15, AFS 24, AFS 1.1 mm 37 L/h
15E

Proper There is a way to determine the proper Capillary Device. This determination
Capillary is based upon the Feed water Hardness, Alkalinity and Pressure.

Continued on next page

ESSENTIAL How It Works Guide - Components & Software V0.3 Page 16 of 45

Capillary Device, Continued

RO recovery The RO Recovery for each system is shown in the table below. The RO
Recovery can change if the RO Reject flow to the drain changes. Thus, the
flow through the Capillary Device directly changes the RO Recovery.

RO Recovery at 1 bar and varying capillary diameter

System 0.7 mm 0.8 mm 0.9 mm 1.0 mm 1.1 mm
Elix 3, RiOs 5 32 %
Elix 5, RiOs 8, AFS 8D, 32 %
AFS 8 HF
Elix 10, RiOs 16, AFS 43 %
16 HF, AFS 10E
AFS 16D 40 %
Elix 15, AFS 24 HF, 39 %
AFS 15E

Example: If an Elix Essential 10 is fed with 5 bar feed water, then the RO
Reject flow to drain would be 31 L/h. The RO Permeate flow would be 16
L/h. Thus the RO System recovery is 16 / (16+31) = 35%.
The same system fed with 1.5 bar feed water would need a 1 mm Capillary
device to keep a similar RO Recovery.

ESSENTIAL How It Works Guide - Components & Software V0.3 Page 17 of 45

Flow Controller

Purpose The Flow Controller limits the amount of RO Reject flow to 60L/h from the
RO Cartridge.

Principle A pressure is applied to the flow controller. The flow controller has a
membrane with a small hole in its middle that becomes larger as the pressure
is higher. That hole controls the amount of water passing through it.

Looking inside A picture of the Flow Controller is shown below.

Item Description Picture

A Flow Controller made up of a
C
disk with a hole in its centre.
A
B Pressure Sensor (removed
from Manifold to see Flow
Controller).
C Torx 10 screw hole (4 of them
used to mount plate that holds B
Pressure Sensor in-place).

ESSENTIAL How It Works Guide - Components & Software V0.3 Page 18 of 45

Pressure Regulator

Introduction The Internal Pressure Regulator (‘IPR’) is used to control the water pressure:
• after the Progard Pack,
• before the RO Pump, and
• before the Capillary Device.

Note: because the IPR sets the pressure drop across the Capillary Device, the
IPR setting (output pressure) changes the RO Reject flow to drain.

Principle An IPR is opened in the picture below.

Stage Function Diagram

A Water flows into the IPR
through the ‘IN’ Port. A
B A metal plate, located on a
diaphragm (held by hand in B
bottom photo) pushes a hollow
metal pin down (centre of IPR
in top photo).
C When the pin is pushed down, C
water enters the IPR. A spring
is located below the pin. If the OUT
OUT
pin is pushed all the way up, no
water can enter the IPR.
D The tension of the spring
balances with the force from D
the diaphragm resulting in the
outlet pressure. If the spring
tension is changed, then the
force from the diaphragm
changes.

Default setting The IPR is set to 1 bar by default.

Dynamic vs. When an IPR is adjusted to a particular outlet pressure, then this pressure is
static pressure only maintained when water is flowing through the IPR.

Continued on next page

ESSENTIAL How It Works Guide - Components & Software V0.3 Page 19 of 45

Pressure Regulator, Continued

Setting Follow the instructions below to set the IPR.

Step Action Photo

1 Locate the adjustment knob for
the IPR.
2 Loosen the retaining nut. 1
NOTE: the IPR was removed
from the cabinet to show the
retaining nut better.
3 Use a flat head screwdriver and
turn:
• clockwise to increase pressure,
or
• counter clockwise to decrease
pressure.
4 • Go to READY Mode.
• Go to STANDBY Mode.
2 3
NOTE: this depressurises the
system during which time the
pressure after the IPR is
measured.
5 • Go to READY Mode.
• On Millitrack, the pressure after
the IPR is measured each time
the system goes into TANK
FILLING Mode.
• View the TAP WATER
PRESSURE.
6 If necessary, repeat steps 3, 4 and
5 above.

Continued on next page

ESSENTIAL How It Works Guide - Components & Software V0.3 Page 20 of 45

Pressure Regulator, Continued

Back Pressure • The BPR is used to maintain the pressure in the distribution loop and to
Regulator adjust the distribution pressure according to the analyzer feed pressure
requirements.
• It is set at 2 bar ± 0.1 by default but it can be adjusted between 0.9 and 3.0
bar ± 0.1 using Millitrack software.
• It is installed on the return loop between the tank and the system connection
n° 8. It has two ports connection.

ESSENTIAL How It Works Guide - Components & Software V0.3 Page 21 of 45

 Electronic Devices
Printed Circuit Board

Introduction The printed circuit board is called PCB and can be a main PCB or interface
PCB. There are several printed circuit boards like the main PC board, the
TAG reader PC board, etc.

Elements On a main PC board, the following elements can be found.

composing a
main PC board Element Function
Connectors Power supply connector: power supplies to the main PC
board various voltages required for its operation and its
peripherals (electrical components and devices).
Electronic Microcontroller: integrated electronic circuit which is
components composed of a processor, memories, peripherals units and
input/output interface.
Software Software is a group of programs, data and documentation.
It is stored as a group of files in a memory.
Ex: [acme.exe] is software.
Firmware Group of instructions and data structure integrated in an
electronic hardware. It manages the internal operation of an
electronic device.
Ex: [acme_pic_v2.5.hex] is a firmware.
Bus • Communication system between electronic components.
• CAN bus (Controller Area Network) is mainly used on
systems.
Connections Input and output connections.

Micro There are two types of processor:

processors • Coldfire: it’s a microprocessor that controls the process, the Ethernet
communication, the history log and RFID tag.
• PIC: it’s a microcontroller that controls actuators or electrical components
(e.g. pumps, electro valves, UV ballast, EDI power supply board,
LCD/keypad, etc) and all measurement or sensor circuits.

Real Time • The RTC is a high precision clock for an electronic system, used for dating
Clock and initiating events based on hour.
• RTC super capacity autonomy is 7 days when capacitor is fully charged and
system is not powered. After 7 days, the capacitor is discharged and the date
and time lost. It may take several hours for capacitor to be fully charged
again while system is powered.
• Once the capacitor is discharged and the system powered on, it prompts the
user to enter the date and time.

Continued on next page

ESSENTIAL How It Works Guide - Components & Software V0.3 Page 22 of 45

Printed Circuit Board, Continued

System main The schematic below describes the different process that each chip is taking
PCB care of.

Item Function
Coldfire or It’s the “brain” of the system. Its “memory” SD Ram is
main processor used for data storage. Coldfire is communicating with
Ethernet, RFID and the PIC.
Flash memory • This is the “memory” of the system. The software
package, config.ini, history log file, etc… are stored
on this chip. All the files that can be viewed when
connected via FTP are there.
• The tools delivered in the software package are used to
upgrade or reset the flash memory.
PIC or micro • This µC is controlling the actuators, LCD and keypad,
controller and the sensors circuit.
• It is communicating with the coldfire by CAN bus and
provides the real time clock for the sequence events
for coldfire process tasks.
RTC The super capacitor is providing energy to the RTC
which gives real time to PIC and coldfire process events.

ESSENTIAL How It Works Guide - Components & Software V0.3 Page 23 of 45

RFID – Radio Frequency Identification Device

Purpose • RFID is a method for memorizing and collecting data remotely using radio
frequency technology. RFID uses markers called RFID tag or RFID
transponder.
• RFID tag can be a small sticker which can be applied on objects or
products. RFID tag is made of an antenna combined with an electronic chip
that allows receiving and answering to requests from a radio emitter-
receiver (RFID tag PC board in that case).
• These electronic chips contain an identity and eventually further data. The
RFID are 2 tag reader PC boards and tag label sticker on consumable packs.

Function This identification technology is used to identify the type of consumables, its
presence and to optimize their usage. All these data are stored in the
electronic chip for traceability.

Principle Distance of detection: around 5 to 10 cm.

Detection time: ≤ 1 min (5 sec in real situation)

RFID tag • These active devices emit radiofrequencies that activate the markers by
reader supplying the necessary energy that they need in a short distance.
• The length of the frequency is variable depending on the type of
application.
• A high frequency has the advantage to exchange data (between reader and
label) at higher rates than lower frequency.

Continued on next page

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RFID – Radio Frequency Identification Device, Continued

RFID tag label These passive devices don’t require any source of energy except the one
supplied by the reader during a request.
The marker is very thin, small size and negligible weight. The marker is made
of:
• an antenna,
• a silicon chip, and
• a substrate and/or an encapsulation.

Consumables On the tag label, the following consumable data are stored:
data on tag • type of pack,
label • Catalogue, serial and lot numbers
• Installation date,
• Manufacturing date, and
• Volume processed.

Note: when a new pack is installed, the system recognizes the type of pack
(i.e. if a pre-treatment or a polisher) but the installation date is written once
the rinse is initiated by pressing on the user keypad.

Tag diagnostic • The tag diagnostic tool can be used to verify that the tag reader PC board is
tool functioning correctly.
• If there is a “Pack out” while the pack is in place, remove the pack and
place the tag tool in front of the tag reader.
• Connect to Millitrack software, the tag tool should be recognized in the
following menu:

Millitrack “Advanced Parameters” Message displayed

Maintenance Information DIAGNOSTIC TOOL
TAG RECOGNIZED
Current Alarm & Alert Pack Incorrect

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 Software Package and Web Interface
Software Package

Procedure and All information related to upload and download is found in the Procedure
documents Upload & Download Software/Firmware Guide on the WW Service Support
database.

Software All software information in this document has been verified using an
/firmware Essential System having Software Package 29.
versions This package consists of the following versions of firmware and software.

Program Version Upgradeable

System Application 1.18 Yes
System boot loader 1.8 NA
PIC Application 2.5 Yes
PIC boot loader 2.1 NA
RFID (TAG PC board) 1.0 NA
Web (Millitrack software) 1.16 Yes

Note: “NA” not applicable means that the version cannot be upgraded at all.
The replacement of the PC board is required to have the latest software
version.

History of The versions of each software/firmware are listed below:

version
Program Package 29 Package 30
(01/2012) (03/2012)
System Application 1.18 1.19
System boot loader 1.8 1.8
PIC Application 2.5 2.5
PIC boot loader 2.1 2.2
RFID 1.0 1.0
Web 1.16 1.16

Continued on next page

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Software Package, Continued

Definition • A software package is a group of software and firmware, released in a

zipped file and available on the WW Service Support database.
• A new software package is released when bugs are corrected, improvements
are implemented or a new software/firmware version is released.

Software In a software package, there are two folders:

package
content Folder Content
In the folder “Coldfire_application”, the following
can be seen:

Item Function
Configurations “blank” config.ini used
when initial config.ini is
corrupted or lost.
System* Folder containing
application, execution
and Millitrack resources
files.
ACME_update.exe Application that is used
to update actual
software package –
content of the “System”
folder precisely.
System_Reset.bat Command file for
erasing system memory
and uploading a
software package.
Upload_date.log Upload event history log
file.

HEX file for PIC application – can be updated using

telnet session and Windows cmd.exe.

*The System folder has different files or folder:

• WEB or resources files for Millitrack® embedded software.
• Acme.exe or application that runs the system.
• Autoexec.bat or automatic execution file used to run system application
during system boot.

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Software Package, Continued

Software files When receiving a system from manufacturing, it has the following items in its
stored in memory (this is viewed using FTP – File Transfer Protocol):
system

System software Description

content
CONFIG This folder contains the file “config.ini”:
(Config.ini) • System type
• System catalogue number
• Calibration factors
• System configuration
HISTORY Data files on system events, services and water
quality operations. All these data can be generated
using:
• SAVE A COPY or
• PRINTER FRIENDLY buttons.
SYSLOG Protocol defining system events into “Syslog.txt”.
(Syslog.txt) The purpose of this syslog is to centralize all history
events in order to identify system anomalies.
WEB This folder contains every resource files related to
Millitrack software:
• Visuals and colors
• Animations and interactions
• Content data and structure, etc.
Acme.EXE Application file or program that runs the system.
Autoexec.bat Command file that executes application file when
system starts.
Journal.dat This is the history of events or logging: sequential
recording of all events from system internal process.

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Software Package, Continued

Software • Two tools are provided with the software package and used for this
upgrade tools upgrade:

Tool Purpose
ACME_update.exe • This program is used to upgrade the software
package. It replaces the following files in the
[Launch this Flash memory:
application in
Standby mode]

• Other files are not modified.

System_Reset.bat This command file is used to erase all the files from
the Flash memory. It erases and uploads
[Power off the • saved config.ini or new config.ini (if old one is
system/ Launch the corrupted or not saved) – prompted by the tool :
command file/
Power on the • the software package content:
system]

Note: the uploading tools are provided in each version of software package.
During an upload, use the version of the tools that are coming with the
version of software package. The modified versions of the tools are not
notified.

Manual • When the system is powered on, the boot loader is running during 10 sec
software before the application “Acme.exe” is loaded. During these 10 sec, the
upgrade connection to the system with a Telnet* session is possible in order to
establish a safe connection and upgrade the software package.

* Telnet is a network protocol that allows creating a TCP (Transmission

Control Protocol) connection in order to transmit data to the system.

• IMPORTANT! On Windows 7, the Telnet client is not activated. It has to

be activated in order for the uploading tools to operate properly. See the
Procedure Upload & Download Software/Firmware Guide for activating
the Telnet client.

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Software Package, Continued

Manual • To create a Telnet session manually, follow the steps below:

software
upgrade Action Tasks
(continued)
Preparation • Network settings are configured on the laptop.
• Ethernet cable is connected.
• System is powered off.
Telnet command • Click on keyboard shortcut + R.
• Enter in the command field “telnet 192.168.1.69”.
Connection • Power on the system.
• Bootloader is running and the icon is blinking.
• Count 5 blinking and click “OK” on the laptop to
validate the Telnet command.
Telnet session • A black window is displayed: connection is
established.
• Do not close this window or the Telnet session is
interrupted.
FTP connection • Launch Windows explorer or + E.
• Type “ftp://FSE@192.168.1.69” in the address field
and press “Return”.
• Enter login “FSE” and password “LWFSE”.
• The Flash memory is now accessed: delete old files
and copy new files.
Ending • Close the command window to end the Telnet
connection session.
• Reboot the system.

Config.ini • If for some reason the “config.ini” file is corrupted or has not been saved, a
blank “config.ini” must be used for recovering the system type. Though,
putting a blank “config.ini” from the software package makes the system as
it was new. When powered, the system displays – PC –. This – PC –
connection has to be cancelled by pressing for 3 seconds to go to Standby
mode.
• IMPORTANT! All configuration and calibration factors have to be entered
once again using Millitrack software.

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Web Interface – Installation Step

First • When typing the IP address of the system in web browser on a brand new
connection system, Installation Step web page is displayed (when LCD is displaying –
PC -). Installation Step is used for installing the system using a laptop.
• If the – PC – connection is cancelled (for installing the system using the
MMI), it is not possible to display Installation Step web page again.
• Installation Step web page is only displayed once. Canceling or clicking on
makes Installation Step never occur again.

Note: the only way to display Installation Step again, is to upload a blank
“config.ini” from the software package.
Attention! A blank config.ini has no serial number, no calibration factors and
no configuration settings.

Definition • When installing the system for the first time using laptop, INSTALLATION
STEP web page is displayed for helping to simplify installation process by a
mouse click.
• Up to 5 different steps – depending on the type of system – can be started
using this web page.

Step Description
1 SET DATE Check and/or set the system date and time.
2 PROGARD FLUSH • Flush out a new pretreatment pack.
• Fill the system with feed water
3 RO RINSE Initiate 4 hours of RO rinse which can be
cancelled after 1 hour.
4 POLISHER RINSE Flush out a new polisher pack.
5 FINAL RINSE Flush out a new final filter.

Note: INSTALLATION STEP is NOT Millitrack software.

• Some configurations can be done during the steps like choosing the type of
tank, changing the set points, activating options, etc.

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Web Interface – Installation Steps, Continued

Details on each • SET DATE: as the RTC battery has a short autonomy, when powering on
step the system for the first time, it may be necessary to set the date and time.
This is very important as the date and time is used for software events,
managing timers on consumables lifetime, history reports, etc.
• PROGARD FLUSH: when clicking on START button, it writes the
Installation Date on the tag label. This flush is lasting 13 minutes when
replacing the pack in a normal maintenance procedure. For the installation,
the user has to cancel after 5 min, the time for the system to be filled with
feed water (that avoids LOW PRESSURE when starting RO rinse).
• RO RINSE: a timer of 240 min decrements and a red button STOP is
displayed when reaching 179 min. Stop RO rinse when STOP button is
displayed.
• POLISHER RINSE: a timer of 4 min is started when the rinse is initiated.
This is done without the final filter.
• FINAL RINSE: a timer of 4 min is started when the rinse is initiated. This
is done for rinsing and air purging the final filter.

Quit • When all the steps are done, the web page displays a button QUIT
Installation INSTALLATION PAGE. The closing of the page has to be confirmed: this
Step resets all the timers related to UV lamp, cleaning and sanitization, reminder
messages for service contracts, etc.
• When clicking this button, the internet browser refreshes the page and
Millitrack software is displayed.

AFS 8D “Low When installing an AFS 8D, it is possible to lower the RO permeate flow rate
Flow” to make an “AFS low flow”. This is called the “Type III Water Production”
parameter.

• This feature is only available on

AFS 8D.
• This can be adjusted in Installation
Step or Millitrack software.
• This is equivalent to adjust the
“Flow Factor” which lowers the
voltage to the RO pump.
• High setting is equivalent to Flow
factor = 1.0 (default)
• Low setting is equivalent to Flow
Factor = 0.7 (AFS 8D low flow)

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Web Interface - Millitrack® Software

Definition • Millitrack® is embedded software: it means that Millitrack® is stored in the

system’s memory. It is part of the software package.
• Millitrack® software is an interface that can be displayed with any type of
web browser when system is connected to a computer via Ethernet protocol.

Note: Millitrack® has been validated to be displayed on Internet Explorer 8.

Analogy Millitrack® is like a small “web site” that can display information for
configuring and controlling the system, using a laptop, a computer connected
to a server or any device having an Ethernet connection.

Characteristics • Millitrack® software is displayed in HTML (Hyper Text Markup

Language)
• Dashboard animation is running under Flash®.
• The content is coded in XML and CSS languages.
• Interactivity on web pages is coded in JavaScript.

Standard For accessing and using Millitrack® software, read the following SOP:
Operating • Millitrack® Essential Activation Procedure for Customer
Procedure • Millitrack® Essential Activation Procedure for Service
• Millitrack® Essential Activation Key for Service

 All SOP (Standard Operating Procedure) can be found on the WW Service

Support database, in the Software section, for Essential Platform.

Login role There are two types of Role when connecting to Millitrack® software:

Role Purpose Activation period

USER End user/ Permanent: once the activation key is
customer entered and license agreement accepted
SERVICE Service 120 days: the activation key is renewed
Representative every 4 months

Note:
• The activation key for user must be entered once for all and is linked to the
system.
• The activation key for service must be entered each time when connecting
to Millitrack on all Essential and Integral systems.

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Web Interface - Millitrack® Software, Continued

Service • The service activation key is made of 17 digits.

activation key • In the data of the service activation key, there are a Validity Date (Sept. 10-
data 2012) and a Validity Duration (120 days).
• In the persistent data, the system saves the last memorized valid activation
key and a timer (120 days) which decrements when the system is powered
on.
• When a service activation key is entered in Millitrack software, the system
compares this activation key with the last memorized valid activation key.
That gives three possibilities:

Case Description Result

A The Validity Date of the The key is not valid because it’s too
new key is older than the old.
one memorized.
B The Validity Date of the The key is valid: the system saves this
key is newer than the one new key and starts the timer with the
memorized (or no key is Validity Duration of this new key (120
memorized). days timer with this new key)
C The Validity Date of the In that case, the system checks if the
new key is the same than timer has expired or not:
the one memorized (or no
key is memorized). Key is valid? Timer
YES, if the timer 120 days is still
has not expired running
NO, if timer has 120 days has
expired expired

Trial period A 15 days trial is available for customer when USER role is selected (1) and
license agreement is accepted (2). Click on IDENTIFICATION (3) to access
Millitrack® software.

2
3

Note: this 15 days trial is activated each time Millitrack® Service Activation
Key for Service is entered by a Service Representative.

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Web Interface - Millitrack® Software, Continued

Terminology The software/firmware naming used in Millitrack® software are defined in

the table below:

“Advanced Parameters” Software package

System Version System Application
Boot Loader µP Version System boot loader
Auxiliary µC Version PIC Application
Boot Loader Auxiliary µC Version PIC boot loader
Reader Version RFID
V1.16 (on the bottom of Millitrack) Web

Save a copy or
printer
friendly? • When clicking that button on Millitrack, a new browser page is displayed
with the content in XML code. This XML code can be used to display data
(i.e. history report data) in a web page or other software that can use this
XML code.

• This button is used to generate history report data already formatted in a

new browser window. This can be saved into PDF or image for archiving.

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 Man Machine Interface or MMI
Display and keypad

Introduction The man machine interface is composed of

• A display or LCD (Liquid Crystal Display)
• A backlight LED
• A keypad

Display and The display is made of segments and icons. Different area can display
icons different kind of information.

Part Function
1 System status or software navigation.

Icon Description
Maintenance menu or Standby mode. Cleanings or
lifetimes reset can be done here.
Configuration parameters: set points value, date and
time, economic mode and ASM configuration can
be changed here.
This icon is displayed when system is in
• Rinsing mode
• Flush A (3 min RO flush)
• Flush B (15 min Progard flush or cleaning
sequence)
• Depressurization sequence (8 sec)
• Maintenance countdown sequence (cleaning, RO
rinse, etc)

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Display and keypad, Continued

Display and
icons (continued) Part Function
2 Maintenance or warning icons.

Icon Description
RO Cl2 cleaning (84 days)

Final filter replacement (90 or 182 days depending

on the type of final filter)
System sanitization (182 days)

Product water quality below set point.

Low feed water pressure.

Water leak detected (when water leak detector is

installed)
Call Merck Millipore

Call Merck Millipore

3 Values or configuration parameters.

4 Units or words can be displayed using a 7 segments digit.
5 System frame associated with consumables or RO cleaning
icons.

Icon Description
New pretreatment or polisher pack is
or detected. Pack flushing or rinsing is required.
Pretreatment or polisher pack replacement is
or required within 15 days.
Pretreatment or polisher pack replacement is
or required.
Pretreatment or polisher tag reader is
or disabled for 24 hours (below alarm will be
displayed after 24 hours).
Pack out or incorrect pack.
or
RO CL2 cleaning is required.

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Display and keypad, Continued

Display and
icons (continued) Part Function
6 Tank level display.

Icon Description
Tank full display. Fixed icon.

Tank filling display: top bar is blinking.

Tank empty display: the outline is blinking and the

whole display is red.

Alert display An alert message is displayed in two ways:

• Maintenance icon associated with yellow background display or yellow
icons.
• Error codes with a yellow background display associated with Call Service
Representative icon.

Alert icon Alert error code

minor major

major

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Display and keypad, Continued

Alarm display An alarm message is displayed in two ways:

• Alarm icon associated with red background display.
• Error codes with a red background display associated with Call Merck
Millipore icon.

Alarm icon Error code

Low feed pressure icon is displayed Error 14 and Call Merck Millipore
with a red color background. icon are displayed with a red color
background.

Note: if two alarm messages are displayed, press on arrow keypad button to
display the error code.

1- Initial display 2- Action 3- Error display

Press button several
times.

Keypad action The keypad has 4 buttons. They are described below:

Button Possible action

Mode key button is used to
• navigate between different system modes (e.g. Maintenance
to Configuration),
• change between different process state (e.g. Ready to
Standby), or
• clear some alarm stop messages (e.g. Low Feed Pressure).
Left or right key buttons are used to
• navigate in the system software,
• access secondary data value in Ready mode, or
• change configuration or values parameters.
Validate key button is used to
• enter selected parameter setting,
• reset alert lifetime and start a maintenance sequence,
• cancel an alarm stop message,
• enter or exit secondary data value in Ready mode, or
• cancel – PC – connection during first installation.

• A single press on a keypad button allows navigating between main menus,

sub menus or to change a parameter.
• A long press (a few seconds) allows starting a specific action like a
maintenance process, entering a sub menu or canceling a process (e.g. – PC
– connection at first installation).

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Display and keypad, Continued

Keypad help Keypad help icon is displayed if an action is associated to the corresponding
indicators keypad button.

• A fixed key help icon: an action can be done by pressing the corresponding
key button. 1 to 3 key help icons can be displayed at the same time.
• A blinking key help icon: an action is required by pressing the
corresponding key button. Only one key help icon can be displayed at the
same time. This is prompted when a change in maintenance, in an alarm, in
a system parameter needs attention from user.
• No key help icon: the keypad button is disabled.

Description of The table below describes some menus of the software MMI.
some displays
Menu Description
The laptop can be or is connected to the system. This
is displayed when
• First installation of the system is done, and
• “Enable tests” button on DASHBOARD in
Millitrack software is activated.
Lab closed allows system going in Tank Filling for
30 min every day between 10:00-10:30 AM.
System sanitization is made of 3 different cycles
SAN1, SAN2 and SAN3.This process enables to
sanitize the whole system and the tank.
In this menu, IP address can be viewed depending on
the network configuration:
• System default IP address can be displayed using
point to point connection (i.e. 192.168.1.69).
• Different IP address can be displayed when entered
manually or attributed automatically by the DHCP
server.
If a different IP address has been entered using
Millitrack software (e.g. 192.168.1.72), confirm this
menu to switch back to the system default one
(192.168.1.69).

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Display and keypad, Continued

Advanced Some menus in the MMI can be accessed using a code.

settings
Code Function
This is the menu where you can enter the code. It’s
found in Configuration .
CODE 147
Pretreatment tag reader override for 24 hrs.
CODE 159
Service parameter menu:
• tank volume,
• tank empty and tank full level calibration, and
• final filter type lifetime activation.
CODE 258
Polisher tag reader override for 24 hrs.
CODE 357
Distribution pump lifetime reset 9000 hrs.
CODE 369
240 min RO Rinse sequence. RO Rinse can be
cancelled when timer reaches 180.

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Display and keypad, Continued

System • If the Installation Step is not used for installing the system, it is possible to
installation install the system using the Man Machine Interface.
• This – PC – connection has to be cancelled by pressing for 3 seconds to
go to manual installation.
• The table below describes the summary steps for installing the system
without Installation Step web page:

Step Description
1 Set Date • If date and time are lost, system prompts to enter
the new date and time automatically.
• Probably the super capacitor is discharged and RTC
lost data.
2 Progard Flush • System detects a new pack and prompts the user to
start the Progard Flush.
• A keypad action is necessary to start this sequence.
• This sequence has to be cancelled after 5 min or
when key help indicator is displayed. System goes
in Standby mode.

Attention! If the Progard Flush is not cancelled,

system goes automatically in Tank Filling mode at
the end of 15 min Progard Flush.
3 RO Rinse • Code 369 has to be entered to start the RO Rinse.
• It can be cancelled after 1 hour or prompt by the
system.
4 Polisher Rinse • When tank has enough water, polisher pack can be
installed.
• System detects the new pack and prompts the user
to start Polisher rinse. This lasts for 3 min.
5 Final Rinse • Final filter has to be installed.
• System prompts the user to start the final rinse. This
lasts for 3 min.

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First installation with MMI - remarks

Introduction When powering ON a brand new system for installation, after 10 sec, a – PC –
message is displayed. This – PC – connection has to be cancelled for installing
the system using MMI.

Note: there is no specific “menu” for installing the system with MMI
compared to Installation Step web page.

Date and time Most of the time, the system asks to enter the date and time before initiating
any process. Make sure to check or to configure properly the date and time as
it has an impact on all timers (consumables, UV lamp, cleaning, etc).

Resetting timers Comparing to Installation Step web page, the installation using MMI does not
allow to automatically reset timers on
• UV lamp lifetime,
• final filter lifetime, and
• Cl2 Cleaning.

The alert messages related to the previous list could occur when the date and
time have been configured. In that case, they have to be reset manually by
resetting the lifetime or initiating and cancelling the cleaning.

Note: cancelling the cleaning is followed by a 15 min flush (Flush B: refer to

the Process and Operating Status guide).

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Table of alarms and alerts
Error Description Icon Timer System
01 Tap feed cond > SP Er01 + 1 min All systems
02 Feed temp > SP Er02 + 1 min All systems
03 Permeate cond > SP + 5 min RiOs (icons), other systems (error)
04 RO % rejection < SP Er04 + 5 min All systems
05 Feed cond < MIN Er05 + 10 sec All systems
06 Feed cond > MAX Er06 + 10 sec All systems
07 Permeate temp< MIN Er07 + 10 sec All systems
08 Permeate temp > MAX Er08 + 10 sec All systems
09 Permeate cond < MIN Er09 + 10 sec All systems
10 Permeate cond > MAX Er10 + 10 sec All systems
11 Elix temp < MIN Er11 + 10 sec Elix, AFS HF EDI
12 Elix temp > MAX Er12 + 10 sec Elix, AFS HF EDI
13 Elix res < MIN Er13 + 10 sec Elix, AFS HF EDI
14 Elix res > MAX Er14 + 10 sec Elix, AFS HF EDI
15 Distribution temp < MIN Er15 + 10 sec AFS HF, AFS D
16 Distribution temp > MAX Er16 + 10 sec AFS HF, AFS D
17 Distribution res < MIN Er17 + 10 sec AFS HF, AFS D
18 Distribution res > MAX Er18 + 10 sec AFS HF, AFS D
19 Distribution auto stop Er19 + 18 min AFS D
20 Network cable is unplugged Er20 + - All systems
21 No response from DHCP Er21 + - All systems
22 Incorrect IP address Er22 + - All systems
24 Replace UV lamp Er24 + - Elix, AFS HF, AFS D
25 Check UV lamp Er25 + - Elix, AFS HF, AFS D
26 Replace ASM UV lamp Er26 + - Elix, RiOs
27 Check ASM UV lamp Er27 + - Elix, RiOs
28 Replace distribution pump Er28 + - AFS HF, AFS D
29 Elix product res < SP + 1 min Elix (icons), AFS HF EDI (error)
30 Coldfire not responding Er30 3 min All systems
31 Distribution over pressure Er31 + 1 sec AFS HF, AFS D

Alert minor Alarm

Alert Alarm Stop

Table continues on the next page

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Error Description Icon Timer System
- Distribution res < SP + 10 sec AFS HF, AFS D
- Low pressure + 1 min All systems
- Progard pack out - 5 sec All systems
- Progard pack incorrect - 5 sec All systems
- Polisher pack out - 5 sec AFS HF, AFS D
- Polisher pack incorrect - 5 sec AFS HF, AFS D
- Replace Progard - - All systems
- Replace Polisher - - AFS HF, AFS D
- Replace Progard soon - - All systems
- Replace Polisher soon - - AFS HF, AFS D
- Replace final filter - AFS HF, AFS D
Replace final filter soon - - AFS HF, AFS D
- Start CL2 cleaning - All systems
- Start system sanitization - All systems
- Tank empty - - All systems
- Water detected - All systems

Alert minor Alarm

Alert Alarm Stop

Reminder • Alert minor - yellow: replace a consumable within 15 days.

• Alert major - yellow: replace a consumable now or an error code with a Call
a Service Representative icon.
• Alarm - red: electronic or water quality issue but system can still produce
water. It is displayed with an icon or an error code associated with a Call
Service Representative icon.
• Alarm stop – red: system has stopped because a major function is in trouble.
the system displays an icon or an error code associated with a Call Service
Representative icon.

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