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Synergy systemSynergy UV systemUser manual

NoticeThe information in this document is subject to change without notice and should not be construed as acommitment by Millipore SAS. Millipore SAS assumes no responsibility for any errors that might appear in thisdocument. This manual is believed to be complete and accurate at the time of publication. In no event shallMillipore SAS be liable for incidental or consequential damages in connection with or arising from the use of thismanual.We manufacture and sell water purification systems designed to produce pure or ultrapure water with specificcharacteristics (µS/cm, T, TOC, CFU/ml, Eu/ml) when it leaves the water purification system provided that theSynergy Systems are fed with water quality within specifications, and properly maintained as required by thesupplier.We do not warrant these systems for any specific applications. It is up to the end user to determine if the qualityof the water produced by our systems matches his expectations, fits with norms/legal requirements and to bearresponsibility resulting from the usage of the water.Copyright 2012 MILLIPORE SAS. PRINTED IN FRANCE. ALL RIGHTS RESERVED. THIS BOOK OR PARTS THEREOF MAY NOTBE REPRODUCED IN ANY FORM WITHOUT THE WRITTEN PERMISSION OF THE PUBLISHERS.THE PHOTOS ARE NON-CONTRACTUAL.FTPF09574V3.0 – 05/2012TrademarksMillipore, Synergy, EDS-Pak, Elix, Millipak and BioPak are registered trademarks of Merck KGaA.SynergyPak and VOC-Pak are trademarks of Merck KGaA.The “M” Mark is a trademark of Merck KGaA.All other trademarks are trademarks of their respective manufacturers.

Product warranty and limitation of liabilityThe applicable warranty and limitation of liability for the products listed in this publication may be found athttp://www.millipore.com/ec/cp3/terms within the "Terms and Conditions of Sale" applicable to your purchasetransaction.Directive 2002/96 EC: For European users onlyThe symbol “crossed bin” on a product or its packaging indicates that the productshould not be treated like household waste when discarded. Instead the productshould be disposed of at a location that handles discarded electric or electronicequipment.Proper disposal of equipment containing electric or electronic components will helpto reduce pollution effects to the environment or to human health. Proper recyclingof these products helps in environmental preservation and helps to protect naturalresources. For more information about recycling of products containing electric orelectronic components, please contact your local recycling representative ororganisation.

Table of ContentsIntroduction . 1Using this Manual . 1Safety Information . 1Contacting Millipore SAS . 2Product Information . 3Synergy System Overview . 3Synergy System Product Water Specifications . 3Schematic of Main Components . 4Operating principle . 4Technical Specifications . 5Pre Installation . 7Installation Requirements . 7Optional Equipment You May Need . 7Unpacking the Synergy System What’s Inside? . 7Installation . 9Connection of Tubing . 9Connection of the Power Cord Turning on the System Power . 10Installation of the SynergyPak cartridge . 11Installation of the Tygon Tubing . 13Purging Air from the System . 14Hydrating the System . 14Installation and Rinsing of the Final Filter . 15How to Calibrate the Flowrate from the Synergy System (F02) . 16How to Show Resistivity or Conductivity Units (C01) . 18How to Set the Resistivity Setpoint (C02) . 19Using the Synergy System . 21Understanding the Display . 21How to Get Water from the Synergy System. 21How to Dispense an Exact Amount of Product Water (F01). 22Operating Modes . 23How to view the Product Resistivity and Temperature in Pre Operate mode . 25How to recirculate water manually before dispensing . 25How to Understand Synergy System messages . 26

Maintenance.27Maintenance Schedule. 27How to Replace the SynergyPak cartridge . 28How to Replace the Final Filter . 31How to Clean the Screen Filter. 32How to Replace the UV Lamp (UV System only) . 33How to View or Reset the UV Lamp Timer (C03) . 36Troubleshooting.39Ordering Information .41Catalogue Numbers for Synergy Systems . 41Catalogue Numbers for Consumables . 41Catalogue Numbers for Accessories . 41

IntroductionUsing this ManualThis User Manual is a guide for use during the installation, normal operation and maintenance of a SynergySystem or Synergy UV Water Purification System. ‘Synergy’ is used in this manual to refer to either the Synergy orthe Synergy UV System unless otherwise noted. It is highly recommended to completely read this manual and tofully comprehend its contents before attempting normal operation or maintenance of the Water PurificationSystem.Safety InformationYour Synergy System should be operated according to the instructions in this manual. In particular, the hydraulicand electrical specifications should be followed and met. It is important to use this equipment as specified in thismanual; using this equipment in a different manner may impair the safety precautions of the Synergy System.SymbolWhat it meansThis HAZARD symbol is used to refer to instructions in this manual that need to be done safely andcarefully.This ATTENTION symbol is used to refer to instructions in this manual that need to be donecarefully.This UV RADIATION sticker is used to refer to a position on the system cabinet or inside of it whereexposure to UV light is possible.This DANGER sticker is used to refer to a position on the system cabinet or inside of it that could behazardous.This ELECTRICAL GROUND sticker is used to refer to a position on the system cabinet or insidewhere an electrical ground connection is made.This ELECTRICAL DANGER sticker is used to refer to a position on the system cabinet or insidewhere an electrical danger could exist.1

IntroductionContacting Millipore SASInternetThe Millipore SAS Internet Site can be used to find addresses, telephone/fax numbers and other information.Internet Site Address: millipore.com/lab waterManufacturing SiteMillipore SAS67120 MolsheimFRANCE2

Product InformationSynergy System OverviewDISPLAYThe DISPLAY is used tomonitor the water qualityand system status.DISPENSINGBUTTONKEYPADThe DISPENSING BUTTONis used to get ProductWater.The KEYPAD is used toaccess operating functionsand system settings.Synergy System Product Water SpecificationsWater FlowrateSpecificationsUp to 1.5 LPM (with Final Filter)Product WaterQualityResistivityTotal Organic Carbon (TOC)Micro-Organisms18.2 MΩ.cm @ 25 C 5 µg/L (ppb) (with UV) 10 µg/L (ppb) (without UV) 0.1 CFU/ml (with Final Filter)3

Product InformationSchematic of Main Components1234Inlet Solenoid ValveBooster PumpUV Lamp 185 nm (UV System)SynergyPak 1, 2 or 35678Product Resistivity CellPoint-of-Use (POU) Solenoid ValveRecirculation LoopFinal FilterOperating principleThe Synergy Water Purification System is fed with pretreated water (Elix , RO, distilled or DI water) coming froma tank or a loop.When Product Water is being dispensed, the Inlet Solenoid Valve opens and the Booster Pump turns on. Thepretreated water is then pumped into the UV Lamp (UV System). The UV Lamp emits light at 185 nm and 254 nm.It is used to reduce levels of organic molecules in the water. The UV Lamp is a consumable device that needs to beperiodically replaced during the maintenance of the system. The water is then sent to the SynergyPak cartridge todeionize the water. There are three types of SynergyPak cartridge. SynergyPak 1 is used for RO, distilled or Elixfeedwater. SynergyPak 2 is used for pretreated water from clean DI (particulate-free). SynergyPak 3 is used forpretreated water from dirty DI (non particulate-free). The SynergyPak cartridge is a consumable device that needsto be periodically replaced during the maintenance of the system.The Final Filter is a membrane based filter that removes all particles and bacteria with a size greater than thefilter pore size. The Final Filter is a consumable device.4

Product InformationTechnical SpecificationsDimensionsSystem Height, Width and Depth54 cm14.9 cm29.0 cm38 cmShipping Box Height: 56 cm Width: 42 cm Depth: 64 cmWeightSystemOperating WeightDry WeightShipping WeightSynergy8.8 kg5.3 kg9.5 kgSynergy UV9.4 kg5.9 kg10.1 kgNoise LevelA Synergy System has a maximum noise level of 36 dB at a distance of 1 metre away.Electrical 100 VAC 10%, 50/60 Hz. 0.56 amp source, 2 amp T (Time Lag) fuse, Power 80 VA 120 VAC 10%, 50/60 Hz. 0.56 amp source, 2 amp T fuse, Power 80 VA 230 VAC 10%, 50/60 Hz. 0.31 amp source, 2 amp T fuse, Power 80 VAThe source of electrical power should be within 2.5 metres of thesystem. The source of electrical power must be earth grounded.5

Pre InstallationInstallation RequirementsFeedwaterRequirementsType of FeedwaterFlowrateMinimum PressureMaximum PressureTemperatureConductivityTOCElix, RO, distilled or DI water 1.5 LPM (Litres per minute) 0 bar (Feed from a tank) 0.5 bar5 to 35 C 100 µS/cm 50 ppbNOTE:If the feedwater pressure is greater than 0.5 bar, then the Pressure Regulator(ZFMQ000PR) is required.FeedwaterConnection NeededEnvironmentalRequirementsFeedwater Piping ConnectionIndoor Use OnlyStorage TemperatureOperating TemperatureRelative HumidityAltitudeInstallation CategoryPollution Degree1/2 inch Male GAZ, NPTM or BSPM5 C T 40 C5 C T 40 CShould not exceed 80% for temperatures below 31 CShould stay within 50% to 80% between 31 C and 40 C. 3000 metresII2Optional Equipment You May NeedWall MountingBracketThe Millipore SAS Catalogue Number for the Wall Mounting Bracket is WMBSMT002.The mounting hardware for attaching the bracket to a wall is not included and must besupplied.Unpacking the Synergy System What’s Inside?Open the Synergy System Shipping Box. Use the checklist included in the AccessoriesBag to make sure all items were shipped and are accounted for. It is highly suggestedto become familiar with the items that are shipped since these will be used in theInstallation section of this manual.Contact Millipore SAS if an item is missing.7

InstallationConnection of TubingA Rotate the Synergy System so you can see the back of the system(see photo A).Feedwater tubingFeedwater TubingB Locate the Feedwater Tubing exiting from the bottom of thesystem (B).A 1/2 inch Female GAZ fitting with a screen filter is attached at theend of this tubing.Unroll it until the fitting reaches the Feedwater source. Apply white tape on the thread of the 1/2 inch Male GAZ valve orfitting of the Feedwater source.C Connect the fitting to the valve (C).9

InstallationConnection of the Power Cord Turning on the System PowerA Open the front cover of the system (A).(this may require to remove the final filter)This will allow the system to go into STANDBY mode once thesystem is powered.B Plug the Power Cord into the system (B). Plug the other end of the Power Cord into an appropriate source ofelectrical power (i.e. wall outlet).The system is immediately powered. Open the Feedwater Supply Valve.Start-up DisplaysC10 Once the system is powered, the system will start to displayinformation about the software before going into STANDBYmode (C).

InstallationInstallation of the SynergyPak cartridgeHAZARDDo not touch the UV Lamp when replacing the SynergyPak cartridge.InstallationA Make sure the front cover is opened.STANDBY should be viewed on the Display (A). Remove the SynergyPak cartridge from its shipping box. Remove the protective caps on the ports of the SynergyPak cartridgeand from the system.B Locate the O-rings on the ports (B).Wet them with water. It is preferable to wet them with ultrapurewater.11

InstallationC Install the SynergyPak cartridge until it is fully seated into thesystem ports as shown (C, D).DE12 CLOSE THE FRONT COVER.

InstallationInstallation of the Tygon TubingATTENTIONADo not use any white tape on the threads of the Barbed Fitting. An O-ring islocated inside the POU Dispenser to ensure water tightness between the threadsof the POU Dispenser and the Barbed Fitting. Locate the clear Tygon Tubing and the Barbed Fitting from theAccessories Bag. Screw the Barbed Fitting onto the bottom end of the POUDispenser (A).B Push one end of the Tygon Tubing onto the end of theBarbed Fitting (B).Place the other end of the Tygon Tubing in a sink.13

InstallationPurging Air from the SystemA At this time you should have installed the SynergyPak cartridge,Barbed Fitting and the Tygon Tubing. Air trapped in the SynergyPakcartridge should now be purged from the system. Press the Dispensing Button once to put the system intoDISPENSING mode (A). Dispense about 3-4 Litres of water from the system.Hydrating the System At this time, the Final Filter is not installed. Leave the systemovernight or for several hours in PRE OPERATE mode (see SectionOperating Modes). The system will regularly recirculate water andrinse off purification media inside the SynergyPak cartridge. Do notleave the system in STANDBY mode. (The next morning) Press the Dispensing Button once to put thesystem into DISPENSING mode. Allow about 1 Litre of water to be dispensed from the system. Press the Dispensing Button once again. The system will finishdispensing water. Remove the Tygon Tubing and the Barbed Fitting from the POUDispenser. The Final Filter needs to be installed.(See Section Installation and Rinsing of the Final Filter).14

InstallationInstallation and Rinsing of the Final FilterA Obtain a Final Filter. It can be the Millipak Express 20 or theBioPak Ultrafiltration Cartridge. Remove the Tygon Tubing and the Barbed Fitting from the POUDispenser. Screw the Final Filter onto the end of the POU Dispenser.The Final Filter should be turned until it is hand tight (A).Do not over tighten the Final Filter.ATTENTIONBDo not use white tape on the threads of the Final Filter.The POU Dispenser has an O-ring inside which provides a watertight seal. Press the Dispensing Button once. This will bring the system intoDISPENSING mode. Locate the air vent valve (not present on all types of Final Filters) onthe top side of the Final Filter.Open this slowly but do not remove it.(B).Allow any air on the clear side of the Final Filter to be vented out.ATTENTIONAir will not pass through the membrane filter in the Final Filter. If there istrapped air, then a reduction in Product Water flowrate can result. Dispense about 1 Litre of water. Make sure all air is purged out. Press the Dispensing Button once again. The system will finishdispensing water. Leave the system in PRE OPERATE mode.ATTENTIONIt is highly recommended not to put Tygon Tubing or any other type of tubingon the end of the Final Filter. This can compromise the Product Water quality(bacteria can grow in the Tygon Tubing). The Water System is now ready for use.15

InstallationHow to Calibrate the Flowrate from the Synergy System (F02)Before calibrating the Product flowrate from the Synergy System, you will need a 1 Litre graduated cylinder tomeasure the total volume of water that will be dispensed. The Final Filter should be installed.1Press the Main and “-“ Buttons togetherto enter the menu. The Display will showF01.2Press the Main Button once. The Displaywill show F02 and the 60 second timer.The graduated cylinder will be blinking.3Press the Dispensing Button once. Thesystem will dispense water for 60 seconds.The Display will show the timer countingdown.Continued on next page16

Installation4Measure the total volume of water (inLitres) dispensed from the system using a1 L graduated cylinder.5Press the “ ” or “-“ Button to match thevolume Display to the volume measured.6To exit the menu, press and hold theMain Button for 2 seconds.To display the next menu option, pressthe Main Button once.17

InstallationHow to Show Resistivity or Conductivity Units (C01)With Temperature Compensated or non Temperature Compensated valuesTemperature compensation is a way of ‘standardizing’ Resistivity or Conductivity to measurements that would beseen if the water temperature was 25 C.1Press the Main and “ “ Buttons togetherto enter the menu. The Display will showC01 and the units chosen. The followingDisplay shows Temperature CompensatedResistivity Units: MΩ.cm @25 C.2Press the “ ” or “-“ Button to selectNon Temperature Compensated ResistivityUnits: MΩ.cm.3Press the “ ” or “-“ Button to selectTemperature Compensated ConductivityUnits: µS/ cm @25 C.4Press the “ ” or “-“ Button to select NonTemperature Compensated ConductivityUnits: µS/cm.5To exit the menu, press and hold the MainButton for 2 seconds.To display the next menu option, press theMain Button once.18

InstallationHow to Set the Resistivity Setpoint (C02)The Resistivity Setpoint is used to inform you when the Product resistivity is low. When the resistivity is below thesetpoint, the Resistivity display will flash and the red Pack Alarm will be blinking (see Section How to UnderstandSynergy System messages). The factory default resistivity value is set to 15 MΩ. cm @25 C.1Press the Main and “ “ Buttons togetherto enter the menu. The Display will showC01.2Press the Main Button once. The Displaywill show C02 and the ResistivitySetpoint value.3Press the “ ” or “-“ Button to adjust theResistivity Setpoint from1.0 MΩ.cm @25 Cto 18.0 MΩ.cm @25 C.If Conductivity Units are chosen in C01,then the Setpoint can be adjusted from0.999 µS/cm @25 C to0.055 µS/cm @25 C.NOTE:The Conductivity Setpoint display needs to be multiplied by 0.001 to getthe real value. For example, if the Display reads “055” µS/cm @25 C, thenyou would multiply 055 x 0.001 0.055. Thus, the real ConductivitySetpoint reading is 0.055 µS/cm @25 C.4To exit the menu, press and hold the MainButton for 2 seconds.To display the next menu option, press theMain Button once.19

Using the Synergy SystemUnderstanding the DisplayThe Display is used to view information about the Operating Modes, the Operating Parameters and Maintenanceor Alarm messages.Operating ModesOperating ParametersMaintenance or AlarmsUV System onlyHow to Get Water from the Synergy SystemUsing the Dispensing ButtonThere are two ways to get water using the Dispensing Button:Press once and release.To stop dispensing water,press the Dispensing Button once again.ORPress and hold down.To stop dispensing water,release the Dispensing Button.21

Using the Synergy SystemHow to Dispense an Exact Amount of Product Water (F01)1Press the Main and “-“ Buttons togetherto enter the menu. The Display will showF01.2Press the “ ” or “-“ Button to adjust theexact amount of Product Water (in Litres)needed. Pre-set volumes of water can beadjusted from 0.25 L to 9.75 L in0.25 increments.NOTE:The accuracy of this is dependent upon the accuracy of the FlowCalibration performed in Section How to Calibrate the Flowrate from theSynergy System.3Press the Dispensing Button once. Thesystem will dispense water. The Displaywill show the amount of water dispensedand the Product resistivity.NOTE:To stop dispensing water, press the Dispensing Button once again.4To exit the menu, press and hold the MainButton for 2 seconds.To display the next menu option, press theMain Button once.22

Using the Synergy SystemOperating ModesStandbySTANDBY mode is displayed when the frontcover is removed. The system willdepressurize during which STANDBY will beblinking on the Display for 10 seconds. Allsystem operations are disabled. STANDBYmode is selected before attemptingmaintenance on the system.Pre OperatePRE OPERATE mode is displayed when thesystem is not dispensing water and not inStandby mode.The system will have a 3-minute autorecirculation every 2 hours in PRE OPERATEmode. The Booster Pump turns on. This willenhance the quality of the Product Waterdelivered from the system. Recirculationcan also be activated manually for up to3 minutes.The resistivity and temperature of theProduct Water is displayed duringrecirculation. The resistivity andtemperature remain displayed for up to10 seconds after recirculation is finished.23

Using the Synergy SystemDispensingDISPENSING mode is displayed whenProduct Water is being dispensed.DISPENSING mode occurs because theDispensing Button was pressed down.The Booster Pump turns on.The resistivity and temperature of theProduct Water is displayed duringdispensing. The resistivity and temperatureremain displayed for up to 10 seconds afterdispensing is stopped.Auto-DispensingAUTO-DISPENSING mode is displayed whenselecting menu option F01. AUTODISPENSING mode is used to dispense preset volumes of water from the SynergySystem.The amount of water dispensed and theresistivity are shown while water is beingdispensed. The resistivity remains displayedfor up to 10 seconds after dispensing isstopped.24

Using the Synergy SystemHow to view the Product Resistivity and Temperature in Pre Operate modePress:The Display will show the last Productresistivity and temperature values measuredduring DISPENSING mode or duringRECIRCULATION. The values are displayed for5 seconds.NOTE:The Product resistivity and temperature are displayed automatically duringDISPENSING mode or during RECIRCULATION.How to recirculate water manually before dispensingThis option is used to enhance the quality of the Product Water before dispensing water. The Booster Pump willturn on and water will recirculate for up to 3 minutes. An auto-recirculation occurs for 3 minutes every 2 hours.Press:The Display will show the Product resistivityand temperature.NOTE:To dispense water, press the Dispensing Button during recirculation.Recirculation will stop and water will be dispensed.25

Using the Synergy SystemHow to Understand Synergy System messagesPack Alarm The system will prompt you to change the SynergyPak cartridge using a red PackAlarm icon. The Display will show the red Pack Alarm blinking. The SynergyPakcartridge is changed due to either the amount of time it has been used or from theamount of water that has passed through it. When the Resistivity display is blinking, the red Pack Alarm will also be blinking. Thisindicates that the SynergyPak cartridge should be replaced. This message is shownwhen the Product resistivity is less than the Resistivity Setpoint. The ResistivitySetpoint can be seen in menu option C02. When the red Pack Alarm is displayed as a steady icon, the SynergyPak cartridge isnot installed correctly or not installed at all. If the SynergyPak cartridge has beenreinstalled and the Alarm is still displayed, then contact your technical support.UV Lamp Alarm The system will prompt you to change the UV Lamp using a red UV Lamp Alarm icon.The Display will show the red UV Lamp Alarm blinking. The message is shown whenthe UV Timer displays 0 days. The UV Timer can be viewed in menu option C03. Thereplacement of the UV Lamp involves the installation of a new UV Lamp and amanual reset of the UV Timer. When the red UV Lamp Alarm is displayed as a steady icon, the UV Lamp is notinstalled correctly or not installed at all. If the UV Lamp has been reinstalled and theAlarm is still displayed, then contact your technical support.26

MaintenanceMaintenance ScheduleIn order to maintain good performance of your water system respect the maintenance schedule and replaceconsumables as required.What to doSynergyPakcartridgeReplacementWhen?When the PackAlarm display isblinking.How to?See Section Howto Replace theSynergyPakcartridgeWhen thesystem resistivitydisplay isblinking.Final FilterReplacementThe Final Filter is replaced when theSynergyPak cartridge is replaced or whenthe Product Water flowrate drops.See Section Howto Replace theFinal FilterFlowCalibrationWhen the Final Filter is replaced, orperiodically.See Section Howto Calibrate theFlowrate from theSynergy SystemUV LampReplacementand UV TimerResetWhen the UVLamp Alarmdisplay isblinking.See Section Howto Replace the UVLamp (UV Systemonly) and How toView or Reset theUV Lamp Timer(C03)Screen FilterCleaning2 times a year or as necessary.See Section How toClean the ScreenFilter27

MaintenanceHow to Replace the SynergyPak cartridgeHAZARDDo not touch the UV Lamp when replacing the SynergyPak cartridge.Removing the SynergyPak cartridgeA Open the front cover (this may require to remove the final filter) togo into STANDBY mode.Press the Dispensing Button once.The system will dispense water.Wait for the system to depressurize.The Display will show STANDBY blinking for 10 seconds. Remove the Final Filter.B Press your thumbs on the system and swing the pack towardsyou (B)C Remove the pack from the system (C).28

MaintenanceInstallationD Remove the new SynergyPak cartridge from its shipping box. Remove the protective caps on the ports

This User Manual is a guide for use during the installation, normal operation and maintenance of a Synergy System or Synergy UV Water Purification System. 'Synergy' is used in this manual to refer to either the Synergy or the Synergy UV System unless otherwise noted. It is highly recommended to completely read this manual and to

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