Source note. This schedule is compiled from the operating manual chapters that were machine‑readable
(A – General & Safety, C – Technical Data / Product Description, E – Commissioning / Decommissioning,
F – Operation / Monitoring, G – Troubleshooting) and the manual's Wear & Spare Parts list.
The manual's dedicated Chapter H “Maintenance / Disinfection” periodic table could not be auto‑extracted from the
21 MB combined PDF (the reader stopped just before it). The rows below are all sourced & chapter‑referenced;
the exact Chapter H interval table can be transcribed in verbatim once those pages are supplied.
Responsible party (per manual roles / password levels, Ch. A §2.5–2.6 & Ch. F):
Operator / User Daily operation, monitoring, alarm acknowledgement, hot‑sanitisation start, week‑timer (User pw 1234)
Technician Logging, diagnosis, calibration, communication, HS sequences (Technician pw)
Service / Manufacturer Chemical disinfection, default settings, part replacement, repairs (Service pw / Herco)
Plant Operator (org.) Ensures qualified staff, training, records, safe isolation
Alarm category (Ch. G):
Cat I Warning — yellow, unit keeps running
Cat II Fault — red, unit keeps running
Cat III Fault — red, emergency shutdown
1 · Continuous Monitoring — each measured valueCh. F §4–6 · Ch. G §1.4
The DIATRON 5500‑II monitors every value continuously and logs it (SD card / USB). The Operator watches the display and acknowledges alarms; Cat II/III faults or anything needing a repair are escalated to qualified technical / service staff.
| Monitored value | Tag |
Alarm / trigger & category |
Action | Responsible |
| Feed‑water conductivity | Q01 |
FC010 sensor out of range |
Acknowledge; check probe | Operator |
| Permeate conductivity RO pass 1 | Q02 |
FC012 > P063 warning · FC013 > P064 fault · FC011 sensor fail |
Acknowledge; persistent → check membranes / calibrate |
Operator → Technician |
| Permeate conductivity loop supply | Q03 |
FC015 warning · FC016 > P084 fault · FC014 < P082 |
Cat III → emergency shutdown; manual reset after cause removed |
Operator → Service |
| Feed‑water temperature | T01 |
FC018 > P033 warning · FC017 sensor fail |
Acknowledge; check feed / heating | Operator |
| Permeate temp RO pass 1 | T02 |
FC020 warning · FC021 fault · FC019 sensor fail |
Acknowledge; investigate over‑temperature | Operator |
| Permeate temp loop supply | T03 |
FC023 warning · FC024 fault (→ recirc. until OK) · FC022 sensor fail |
Acknowledge; unit recirculates until temp OK | Operator |
| Loop & hot‑san. temps | T04–T09, T11, T12 |
FC025–FC033 sensor / over‑temp → hot sanitisation aborted, cool‑down |
Check heaters / sensors; re‑run HS |
Technician |
| Fine‑filter differential | Pr01–Pr02 |
FC044 “Check fine filter F1” > P183 |
Replace fine‑filter cartridge F1 |
Operator / Technician |
| Operating pressure pass 1 | Pr05 / Pr06 |
FC046 / FC047 too high |
Manual reset after cause removed; check valves / membranes |
Technician |
| Operating pressure pass 2 | Pr08 / Pr09 |
FC048 / FC049 too high · FC043 low pressure pass 2 |
Manual reset; check pump P2 / valves |
Technician |
| Permeate loop pressure | Pr04 / Pr10 |
FC045 low pressure loop · FC042 permeate over‑pressure |
Check loop / overflow valve DV02 setting |
Technician |
| Flow sensors (all) | Fl01–Fl05 |
FC004–FC008 no flow pulses (300 s) |
Acknowledge; check paddle‑wheel sensor | Operator |
| Loop leakage detection | Fl01–Fl02 Δ |
FC009 difference > P015 → shutdown |
Locate & stop leak; manual reset |
Operator → Service |
| Holding‑tank level | B1 |
FC040 tank empty (shutdown) · FC041 tank full |
Check feed supply / level switch |
Operator |
| Valve position transmitters | G02 (V10), G03 (V11) |
FC002 / FC003 position ≠ operating mode |
Correct valve position / sensor gap |
Technician |
2 · Routine Operating ChecksCh. F §2 · G §1.1
| Task | Interval | Responsible | Ref. |
|---|
| After dialysis, switch the unit to STANDBY (not OFF) to prevent microbiological contamination during idle time |
Every session / daily | Operator | Ch. F §2.3 |
| Keep holding‑tank B1 cover closed; never drink / use permeate for drinks |
Continuous | Operator | Ch. F §2 |
| Review current operating values (temperature, conductivity, feed/return flow, consumption) |
Daily | Operator | Ch. F §5 |
| Ensure SD card is inserted; back up log data to USB |
Periodic | Operator / Technician | Ch. F §4 |
| Keep operation & service records available (needed by manufacturer for support) |
Rolling — last 4 months | Plant Operator | Ch. G §1.1 |
3 · Disinfection, Hot Sanitisation & PreservationCh. C §4.2 · E · F
| Task | Interval / trigger | Responsible | Ref. |
|---|
| Chemical disinfection — ~0.2% peracetic acid; ~30 min recirculation + ~2 h hold + flush; confirm disinfectant‑free before return to service |
Regularly, per site hygiene plan (idle‑time only). Prevents deposits & microbial growth |
Service (service pw) + Operator (PPE / chemical handling) | Ch. C §4.2 · F pw‑levels |
| PPE when handling peracetic acid / preservative — eye protection, rubber gloves, apron; remove spills immediately |
Whenever chemicals handled | Operator | Ch. A §2.7 · E §2.2 |
| Hot sanitisation up to 90–95 °C (Hercotherm G 18 kW) via week timer — programmes HS1–HS4 |
Scheduled (auto week timer), per hygiene plan | Operator starts (User pw) | Ch. F §3 · C |
| Preserve the unit (sodium bisulphite + glycerine) when idle |
If idle > 7 days | Service / Technician | Ch. E §2.1 |
| Replace preservation agent; flush & disinfect before re‑commissioning |
After 12 months at the latest | Service / Technician | Ch. E §2.1 |
4 · Pre‑treatment & Feed‑water CareCh. A §2.11 · C · D
| Task | Interval | Responsible | Ref. |
|---|
| Check activated‑carbon filter; replace when exhausted (dispose per local rules) |
At regular intervals | Operator / Technician | Ch. A §2.11 |
| Verify feed water stays within spec: softened, particle‑free, free chlorine not detectable, max TDS 1000 mg/l, SDI₁₅ ≤ 3, 5–25 °C, 1.5–6 bar |
Ongoing | Operator | Ch. C §2 |
| Replace fine‑filter cartridge F1 on differential‑pressure alarm (FC044) |
On alarm / condition‑based | Operator / Technician | Ch. G §1.4 |
5 · Wear & Spare‑Part Replacement IntervalsManual: Wear & Spare Parts list (AF20‑008099)
Replacement / service basis stated in the manual: 5,000 operating h/yr (RO), 150 hot disinfections/yr (RO), 50 hot disinfections/yr (loop). Items marked S are carried on the service vehicle. Replacement is a Service / Manufacturer task.
| Component | Tag(s) | Replacement interval | Responsible |
|---|
| Membrane modules (LOW4 / ESPA4) | X1.1‑1.3 / X2.1‑2.3 | 4–8 years | Service |
| Sets of sealings | V14, V03, V05… | 30,000 h or 10 years / as needed | Service |
| Sealing set (hot‑dis. duty) | — | 1,000 hot dis. or 10 years / as needed | Service |
| Pump shaft seals CRN 3‑25 / CRN 3‑19 | P1 / P2 | 6 yr / 2–5 yr | Service |
| Pump seal set CM‑G 3‑3 | P3 | 6 years | Service |
| Inline flow sensor 3SP | L01 / L02 / L03 | 15,000 h or 3 years | Service |
| Paddle‑wheel flow fittings | Fl01–Fl05 | 30,000 h / as needed | Service |
| Control‑cabinet ventilation filter mats | 1M2 | 1 year | Technician |
| Conductivity measuring cells (ZK1.0 / ZK0.1) | Q01 / Q02 / Q03 | As needed | Service |
| Motor contactors 5.5 kW / 7.5 kW | 1K1,1K2 / 2K2A,2K2B | 200 hot dis. or 3 years | Service |
| DIATRON 5500‑II CPU/Display, basic & extension modules | A0 / A1 / A2 | 6 years | Service |
| Solenoid / ball / needle / sampling valves, overflow & check valves | V01, V09, DV01–DV04… | As needed | Service |
| Motor‑protection switches, circuit breakers, fuses, relays | 1Q1‑1Q3, 2F2… | As needed | Service |
| Hercotherm heater / transmitter TMT127 / bimetal / PT100 | W2A/W2B, T04/T05 | 7‑day lead / as needed | Service |
6 · Responsibility & Safety Framework for MaintenanceCh. A §2.5, 2.6, 2.10, 2.12
| Duty | Responsible | Ref. |
|---|
| Define scope, competence & supervision of personnel; train staff who lack the required knowledge | Plant Operator | Ch. A §2.6 |
| Ensure operation, maintenance, inspection & assembly are done only by suitably qualified staff (medical tasks: doctor / dialysis nurse) | Plant Operator | Ch. A §2.5 |
| Before repair/maintenance: take unit out of service, secure against restart, de‑energise & depressurise, wear PPE, reinstate all guards afterwards | Service / Technician | Ch. A §2.10 |
| Use only original / manufacturer‑approved spare parts; no unauthorised modification or controller patch (else warranty & conformity void) | Service / Manufacturer | Ch. A §2.12 |
| Emergency control mode (unmonitored conductivity) only after consulting the doctor in charge | Operator + doctor | Ch. F §2 |