ip-man-vnx50hh2 june 2009 manual...

IONPURE®

VNX50HH-2 CEDI Modules

Operation &

Maintenance Manual

IP-MAN-VNX50HH2 June 2009

Manual Covers Part#:

• IP-VNX50HH-2
10 Technology Drive
Lowell, Massachusetts 01851 Tel: (866) 876-3340 Fax: 978-934-9499

IONPURE ® VNX50HH-2 CEDI Modules

IP-MAN-VNX50HH2

TABLE OF CONTENTS DISCLAIMER STATEMENT 4

PROPRIETARY RIGHTS STATEMENT 4

OPERATING MANUAL REVISION HISTORY 5

1. INTRODUCTION 5

1.1. VNX50HH-2 model module Overview 5

1.2. Using this manual 6

1.3. Installation Precautions 6

1.4. Operating Precautions 6

1.5. Shutdown Precautions 7

2. PRE-INSTALLATION: PREPARATION & REQUIREMENTS 7

2.1. Tools and Equipment 7

2.2. Electrical and Plumbing Connections 8

2.3. Inspect the Module 10

2.4. Operating Requirements 10

2.5. Flow Rates and pressure drops 11

3. VNX MODULE INSTALLATION AND OPERATION 12

3.1. Moving the VNX Module into Place 12

3.2. Water Connection Configuration and Fittings 12

3.3. Electrical Connections 15

4. DETERMINE OPERATING DC CURRENT PRIOR TO STARTUP 16

5. START-UP PROCEDURE 16

5.1. Test interlocks 16

5.2. Notes on Recovery, Silica and Hardness 16

5.3. Startup of VNX-HH modules 17


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6. MAINTENANCE AND TROUBLESHOOTING 18

6.1. General Maintenance Guidelines 18

6.2. Specific Maintenance Guidelines 18

6.3. Cleaning Circumstances 19

6.4. Sanitization Circumstances 19

6.5. Required Cleaning and Sanitizing Equipment 19

6.6. System Preparation for Cleaning or Sanitization 20

6.7. Cleaning and Chemical Sanitization Procedures 21

6.8. Cleaning with 2.0% Hydrochloric Acid (HCl) 22

6.9. Cleaning with 5% Brine + 1% Caustic Solution 24

6.10. Cleaning or Sanitizing with Sodium Percarbonate 25

6.11. Sanitizing with Peracetic Acid 27

7. TROUBLESHOOTING 31

8. SHUTDOWN AND STORAGE 38

8.1. SYSTEM SHUTDOWN 38

8.2. STARTUP AFTER SHUTDOWN 38

APPENDIX A: VNX50HH-2 MODULE SPECIFICATIONS 39

APPENDIX B: VNX50HH LAYOUT & ELEVATION DRAWING B-1 40

APPENDIX B: VNX50-HH - PID DRAWING B-2 41

APPENDIX B: VNX50-HH - ELECTRICAL CONNECTIONS DRAWING B-3 42

APPENDIX C: PORT ADAPTER AND PLUG DRAWINGS 43


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DISCLAIMER STATEMENT

The operation and maintenance manual should provide complete and accurate information to meet your operating and/or service requirements based on the information available at the time of publication. The information in this manual may not cover all operating details or variations or provide for all conditions in connection with installation, operation and maintenance. Should questions arise which are not answered specifically in this manual, contact your water system supplier. IONPURE reserves the right to make engineering refinements that may not be reflected in these manuals. The material in these manuals is for informational purposes and is subject to change without notice. PROPRIETARY RIGHTS STATEMENT

This manual discloses information in which IONPURE has proprietary rights. Neither receipt nor possession of this manual confers or transfers any right to the client, and by its retention hereof, the client acknowledges that it will not reproduce or cause to be reproduced, in whole or in part, any such information except by written permission from IONPURE. The client shall have the right to use and disclose to its employees the information contained herein for the purpose of operating and maintaining the IONPURE equipment, and for no other purpose. In the event the content of this manual is altered or section/items are omitted during a reproduction, in whole or in part, and instructions or definitions within the reproduction result in personal injury to those who follow the altered instructions, the burden of responsibility for personal injury falls solely on the party who effects the reproduction. MANUAL USER'S GUIDE This manual describes the procedures necessary to install, operate, and maintain your IONPURE Continuous Electrodeionization modules. Please read this manual carefully before installing and operating your modules. The module warranty may be voided if installation or operation instructions are not followed correctly. Notes, Warnings, Cautions are used to attract attention to essential or critical information in a manual. Warnings and Cautions will appear before the text associated with them, and notes can appear either before or after associated text. NOTE: Notes are used to add information, state exceptions, and point out areas that may be of

greater interest or importance.

Cautions indicate a situation that may cause damage or destruction of equipment or may pose a long term health hazard. Warnings indicate condition, practices, or procedures which must be observed to avoid personal injury or fatalities.

IONPURE continually strives to provide safe, efficient, trouble-free equipment using the optimum technology for your application. If problems should develop, IONPURE's worldwide network of technical support will be available to provide assistance. For service, sales, parts, or additional manual copies, please visit the website: www.ionpure.com.


IP-MAN-VNX50HH2

OPERATING MANUAL REVISION HISTORY

EVENT DATE DESCRIPTION Original publication August 2009 Operation & Maintenance Manual 1. INTRODUCTION

This section contains the following instructions:

• VNX50HH-2 model module overview - Brief introduction to components and models • Using this Manual - How to use this Manual • Precautions - Precautions to prevent personal injury or equipment damage during installation

1.1. VNX50HH-2 model module Overview VNX50HH-2 modules are designed to be installed in either single or multiple Continuous Deionization VNX systems. Their compact state-of-the-art design assures ease of installation, maintenance, and service. Compared to the VNX50-2 the VNX5HH-2 module was designed for higher feed water hardness tolerance. They are differentiated by a green ‘HH” marking on the vessel of the VNX50HH-2 module. VNX50HH-2 modules are available in the following size:

Part Number Nominal Flow Description

IP-VNX50HH-2 40 gpm (9.1 m3/h) Single VNX module, VNX type For more information on the VNX module specifications and flow rates, see Sections 2.2, 5.2 and/or Appendix A of this Manual. Figure 1-1: Angle and Side views of VNX50HH-2 Modules


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1.2. Using this manual

Service technicians should review this manual prior to going to the site. It lists tools and materials needed to install the modules. It also outlines the site information required to prepare for installation.

NOTE: The warranty may be void if installation or operation instructions contained in this manual are not followed exactly.

This Manual describes the installation, operation, and routine maintenance of the VNX50HH-2 modules. It also contains information on basic troubleshooting (Section 7).

IONPURE strongly recommends all users read the entire contents of the manual. If the VNX50HH-2 module is not operating properly after going through the basic troubleshooting exercises, contact your Local Service Provider.

1.3. Installation Precautions

• DO NOT OPEN THE VNX MODULE. OPENING THE MODULE WILL VOID THE WARRANTY AND CAUSE IRREVERSIBLE DAMAGE

• During operation, the electrode wiring inside the module junction boxes are at high voltage and present a shock hazard. THEREFORE, BEFORE TOUCHING THE INSIDE OF THE JUNCTION BOX, CONFIRM THAT AC POWER HAS FIRST BEEN DISCONNECTED AND LOCKED OUT ACCORDING TO STANDARD LOCKOUT/TAGOUT PROCEDURES.

• To eliminate the possibility of electric shock, confirm that all GROUND WIRES ARE PROPERLY CONNECTED. Thoroughly read all the information in this manual before operating the VNX model modules.

• THE MODULE MUST BE OPERATED ACCORDING TO THE DESIGN SPECIFICATIONS FOR TEMPERATURE AND HUMIDITY.

• IMPORTANT - Pipe sections prepared for installation must be inspected, and be free of debris from storage or cutting tool particles. This must be done before installation.

• IMPORTANT - Because VNX modules have narrow flow distribution channels, plugging by particles can cause permanent damage. Always install pressure gauges, sampling ports, sensors, etc. in tee fittings. Do not drill or tap into piping. After installing gauges, sampling ports, sensors, etc., always flush out the piping before connecting to the VNX module to remove any debris.

• Installation of the VNX module must be completed in accordance with the procedures outlined in this manual. If deviations from the prescribed procedures are deemed necessary to achieve the desired performance, consult your local Service Provider.

1.4. Operating Precautions • DO NOT APPLY POWER TO THE VNX MODULE UNTIL PROPER FLOW AND PRESSURE HAVE

FIRST BEEN CHECKED AND VERIFIED.

• Allow for proper inlet and outlet connections. NEVER BLOCK OFF (DEAD-HEAD) ALL OF THE VNX OUTLET pipe connections. Dead-heading by blocking all outlets can result in over-pressurization, leading to permanent damage.


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• Do not operate the module under conditions other than those stated in the module manual. The prescribed feed water and electrical requirements, and flow configurations, must be followed at all times. If the feed water quality or the product water requirements change, contact the IONPURE Technical Support department for assistance.

Once every six months:

• Make sure all wiring connections are tight

• Test safety interlocks such as flow switches or connections to upstream equipment

1.5. Shutdown Precautions • Confirm that the pressure in the unit is relieved until all pressures inside the unit are atmospheric.

(i.e., all pressure gauges should read zero).

• Drain standing water and plug all inlets and outlets.

2. PRE-INSTALLATION: PREPARATION & REQUIREMENTS

This section contains the following pre-installation information: • Tools and equipment - Tools and equipment needed to install the module • Module Inspection - Inspecting the VNX module for damage • Operating conditions - Temperature range, space requirements, electrical connections, feed water

specifications, plumbing and drain requirements

2.1. Tools and Equipment The following items are required to unpack, position, and install the VNX module:

• Spreader bar mechanism to move the module into place • Slip joint pliers • Wire cutters/strippers • Phillips head screwdriver

Spreader bar

Strapping rated for at least

1000 lbs (454 kg)


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2.2. Electrical and Plumbing Connections Electrical An electrical junction box is included and mounted on the VNX 50HH-2 modules. A single conduit connection is required through a 7/8” thru hole to provide power to the CEDI module. The junction box follows DC wire color conventions.

• Red + • Black –

Figure 2-1: Junction Box End of Module

Inlet and Outlet plumbing connections Ionpure VNX50HH-2 modules have molded PPO end blocks with FEMALE connections. There are four (4) necessary custom ACME thread connection points (for more information see Connection Drawings in Appendix B:

• Product Inlet (Dilute Feed) • Product Outlet (Product) • Reject Inlet (Concentrate Feed) • Reject Outlet (Reject)

Labels (as shown on the right) are used for port identification.


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Table 2-1: Typical inlet/outlet configurations.

Module Port Locations and Connection Types Module Model Connection type Recommended Configuration Inlet/outlet Configuration

VNX50HH-2

PVC included and installed with module

Polypropylene available as a separate purchased kit

Same side inlet and outlet OR Side inlet opposite side outlet

Product ConnectionReject Connection

NOTE – VNX50HH-2 Modules must be connected with CEDI product water to the Reject inlet (Concentrate inlet)

Available Connection Types PVC – 1-1/2” Female Socket PP - 50mm Butt Weld PVDF – 50mm Butt Weld

Grounding of the module piping

DILUTE IN

DILUTE OUT

FI

PI

C PI

RO Permeate

CEDI Reject

PIFICEDI Product

CONC IN

CONC OUT

PI

Figure 2-2: Depicts the flow diagram for the VNX-HH. Note – Product water (Dilute out) feeds the Concentrate Inlet.

To avoid the risk of electrical shock, some form of grounding must be used on any stream where the plumbing is stainless steel or if there are samples points or instrumentation in close proximity to the module. For sanitary

applications, a grounding cap can be used, Ionpure part number 49/S4501-124, which is actually a ¾” TC cap with a welded stud to be wired to ground. For non-sanitary applications, a ¼” SS threaded grounding rod can be used, Ionpure part number ZIVC00160.


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Figure 2-3: Grounding Rod

2.3. Inspect the Module • Do not uncrate the module prior to moving it into its final location. After uncrating it, inspect it

for any signs of damage. If damage is apparent, immediately notify your Local Service Provider and the carrier.

2.4. Operating Requirements

In order to operate to specification, the VNX module must have the following conditions present. If any of these conditions are unmet, do not attempt to install the VNX module without specific instructions from your Local Service Provider’s Technical Support.

• Operating Environment

The VNX module requires indoor installation out of direct sunlight. The maximum ambient room temperature should not exceed 113 °F (45° C). The module can tolerate humidity of up to 90%, as long as condensation does not occur.

• Space Requirements

The physical dimensions of the VNX Module are given in appendix A. In addition to the size of the module itself, the arrangement of the piping and electrical connections determine the amount of space the module needs to operate. This arrangement varies from site to site, depending on the conditions at a particular location.

• Electrical Requirements

The VNX module requires the following power sources. In all cases the cathodes must be at ground potential.

Table 2-2: Electrical requirements for the VNX Modules

Model Nominal Flow Rate DC Power

VNX50HH-2 40 gpm (9.1 m3/hr) 0-600 VDC, 8 Amps


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• Feed Water Requirements – RO Permeate

Feed water for the VNX module must always meet the specifications outlined in Table 2-3. In most cases, pre-treating VNX module feed water with reverse osmosis (RO) will bring it within these specifications. Depending on the conditions, however, some sites may require additional pretreatment. To determine if additional pretreatment is required, compare the VNX feed water (RO Permeate) on site with the feed water requirements listed below.

Table 2-3: Feed Water Requirements for the VNX50HH Modules

Module Model VNX50HH-2 Feed water source RO permeate

Feed water conductivity equivalent including CO2

*< 40 µS/cm

Silica (SiO2) < 1 ppm Iron, Manganese, Sulfide < 0.01 ppm

Total chlorine < 0.02 ppm as Cl2Total Hardness ≤ 2.0 ppm as CaCO3

Dissolved organics (TOC) < 0.5 ppm Operating pH range 4 – 11

Operating Temperature 40 - 113 °F (5 – 45 °C) Inlet pressure <100 psi ( 7 bar)

Note: Recycling the VNX reject to the RO feed will cause the CO2 load on the VNX to increase, and may have an impact on the VNX product water quality. Please refer to Ionpure.com for additional reject stream system design guidance including the following paper from Jonathan Wood and Joe Gifford (“Process and System Design for Reliable Operation of RO/CEDI Systems”)

• Drain Requirements

Place the VNX module near a drain that can accommodate at least 100% of the total feed flow.

2.5. Flow Rates and pressure drops • See Appendix A


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3. VNX MODULE INSTALLATION AND OPERATION

This section contains the following installation information: • Moving and unpacking - Moving the Module into place and unpacking it • Connecting the Module - Connecting the plumbing and electrical.

3.1. Moving the VNX Module into Place Confirm that the pre-installation requirements outlined in Section 2 are met and the system is ready for VNX Module installation.

• Remove any packaging materials and move the module to its operating location. (See Section 2). Use safe lifting practices when moving the module.

• Remove the yellow dust plugs that seal the inlet and outlet ports on the

module. Failure to remove yellow dust plugs can cause permanent damage to the modules.

3.2. Water Connection Configuration and Fittings

Pre-Flushing - Make sure all upstream pretreatment equipment and piping have been thoroughly flushed with particle-free water before connecting them to the VNX Module. Flushing removes any particles left in the piping

from cutting and assembly. If particles remain, they could plug the passages inside the VNX Module.

NOTE - Failure to properly flush the pretreatment water system of installation debris to drain prior to flowing water to the CEDI can result in particulate fouling that may be irreversible.

Plug Removal - Remove yellow dust plugs from the connection ports.

Connections - Ionpure VNX modules have a Molded PPO endplate with FEMALE ACME thread connections. Connection adapters and plugs are factory installed into the female ACME thread ports. There are four (4) necessary connection points:

• Product Inlet (Dilute Feed) • Product Outlet (Product) • Reject Inlet (Concentrate Feed) • Reject Outlet (Reject)

See Table 2-1 in Section 2.2 for module specific port locations or refer to the module layout drawings in appendix B. Connection adapter drawings can be located in appendix C.


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Modules are shipped with the connection ports installed. Product and Reject ports are labeled with color coded identification (see figure above). Blue Product port inlets (I) and outlets (O) are identified with Blue labels affixed near the appropriate end block connection points. Red Reject port inlets (I) and outlets (O) are identified with Red labels affixed near the appropriate end block connection points. See appendix C for PVC and PP adapter drawings. If alternate approved connection orientations are required, insure that connections to this type of module INCLUDE THE USE OF O-RINGS. For additional module specific connection information see appendix B.

• The unit comes with 4 factory installed PVC connection adapters.

• The unit comes with 4 factory installed PVC plugs.

There are several important points regarding the piping connections:

Sealing Mechanism - The seal is created by a dual o-ring between the smooth hole wall of the end block and the connection adapter. This is similar to an RO end adapter that seals into an RO pressure vessel end cap. The female threads in the endplate are ACME threads. They are NOT TAPERED pipe threads and DO NOT CREATE the seal, they allow the sealing surfaces to move towards each other and hold the piping adapter in place.

Use of Sealants - DO NOT use Teflon® tape or any other pipe sealant (e.g. Dope) on the ACME thread adapters. The use of these products on the ACME thread adapter will prevent good sealing.


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O-rings – O-rings are included with the plugs and pipe adapters. Connection adapters use white O-rings size (2-222) and an orange O-ring size (2-221) and are made of Silicon. The slightly larger o-ring (white) is 222.

2-221 Oring

2-222 Oring

2-221 Oring

2-222 Oring

Plug PVC Connection Adapter PVC

Piping Adapter Material - To avoid corrosion, the piping adapters and plugs must be non-metallic. Factory supplied plugs and adapters are made of PVC. Additional high purity adapter kits are available if required for installation. See Appendix C for the Polypropylene plug/adapter drawings.

Tightening - Adapters should be tightened to ensure that orings are engaged in the endplate. The maximum torque necessary to install adapters and plugs will be less than 6 ft-lbs to engage the oring and ensure a leak free seal.


3.3. Electrical Connections

Electrical Connections

• VNX modules have on-board electrical junction boxes and follow common DC voltage color conventions. Only one electrical connection is required per module. Power connections to the module junction box should be made with 12AWG (3.31mm2) wire and conduit connections should be supplied through the 7/8” junction box thru hole. DC wire color conventions.

o Red + o Black –

Electrical Precautions

• Ensure that polarity of DC connections is correct before applying DC power. Operation with polarity reversed will permanred and black wires are correctly oriented on

• Do not run AC and DC wiring within the and lead to malfunctions.

• Disconnect poweaccepted Lockousystem.

• All wiring done in the field must conform to loProvider if there is a conflict between the inst

• Power connections from the modules shocapable of meeting the DC power requiremen

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ently damage the cathode. It is critical that the the positive (+) and negative (-) terminal blocks.

same conduit. This may cause interference

r before opening any enclosure and follow t/Tag out procedures when working on the

cal electrical codes. Consult your Local service ructions in this manual and the local codes. uld be connected to a suitable power supply ts of the module.


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4. DETERMINE OPERATING DC CURRENT PRIOR TO STARTUP

The VNX50HH-2 modules are designed and tested to operate correctly at 8 amps. If the feed water meets the influent quality requirements for the VNX50HH-2, the current will be set independent of the Feed Water Conductivity (FCE). Set the power supply to operate in constant amperage mode and set the amperage at 8 Amps DC. Note – This procedure is different from our typical startup amperage calculation that would be calculated based on the Feed Water Conductivity Equivalent (FCE).

5. START-UP PROCEDURE

5.1. Test interlocks

• Test flow switches and other interlocks, including the RO interlock if applicable • Test pressure relief if applicable

• Set alarm points

5.2. Notes on Recovery, Silica and Hardness

VNX50HH-2

• VNX recovery of 90% is limited to systems with feed water total hardness of less than 1 ppm

as CaCO3. For systems operating with CEDI feed water hardness from 1 – 2 ppm as CaCO3 the maximum water recovery is limited to 80%. In addition there is a minimum reject flow of 2.6 gpm per VNX modules.

• For normal recovery of 80-90%, feed water silica must be ≤ 1 ppm as SiO2

Table 5-1: Flow Range

Hardness (as CaCO3)

Recovery Flow Range Dilute Feed

Gpm [m3/hr]

Concentrate feed from

Dilute (CEDI Product)

Gpm [m3/hr]

Net Product

Gpm [m3/hr] Minimum 25 [5.68] 5 [1.14] 20 [4.54] Nominal 50 [11.36] 10 [2.27] 40 [9.08] 1-2 ppm 80% Maximum 62.5 [14.2] 12.5 [2.84] 50 [11.36]

Minimum 25 [5.68] 2.6 [0.59] 22.4 [5.09] Nominal 50 [11.36] 5 [1.14] 45 [10.22] <1 ppm 90% Maximum 62.5 [14.2] 6.2 [1.41] 56.3 [12.79]


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100Rate Flow Feed

Rate FlowProduct Recovery % ×= 100Recovery %

Rate FlowProduct Rate Flow Feed ×=

5.3. Startup of VNX-HH modules

• Make sure that modules are correctly connected to the DC power source.

• Make sure that the VNX product line is directed to drain.

• Turn on the feed water. Adjust valves to obtain the desired flows and pressures in the product and reject streams. The reject flow is set depending on the feed water hardness level. Section 5.2 examines the necessary flow calculations and flow restrictions for the VNX50HH-2 Module. Ensure that the piping connections have been established using CEDI product to feed the concentrate (Reject) inlet.

• Concentrate feed pressure and Dilute Outlet pressure will be equal for the VNX50HH-2

Module due to the concentrate feed requirements. Valves should be adjusted to ensure that the module is operating with the correct recovery and adjusted to ensure that the product outlet pressure is about 2-10 psig higher than the reject outlet pressure at the desired flow rates. See Example Pressure Scenario Below.

25 PSIG 50 PSIG 25 PSIG Outlet

• Adjust the DC power supply to the current setting of 8 amps. See Section 4 for more details.

• Test all flow switches and interlocks to ensure VNX DC power is shut off when flow is interrupted.

• Continue to direct the product water to drain until it reaches the desired quality.

• Once product reaches the desired quality, connect to process. Readjust pressures as

required to maintain product outlet pressure 2-10 psi above the reject outlet pressure.

• When the system is at steady state (quality in specification and stable operation), record operating data on the data sheet provided at the end of section 7.

Dilute

Concentrate

FEED

25 PSIG FEED

15 PSIG

Dilute Outlet

_ Conc Outlet

15 PSIG 10 PSID

Equation 5-1: Recovery Equations

Outlet Dilute outlet compared to the Concentrate Outlet


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6. MAINTENANCE AND TROUBLESHOOTING

The following section details the maintenance procedures for the VNX module. It contains general maintenance information and specific maintenance information for cleaning and sanitizing the modules.

The cleaning chemical volumes and flows detailed in this section are for a single VNX module. Multiply chemical volumes by number of modules in system

This section also lists possible problems and troubleshooting procedures for the VNX module. All operators and personnel involved with the module should read and become familiar with all maintenance and troubleshooting procedures.

6.1. General Maintenance Guidelines

Operating Data Log Sheet

VNX system log sheets should be filled out daily to provide early detection of problems that could jeopardize the warranty and potentially damage the module. A typical log sheet is included at the end of the troubleshooting in Section 7. Because instrumentation may vary depending on the type of system the module is installed into, this log sheet may not apply to your particular system. The system manual should contain log sheets more appropriate for your particular system. However, the items in bold must be filled out to maintain module warranty. Periodic Maintenance

Perform the following tests at least once every six months. Check the Troubleshooting portion in Section 7 for any recommendations that are not listed below.

• Check for any water leakage from the module. If leakage is observed,

see the Troubleshooting subsection for possible solutions. • Periodically tighten all electrical connections.

6.2. Specific Maintenance Guidelines

Periodically, the VNX module may need cleaning or sanitization. Cleaning the module removes scale and resin/membrane foulants.

Before starting any cleaning or sanitization procedure, see subsection 6.7 for recommended cleaning solutions

Do not run a cleaning or sanitizing solution through the system with DC power to the VNX module. Make sure the DC power is off before cleaning.


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6.3. Cleaning Circumstances

The module may need CLEANING if:

• product differential pressure increases by 50% without a change in temperature and flow, or

• reject differential pressure increases by 50% without a change in temperature and flow, or

• product quality declines without a change in temperature, flow, or feed conductivity, or

• the module electrical resistance increases by 25% without a change in temperature.

The above factors may indicate module fouling or scaling. Contact your Local service Provider to determine if the module needs cleaning or for the best cleaning procedure.

6.4. Sanitization Circumstances

The system may require periodic SANITIZATION if the product water calls for low levels of bacteria (user specific requirement).

6.5. Required Cleaning and Sanitizing Equipment

The following equipment must be constructed of material compatible with the recommended cleaning solutions.

Thoroughly flush all plumbing and other equipment before cleaning or sanitization to remove debris that might damage the system.

During cleaning, the following equipment is required:

Tank Connect a tank to the VNX system. The tank should be large enough to accommodate solution volumes as shown in this section. The cleaning solution will be prepared in this tank. Pump Install a cleaning pump between the system and the cleaning tank. The pump must provide a minimum discharge pressure of at least 30 psig (2 bar) for VNX50-HH installations. For the best results, size pumps for the maximum possible flow up to the values listed in Table 6-1. The construction materials of the wetted surfaces in the pump must be compatible with the cleaning solutions. Plastics generally work well with most cleaning chemicals. During cleaning or chemical sanitization, adjust flow rates as follows to maintain flow velocity in all spacers (use the highest flow rate possible per Table 6-1):

Table 6-1: Cleaning Flow Rates

VNX50-HH min – max

Product Flow 25-50 gpm (5.7 -11.4 m3/hr)

Dilute Flow 30-75 gpm (6.8 – 17 m3/hr)

Reject Flow Calculation

0.5 x Product Flow

Reject Flow 5-25 gpm (1.14 - 5.7 m3/hr)

Pump Capacity 30-75 gpm (5.7 - 17 m3/hr)


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The preferred cleaning flow rates are nominal product flow and reject flow base on the module reject flow calculations in Table 6-1. Valves and Hoses Figure 6-1 shows a typical flow diagram for cleaning or sanitizing a VNX system. Valves are needed for mixing, cleaning, and draining the tank. Flexible hose is ideal for connecting cleaning equipment to the system. Verify that the construction materials of the valves and hose are compatible with the cleaning solutions.

6.6. System Preparation for Cleaning or Sanitization

NOTE: The following cleaning procedures are based on the piping setup shown in Figure 6-1. If your piping setup is different, you may need to alter these procedures.

• Turn off the DC power supply.

• Close the following valves to the VNX system:

o Feed Valve

o Product Valve

• Connect the discharge of the cleaning pump to the VNX feed CIP connection.

• Connect the module’s feed, reject and product CIP connections to the cleaning tank.

• Verify that all piping connections are secure.

• Close cleaning pump discharge valve until ready to pump the cleaning solution into the VNX system.


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Figure 6-1: Typical VNX-HH System Piping for Cleaning and Sanitization.

6.7. Cleaning and Chemical Sanitization Procedures

• Avoid direct skin contact with cleaning chemicals. Wear safety glasses and protective clothing.

• Pressure test cleaning skid with water before adding chemicals to tank.

• Flush all hoses and tank with clean water BEFORE adding chemicals.

• To reduce the possibility of chemical sprays, relieve the pressure in chemical lines before

disassembly.

• Follow the manufacturer’s chemical safety instructions on the container labels.

• Check the pH level in any solution before letting it flow to the drain. Follow all discharge

limitations.

• Do not run a cleaning solution through the system when DC power is applied to the module. Make sure the DC power is off before cleaning.


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The system can be cleaned and sanitized with any of five (5) different solutions, depending on what needs to be removed:

• Hydrochloric acid (2%) – For removing scale and metal oxides. • Sodium chloride/sodium hydroxide (5% brine/1% caustic) – For removing organic

foulants and biofilm. • Sodium percarbonate – For removing organic foulants, reducing pressure drop, and

sanitizing. • Peracetic Acid – Used for routine sanitizing to discourage the growth of bacterial films. • Aggressive Multi-Agent cleaning for Biofilm– Recommended for general biofouling with

increase in pressure drop. This aggressive cleaning protocol consists of 5% sodium chloride followed by a 2% sodium hydroxide and then followed by a 1% sodium percarbonate with a final 5% sodium chloride flush. The combination of these treatments performed sequentially has proven to be more effective than any single treatment performed separately.

• Aggressive Multi-Agent cleaning for Fouling/scaling – Recommended for fouling and scale remediation with drop in performance combined with increased electrical stack resistance. Aggressive sequential cleaning protocol of salt (5% sodium chloride) then followed by caustic (2% sodium hydroxide) followed by acid (2% hydrochloric acid) with a final 5% sodium chloride flush (see Service Bulletin 2007-02). Extended soaking or increasing the acid concentration in the range from 2%-4% HCl based on the severity of electrical stack resistance increase increases the benefits of this treatment.

NOTE: If you are unsure whether the module is scaled or organically fouled, clean first with brine, then

caustic clean followed by acid clean.

6.8. Cleaning with 2.0% Hydrochloric Acid (HCl)

Hydrochloric acid is a corrosive chemical. Wear safety glasses, gloves, and protective clothing when using this or any corrosive chemicals.

Cleaning with Hydrochloric Acid involves three steps:

1. Hydrochloric acid treatment (2% HCl),

2. A salt flush (5% NaCl), and

3. Water flush. STEP 1: Recirculating the HCl Solution

NOTE: This is the minimum amount of HCl required. It may be necessary to use additional HCl to effectively clean a scaled Module. Monitor the pH of the solution during the recirculation period. If the pH begins to rise, add more HCl to maintain a pH of approximately 0.5. Circulating HCl through the system removes scale and metal oxides from the module.

Chemicals necessary for Step 1 (2% HCl) VNX50-HH Water (RO permeate or CEDI product) 99 gal (375 liters) 36.5% Hydrochloric Acid (HCl) 4.2 gal (16.2 liters)

NOTE: The following cleaning procedures are based on the piping setup shown in Figure 6-1.

1. Prepare the VNX system for chemical cleaning. Follow the instructions in Section 6.5 and 6.6. Make sure the tank drain valve is closed.

http://www.ionpure.com/index.php?option=com_docman&task=doc_download&gid=207&Itemid


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2. Fill the tank with the required amount of water.

3. Mix the required amount of 36.5% (concentrated) HCl with the water in the tank. Additional HCl may be required during the recirculation period.

4. Open the pump suction and pump bypass valves completely.

5. Start the cleaning pump.

6. When chemicals are well mixed, gradually open the pump discharge valve while closing the pump bypass valve to adjust the product and reject flow rates to the values given in Section 6.5.

7. Recirculate the solution through the module for 30 minutes. Longer contact time may be desirable in some instances. If longer contact time is desired, contact Ionpure Technical Support.

8. Monitor the pH of the solution during the recirculation period. If the pH begins to rise, add more HCl to maintain a pH of approximately 0.5.

9. Turn off the cleaning pump.

10. Check pH. Neutralize if necessary. Drain the tank.

STEP 2: Salt Flush To Drain

This salt flush rinses the cleaning solution from the module, and returns the ion exchange resin to the sodium and chloride forms.

Chemicals needed for Step 2 (5% NaCl) VNX50-HH Water (RO permeate or CEDI product 180 gal (675 liters) Sodium chloride (NaCl) 75 lbs (34.2 kg)

1. Remove product and reject outlet lines from the cleaning tank, and direct to

drain.

2. Fill the tank with the water.

3. Dissolve the sodium chloride (NaCl) in the water.

4. Start the cleaning pump and flush through the module to drain for about three minutes.


6. Drain the tank.

STEP 3: Water Flush To Drain

Water flushes the cleaning solution and salt out of the system, and prepares the system for return to operation. 1. Close the pump discharge valve. Keep product and reject lines directed to drain

and disconnect the cleaning equipment from the module.


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2. Turn on the feed water supply to the system. Slowly open the feed valve to allow RO product water to flow through the module to drain.

3. After flushing all residual cleaning solutions from the system, follow the initial start-up procedures in Section 5 of this manual. Start without the DC power applied to the VNX module for five minutes and then restore normal DC power.

6.9. Cleaning with 5% Brine + 1% Caustic Solution

Sodium Hydroxide is a corrosive chemical. Wear glasses, gloves, and protective clothing when using this or any corrosive chemicals.

A 5% sodium chloride (NaCl)/1% sodium hydroxide (NaOH) solution works well for removing organic foulants from the module. Also see Ionpure.com for Service Bulletin IPSB-2007-2.

This procedure involves two steps:

1. Brine/caustic cleaning.

2. Water flush.

STEP 1: Cleaning Solution Recirculation

This step removes organic foulants from the module.

Chemicals necessary for Step 1: VNX50-HH Water (RO permeate or CEDI product) 99 gal (375 liters) Sodium chloride (NaCl) 42 lbs (18.75 kg) Sodium hydroxide (NaOH) pellets OR 50% NaOH

8.25 lbs (375 kg) 1.29 gal (4.8 liters)

NOTE: The following cleaning procedures are based on the piping setup shown in Figure 6-1

1. Prepare the VNX system for chemical cleaning. Follow the instructions in Section 6.5. Make sure the cleaning tank drain valve is closed.


3. Open the cleaning pump bypass valve and suction valve completely.

4. Start the cleaning pump.

5. Dissolve the specified amount of sodium chloride (NaCl) in the water.

6. Dissolve or mix the specified amount of sodium hydroxide (NaOH) in the water.

7. When chemicals are well mixed, gradually open the cleaning pump discharge valve while closing the bypass valve to adjust the product and reject flow rates to the values given in Section 6.5.

8. Recirculate the solution through the module for 30-60 minutes.




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This Step flushes the cleaning solution out of the system, and prepares the system for return to operation.

1. Remove product and reject lines from the cleaning tank and direct to drain.

2. Close the cleaning pump discharge valve.


4. After flushing all residual cleaning solutions from the system, disconnect the cleaning equipment.

5. Follow the initial start-up procedures in Section 5 of this manual. Start without the DC power applied to the VNX module for five minutes, and then apply normal operating DC power.

6.10. Cleaning or Sanitizing with Sodium Percarbonate

Sodium percarbonate, sodium carbonate, and hydrogen peroxide are corrosive chemicals. Avoid contact with these chemicals.

Do not use powdered sodium percarbonate. It may contain impurities that could harm the module.

Sodium percarbonate is a combination of sodium carbonate (soda ash) and hydrogen peroxide. It is an effective biocide and it reduces organic fouling and plugging. In addition, it is an effective cleaner for removal of biofilms. Flush the VNX module with a 5% Sodium Chloride (NaCl) solution both before and after sodium percarbonate sanitization. The initial NaCl rinse removes metal ions, particularly calcium, and magnesium ions from the module.

The sanitization procedure for sodium percarbonate involves five steps:

1. An initial salt flush

2. A water flush

3. The percarbonate cleaning

4. A second salt flush

5. A final water flush

STEP 1: Initial Salt Flush To Drain

This initial 5% NaCl rinse removes any metal ions, particularly calcium and magnesium ions, from the module.

Chemicals needed for Step 1 (5%NaCl): VNX50-HH Water (RO permeate or CEDI product) 180 gal (675 liters) Sodium chloride (NaCl) 75 lbs (34.2 kg)

NOTE: The following cleaning procedures are based on the piping setup shown in Figure 6-1


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1. Follow the instructions in Section 6.5 to prepare the VNX system for cleaning or sanitization. Make sure that the cleaning tank drain valve is closed.


3. Dissolve required amount of sodium chloride (NaCl) in the tank water.

4. Open the cleaning pump suction valve and bypass valve completely.

5. Divert the product and reject to drain.

6. Start the cleaning pump. When chemicals are well mixed, gradually open the cleaning pump discharge valve while closing the cleaning pump bypass valve to adjust the product and reject flow rates to the values given in Section 6.5.

7. Flush the salt solution to drain for about 3 minutes.


9. Drain the tank.


Water flush rinses the salt solution from the module before cleaning solution is introduced.

Chemical necessary for Step 2: VNX50-HH Water (RO permeate or CEDI product) 180 gal (675 liters)


2. Start the cleaning pump and flush to drain for about three minutes.


4. Drain the tank.

STEP 3: Cleaning Solution Recirculation

This 1% sodium percarbonate step removes organics and biofilm.

Chemicals necessary for Step 3 (1% 2Na2CO3 3H2O2) sodium percarbonate:

VNX50-HH

Water (RO permeate or CEDI product) 99 gal (375 liters) 100% Sodium carbonate (Na2CO3) 8.25 lbs (3.75 kg) 30% Hydrogen peroxide (H2O2) 2.4 gal (8.4 liters)


2. Connect the product and reject lines to the cleaning tank.


4. Dissolve the sodium carbonate (Na2CO3) in the water. Make sure the sodium carbonate is fully dissolved before proceeding to the next step.

5. Mix the 30% hydrogen peroxide (H2O2) into the solution in the tank.



IP-MAN-VNX50HH2

7. Start the cleaning pump. When chemicals are well mixed, gradually open the cleaning pump discharge valve while closing the bypass valve to adjust the product and reject flow rates to the values given in Section 6.5.

8. Recirculate the solution through the module for 30 minutes. Some gas will be produced. In addition, the module pressure drop will increase during this procedure.






1. Remove product and reject outlet lines from the cleaning tank, and direct to drain.





6. Drain the tank.

STEP 5: Water Flush to Drain

This step flushes the cleaning solution out of the system, and prepares the system for return to operation.

1. Close the cleaning pump discharge valve. Keep product and reject lines directed

to drain and disconnect the cleaning equipment from the module.


3. After flushing all residual cleaning solutions from the system, follow the initial start-up procedures in Section 5 of this manual. Start without the DC power applied to the VNX module for five minutes, and then apply normal operating DC power.

6.11. Sanitizing with Peracetic Acid

Peracetic Acid is a mixture of corrosive chemicals. Avoid contact with these chemicals.


IP-MAN-VNX50HH2

Do not run a sanitization solution through the system when DC power is applied to the VNX module.

The sanitization procedure for Peracetic Acid involves five steps:

1. An initial salt flush

2. A water flush

3. The Peracetic Acid cleaning

4. A second salt flush

5. A final water flush

STEP 1: Initial Salt Flush To Drain This initial 5% NaCl rinse removes any metal ions, particularly calcium and magnesium ions, from the module.


NOTE: The following cleaning procedures are based on the piping setup shown in Figure 6-1.

1. Follow the instructions in Section 6.5 to prepare the VNX system for cleaning or sanitization. Make sure that the cleaning tank drain valve is closed.


3. Dissolve required amount of sodium chloride (NaCl) in the tank water.


5. Divert the product and reject to drain


7. Flush the salt solution to drain for about 3 minutes.


9. Drain the tank.


Water flush rinses the salt solution from the module before cleaning solution is introduced.

Chemical necessary for Step 2: VNX50-HH Water (RO permeate or CEDI product) 180 gal (675 liters)



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4. Drain the tank.

STEP 3: Sanitization Solution Recirculation and Soak

This step sanitizes the system.

Chemicals needed for Step 3: VNX50-HH Water (RO permeate or CEDI product) 99 gal (375 liters)

Peracetic Acid Solution* 0.99 gal (3.75 liters)

* Quantity based on a peracetic acid solution of 20% Hydrogen Peroxide with 4% peracetic acid. Do not exceed a final concentration of 0.2% peroxide and 0.04% peracetic acid


2. Connect the product and reject lines to the cleaning tank.


4. Mix the peracetic acid solution into the tank.



7. Recirculate the solution through the module for 30 minutes.


9. Allow the system to soak in the peracetic acid solution for up to 90 minutes.




Chemicals needed for Step 4 (5%NaCl):

VNX50-HH

Water (RO permeate or CEDI product)

180 gal (675 liters)

Sodium chloride (NaCl) 75 lbs (34.2 kg)

1. Remove product and reject outlet lines from the cleaning tank, and direct to drain.



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6. Drain the tank.

STEP 5: Water Flush to Drain

This step flushes the cleaning solution out of the system, and prepares the system for return to operation.

1. Close the cleaning pump discharge valve. Keep product and reject lines directed to

drain and disconnect the cleaning equipment from the module.


3. After flushing all residual cleaning solutions from the system, follow the initial start-up procedures in Section 5 of this manual. Start without the DC power applied to the VNX module for five minutes, then slowly ramp up to apply the normal DC power.


IP-MAN-VNX50HH2

7. TROUBLESHOOTING

The troubleshooting chart in this Section is a diagnostic guide. If the VNX system does not respond to the recommended solutions, do not attempt further repairs. Call your Local Service Provider. Before calling:

• Become thoroughly familiar with the module and all troubleshooting procedures.

• Prepare a list of all problems encountered while operating the equipment.

• Have your monitoring log sheets at hand.

• Have your module’s model and serial numbers at hand. This information can be found on the end plate on the plumbing side (Cathode).

Table 7-1: Troubleshooting Procedures for VNX modules

PROBLEM CAUSE SOLUTION

Module has loosened during shipment, movement, or operation

Contact Ionpure Technical support Module leaks

Module is faulty Contact your Local Service Provider

Plumbing leaks Module adapters are loose Tighten adapters, check O-rings

Poor water quality with power ON to unit

Operating current incorrectly set

Measure feed conductivity and CO2. Recalculate current according to Section 4 and adjust as necessary.

Module is fouled, scaled, or oxidized

See Troubleshooting flow chart at the end of this section.

Obstruction downstream Check if a downstream valve is inadvertently closed.

System is plugged with particulate matter or fouled

See Troubleshooting Flow Chart at the end of this section.

Loss of flow and/or increase in feed pressure

Loss of feed flow 1. Check if an upstream valve is inadvertently closed. 2. Check for leaks or if an upstream bypass valve is inadvertently open. 3. Check feed source output (for example, a pump).


IP-MAN-VNX50HH2

VNX MODULE LOG SHEET

Customer Name: ___________________________Module Serial Number: _____________

DATE

TIME OF DAY

FEED WATER TEMPERATURE °C

FEED WATER TOTAL HARDNESS ppm CaCO3

FEED WATER TOTAL CHLORINE ppm as Cl2

FEED CARBON DIOXIDE ppm as CO2

FEED CONDUCTIVITY µmho/cm

PRODUCT RESISTIVITY Mohm-cm

DC VOLTAGE volts

DC CURRENT amps

MODULE RESISTANCE (volts/amps) ohms

PRODUCT FLOW gpm or m3/h

REJECT FLOW gpm or m3/h

DILUTE INLET PRESSURE psig or bar

DILUTE OUTLET PRESSURE psig or bar

PRODUCT DP (Dilutein – Diluteout) psig or bar

CONCENTRATE INLET PRESSURE psig or bar

CONCENTRATE OUTLET PRESSURE psig or bar

CONCENTRATE DP (Concin - Concout) psig or bar

COMMENTS:


IP-MAN-VNX50HH2

Are anyDC wires loose?

Tighten connections

Feedwater temp

drop?

Excesshardness inCEDI reject?

Increase in DC voltageis normal

Acid clean,reduce CEDI feedhardness and/or

lower CEDI recovery

Yes

No

No

Yes

Yes

No

Call you local serviceprovider

Troubleshooting Flow Chart - Increase in DC VoltsPage 1 of 1

START HERE

Caustic clean,reduce CEDI feed

silica and/orlower CEDI recovery

Excesssilica in

CEDI reject?Yes

No

Cleaning removedorganics from resin:

review process designand operation

Does NaCl/NaOHcleaning help? Yes

No


IP-MAN-VNX50HH2

RO making too little

water?

Clean RO orincrease RO pressureor increase RO feed

temperature

CEDI control valves closed too

far?

Does percarbonatecleaning CEDI

help?

CEDI ∆P much higher in

NaOH than NaCl? *

Readjust CEDI control valves, inlet

and/or outlet

Pluggage due toparticulates or

biofouling - evaluatesystem design and

operation

CEDI resin damaged.Call Technical

Support

Yes

No

No

Yes

Yes

Yes

No

Call your local serviceprovidor

Troubleshooting Flow Chart - Low CEDI Product or Reject FlowPage 1 of 1

Product flowmeterincorrect?

Recalibrate or replaceflow meterYes

No

START HERE

* Compare product pressure drop when circulating5% NaCl solution as opposed to 1% NaOH solution

No

Does Multi-Agent cleaning

help?

Pluggage due toparticulates or

biofouling - evaluatesystem design and

operation

Yes

No


IP-MAN-VNX50HH2

Reduce TDS(clean or replaceRO membranes)

or lower CEDI prodflow

CEDIfeed CO2changed?

CEDIfeed SiO2too high?

Yes

Go to next flowchart

Troubleshooting Flow Chart - Low CEDI Product Water QualityPage 1 of 3

CEDIfeed TDSchanged?

Adjust DC amperageUp for higher TDS

Down for lower TDS

START HERE

Check IP-Pro:is desired quality

possible?Yes Yes

No

No


possible?

Adjust DC amperage:up for higher CO2

down for lower CO2

YesYes

Increase pH aheadof RO to remove CO2

(contact Tech Support)or lower CEDI prod

flow

No

No

No

Clean or replaceRO membranes or

reduce RO recovery


IP-MAN-VNX50HH2

Have DC voltsincreased?

Reduce flow or reduce feed

conductivity equivalent

See separatetroubleshooting

chart for DC voltsYes

No

Go to Next Flowchart

Product flowincreased?

Yes


Continued from previousflowchart

Increase DC amperage


possible?Yes

No

No

Is reject out psi> product out psi?

No

Adjust product out to2-5 psi > reject outYes

Go to chart forDC Volts


IP-MAN-VNX50HH2

Did cleaning restore flow?

Clean CEDI with NaCl/NaOH and

Na2CO3/H2O2

Resin oxidized(affects flow & quality)

or fouled(affects quality)

Has product flowdecreased?


Continued fromPrevious Flowchart

No

Yes

Contact Ionpure TechnicalSupport

www.ionpure.com

Did cleaningrestore quality?

No

Removed particulatesand/or biofilm:review process

design & operation

Yes

Also removedorganics from resin:

review processdesign & operation

Yes

No

Check feed water Cl2Check sanitization

procedure


IP-MAN-VNX50HH2

8. SHUTDOWN AND STORAGE

This section contains shutdown procedures for a VNX module. Under certain circumstances, bacterial growth can occur quickly in water left stagnant within each module and the overall system.

8.1. SYSTEM SHUTDOWN

• Shut off feed water to VNX module(s)

• Drain standing water out of VNX module(s)

• Close isolation valves to prevent evaporation of water in membranes and resins.

8.2. STARTUP AFTER SHUTDOWN

• Divert product outlet to drain.

• Turn on feed water to VNX module(s)

• Operate unit with DC power on, flushing to drain.

• If desired, sanitize VNX module(s).


IP-MAN-VNX50HH2

APPENDIX A: VNX50HH-2 MODULE SPECIFICATIONS

A.1 Module Dimensions and Weight

PART NUMBER DIMENSIONS, WEIGHT IP-VNX50HH-2

Height: 20 in (50.8 cm) Width: 20 in (50.8 cm) Length: 84.6 in (214.9 cm) Weight (wet): 825 lb (375 kg)

A.2 VNX50-HH Module Inlet & Outlet Connections

Piping Connections Size of installed PVC ports on module

Alternate Polypropylene Kit

Dilute Inlet 1 ½ ” Sch-80 female socket 50mm Butt Weld Product Outlet 1 ½ ” Sch-80 female socket 50mm Butt Weld Concentrate Inlet 1 ½ ” Sch-80 female socket 50mm Butt Weld Reject Outlet 1 ½ ” Sch-80 female socket 50mm Butt Weld

See Drawings in Appendix B for location of connections. See Drawings in Appendix C for Connection Drawings.

A.3 VNX50-HH Module Flow Rates, Pressure Drops & Plumbing Connections

Module VNX50-HH 80% Recovery Flow Rates: gpm (m3/hr) 80% Recovery minimum: 20 (4.5) 80% Recovery nominal: 40 (9.1) 80% Recovery maximum: 62.5 (11.4) Pressure Drop psid (bar) Typical @ nominal flow 20-30 (1.4-2.1)

Feedwater Conductivity (FCE) <40 µS/cm Product Resistivity (RO Permeate) > 16 megohm-cm*

Temp range 5-45 °C Recovery 80-90% Silica Removal >90% Sodium Removal ≥99.5% Chloride Removal ≥99.8% Feed / Product Plumbing orientation

Inlet and outlet can be on same end or opposite ends

Concentrate inlet / Reject Plumbing orientation

Inlet and outlet can be on same end or opposite ends

* Actual performance can be evaluated using IP-Pro projection software available from Ionpure.


IP-MAN-VNX50HH2

APPENDIX B: VNX50HH LAYOUT & ELEVATION DRAWING B-1


IP-MAN-VNX50HH2

APPENDIX B: VNX50-HH - PID DRAWING B-2


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APPENDIX B: VNX50-HH - ELECTRICAL CONNECTIONS DRAWING B-3


IP-MAN-VNX50HH2

APPENDIX C: PORT ADAPTER AND PLUG DRAWINGS VNX50-HH - PVC CONNECTION DRAWING C-1


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Page 44 IP-MAN-VNX50HH2

APPENDIX C: VNX50HH-2 - PVC PLUG DRAWING C-2


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Page 45 IP-MAN-VNX50HH2

APPENDIX C: VNX50-HH - PP CONNECTION DRAWING C-3


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APPENDIX C: VNX50-HH - PP PLUG DRAWING C-4

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