Ionpure Ip-vnx28ep-2 Manual

IONPURE®

VNX CEDI

Modules

Operation

Maintenance

Manual

IP-MAN-VNX-1019-EN

Rev 1

October 2019

This manual covers

model numbers:

·IP-VNX28EP-2

·IP-VNX55EP-2

·IP-VNX55E-2

·IP-VNX55EX-2

·IP-VNX55HH-2

·IP-VNX15CDIT-2

·IP-VNX30CDIT-2

·IP-VNX-MAX-1

·IP-VNX-MINI-1

Evoqua Water Technologies, LLC

558 Clark Road

Tewksbury, Massachusetts 01876, USA

ionpure@evoqua.com (email)

www.ionpure.com (web)

Visit web site to find local Ionpure contact

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TABLE OF CONTENTS

DISCLAIMER STATEMENT 5

PROPRIETARY RIGHTS STATEMENT 5

OPERATING MANUAL REVISION HISTORY 6

1. INTRODUCTION 7

1.1. VNX55 product family overview 7

1.2. Using this manual 8

1.3. Installation Precautions 8

1.4. Operating Precautions 9

1.5. Shutdown Precautions 9

2. PRE-INSTALLATION: PREPARATION & REQUIREMENTS 10

2.1. Tools Required 10

2.2. Unpacking and Moving VNX Modules 10

2.3. Electrical and Plumbing Connection Requirements 11

2.4. Operating Requirements 11

2.4.1. Operating Environment 11

2.4.2. Space Requirements 11

2.4.3. Module Orientation 12

2.4.4. Electrical Requirements 12

2.4.5. Feed Water Requirements 12

2.4.6. Drain Requirements 13

2.5. Flow Rates and pressure drops 13

3. VNX MODULE INSTALLATION 14

3.1. Preparation 14

3.2. Water Connection Configuration and Fittings 14

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3.2.1. VNX Piping Adapter Sealing Mechanism 15

3.2.2. VNX Piping Configurations 17

3.3. Electrical Connections 18

3.3.1. Electrical Precautions 18

3.4. RO/CEDI System Design Considerations 18

4. PREPARATION FOR STARTUP 20

4.1. Verify Feed Water Meets VNX Quality Requirements 20

4.2. Estimate DC Current Required 20

5. START-UP PROCEDURE 21

5.1. Test Interlocks 21

5.2. Startup of VNX Modules 21

5.3. Minimum Reject Flow Rate 21

5.4. Water Recovery 22

5.4.1. Example calculation of recovery 22

5.4.2. Example calculation of reject flow 22

6. MAINTENANCE AND TROUBLESHOOTING 23

6.1. General Maintenance Guidelines 23

6.2. Approved Cleaning Procedures 23

6.3. Cleaning and Sanitization Prompts 24

6.4. Clean-In-Place (CIP) System Construction 24

6.5. Chemical Cleaning and Sanitization Precautions 26

6.6. Typical Procedure for Cleaning or Sanitization 26

6.7. Cleaning Solution Recipes 28

7. TROUBLESHOOTING 31

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8. SHUTDOWN AND STORAGE 38

8.1. System Shutdown 38

8.2. Startup After Shutdown 38

8.3. Rebuild or Repair 38

8.4. Disposal 38

APPENDIX A: VNX MODULE SPECIFICATIONS 39

APPENDIX B: VNX55 LAYOUT & ELEVATION DRAWING B-1 42

APPENDIX B: VNX ELECTRICAL CONNECTIONS DRAWING B-2 43

APPENDIX C: VNX PORT PVC ADAPTER DRAWING C-1 44

APPENDIX C: VNX PORT PVC PLUG DRAWING C-2 45

APPENDIX C: VNX PORT PP ADAPTER DRAWING C-3 46

APPENDIX C: VNX PORT PP PLUG DRAWING C-4 47

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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 the associated text.

NOTE: Notes are used to add information, state exceptions, and point out areas

that may be of greater interest or importance.

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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.

OPERATING MANUAL REVISION HISTORY

Event Date Description

First publication 03-2018 VNX Family Operation & Maintenance Manual

Revision 1 10-2019

2.2 Added lifting statement for vertical installations

3.3 Added torque specification for terminal strip

Corrected flows in Table 6-1a for 55E and 55EX

Updated Section 4.2 DC Current Required

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1. INTRODUCTION

1.1.VNX55 Product Family Overview

Ionpure VNX modules are the highest flow rate CEDI devices available. Their compact

state-of-the-art design assures ease of installation, maintenance, and service. VNX

modules are available in the following sizes:

Model Number Nominal Flow Description

IP-VNX-MINI-1 52.8 gpm (12 m3/h) Small footprint, enhanced performance

IP-VNX-MAX-1 66 gpm (15 m3/h) High flow, enhanced performance

IP-VNX28EP-2 27.5 gpm (6.25 m3/h) Enhanced performance

IP-VNX55EP-2 55 gpm (12.5 m3/h) Enhanced performance

IP-VNX55E-2 55 gpm (12.5 m3/h) Microelectronics, polishing loop

IP-VNX55EX-2 55 gpm (12.5 m3/h) Microelectronics, makeup

IP-VNX55HH-2 55 gpm (12.5 m3/h) High hardness

IP-VNX15CDIT-2 15 gpm (3.4 m3/h) Thin cell

IP-VNX30CDIT-2 30 gpm (6.8 m3/h) Thin cell

For more information on the VNX module specifications and flow rates, see Section 2.4

and Appendix A of this Manual.

Figure 1-1: Angle and Side views of VNX Modules

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1.2.Using This Manual

Service technicians should review this manual prior to going to the installation 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 VNX

modules. It also contains information on basic troubleshooting (See Section 7).

IONPURE strongly recommends all users read the entire contents of the manual. If the

VNX module is not operating properly after going through the basic troubleshooting

exercises, contact your Local Service Provider.

1.3.Installation Precautions

·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 TO THE DC

POWER SUPPLY HAS FIRST BEEN DISCONNECTED AND

LOCKED OUT ACCORDING TO STANDARD LOCKOUT/

TAGOUT PROCEDURES.

·To minimize the possibility of electric shock, confirm that all ground

wires are properly connected.

·Do not open the VNX module. Opening the module will void the

warranty and cause irreversible damage.

·The module must be operated according to the design

specifications for temperature and humidity.

·Metal piping should never be connected directly to the module.

Non-metallic piping adapters are required at the module inlets and

outlets. It is then allowable to transition to metallic piping.

·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.

·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.

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·Always flush out the piping to remove any debris before operating

the VNX module.

·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.

·Never block off (dead-head) the VNX outlets. Dead-heading the

outlets can result in over-pressurization, leading to permanent

damage.

·Do not operate the module under conditions other than those

stated in the module manual. The prescribed feed water

requirements, 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:

oMake sure all wiring connections are tight.

oTest 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 valve off or plug all inlets and outlets. This is to minimize

bacteria growth and prevent drying of ion exchange resins during shutdown.

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2. PRE-INSTALLATION: PREPARATION & REQUIREMENTS

2.1.Tools Required

·Lifting straps and forklift or block and tackle to move the module into place

·Slip joint pliers, for tightening of plumbing connectors

·Wire cutters/strippers, for wiring connections

·Phillips head screwdriver, to connect wire at terminal strip

2.2.Unpacking and Moving VNX Modules

·After uncrating the module, inspect it for any signs of damage. If damage is apparent,

immediately notify the carrier and your CEDI System Provider.

·The VNX modules can weigh 300-600 lbs. (136-273 kg) dry, depending on size, and

will require mechanical assistance for lifting and moving into position. See Figure 2-1

for one example of how to lift a VNX module.

·For vertical installations the module can be lifted from one end (not shown).

·Ensure that lifting apparatus has appropriate load rating.

Figure 2-1 Lifting VNX module via housing FlexMounts

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2.3.Electrical and Plumbing Connection Requirements

·An electrical junction box is included with all VNX modules, mounted on one of the

VNX endblocks. A single conduit connection is required through a 7/8” (22 mm)

through-hole to provide power to the CEDI module.

·Connection of the DC power supply to the VNX module requires 12 AWG (3.31 mm2)

wire. All wiring should be done in accordance with local electrical codes.

·Ionpure VNX modules have cast metal end blocks with four (4) custom, ACME-thread

FEMALE connection points. These require special plumbing adapters or plugs,

constructed to the drawings provided in Appendix B. The 4 connections are:

oProduct (Dilute) Inlet

oProduct (Dilute) Outlet

oReject (Concentrate) Inlet

oReject (Concentrate)Outlet

·The VNX modules are shipped with PVC piping adapters with 1-1/2” SOC connections

oKit model number IP-VNX-CK-PVC-2, part number W3T17350

·Optional polypropylene adapters with 50 mm butt weld connections are available

oKit model number IP-VNX-CK-PP-2, part number W3T17348

·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 near the module.

oFor sanitary applications, a grounding cap can be used, Ionpure part number

W3T83436, which is actually a ¾” TC cap with a welded stud to be wired to

ground.

oFor non-sanitary applications, a ¼” SS threaded grounding rod can be used,

Ionpure part number W2T211647.

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.

2.4.1. Operating Environment

The VNX module requires indoorinstallation out of direct sunlight. The maximum ambient

temperature should not exceed 113 °F (45° C). The module can tolerate humidity of up

to 90%, as long as condensation does not occur.

2.4.2. Space Requirements

The physical dimensions of the VNX modules are given in appendix A.1. In addition to

the size of the module itself, the arrangement of the piping and the electrical connections

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will determine the amount of space the module needs to operate. This arrangement

varies from site to site. Space should be allowed for module servicing/replacement.

2.4.3. Module Orientation

The VNX modules can be installed vertically or horizontally. If orientated in the vertical

position, the junction box end should be facing down. This is done to remove the

possibility of the junction box flooding. When mounting in the horizontal position, the

modules should be stacked no higher than four (4) modules high.

2.4.4. Electrical Requirements

The VNX module power requirements are listed in Table 2-2. In all cases the cathodes

must be at ground potential. Connections are shown in section 3-3.

Table 2-2. Electrical Requirements for the VNX Modules

NOTE: The 600V DC3 power supply can be used even if required DC Voltage is lower.

This may help protect against upsets due to feed water changes, scaling or fouling.

2.4.5. Feed Water Requirements

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 on site with the feed water requirements listed below.

NOTE: Recycling the VNX reject to the RO feed will cause the CO2load on the VNX to

increase, and may have an impact on the VNX product water quality. Please refer to

VNX Model Nominal Flow Rate DC Volts DC Amps

IP-VNX-MINI 52.8 gpm (12 m3/h) 480 1 - 7

IP-VNX-MAX 66 gpm (15 m3/h) 600 1 - 7

IP-VNX28EP-2 27.5 gpm (6.25 m3/h) 300 1 - 6.6

IP-VNX55EP-2 55 gpm (12.5 m3/h) 300 2 - 13.2

IP-VNX55E-2 55 gpm (12.5 m3/h) 300 10 - 13.2

IP-VNX55EX-2 55 gpm (12.5 m3/h) 300 10 - 13.2

IP-VNX55HH-2 55 gpm (12.5 m3/h) 600 2 – 8.0

IP-VNX15CDIT-2 15 gpm (12.5 m3/h) 600 1 - 6.6

IP-VNX30CDIT-2 30 gpm (12.5 m3/h) 600 2 – 13.2

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Ionpure.com for additional reject stream system design guidance including the following

paper: “Process and System Design for Reliable Operation of RO/CEDI Systems”,

Jonathan Wood and Joe Gifford, International Water Conference, 2004 (Paper 47).

Table 2-3. Feed Water Requirements (except hardness, silica), also see A.3

Parameter EP, Max, Mini, HH E, EX CDIT

Feed water source RO permeate

or DI water 2-pass RO

or DI water RO permeate

FCE (µS/cm) ≤40 µS/cm ≤10 µS/cm ≤100 µS/cm

Iron, manganese, sulfide ≤0.01 ppm ≤0.01 ppm ≤0.01 ppm

Total chlorine (as Cl2)≤0.02 ppm ≤0.02 ppm ≤0.02 ppm

TOC (ppm as C) ≤0.5 ppm ≤0.5 ppm ≤0.5 ppm

Operating pH range 4 – 11 4-11 4 – 11

Feed water temperature

(10°C minimum for VNX-Max) 41 - 113 °F

(5 – 45 °C) 68 – 113 F

(20-45C) 41 - 113 °F

(5 – 45 °C)

Inlet pressure ≤100 psig

(6.9 bar)

≤100 psig

(6.9 bar)

≤100 psig

(6.9 bar)

Table 2-4. Module-Specific Feed Water Hardness and Silica Requirements

VNX Model Silica (as SiO2) Hardness (as CaCO3)

IP-VNX-MINI ≤1.0 ppm ≤1.0 ppm

IP-VNX-MAX ≤1.0 ppm ≤1.0 ppm

IP-VNX28EP-2 ≤1.0 ppm ≤1.0 ppm

IP-VNX55EP-2 ≤1.0 ppm ≤1.0 ppm

IP-VNX55E-2 ≤0.2 ppm ≤0.1 ppm

IP-VNX55EX-2 ≤0.5 ppm ≤0.1 ppm

IP-VNX55HH-2 ≤1.0 ppm ≤2.0 ppm

IP-VNX15CDIT-2 ≤2.0 ppm ≤4.0 ppm

IP-VNX30CDIT-2 ≤2.0 ppm ≤4.0 ppm

2.4.6. Drain Requirements

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

2.5.Flow Rates and Pressure Drops

See Appendix A

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3. VNX MODULE INSTALLATION

3.1.Preparation

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. Use safe lifting practices when moving the module

(see Section 2.2).

·To avoid corrosion, the piping adapters and plugs must be non-metallic.

·Modules are shipped with PVC connection adapters and plugs installed.

·Optional polypropylene PP adapters and plugs are available

·If other adapter types are required, the module end must be made to the dimensions

provided in drawings C-1 through C-4 in Appendix C. This is essential to ensure

proper sealing of the adapter in the endblock.

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

the module (see Figure 3-1). Failure to remove yellow dust plugs can

cause permanent damage to the modules.

Figure 3-1 VNX PVC adapter with yellow shipping plug

3.2.Water Connection Configuration and Fittings

·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 fromcutting 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.

Remove this

yellow dust plug

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Ionpure VNX modules have a cast aluminum endplate with female ACME thread

connections. There are four (4) connection points:

·Product (Dilute) Inlet

·Product (Dilute) Outlet

·Reject (Concentrate) Inlet

·Reject (Concentrate) Outlet

Product and reject port locations are identified with color coded labels affixed near the

appropriate endblock connection points. Product port inlets (I) and outlets (O) are

identified with BLUE labels, and reject port inlets (I) and outlets (O) are identified with

RED labels. Figure 3-2 (below) shows what the labels look like.

Figure 3-2 VNX Port Labels

Detailed dimensions of the VNX module port locations are given in the layout and

elevation drawing in Appendix B, Drawing B-1.

3.2.1. VNX Piping Adapter Sealing Mechanism

The female threads in the VNX endplate are ACME threads. They are NOT TAPERED

pipe threads and the threads DO NOT CREATE the seal, they allow the sealing surfaces

to move towards each other and they hold the piping adapter in place. The seal comes

from the silicone through-port gasket that isolates the endblock and creates a sealing

surface directly to the internal VNX spacer. See Figure 3-3, below.

NOTE: Do NOT use Teflon®tape or any other pipe sealant (such as pipe dope) on the

ACME thread adapters or plugs. The use of these products on the ACME threads will

prevent proper sealing of the adapters or plugs.

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Figure 3-3 VNX Piping Adapter Sealing Mechanism

Do not install O-rings on the circumference of the VNX ACME-thread piping adapters or

plugs. The O-rings make it more difficult to properly tighten these parts.

Tighten the adapter or plug until the gap between the endblock and the “shoulder” on the

piping adapter or plug is between 0.03” (0.76 mm) and 0.06” (1.52 mm). This is shown

in Figure 3-4, below. It should be possible to accomplish this by hand but if necessary a

wrench can be used. You should only need 10-30 ft-lbs (13.6 – 40.7 N-m) of torque.

Figure 3-4 Proper Tightening of VNX Piping Adapter

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3.2.2. VNX Piping Configurations

Because the internal piping of a VNX module can vary depending on model, external

connections can vary as well. Consult the table below for the correct configuration for

your specific VNX module.

Table 3-1 VNX Module Piping Connections

Model Recommended Configuration Comments

IP-VNX28EP-2

IP-VNX55EP-2

IP-VNX55HH-2

IP-VNX15CDIT-2

IP-VNX30CDIT-2

IP-VNX-MAX

IP-VNX-MINI

Product:

Inlet & outlet on same side OR