Ion Technologies IT- DS05-S Operation & Maintenance Manual
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Ion Technologies IT- DS05-S Operation & Maintenance Manual

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IONTECH
®
IT- DS
EDI Modules
Operation
&
Maintenance
Manual
IT-DS
Sept 2015
Revision 0
Manual Covers
Part#:
IT- DS05-S
IT- DS10-S
IT- DS20-S
IT- DS30-S
IT- DS50-S

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Summary of Contents for Ion Technologies IT- DS05-S

  • Page 1 IONTECH ® IT- DS EDI Modules Operation & Maintenance Manual IT-DS Sept 2015 Revision 0 Manual Covers Part#: IT- DS05-S IT- DS10-S IT- DS20-S IT- DS30-S IT- DS50-S...

  • Page 2: Table Of Contents

    IONTECH ® IT- DS EDI Modules DISCLAIMER STATEMENT PROPRIETARY RIGHTS STATEMENT OPERATING MANUAL REVISION HISTORY INTRODUCTION 1 .1 IT-DS Module Overview 1 .2 Using this Manual 1 .3 General Installation Precautions 1 .4 Operating Precautions 1 .5 Shutdown Precautions PRE-INSTALLATION PREPARATION & REQUIREMENTS 2 .1 Tools and Equipment 2 .2...
  • Page 3 IONTECH ® IT-DS EDI Modules 3 .5 START-UP Procedure 3.5.1 Start-up IT-DS module 3 .6 Recovery, Silica and Hardness MAINTENANCE AND TROUBLESHOOTING 4 .1 General Maintenance Guidelines 4.1.1 Operating Data Log Sheets 4.1.2 Periodic Maintenance 4 .2 Specific Maintenance Guidelines 4.2.1 Cleaning Circumstances 4.2.2 Sanitization Circumstances 4.2.3 Required Cleaning and Sanitizing Equipment...

  • Page 4: Disclaimer Statement

    IONTECH ® IT-DS EDI Modules 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.

  • Page 5: Operating Manual Revision History

    IONTECH ® IT-DS EDI Modules OPERATING MANUAL REVISION HISTORY EVENT DATE DESCRIPTION Original publication September 2010 Operation & Maintenance Manual IT-DS MAN Rev 0...

  • Page 6: Introduction

    Table 1-1: Model numbers and nominal flow rates. Moduel Number Nominal Flow Description IT- DS05-S 2 gpm [0.44 m /hr] Single IT-DS Type – 4 Cell IT- DS10-S 5 gpm [1.1 m /hr] Single IT-DS Type –...

  • Page 7: Using This Manual

    IONTECH ® IT- DS EDI Modules Figure 1-2 Angle View IT-DS module 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.
  • Page 8 IONTECH ® IT-DS EDI Modules DURING SHIPMENT, THE PRESSURE FROM THE INCOMING WATER CAN CAUSE PERMANENT DAMAGE. SEE SECTION 3.2 BOLT TORQUE MUST BE CHECKED AND THE MODULE TIGHTENED AS REQUIRED BEFORE FLOWING WATER INTO THE MODULE. REFERRING TO FIGURE 3-1 AND TABLE 3-1, TIGHTEN AS REQUIRED.

  • Page 9: Operating Precautions

    IONTECH ® IT-DS EDI Modules  Installation of the IT-DS 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 IT-DS MODULE UNTIL PROPER FLOW AND PRESSURE HAVE FIRST BEEN CHECKED AND VERIFIED.

  • Page 10: Electrical And Plumbing Supplies

    IONTECH ® IT-DS EDI Modules  Screwdrivers (flat blade and Phillips head)  IT-DS module handles for moving & positioning unit (IONTECH part number IT-DSHANDLES) 2.2 Electrical and Plumbing Supplies The amounts, sizes, and types of these supplies will vary from site to site. Check before hand to determine the site needs.

  • Page 11: Space Requirements

    Figure 2-2. Figure 2-2 Module Grounding Requirements Table 2-1 IT-DS Series Power Requirements Module Design Design Type DC volts DC Amps IT- DS05-S 0~55 IT- DS10-S 0~135 IT- DS20-S 0~240 IT- DS30-S 0~320 IT- DS50-S 0~400 2.4.4 Feed Water Requirements - RO Permeate...

  • Page 12: Drain Requirements

    IONTECH ® IT-DS EDI Modules Table 2-2 Feed Water Specifications Feed Water Source RO permeate Feed Water Conductivity Equivalent, < 40 μS/cm including CO Silica (SiO < 1 ppm Iron (as Fe, Mn, S) < 0.01 ppm Maximum Total Chlorine (as Cl) <...

  • Page 13: Checking Module Torque - First Time Operation

    IONTECH ® IT-DS EDI Modules 3.2 Checking Module Torque - First time operation If the nuts on the threaded tie bars have loosened during shipment, the pressure from the incoming water can cause permanent damage. Therefore the bolt torque must be checked and the module tightened as required before flowing water into the module.
  • Page 14 IONTECH ® IT-DS EDI Modules Tightening End Plate Tie-bar Nuts Sequence: Figure 3-1 shows the sequence in which to tighten the tie bars. In other words, start the tightening process with # 1, and finish with # 14. Torque Specification: Table 3-1 gives the torque specification for each tie-bar, as numbered in Figure 3-1.

  • Page 15: Connect Plumbing Fittings

    IONTECH ® IT-DS EDI Modules 3.3 Connect Plumbing Fittings Make sure all upstream pretreatment equipment and piping have been thoroughly flushed with particle-free water before connecting them to the IT-DS Module. Pre-Flushing - Make sure all upstream pretreatment equipment and piping have been thoroughly flushed with particle-free water before connecting them to the IT-DS Module.

  • Page 16: Electrical

    IONTECH ® IT-DS EDI Modules 3.4 Electrical 3.4.1 Electrical Precautions Do not run AC and DC wiring within the same conduit. This may cause interference and lead to malfunctions. Disconnect power before opening any enclosure and follow acceptable Lockout/Tagout procedures when working on the system. All wiring done in the field must conform to local electrical codes.
  • Page 17 IONTECH ® IT-DS EDI Modules NOTE: A carbon dioxide test kit is necessary to measure the CO2 concentration in the feed water. The DC current set point is determined based on the following site conditions: • Feed water conductivity • Feed water carbon dioxide concentration •...

  • Page 18: Start-Up Procedure

    IONTECH ® IT-DS EDI Modules NOTE: The above calculations assume 20% current efficiency, which is suitable for many applications. However, certain applications, such as those requiring high silica removals, may require operating at 10% current efficiency, or two times the amperage calculated above.

  • Page 19: Maintenance And Troubleshooting

    IONTECH ® IT-DS EDI Modules For recovery of 90-95%, feed water silica must be  1 ppmasSiO Table 3-3 Minimum Concentrate Flow Rates Module Type No. cells Minimum Concentrate Flow Rate IT-DS05-S 0.07 gpm [16.2 lph] IT-DS10-S 0.16 gpm [35.6 lph] IT-DS20-S 0.27 gpm [61.4 lph] IT-DS30-S...

  • Page 20: Periodic Maintenance

    IONTECH ® IT-DS EDI Modules manual should contain log sheets more appropriate for your particular system. However, the items in bold must be filled out to maintain module warranty. 4.1.2 Periodic Maintenance Perform the following tests at least once every six months. Check the Troubleshooting portion of this Section for any recommendations that are not listed below.

  • Page 21: Required Cleaning And Sanitizing Equipment

    IONTECH ® IT-DS EDI Modules environment that does not promote bacterial growth. However, high feed water bacterial counts may necessitate sanitization. 4.2.3 Required Cleaning and Sanitizing Equipment The following cleaning equipment and descriptions must be constructed of materials compatible with the recommended cleaning solutions. During cleaning, the following equipment is required: Tank Connect a 50-gallon (190-liter) or larger tank to IT-DS system.

  • Page 22: System Preparation For Cleaning Or Sanitization

    IONTECH ® IT-DS EDI Modules 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. 4.2.4 System Preparation for Cleaning or Sanitization NOTE: The following cleaning procedures are based on the piping set up shown in Figure 4-1. If your piping setup is different, you may need to alter these procedures.

  • Page 23: Cleaning And Chemical Sanitization Procedures

    IONTECH ® IT-DS EDI Modules 4.3 Cleaning and Chemical Sanitization Procedures • Avoid direct skin contact with cleaning chemicals. Wear safety glasses and protective clothing. • Pressure test the cleaning skid with water before adding chemicals to the tank. • Flush all hoses and tank with clean water BEFORE adding chemicals.

  • Page 24: Cleaning With 2.0% Hydrochloric Acid (Hcl)

    IONTECH ® IT-DS EDI Modules NOTE: If you are unsure whether the module is scaled or organically fouled, clean first with brine/caustic and then follow with the cleaning hydrochloric acid. 4.3.1 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.

  • Page 25: Cleaning With 5% Brine/1% Caustic Solution

    IONTECH ® IT-DS EDI Modules This salt flush rinses the cleaning solution from the module, and returns the ion exchange resin to the sodium and chloride forms. Chemicals necessary IT-DS05-S IT-DS10-S IT-DS20-S IT-DS30-S IT-DS50-S for Step 2 (5% NaCl) 12 gal 24 gal 36 gal 60 gal...

  • Page 26: Cleaning Or Sanitizing With Sodium Percarbonate

    IONTECH ® IT-DS EDI Modules Table 4-3 Brine / Caustic Cleaning Chemicals Chemicals necessary IT-DS05-S IT-DS10-S IT-DS20-S IT-DS30-S IT-DS50-S for Step 1- brine/caustic 33 gal 45 gal Water (RO permeate or 6.5 gal 13 gal 20 gal (125 (169 (25 liters) (50 liters) (75 liters) CEDI prod)
  • Page 27 IONTECH ® IT-DS EDI Modules Do not use powdered sodium percarbonate. It may contain impurities that can 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.
  • Page 28 IONTECH ® IT-DS EDI Modules Chemicals necessary IT-DS05-S IT-DS10-S IT-DS20-S IT-DS30-S IT-DS50-S for Step 2 (Water Flush) 12 gal 24 gal 36 gal 60 gal 90 gal Water (RO permeate or (135 (225 (335.5 CEDI prod) liters) liters) liters) liters) liters) Fill the tank with the required amount of water.

  • Page 29: Cleaning Or Sanitizing With Peracetic Acid

    IONTECH ® IT-DS EDI Modules Chemicals necessary IT-DS05-S IT-DS10-S IT-DS20-S IT-DS30-S IT-DS50-S for Step 4 (5% NaCl) 12 gal 24 gal 36 gal 60 gal 90 gal Water (RO permeate or (135 (225 (335.5 CEDI prod) liters) liters) liters) liters) liters) 5 lbs 10 lbs...
  • Page 30 IONTECH ® IT-DS EDI Module Chemicals necessary IT-DS05-S IT-DS10-S IT-DS20-S IT-DS30-S IT-DS50-S for Step 1 (5% NaCl) 12 gal 24 gal 36 gal 60 gal 90 gal Water (RO permeate or (135 (225 (335.5 CEDI prod) liters) liters) liters) liters) liters) 5 lbs 10 lbs...
  • Page 31 IONTECH ® IT-DS EDI Modules Chemicals necessary for Step 3 (Peracetic IT-DS05-S IT-DS10-S IT-DS20-S IT-DS30-S IT-DS50-S Acid) 33 gal 454 gal 6.5 gal 13 gal 20 gal Water (RO permeate (125 (200 (25 liters) (50 liters) (75 liters) or CEDI prod) liters) liters) 0.07 gal...

  • Page 32: Cleaning And Sanitizing With Multiple Cleaning Agents

    IONTECH ® IT-DS EDI Modules After flushing all residual cleaning solutions from the system follow the initial start-up procedures in Section 3.5 of this manual. Start without the DC power applied to the IT-DS module for five minutes, then turn on the DC power at normal operating voltage and amperage.

  • Page 33: Troubleshooting

    IONTECH ® IT-DS EDI Modules 4.4 Troubleshooting The troubleshooting chart in this Section is a diagnostic guide. If the IT-DS 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.
  • Page 34 IONTECH ® IT-DS EDI Module IT-DS MODULE LOG SHEET Customer Name: _ _ Module Serial Number: _ _ DATE* TIME OF DAY* FEED WATER TEMPERATURE* ℃ FEEDWATERTOTAL HARDNESS ppm CaCO FEED WATER TOTAL CHLORINE ppm as Cl FEED CARBON DIOXIDE ppm as CO FEED CONDUCTIVITY μmho/cm...
  • Page 35 IONTECH ® IT-DS EDI Modules Troubleshooting Flow Chart - Increase in DC Volts Page 1 of 1 START HERE Are any DC wires Tighten connections loose? Feed Increase in DC voltage water temp is normal drop? Acid clean, Excess reduce EDI feed hardness in hardness and /or EDI reject?
  • Page 36 IONTECH ® IT-DS EDI Modules Troubleshooting Flow Chart - Low EDI Product or Reject Flow Page 1 of 1 START HERE Product Recalibrate or replace flowmeter flow meter incorrect? Clean RO or increase RO pressure making too little or increase RO feed water? temperature EDI control...
  • Page 37 IONTECH ® IT-DS EDI Modules Troubleshooting Flow Chart - Low EDI Product Water Quality Page 1 of 3 START HERE Check IP-Pro: Adjust DC amperage feed TDS is desired quality Up for higher TDS changed? possible? Reduce TDS (clean or replace RO membranes) or lower EDI prod flow...
  • Page 38 IONTECH ® IT-DS EDI Modules Troubleshooting Flow Chart - Low EDI Product Water Quality Page 2 of 3 Continued from previous flowchart Check IP-Pro: Increase Product flow is desired quality DCamperage increased? possible? Reduceflow or reduce feed conductivity equivalent Seeseparate HaveDC volts troubleshooting Go to chart for...
  • Page 39 IONTECH ® IT-DS EDI Modules Troubleshooting Flow Chart - Low EDI Product Water Quality Page 3 of 3 Continued from Previous Flowchart Clean EDI with product flow NaCl/NaOH and decreased? Contact IONTECH Technical Removed particulates Support Did cleaning and/or biofilm: www.Iontechbj.com restore flow? review process...

  • Page 40: Shutdown And Storage

    IONTECH ® IT-DS EDI Modules 5 Shutdown and Storage This section contains shutdown procedures for a IT - DS module. Under certain circumstances, bacterial growth can occur quickly in water left stagnant within each module and the overall system. 5.1 System Shutdown Shut off feed water to IT - DS module(s) Drain standing water out of IT - DS module(s) Close isolation valves to prevent evaporation of water in membranes and resins.

  • Page 41: Appendix A: It-Ds Module Specifications

    IONTECH ® IT-DS EDI Modules Appendix A: IT-DS Module Specifications A. 1 Dimensions and Weight Dimensions, IT-DS05-S IT-DS10-S IT-DS20-S IT-DS30-S IT-DS50-S Weight 605.5mm 605.5mm 605.5mm 605.5mm 605.5mm Height: （23.8 in） （23.8 in） （23.8 in） （23.8 in） （23.8 in） 318.4mm 318.4mm 318.4mm 318.4mm 318.4mm...

  • Page 42: Appendix B: Junction Box Electrical Connections It-Ds

    IONTECH ® IT-DS EDI Modules Appendix B: Junction Box Electrical Connections IT-DS Ground Terminal Cathode Anode DC Power IT-DS MAN Rev 0...

  • Page 43: Appendix C : Layout And Elevation Drawing It-Ds

    IONTECH ® IT-DS EDI Modules Appendix C : Layout and Elevation Drawing IT-DS IT-DS MAN Rev 0...

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