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Summary of Contents for IONPURE IP-LXM04HI-3
- Page 1 ® IONPURE LX-HI CEDI Modules Operation & Maintenance Manual IP-LX3HIMAN June, 2014 Revision H Manual Covers Part#: IP-LXM04HI-3 IP-LXM10HI-3 IP-LXM18HI-3 IP-LXM24HI-3 IP-LXM30HI-3 IP-LXM45HI-3 10 TECHNOLOGY DRIVE LOWELL, MASSACHUSETTS 01851 TEL: (866) 876-3340 EMAIL: ionpure@evoqua.com...
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Page 2: Table Of Contents
® IONPURE LX-HI CEDI Modules TABLE OF CONTENTS DISCLAIMER STATEMENT PROPRIETARY RIGHTS STATEMENT OPERATING MANUAL REVISION HISTORY INTRODUCTION LX Module Overview Using this Manual General Installation Precautions Operating Precautions Shutdown Precautions PRE-INSTALLATION PREPARATION & REQUIREMENTS Tools and Equipment Electrical and Plumbing Supplies... - Page 3 ® IONPURE LX-HI CEDI Modules START-UP Procedure 3.5.1 Start-up LX module Recovery, Silica and Hardness MAINTENANCE AND TROUBLESHOOTING General Maintenance Guidelines 4.1.1 Operating Data Log Sheets 4.1.2 Periodic Maintenance Specific Maintenance Guidelines 4.2.1 Cleaning Circumstances 4.2.2 Sanitization Circumstances 4.2.3 Required Cleaning and Sanitizing Equipment 4.2.4...
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Page 4: Disclaimer Statement
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. -
Page 5: Operating Manual Revision History
® IONPURE LX-HI CEDI Modules OPERATING MANUAL REVISION HISTORY EVENT DATE DESCRIPTION Original publication June 2004 Operation and maintenance instructions Rev A October 2004 Modified flow rates for cleaning Section 4.0, Revised Appendix B Rev B January 2005 Changed torque sequence... -
Page 6: Introduction
Table 1-1: Model numbers and nominal flow rates. Order Number Model Number Nominal Flow Description Single LX Type – 4 Cell W3T17316 IP-LXM04HI-3 2 gpm [0.44 m /hr] W3T17287 IP-LXM10HI-3 Single LX Type – 10 Cell 5 gpm [1.1 m /hr] Single LX Type –... -
Page 7: Using This Manual
CEDI modules. It also contains information on basic troubleshooting. (See Section 4.5) IONPURE strongly recommends all users read the entire contents of the manual. If the LX Series module is not operating properly after going through the basic troubleshooting exercises, contact your local service provider. -
Page 8: Operating Precautions
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: ... -
Page 9: Pre-Installation Preparation & Requirements
For sanitary applications, a grounding cap can be used, IONPURE part number W3T83436, which is actually a 3/4” TC cap with a welded stud to be wired to ground. For non- sanitary applications, a 1/4” SS threaded grounding rod can be used, IONPURE part number W2T211647 (see Figure 2-1). -
Page 10: Inspect The Module
2.4.3 Electrical Requirements Power requirements for the LX modules are listed in Table 2-1 Connections using Ionpure® power controller are shown in Figure 2-2 and Appendix B. If using third party power supplies ensure that the local earth ground and cathode are at the same electrical potential to ensure safe operation and avoid electrode corrosion. -
Page 11: Feed Water Requirements - Ro Permeate
Note: Recycling the LX reject to the RO feed will cause the CO load on the LX to increase, and may have an impact on the LX 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”... -
Page 12: Lx Module Installation & Operation
® IONPURE LX-HI CEDI Modules 3 LX Module Installation & 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. - Page 13 (cathode) end of the module. Set the torque wrench to 10 ft-lbs. Using the 19 mm extra deep socket (IONPURE part number W2T210908) mounted on the torque wrench and turn all 14 tie-bar hex nuts (anode end) to 10 ft-lbs following the sequence in Fig.
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Page 14: Connect Plumbing Fittings
® IONPURE LX-HI CEDI Modules 3.3 Connect Plumbing Fittings Pre-Flushing - Make sure all upstream pretreatment equipment and piping have been thoroughly flushed with particle-free water before connecting them to the LX Module. Flushing removes any particles left in the piping from cutting and assembly. If particles remain, they could plug the small internal passages inside the LX Module. -
Page 15: Electrical
® IONPURE LX-HI CEDI 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. - Page 16 ® IONPURE LX-HI CEDI Modules Set the electrical current at the specific setting required to meet product water quality specifications as estimated below. The DC current set point is determined based on the following site conditions: • Feed water conductivity in µS/cm.
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Page 17: Start-Up Procedure
Adjust the DC power supply to the current setting calculated in Section 3.4.3. Or use the DC Startup Current Calculator available on Ionpure.com. Test all flow switches and interlocks to ensure LX DC power will shut off when flow is interrupted. -
Page 18: Maintenance And Troubleshooting
® IONPURE LX-HI CEDI Modules softening or with two-pass RO. In addition there is a minimum reject (concentrate) flow with requirements listed below in Table 3-3. Therefore, 95% recovery is not always attainable for less than nominal product flow rates. -
Page 19: General Maintenance Guidelines
® IONPURE LX-HI CEDI Modules 4.1 General Maintenance Guidelines 4.1.1 Operating Data Log Sheets LX 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 this section 4.1.1. -
Page 20: Sanitization Circumstances
Ionpure recommends a polypropylene high quality 5 micron nominal (90% efficiency) depth filter cartridge for the cleaning skid arrangement. Filter materials must be compatible with the cleaning and sanitization fluids. -
Page 21: System Preparation For Cleaning Or Sanitization
® IONPURE LX-HI CEDI Modules Table 4-1 Recommended Cleaning Flow Rates per LX Modules Flow Rates (gpm) Compartment LX-4 HI LX-10 HI LX-18 HI LX-24 HI LX-30 HI LX-45 HI Product 22.5 Reject 11.25 (Concentrate) Pump 13.5 22.5 33.75 Capacity Use the highest flow rates possible up to the values above. -
Page 22: Cleaning And Chemical Sanitization Procedures
® IONPURE LX-HI CEDI Modules Figure 4-1 Typical cleaning skid arrangement 4.3 Cleaning and Chemical Sanitization Procedures 1. Avoid direct skin contact with cleaning chemicals. Wear safety glasses and protective clothing. 2. Pressure test the cleaning skid with water before adding chemicals to the tank. -
Page 23: Cleaning With 2.0% Hydrochloric Acid (Hcl)
® IONPURE LX-HI CEDI Modules Make sure the DC power is off before cleaning. Do not run a cleaning solution through the system when DC power is applied to the module. The system can be cleaned and sanitized with any of five (6) different solutions, depending on what needs to be removed: ... - Page 24 ® IONPURE LX-HI CEDI Modules STEP 1: Recirculating The HCl Solution NOTE: The quantities in Table 4-2 represents 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.
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Page 25: Cleaning With 5% Brine/1% Caustic Solution
® IONPURE LX-HI CEDI Modules Remove product and reject outlet lines from the cleaning tank, and direct to drain. Confirm the discharge and drain valves are closed. Fill the tank with the water. Completely open the pump suction valve and the by-pass valve. - Page 26 ® IONPURE LX-HI CEDI Modules Table 4-3 Brine / Caustic Cleaning Chemicals Chemicals necessary for Step LX-4 HI LX-10 HI LX-18 HI LX-24 HI LX-30 HI LX-45 HI 1- brine/caustic Water (RO permeate or 6.5 gal 13 gal 20 gal...
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Page 27: Cleaning Or Sanitizing With Sodium Percarbonate
® IONPURE LX-HI CEDI Modules 4.3.3 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 can harm the module. - Page 28 ® IONPURE LX-HI CEDI Modules STEP 2: Water Flush To Drain Water flush rinses the sodium chloride solution from the module before cleaning solution is introduced. Chemicals necessary for Step 2 (Water LX-4 HI LX-10 HI LX-18 HI LX-24 HI...
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Page 29: Cleaning Or Sanitizing With Peracetic Acid
® IONPURE LX-HI CEDI Modules STEP 4: Sodium chloride Flush To Drain This sodium chloride flush rinses the cleaning solution from the module and returns the ion exchange resin to the sodium and chloride forms. Chemicals necessary LX-4 HI LX-10 HI... - Page 30 ® IONPURE LX-HI CEDI Modules An initial sodium chloride flush A water flush The Peracetic Acid cleaning A second sodium chloride flush A final water flush STEP 1: Initial Sodium chloride Flush To Drain This initial 5% NaCl rinse removes any metal ions, particularly calcium and magnesium ions, from the module.
- Page 31 ® IONPURE LX-HI CEDI Modules STEP 3: Sanitization Solution Recirculation and Soak This step sanitizes the system. Chemicals necessary for LX-4 HI LX-10 HI LX-18 HI LX-24 HI LX-30 HI LX-45 HI Step 3 (Peracetic Acid) Water (RO permeate or 6.5 gal...
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Page 32: Cleaning And Sanitizing With Multiple Cleaning Agents
® IONPURE LX-HI CEDI Modules Turn off the cleaning pump. Close the discharge valve. Drain the tank following all local discharge limitations. STEP 5: Water Flush to Drain This step flushes the cleaning solution out of the system, and prepares the system for return to operation. -
Page 33: Hot Water Sanitization
Step 1: Hot water Introduction NOTE: The following cleaning procedures are based on the piping setup shown in Figure 4.1. Many other sanitization configurations are possible. If uncertain about the suitability of a sanitization configuration, contact Ionpure Technical Support. (866) 876-3340 IP-LX3HIMAN Rev H... - Page 34 ® IONPURE LX-HI CEDI Modules NOTE: With the LX-HI model it is not necessary to gradually heat up before or cool down after hot water sanitization. 1. Follow the instructions in section 4.2.4 to prepare the module for cleaning. 2. Confirm the drain valve is closed.
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Page 35: Troubleshooting
® IONPURE LX-HI CEDI Modules 4.5 Troubleshooting The troubleshooting chart in this Section is a diagnostic guide. If the LX system does not respond to the recommended solutions, do not attempt further repairs. Call your Local Service Provider. Before calling: ... - Page 36 ® IONPURE LX-HI CEDI Modules LX MODULE LOG SHEET Customer Name: ___________________________Module Serial Number: _____________ DATE TIME OF DAY °C FEED WATER TEMPERATURE ppm CaCO FEED WATER TOTAL HARDNESS ppm as Cl FEED WATER TOTAL CHLORINE FEED CARBON DIOXIDE ppm as CO FEED CONDUCTIVITY µmho/cm...
- Page 37 ® IONPURE LX-HI CEDI 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 CEDI feed...
- Page 38 ® IONPURE LX-HI CEDI Modules Troubleshooting Flow Chart - Low CEDI 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...
- Page 39 ® IONPURE LX-HI CEDI Modules Troubleshooting Flow Chart - Low CEDI Product Water Quality Page 1 of 3 START HERE CEDI Check IP-Pro: Adjust DC amperage feed TDS is desired quality Up for higher TDS changed? possible? Down for lower TDS...
- Page 40 ® IONPURE LX-HI CEDI Modules Troubleshooting Flow Chart - Low CEDI Product Water Quality Page 2 of 3 Continued from previous flowchart Check IP-Pro: Increase Product flow is desired quality DC amperage increased? possible? Reduce flow or reduce feed conductivity equivalent...
- Page 41 Troubleshooting Flow Chart - Low CEDI Product Water Quality Page 3 of 3 Continued from Previous Flowchart Clean CEDI with product flow NaCl/NaOH and decreased? Contact Ionpure Technical Removed particulates Support Did cleaning and/or biofilm: www.ionpure.com restore flow? review process design &...
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Page 42: Shutdown And Storage
Operate unit with DC power on, flushing to drain. If desired, sanitize LX module(s). Rebuild Modules can be returned to Ionpure for rebuild. Contact you OEM or Ionpure for options. 5.4 Disposal Perform a 5 minute flush with 5% NaCl solution. ... -
Page 43: Appendix A: Lx-Hi Module Specifications
85-95% Recovery Note: 95% recovery requires two pass RO or ion exchange softening. See projection software on IP-PRO for application specific determinations available on Ionpure.com. Note: Please refer to Section 3.6: Table 3-3 for minimum concentrate flow rates A. 4 Module pressure differential... -
Page 44: Appendix B: Junction Box Electrical Connections Lx-Hi
® IONPURE LX-HI CEDI Modules APPENDIX B: Junction Box Electrical Connections LX-HI (866) 876-3340 IP-LX3HIMAN Rev H... -
Page 45: Appendix C: Layout And Elevation Drawing Lx-Hi
® IONPURE LX-HI CEDI Modules APPENDIX C: Layout and Elevation Drawing LX-HI (Drawing in PDF or CAD format available on Ionpure.com) (866) 876-3340 IP-LX3HIMAN Rev H... -
Page 46: Appendix D: Materials Of Construction Lx-Hi
® IONPURE LX-HI CEDI Modules APPENDIX D: MATERIALS OF CONSTRUCTION LX-HI Wetted Component Material Federal Register Dilute Spacer Polysulfone 21 CFR 177.1655 Concentrate Spacer Polysulfone 21 CFR 177.1655 End Block Polypropylene 21 CFR 177.1520 Resin Compartment o-rings Silicone Rubber 21 CFR 177.2600...
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