Pentair Pool Products CodeLine 40S Series User manual

Product Bulletin 96897
TM
CodeLine 40S Series
User’s Guide
DANGER - HIGH PRESSURE DEVICE
This vessel may cause loss of life, severe bodily harm, or property damage if not correctly installed, operated and
maintained. Read and understand all guidelines given in this bulletin before attempting to open, operate or service
this vessel. Failure to follow these guidelines and observe every precaution will result in malfunction and could
result in catastrophic failure. Misuse, incorrect assembly, or use of damaged or corroded components can result
in high-velocity release of the end closure. We recommend that only a qualified technician experienced in servicing
high-pressure hydraulic systems, open, close and service this vessel.
Important Safety Precautions
read, understand and follow every guide-
line in this bulleting. Failure to take every
precaution may void warranty and could
result in catastrophic failure.
Do...
install in an area where a vessel or piping
malfunction that result in water leakage
would not damage sensitive or expensive
equipment, such as electronic components.
Do...
verify that head locking components are
properly placed and secured.
Do...
inspect end closures regularly, replace
deteriorated components and correct
causes of corrosion.
Do...
follow membrane element manufacturer’s
recommendations for loading elements into
the vessel (see Replacing Elements).
Do...
operate vessel at pressures and tempera-
tures in excess of their specific rating.
Do not...
service any component until you verify that
pressure is fully relieved from the vessel.
Do not...
use corroded components. Use of such
components may result in catastrophic
failure.
Do not...
pressurize vessel until after visually
inspecting to ensure that the spiral retaining
ring is correctly installed.
Do not...
tolerate leaks or allow end closures to be
routinely wetted in any way.
Do not...
use excessive silicone lubricant.Do not...
pressurize vessel without element in place
unless permeate ports are plugged
internally.
Do not...
overtighten fittings in ports.Do not...
General Information
The 40S Series Fiberglass RO/UF Pressure Vessel is
designed for continuous, long-term use as a housing
for reverse osmosis and ultrafiltration elements in
typical industrial water treatment systems at pressures
of 300, 450 & 600 psi..
The information and guidelines incorporated in this
User’s Guide are intended only as a supplement to
good industrial practice. Full responsibility for correct
operation and maintenance of vessel remains with the
user.
This guide should be used in conjunction with drawing
numbers 40S30(C):#99311; 40S30(NC):#99312;
40S45(C):#99315; 40S45(NC):#99316, 40S60(C):#99313;
40S60(NC):#99314
When properly installed and maintained, the 40S Series
vessels can be expected to provide safe operation over
a long service life.
User Guide 40S Series Rev. B Updated 07/03/11 Page 1 of 13
RO Pressure Vessels
The 40S Series is designed to accommodate any make
of 4-inch nominal diameter element.
The fiberglass shell can be damaged by rigid clamping,
impact, scratches or abrasion. Metal parts must be
maintained free of corrosion to eliminate potentially
unsafe conditions due to corrosion.
Do not... Use petroleum products on Noryl components.
Do not...
Allow petroleum or silicone based products to
come in contact with membrane elements during
installation or maintenance.
Use the vessel at negative pressureDo not...
Stand or climb on the pressure vessels, or theDo not...
feed / concentrate or permeate ports.

CODED 40S: 300 / 450 / 600 psig
Page 2 of 13
Dwg Ref Qty Per Item # Description Materials
Shell
1 1 Shell Filament Wound epoxy/glass
composite. Head locking grooves
internally wound in place.
2 F/C Port CF8M*A/R
3 A/R F/C Port Seal Ethylene Propylene - Square Cut
4 A/R F/C Port Retainer 300 Series SST
Head
5 2 96803 Bearing Plate 316 Stainless Steel / Equivalent.
6 2 96855 Sealing Plate Engineering Thermoplastic.
7 2 45317 Head Seal Ethylene Propylene - O - Ring
8 2 96807 Permeate Port Engineering Thermoplastic.
9 2 45335 Permeate Port Seal Ethylene Propylene - O - Ring
10 2 45242 Port Retainer 300 Series SST
Head Interlock
11 2 45260 Retaining Ring 316 L Stainless Steel.
Vessel Support
12 3* 45058 Saddle Cast Urethane Elastomer
13 3* 47459 Strap Assy 304 Stainless Steel-PVC Cushion.
Element Interface
14 2 Adapter Engineering Thermoplastic.A/R
15 2 PWT/Adapter sealA/R Ethylene Propylene - O - Ring
* 2 each furnished with length code 1,2 & 3.
Item No. 12 and 13 not shown in the section view
Order
Section

NON-CODED 40S: 300 / 450 / 600 psig
Page 3 of 13
Dwg Ref Qty Per Item # Description Materials
Shell
1 1 Shell Filament Wound epoxy/glass
composite. Head locking grooves
internally wound in place.
2 F/C Port CF8M*A/R
3 A/R F/C Port Seal Ethylene Propylene - Square Cut
4 A/R F/C Port Retainer 300 Series SST
Head
5 2 96827 End Plug Engineering Thermoplastic.
6 2 45317 Head Seal Ethylene Propylene - O - Ring
Head Interlock
7 2 45260 Retaining Ring 316 L Stainless Steel.
Vessel Support
8 3* 45058 Saddle Cast Urethane Elastomer
9 3* 47459 Strap Assy 304 Stainless Steel-PVC Cushion.
Element Interface
10 2 Adapter Engineering Thermoplastic.A/R
11 2 PWT/Adapter sealA/R Ethylene Propylene - O - Ring
* 2 each furnished with length code 1,2 & 3.
Item No. 8 and 9 not shown in the section view
Order
Section

Installation
Opening the Vessel
Regardless of when or by whom your vessel may
have been installed, there are a few quick checks
you should make before use. Check that each
vessel is:
Free to expand under pressure - shell not
clamped rigidly in place, no rigid piping
connections to port fittings.
M o u n t e d w i t h c o m p l i a n t m a t e r i a l
(Polyurethane saddle) between the fiberglass
shell and any rigid frame.
Not used in any way to support other
components such as piping, manifolds
hanging from ports.
WARNING
Relieve pressure from vessel
before beginning this procedure.
Contamination Removal
Metal oxidation products and mineral deposits can
interfere with vessel disassembly. Remove all
foreign matter from both ends off vessel as
follows:
Remove contaminants using a small wire brush
or suitable abrasive (such as medium-grade
TM
ScotchBrite ).
Flush away loosened deposits with clean water.
1.
2.
Removing the Head
The head assembly is shown in Figure 1.
Remove head as follows:
Disconnect permeate piping as required at
nearest convenient joint, being careful not to
place undue stress on the threaded connections
of the plastic permeate port(s).
1.
CAUTION
DO NOT tap on fittings as this
could damage the ports.
Lift the tabbed end of the retaining ring up out of the
stainless steel groove in the shell and then away
from the head so that it rests in the end margin of the
TM
vessel. This is best accomplished by using CodeLine
Removal Tool, part number 50303, which is available
from your supplier. This can also be accomplished
using a screwdriver and a pair of pliers if the tool is
not readily available.
1.
With the removal tool the retaining ring can be lifted
upward by simply rotating the tool counterclockwise
after inserting it over the tab on the retaining ring.
(Use the smaller hole). Hold the tool flat against the
end margin and parallel to the vessel bore. It is then
possible to pull the end of the retaining ring straight
out. The retaining ring may snap back into the groove
if this alignment is not closely adhered to. If the
retaining ring is difficult to remove, try soaking with
TM TM
a release agent such as LPS or WD40 , being care-
ful to avoid any contamination of a membrane
element.
Page 4 of 13
Cleaning inside the vessel
Disconnect Permeate Piping
Remove the Retaining Ring from the groove

Page 5 of 13
Once the retaining ring has been removed, examine
the area for burrs or dings which could damage the
TM
head or membrane. If necessary, use ScotchBrite
or 600 grade sandpaper to smooth the area.
3.
Install a ½”NPT x 6” long nipple into the product
port of the head on one end of the vessel .
1.
Grasp the nipple and pull the head straight out. A
small amount of side-to-side movement may be
necessary to start the end plug moving. Care
should be taken to avoid placing too much stress
on the product port threads.
2.
Repeat above procedure for the opposite end of
the vessel.
4.
Remove the 4” retaining ring from the stainless
groove in the shell by rotating your finger behind
the ring as it continues to exit the groove.
2.
When using screwdriver and pliers, pry the tabbed
end of the retaining ring out of the stainless steel
groove with the tip of the screwdriver. Once the end
of the retaining ring is clear of the groove, grab the
tab with the pliers and pull towards the end of the
vessel until the end of the ring is resting in the end
margin of the shell.
Retaining Ring Removal Tool
Removal of Retaining Ring
Removing Head Assembly
Removing the head assembly
Remove and discard plug seal, taking care not
to scratch or otherwise damage the sealing
surfaces.
3.
As soon as possible after removal, disassemble
and check all head components, as described in
Rebuilding the Head and Refurbishing Parts.
5.

Replacing Elements
NOTE
Always remove and install element in
the direction of feed flow. The feed
end (upstream end) is the end plumbed
most directly to the pump.
Removing Elements
Remove heads from both ends of vessels as
described in Opening the Vessel.
Push element(s) out of vessel from the upstream
end.
1.
2.
Inserting Elements
CAUTION
DO NOT lubricate element seals with a
silicone based material (such as Parker Super
TM
O-Lube , the recommended lubricant
for head seals).
Reinstall head assembly at the downstream end
as described in Closing the Vessel. Make sure the
smaller of the two adapters supplied with the vessel
is installed in the permeate port.
3.
Install interconnectors betwe en mu ltiple
elements as each succeeding element is inserted.
6.
Push each element downstream into shell until
the elements fully engage with the downstream
head. If element is hard to push, make sure the
brine seal is properly installed and you are
pushing from the upstream end.
7.
Lubricate element seal sparingly with the
manufacturer’s recommended lubricant or
with glycerine ( a commercially available
lubricant that will not foul elements).
4.
Insert the element with the brine seal (typically
a U-cup seal) installed on the upstream end with
its lip facing upstream.
5.
CAUTION
System malfunctions and element
damage may result if elements are
installed in the wrong direction.
When the elements are installed, close the vessel
as described in the following section.
8.
Page 6 of 13
The following procedures are provided for information
only. Elements should be installed in accordance with
the element manufacturer’s recommendations. Where
conflicts exist, contact the element manufacturer or
Pentair Water for clarification.
To replace elements, proceed as follows:
For multi-element vessels, remove the intercon-
nectors and retain for reinstallation.
3.
Ensure that heads are available in clean, as-new
condition before proceeding. (If in doubt as to
head condition see section on inspecting parts,
).page 12
1.
Check that all required elements are ready for assem-
bly, with no dings or other damage which could
scratch the inside of the vessel.
2.

Closing the Vessel
Prepare and install head assemblies as described
below.
NOTE
Glycerine is a commercially available lubricant
that will not foul elements. However, silicone
lubricant is recommended for this application.
Refurbish or replace head components as
required to ensure as-new condition. (See
Refurbishing Parts). The PWT O-ring should
be replaced each time.
Remove any residual lubricant from the head and
TM
work a fresh, thin film of Parker Super O-Lube
silicone lubricant into the outer diameter of the
bearing seal plates, where it contacts the plate
seal in the vessel.
1.
3.
Insert elements if not already installed, and
insert longer adapter into the remaining head.
Then install this head in the upstream end of
the vessel, using technique given in steps 4 and 5.
7.
Carefully insert retaining ring into its groove. This
is done by inserting the lead end of the spiral
retaining ring (end without bent tab) into the
stainless steel retaining ring groove located in the
shell, and slowly pushing the remaining turns
into the shell.
5.
Check that the spiral retaining ring is fully seated
in groove. If it is not, remove and check for
foreign materials causing the spiral ring not to
fully seat.
6.
Reconnect piping to vessel, as described in
Refurbishing Parts..
8.
Cover O-rings with a thin, even layer of Parker
TM
Super O-Lube silicone lubricant or the lubri-
cant recommended by your element supplier.
2.
CAUTION
DO NOT pressurize vessel
without element(s) properly installed.
Page 7 of 13
Install adapter into one end plug. At
downstream end of vessel, orient end plug
ports into desired position and push plug fully
into vessel. A sharp, forceful thrust may be
needed to enter plug seal into the vessel bore.
4.
Installation of the End Plug Assembly
into the vessel
CAUTION
If vessel is to be pressurized above 125 psi
without elements installed, the central
permeate port should be plugged from the
inside. Solid adapters are available for this
purpose.
Inserting Retaining Ring into the groove
Retaining ring seated in the grooove

CAUTION
DO NOT tolerate any leaks. Leaks can result
in corrosion and eventual catastrophic vessel failute
If threading fittings into the head, avoid
overtightening. Hand tight plus approximately
1/4 turn should produce a satisfactory seal. If
leak occur on pressurization, a small amount of
further tightening may be required.
11.
Pressurize vessel. Inspect for leaks at connections
to the vessel and all around the vessel itself. If
any leaks occur, release pressure from vessel and
tighten fittings as necessary. Then pressurize vessel
and check for leaks again.
12.
CAUTION
Be sure to hold feed/concentrate port
with a wrench when tightening fittings.
Head Disassembly - Coded
NOTE
Head Rebuilding should be performed in
a clean work area. Dust or dirt on O-rings
or other parts can scratch inner surfaces,
with subsequent leakage.
Using a small screwdriver or similar tool
remove the Plug Seal. However do not damage the
sealing surface in any way as it may lead to leakage.
1.
Removal of the Head Seal
Remove Port Retainer from its groove in the Permeate
Take care not to scratch the hard-anodized
the bearing plate.
port.
surface of
2.
Removal of the Port Retainer Ring
Bearing Plate is held in the head assembly by
Port Retainer, Once the Port Retainer is removed
the bearing plate is free to move.
3.
Removal of the Bearing Plate
Remove the Sealing Plate by pressing it out
from one end of the permeate Port.
4.
Removal of the Sealing Plate
Page 8 of 13

Head Disassembly - Coded
Remove the Permeate Port Seal from the Sealing
Plate. However, do not damage the sealing surface
in any wa y as it may lead to leakage.
5.
Removal of the Permeate Port Seal
Remove the PWT / Adapter Seal from the permeate
Port using a small screw driver or similar tool.
However, do not damage the sealing surface
in any wa y as it ma y lead to leakage.
6.
Removal of the PWT/Adapter Seal
NOTE
A small screw driver or similar tool may be used
to remove the O-rings.
However, do not damage the sealing surfaces in any
way as it may lead to leakage.
It is recommended that all seals be replaced each time
the head is assembled.
Page 9 of 13
Head Disassembly - Non Coded
Using a small screwdriver or similar tool
remove the Head Seal. However do not damage the
sealing surface in any way as it may lead to leakage.
1.
Remove the PWT / Adapter Seal from the End Plug
using a small screw driver or similar tool.
However, do not damage the sealing surface
in any wa y as it ma y lead to leakage.
2.
Removal of the Head Seal Removal of the PWT/Adapter Seal

Fig 1. Head Component Identification 40S - Head Disassembled
40S Coded Head Disassembled 40S Non Coded Head Disassembled
Page 10 of 13
Head Disassembly
Head Assembly - Coded
Head must be carefully assembled
following these instructions. Incorrect
assembly can result in
CATASTROPHIC failure.
WARNING
Use only head components in as-new condition. Use
new O-rings each time the head is assembled.
1.
Cover O-rings with a this even layer of Parker Super
TM
O-Lube silicon lubricant or the lubricant recomm-
ended by your element supplier.
2.
Lubricating Plug seals and O-rings
NOTE
Glycerine is a commercially available
lubricant that will not foul elements.
However, silicon lubricant is
recommended for this application.
Assemble the Permeate Port seal in the Sealing plate
groove.
3.
Inserting Permeate Port seal

Head Assembly - Coded
Assemble the PWT / Adapter seal in the Perm-
eate Port seal groove.
4.
Inserting PWT / Adapter Seal
Insert the port retainer end of the permeate
port through the sealing plate. Press firmly
till permeate port bottoms on the sealing
Plate. Please ensure that the side of the sealing
Plate with the Permeate Port seal faces the
permeate port hub.
5.
Installing Sealing Plate
Page 11 of 13
Place the bearing plate over the sealing plate
through the permeate port, ensure that the
port retainer groove on the permeate port is
exposed.
6.
Snap the port retainer ring into the groove
in the permeate port, up against the face
of the bearing plate.
7.
Examine the assembly to ensure that the mating
faces of the Sealing and Bearing Plate are in complete
contact. If they are not, dis-sassemble the head and
start over.
8.
When head is correctly assembled, insert the Head
Seal O-ring into the groove on the outside diameter
of the Seal Plate.
9.
Protect heads from contamination until ready to
assemble into the vessel(s).
10.
Installing Port Retainer
Installing Bearing Plate

Page 12 of 13
Refurbishing Parts
Plastic parts: examine for cracking, softening or
discoloring. This may indicate chemical attack of the
material. Defective parts must be replaced. Alternate
material may be required. Contact your supplier or
TM
CodeLine for assistance.
Bearing/Sealing Plate and Permeate port:
cracked, discolored, sealing areas damaged
(chipped or gouged), port threads stripped or
cross-threaded.
Inspecting Parts
Metal parts: check for corrosion, scratches, dents,
cracks or other damages to insert ring and spiral
retaining ring.
Other parts: examine for any damage, such as
gouges, chips or cracks, that could affect structural
strength or sealing characteristics. The following are
some examples of defects that may require replace-
ment of the affected part.
Spiral Retaining rings: are the sole means of
end plug retention. Parts bent, corroded,
cracked or damaged in any way must not be
used. Carefully check for hairline cracks.
Using a fine wire brush, remove any large
deposits from locking ring groove in the shell.
1.
TM
Using a medium or finer grade of ScotchBrite
and mild soap solution, clean the inside of the
vessel at least 4 inches in from each end. Take
care not to damage feed/concentrate port and its
respective seal.
2.
Use clean water to rinse away all loosened
deposits and soap residue.
3.
Refurbishing Shell
Examine inside of vessel for scratches, gouges,
or other imperfections that could prevent proper
sealing. If such areas exist and leaks are observed
when the vessel is placed back in service , the
shell may need to be replaced.
4.
Remove any large deposits from metal parts
using a wire brush.
1.
Refurbishing Other Parts
Scrub the entire surface with medium grade
TM
ScotchBrite until all contaminants are removed.
2.
Rinse parts clean with fresh water and dry.3.
Inspect all parts for serviceability as specified
above.
4.
Head Assembly - Non Coded
Install the Head Seal on the End Plug as Shown
in the picture
1.
Installing Head Seal
Install the in the End Plug as
Shown in the picture
PWT / Adapter Seal2.
Installing PWT / Adapter Seal

Refurbishing Parts
CAUTION
Use of components damaged by corrosion
can cause catastrophic failure.
Use a wire brush to remove all foreign matter
from threads on pipe fittings.
1.
Remaking Pipe Connections
to Permeate Port
TM
Apply non-hardening thread sealant or Teflon
tape to fitting and install in permeate port. Tighten
fitting a maximum one quarter-turn past hand
tight; the plastic port could be damaged if fittings
are over-tightened.
2.
Fit head and spiral retaining ring as described
in Closing the Vessel (page 7).
3.
Follow steps 1 & 2 above. Be sure to hold feed/
concentrate port with a wrench when tightening
fitting. Movement of the port could damage
shell and/or port.
1.
Remaking Pipe Connections
to Feed/Concentrate Port
Replace all parts that cannot be restored to as-new
condition.
Part Replacement
Replace any parts showing signs of structural
damage or corrosion.
Seals should be replaced as necessary each time the
vessel is serviced. Any parts that need to be replaced
are ava ilabl e from yo ur suppl ier or from
TM
CodeLine .
Page 13 of 13
Shimming
Shutdown the system and remove both of the
vessel fibreglass endcaps.
1.
Drain the vessel.2.
Check the location of the membrane column on
each end of the vessel.
3.
Re-install the end cap on the feed end and make
sure that you can get the end cap in far enough
to get the spiral ring in.
4.
A. You want to look at the distance that the face
of the membrane is from the ramp on the counter
bore of the vessel. Push the membrane column
from the feed so that the brine seal has sufficient
engagement to the 4.00” dia. bore of the vessel.
NOTE
The membrane should be flush to the
counter bore ramp.
Go around to the reject end / downstream end
and remove the square head seal.
5.
Remove the adapter6.
Flush cut membrane or Type II style adapter: Put
a shim or two on the membrane side of the adapter
and re-insert the adapter into the membrane.
Membrane with male product water tube or Type I
adapter: Leave the adapter attached to the membrane
and place a shim on the end of the adapter inserted into
the permeate port. Insert end cap assembly, engage the
adapter and see how far you can push the head assembly
into the vessel.
If it can go deep, check the distance between the back of
the groove on the stainless steel insert ring on the vessel
n
and the fiberglass end cap. If you have at least .150 gap,
take the head out and put another shim on. Repeat the
shimming until you reach the point where you can just
get the end cap and spiral locking ring to engage. (Use no
more than four spacers).
Reinstall end cap square head seal and reinstall
end cap.
7.
Re-start system.8.
NOTE
Ease the water pressure up on start up.
You don’t want to damage the downstream
adapter by ramming the pressure into it.
Run the system and check the water quality to
make sure that your seals are all in the proper
places.
9.