Manual de Lecho Mixto

VPT Series
Two Bed Deionizer

_________________
Model Number
_________________
Serial Number
Operation &
Maintenance Manual
68/S41TX-03XXX
Rev. 0
March, 2003
USFilter
10 Technology Drive
Lowell, MA 01851
Technical Support: 800-875-7873 ext. 5000
Telephone: 978-934-9349
Fax: 978-458-6922
Email: Lowell_TechSupport@usfilter.com
TABLE OF CONTENTS
FOR
VP SERIES TWO-BED DEIONIZER
SECTION
DESCRIPTION
PAGE
PREFACE PAGES
Disclaimer Statement ................................................................................... i
Proprietary Rights Statement ....................................................................... i
Manual Users Guide .................................................................................. ii
Equipment Support .................................................................................... iii
1.0
INTRODUCTION
1.1
1.2
1.3
2.0
General System Description ................................................................... 1-1

System Design Specifications................................................................. 1-4
Glossary of Terminology ......................................................................... 1-5
SAFETY PRECAUTIONS
2.1
2.2
2.3
General Safety Guidelines ...................................................................... 2-1

Specific Safety Precautions .................................................................... 2-5
Material Safety Data Sheets (MSDS's)................................................. 2-10
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
PREPARATION AND STARTUP

Equipment Storage and Installation ........................................................ 3-1
Initial Equipment Receipt and Inspection................................................ 3-2
Storage of Unassembled Components ..................................................... 3-4
Equipment Installation Guidelines........................................................... 3-7
Installation of Utilities and Other Peripheral Equipment ...................... 3-11
System Preparation Checklist ................................................................ 3-13
Inspection of Factory-Installed Distribution Laterals............................ 3-14
Equipment Flush Procedures ................................................................. 3-16
Pressure Testing..................................................................................... 3-18
Vessel Loading ...................................................................................... 3-22
Startup Procedures ................................................................................. 3-25
Deionizer Data Form.............................................................................. 3-27
3.0
TABLE OF CONTENTS
FOR
SECTION
DESCRIPTION
4.0
OPERATION
4.1
4.2
4.3
4.4
4.5
4.6
5.0
PAGE
Theory of Operation................................................................................. 4-1

Process Control Document (Control Write-Up) ...................................... 4-1
Control Overview
Two Bed Operation
Alarms
Data Access Tool
Valve Sequence
Instrumentation
External Interlocks
Duplex Operation
Regenerant Make-Up Procedures ............................................................ 4-1
Backwash Flow temperature Correction ................................................. 4-4
Special Operating Procedures.................................................................. 4-5
Process and Instrumentation Diagram (P & ID) ...................................... 4-5
SAMPLING AND TESTING
5.1
5.2
6.0
Taking Samples for Analysis .................................................................. 5-2

Procedure for Checking Specific Gravity................................................ 5-6
MAINTENANCE AND TROUBLESHOOTING
6.1
6.2
6.3
7.0
Maintenance General ............................................................................... 6-1

Component Maintenance ......................................................................... 6-4
Troubleshooting ....................................................................................... 6-7
SHUTDOWN AND STORAGE
7.1
7.2
7.3
8.0
Shutdown on Power Loss........................................................................ 7-1

Unloading VP Series Deionizers ............................................................ 7-4
Storage ..................................................................................................... 7-5
PARTS LISTS AND DRAWINGS
8.1
8.2
8.3
9.0
Equipment List......................................................................................... 8-1

Recommended Spare Parts List .............................................................. 8-2
Drawings .................................................................................................. 8-3
VENDOR LITERATURE
9.1
Vendor Literature Section........................................................................ 9-1
DISCLAIMER STATEMENT
The VPT Series Two Bed Deionizer Operation and Maintenance (O&M) manual should be used with
the vendor literature in Section 9.0 of this manual. Both sources should provide the most current and
complete information to meet your operating and/or service requirements as available at the time of
publication. However, USFilter assumes no responsibility for the technical content of the vendor
literature in Section 9.0 of this manual.
The information in these manuals may not cover all operating details or variations, or provide for all
conditions concerning installation, operation and maintenance. Should questions arise which are not
answered specifically in this manual, contact the USFilter Service Department at the toll free number on
this manuals front cover.
USFilter 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 USFilter 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 USFilter. 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 USFilter equipment, and for no other purpose.
In the event that this manuals content is altered, or section/items are omitted during a partial or
complete reproduction, and those altered instructions or definitions within the reproduction result in
personal injury to those who follow them, then the burden of responsibility for personal injury falls
solely on the party who affects the reproduction.
MANUAL USERS GUIDE

This O&M manual describes the procedures necessary to install, operate, and maintain your USFilter
liquid treatment system. Please read this manual carefully before installing and operating your
equipment. The equipment warranty may be voided if installation or operation instructions are not
followed correctly.
This manual has been formatted for ease of use, combining the instruction for all USFilter subsystems
into one comprehensive manual. Literature supplied with purchased components being used on USFilter
equipment is being provided in Section 9.0 of this manual.
The nine tabbed sections cover general information applicable to all pieces of equipment in the system.
The table of contents for these sections is located at the front of the manual. The pages within each
section are numbered [section #]-[page #] with the page numbers starting at 1 and incrementing
sequentially.
NOTE:
Page numbering will skip over any special documents and continue on the page
following the document. Special documents will be noted with an introduction
statement that is listed in the table of contents.
Warnings, Cautions, and Notes 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.
WARNING
Warnings indicate condition, practices, or procedures that must be observed

to avoid personal injury or fatalities.
CAUTION
Cautions indicate a situation that may cause damage or destruction of

equipment, or may pose a long term health hazard.
NOTE:
Notes are used to add information, state exceptions, and point out areas that may
be of greater interest or importance.
ii
EQUIPMENT SUPPORT
USFilter continually strives to provide safe, efficient, trouble-free equipment using the optimum
technology for your application. If problems should develop, USFilters worldwide network of technical
support will be available to provide assistance. For service, sales, parts, or additional manual copies, call
your area sales representative or the telephone numbers provided on this manuals front cover.
iii
VP TWO-BED DEIONIZER
INTRODUCTION
Page 1-1
Rev. 0
1.0
1.1
INTRODUCTION
GENERAL SYSTEM DESCRIPTION

USFilters VP Series two bed deionizers are designed and manufactured for industrial
applications. They are rugged, pre-engineered, pre-assembled catalog units that
minimize expensive installation and start-up costs. They require simple utility
connections (raw water inlet, product water outlet, drain, control air and power), resin
loading and initial regeneration for immediate on-line service. Their simple design
maximizes the efficiency and repeatability of the unit during the service and regeneration
modes in order to provide a truly reliable water treatment unit. U.S. Filter offers 11
different models within the VP Series, as outlined below.
Model Number
Product Flow Rate (in gpm)
VPT-016
10
VPT-020
17
VPT-024
24
VPT-030
38
VPT-036
54
VPT-042
74
VPT-048
97
VPT-054
123
VPT-060
153
VPT-066
182
VPT-072
220
The VP Series two bed deionizers consist of an acid regenerated cation vessel piped in
series with a caustic regenerated anion vessel. The cation resin is a strong acid type and
is regenerated with 30% HCl from a carboy, tote or drum. The anion resin is a strong
base, type II and is regenerated with 50% NaOH from a carboy, tote or drum. The
regenerant chemicals are automatically diluted to the proper strength for the regeneration
of the resins.
These pre-engineered units provide high-quality water over the length of the service
cycle. The typical effluent quality is in the 10 to 25 micromho/cm range when the
influent water quality has less than 300 ppm of total dissolved solids as CaCO3 (17.5
grains per gallon). Operating conditions and an influent water analysis are required for
predicting the effluent quality and total volume of water treated before regeneration is
required. Please refer to the Process Influent Guidelines for more information on the
influent water requirements.
INTRODUCTION
1.1.1
Page 1-2
Rev. 0
Mechanical Description
Two pressure vessels are piped in series (left to right orientation). The first vessel
contains cation resin shipped in the sodium form. The second vessel contains anion resin
shipped in the chloride form. The two-bed system must be regenerated before being put
into service with 30% HCl (cation) and 50% NaOH (anion).
The piping is constructed of Schedule 80 PVC using socket-welded and flanged fittings.
Complete piping from the inlet of the cation to the outlet of the anion is provided. Reassembly of the interconnecting piping is required, unless the skid-mounted option is
selected. All automatic valves are spring-to-close, except the backwash, rinse outlets,
and dilution water to the eductors. These are actuated using dry, oil-free, instrument air.
Four structural steel legs, designed for seismic zone 2A (standard) or seismic zone 4
(optional) support each vessel.
The skid-mounting option provides a structural steel open frame secured to both vessels,
eliminating the need for re-assembly of the interconnecting piping. The skid options
consist of frames designed for seismic zone 2A (standard) or seismic zone 4 (optional).
All external steel surfaces are sandblasted and coated with durable epoxy paint. The
interiors of the vessels are sandblasted and lined with a chemical and abrasion-resistant
vinyl ester coating. Baked PVC linings are available as an option.
Regenerant eductors are supplied in the face piping of each vessel and will require the
customer to supply concentrated chemicals within the immediate vicinity of the
equipment.
1.1.2
Electrical Description
To control the operational sequences and monitor the performance of the VP Series two
bed deionizer, a highly reliable solid-state programmable logic controller (PLC), flow
totalizing meter and conductivity monitor are provided. Opening and closing of the
process valves is accomplished using instrument air and solenoid pilot valves located on
the control enclosure. The flow totalizing meter and conductivity monitor is used to
initiate the regeneration sequence. Flow and conductivity meters are mounted in the
panel door for ease of viewing. Adjustment of the factory pre-set step times is easily
accomplished by using the Data Access Tool (DAT) which is provided with the
equipment and located inside of the enclosure. All electrical components are contained
within a NEMA 4 enclosure for protection from humidity, moisture and dust.
1.1.3
Operational Description
The deionizer has two modes of operation, manual and automatic. In the manual mode,
operator intervention is required to start the regeneration sequence and return the unit to
service. A high conductivity alarm and a totalized gallon throughput alarm are provided
to alert the operator that regeneration is required. In the automatic mode, all functions
are performed without operator intervention.
INTRODUCTION
Page 1-3
Rev. 0
When the volume of water treated or the product water conductivity has exceeded the
pre-set values, the unit is automatically taken off-line and the regeneration sequence
begins. A low flow recirculation pump can be supplied as an option to maintain a
minimum flow rate through the deionizer during periods of low or no product water
demand while in the service mode.
Regeneration of the cation and anion vessels occurs sequentially; that is, the cation vessel
is regenerated first, then the anion vessel is regenerated. Anion regeneration water is
derived from the cation vessel. The rated capacity (Kgrains) of the deionizers is based on
the anion resin volume. The regeneration sequence for each vessel consists of four steps:
backwash, chemical in, slow rinse and fast rinse.
Duplex systems will operate in an alternating or parallel fashion. In the alternating
fashion, one set of deionizers will be in the service mode while the other set of deionizers
will be in the regeneration or standby mode. This provides a continuous, uninterrupted
supply of deionized water. In the parallel mode, each deionizer operates independently
as two single units. Each of the deionizers will be provided with a PLC and solenoid
pilot valves, pre-tubed to the process valves and pre-wired to the PLC terminal strip. The
duplex alternating configuration requires wiring of the interlocks between the two
enclosures by the customer.
1.1.4
Design Parameters
The following chart details the design parameters.

Configuration:
Simplex (duplex optional)
Feed Temperature:
45 to 95 F
Feed Pressure:
45 to 100 psig
Maximum Inlet Turbidity:
5 NTU
Maximum Inlet TDS:
500 ppm as CaCO3 (29.2 grains/gallons)

Cation Vessel
2
Anion Vessel
3
Sizing:
8 gpm/ft (2.5 gpm/ft )
8 gpm/ft2 (2.2 gpm/ft3)
Bed Depth:
36 inches
42 inches
Capacities:
20 Kgr/ft3
17 Kgr/ft3
Regeneration:
4.5 lbs (100%) HCl/ft3
6.0 lbs (100%) HCl/ft3
1.56 gallons 30% HCl/ft3
0.90 gallons 50% NaOH / ft3
Freeboard:
INTRODUCTION
1.2
Page 1-4
Rev. 0
SYSTEM DESIGN SPECIFICATIONS

The design specifications for your U.S. Filter Two-Bed Deionizer are listed below. For
specifications of individual components used on the system, refer to the components instruction
sheets in the Vendor Literature Manual at the end of this manual.
1.2.1
Standard Specifications
Pressure Vessels:
Materials:
Carbon steel, butt welded seams
Rating:
100 psig non-code (optional: ASME code & stamp)
Support:
Structural steel legs, seismic zone 4 (optional: zone 2A and 4 skids)
Access Openings
16, 20, and 24 diameter
Non-code: removable head w/ (2) 4 x 6 hand holes

ASME code: flanged top and bottom heads
30 through 72 diameter
(1) 11 x 15 crab style
Process Connections:
Pad flange
Paint
5 to 7 mil DFT epoxy (optional: 20 to 40 mil DFT baked PVC)
Lining
35 to 45 mil DFT vinyl ester (optional 60 to 80 mil DFT baked

PVC)
Distribution Systems:
Upper
PVC radial flow point distributor
Lower (underdrain)
PVC hub with PVC slotted laterals
Piping Systems:
Process
Schedule 80 PVC, socket-welded and flanged
Regenerant
Schedule 80 PVC, socket-welded
Backwash
Schedule 80 PVC, socket-welded & flanged with clear sight glass
Automatic Process Valves:

2 and smaller
PVC bodied, EPDM diaphragm
2-1/2 and larger
Cast iron butterfly, EPDM seats, Nylon-coated disk, SS trim
Actuation
Air-to-open, spring-to-close, except backwash, rinse outlet and

dilution water to the eductors, which are air-to-open and air-to-close
Manual Valves:
Feedwater Sample
(1) PVC ball
Product Water Sample
(2) PVC ball, one on each vessel
Regenerant Sample
(2) PVC ball, on for each regenerant chemical
Gauge Isolation
(3) PVC ball, one for each pressure gauges
INTRODUCTION
1.2.2
Page 1-5
Rev. 0
Instrumentation Specifications
Pressure:
Service Inlet Gauge
(1) 2 dial, 316 stainless steel
Cation Effluent
Service Outlet Gauge
Flow:
Feedwater Sensor
Signet paddlewheel flow element on inlet to cation vessel
Feedwater Monitor
Red Lion digital display with rate and totalized flow mounted in
panel
Quality:
Product Conductivity Sensor
Thornton 240-XXX cell in the effluent piping of the anion vessel
Product Conductivity Monitor
Thornton 200 CR Digital meter mounted in panel
1.2.3
Controls Specifications
Enclosure
NEMA 4 enamel painted steel
Programmable Logic Controller

(PLC)
Allen-Bradley MicroLogix 1500, 24 VDC, fixed I/O type
PLC Input/Output
Allen-Bradley discrete 32 point (12 inputs, 20 outputs)
DAT
Allen-Bradley
Alarm horn
Edwards, NEMA 4
Pushbuttons and lights
Allen-Bradley
Circuit breaker
Square D (panel power switch)
Warning alarms
High effluent conductivity (manual mode only)

Throughput exceeded (manual mode only)
Numeric displays
Red Lion, XX LED for flow rate (gpm) and total gallons
Operator interface
Manual/Automatic selector switch

Alarm silence pushbutton
Regeneration illuminated pushbutton (press and hold to restart)
Service illuminated pushbutton
Solenoid pilot valves
MAC, 45A, 4-way, 24 VDC, manifold-mounted on enclosure
INTRODUCTION
1.2.4
Page 1-6
Rev. 0
Interface Communications Specifications
Input 1 (by others)
Dry contact closure indicates upstream water is available
Input 2 (by others)
Dry, momentary contact closure parallels Service pushbutton
Output 1 (relay)
Configurable to indicate regeneration or Service
1.2.5
Operating Limits
Temperature:
Maximum Feed Temperature
95F
Minimum Feed Temperature
45F
Pressure:
Maximum Feed Pressure
95 psig
Minimum Feed Pressure
45 psig
Maximum Pressure Variability
5 psig (optional; inlet pressure control valve)
NOTE:
If any of the operating conditions are not within the limits given, consult the factory for the
appropriate recommendation and application assistance.
1.2.6
Process Influent Guidelines
Parameter
Guideline
Suspended Solids
5 NTU maximum
Total Dissolved Solids
500 ppm maximum
Alkalinity
30% of total anions
Chlorides
30% of total anions
Sodium
50% of total cations
Silica
10% of total anions
Iron + Manganese
0.3 ppm combined
Free Chlorine
0.2 ppm
Color
5 APHA units
Organics
2.0 ppm TOC as O2
NOTE:
If any of the feedwater parameters are not within the limits given, consult the factory for the
appropriate recommendation and application assistance.
INTRODUCTION
1.2.7
Page 1-7
Rev. 0
Regulations and Standards
Pressure Vessels
Hydrostatically tested at 1.5 times the rated pressure
Surface Preparation
SSPC SP-10 for vessel interior, SSPC SP-6 for external steel
surfaces
Electrical
NEMA 4, (optional UL listed)
Seismic Rating
Zone 4 legs (optional: skid for zone 2A and zone 4)
Piping
Hydro tested to 100 psig minimum
1.2.8
Documentation Package
Documents
Storage, installation and operating instructions

Operating sequence parameters, shipping list, and spare parts list
Drawings
Process & Instrument (P&ID), General Arrangement (GA) and line

wiring
Software
Factory-loaded, ladder logic supplied on disk
Quality Documents
UA-1 form with ASME code vessels
1.2.9
Flow Rate Specifications (in gpm)
Diameter
016
020
024
030
036
042
048
054
060
066
072
Service (design)
10
17
24
38
54
74
97
123
153
182
220
Service (minimum)
10
14
19
23
31
39
47
55
Backwash Cation*
12
17
26
37
51
67
85
105
125
151
Backwash Anion*
Combined Fast
Rinse
10
15
20
27
34
42
50
61
10
17
24
38
54
74
97
123
153
185
220
* The backwash rates are based upon a flow temperature of 60F (16C).
NOTE:
If the service flow rate drops below the minimum values listed, the automatic low flow
recirculation pump accessory should be selected to maintain reliable performance of the
deionization system.
The service flow rate must be limited with a rate-set valve. An unrestricted flow rate will
lower the quality of the effluent.
INTRODUCTION
Page 1-8
Rev. 0
1.2.10 Media Specifications

Diameter
016
020
024
030
036
042
048
054
060
066
072
U.S. Filter C-211: 8% cross-linked strong acid, shipped in sodium form (50 lbs/ft3)
Cation:
Resin Volume (ft3)
10
15
21
28
36
46
57
69
82
Resin weight #
224
336
560
840
1176
1568
2016
2576
3192
3864
4592
Capacity (Kgrains)
80
120
200
300
420
560
720
920
1140
1380
1640
U.S. Filter A-244: strong base, Type II (gel), shipped in chloride form (44 lbs/ft3)
Anion:
Resin Volume (ft3)
4.5
11
17
24
33
42
54
67
81
96
Resin Weight #
198
308
484
748
1056
1452
1848
2376
2948
3564
4224
Capacity (Kgrains)
77
120
190
290
410
560
715
920
1140
1380
1640
NOTE:
The resin capacities listed are nominal values only. The actual operating capacity will
depend on the feed water composition and other operating conditions.
Refer to Section 7, Parts List, for media part numbers and specifications.
1.2.11 Regeneration Flow Rate Specifications (in gpm)
Diameter
016
020
024
030
036
042
048
054
060
066
072
Exhaustion Rinse
10
17
24
38
54
74
97
123
153
182
220
Backwash Cation
12
17
26
37
51
67
85
105
125
151
Acid In
1.7
2.5
4.2
6.3
8.8
11.8
15.1
19.3
23.9
29
34.4
Slow Rinse Cation
1.4
2.1
3.6
5.4
7.5
10.0
12.9
16.4
20.3
24.6
29.3
Fast Rinse Cation
10
17
24
38
54
74
97
123
153
182
220
Backwash Anion
2.9
4.6
6.6
10
15
20
27
34
42
50
61
Caustic In
1.7
2.7
4.2
6.5
9.2
12.6
16.0
20.6
25.6
30.9
36.7
Slow Rinse Anion
1.6
2.5
4.0
6.2
8.7
11.9
15.2
19.5
24.3
29.3
34.8
Final Rinse
10
17
24
38
54
74
97
123
153
182
220
NOTE:
Refer to Section 1.2.13 for step times.

De-cationized water is used for the regeneration of the anion resin.
INTRODUCTION
Page 1-9
Rev. 0
1.2.12 Regeneration Volume Specifications (in gallons)

Diameter
016
020
024
030
036
042
048
054
060
066
072
Exhaustion Rinse
104
168
240
376
544
744
968
1232
1528
1816
2200
Backwash Cation
107
173
248
388
561
767
998
1271
1576
1873
2269
Acid In
42
63
105
158
221
294
378
483
599
725
861
Slow Rinse Cation
30
45
75
112
157
210
270
345
427
517
615
Fast Rinse Cation
62
101
144
226
326
446
581
739
917
1090
1320
Backwash Anion
43
69
99
155
224
307
399
508
630
749
908
Caustic In
77
120
189
292
413
567
722
928
1152
1392
1650
Slow Rinse Anion
34
53
84
129
182
251
319
411
509
616
730
Final Rinse
104
168
240
376
544
744
968
1232
1528
1816
2200
30% HCl
6.3
9.4
16
23
33
44
56
72
89
108
128
50% NaOH
4.2
6.6
10
16
23
31
40
51
63
76
91
Anion Regen
258
411
612
953
1363
1869
2409
3079
3819
4573
5488
Waste Water
604
961
1423
2212
3173
4331
5604
7149
8866
10593
12752
Totals
NOTE:
De-cationized water is used for the regeneration of the anion resin.
1.2.13 Regeneration Sequence:

Time
Step
Liquid
(minutes)
Exhaustion Rinse
Backwash Cation
Acid In
Slow Rinse Cation
Fast Rinse Cation
Backwash Anion
Caustic In
Slow Rinse Anion
Final Rinse
10
15
25
21
6
15
45
21
10
Total Time
168
Water
Water
5% HCl
Water
Water
Water
4% NaOH
Water
Water
* Cation and anion vessels are regenerated sequentially.
INTRODUCTION
Page 1-10
Rev. 0
1.2.14 Customer Connection Specifications (in inches)

Diameter
016
020
024
030
036
042
048
054
060
066
072
Service Inlet
Service Outlet
Drain
Control Air
024
030
036
042
048
054
060
066
072
153
185
220
1.2.15 Utility Requirement

Diameter
016
020
Electrical
110 volts, 1 phase, 60 Hertz, 15 amp
Control Air
80 psig minimum, 100 psig maximum
Feedwater
45 psig minimum, 95 psig maximum
Maximum Drain
(gpm)
Floor Drain
10
16
24
38
54
74
92
123
A floor drain (in addition to waste drain) should be supplied for general purposes.
Option Items:
Low Flow
Recirc.
110 volt, 1 phase, 60 Hertz, 0.5 hp
0.75 hp
NOTE: Duplex-alternating systems must be powered from the same source.
INTRODUCTION
Page 1-11
Rev. 0
1.2.16 Physical Dimensions Specifications

Diameter
016
020
024
030
036
042
048
054
060
066
072
72
72
72
72
72
72
72
72
72
72
72
4 8
5 4
6 0
7 0
8 0
9 0
10 0
11 0
12 0
13 0
14 0
Depth
310
40
42
411
52
55
66
610
70
78
84
Height, non-code
810
81
83
90
96
910
100
105
107
110
114
1,800
2,900
3,800
4,400
6,000
7,860
9,670
11,880
14,880
20,040
25,200
900
1,450
1,600
1,702
2,006
2,358
2,570
2,780
3,380
4,190
5,000
2325
3,740
5,370
9,950
13,650
18,300
22,785
28,300
35,290
44,920
54,550
Side Sheet (inches)

Length
Height, ASME code

Shipping Weight
(lbs)
Crane Capacity
(lbs)
Oper. Weight (lbs)
NOTE:
Does not include operating space requirements or customer-supplied regenerant tanks.

Heights for skid-mounted units will be 4 inches greater than the heights listed.
INTRODUCTION
Page 1-12
Rev. 0
Standard Product Ordering Information:

Sample Part Number:
VPT
060
Configuration
S
Simplex (see note)
Vessel Size
016 16 x 72
020 20 x 72
024 24 x 72
030 30 x 72
036 36 x 72
042 42 x 72
048 48 x 72
054 54 x 72
060 60 x 72
066 66 x 72
072 72 x 72
Vessel Rating
X
100 psig non-code
A
100 psig ASME code
Vessel Support
X
Legs, seismic zone 4
Y
Skid, seismic zone 2A
Z
Skid, seismic zone 4
Lining & Paint
B
PVC / PVC
Controls
P
Solid state PLC
Control Rating
D
NEMA 4 and UL label
Note: Duplex units should be ordered as two (2) simplex units.
INTRODUCTION
Page 1-13
Rev. 0
Accessories Ordering Information:

Sample Part Number:
VP
060
Reserved
Z
Accessory
Size Code
Diam.
16
20
24
30
36
42
48
54
60
66
72
Accessory
LFR
TRP
PRV
LFR
016
020
024
030
036
042
048
054
060
066
072
Size Codes
TRP PRV
100
075S
100
075D
100
100D
125
125S
150
125D
200
200S
200
200D
250
200D
300
250S
300
250D
400
300S
Obsolete PRV Size Codes

100
100
100
125
150
200
200
250
300
300
400
Low flow recirculation pump

Resin trap
Pressure reducing regulator
Note: Accessories must be ordered as separate line items.
LFR
INTRODUCTION
Page 1-14
Rev. 0
Standard Options Available:

Ordering Information:
Specify option code A in
Vessel Rating placeholder.
Description of Option:
100-psig ASME code stamped vessel. This option provides pressure vessels
designed and manufactured according to strict ASME code standards and are
supplied with a code stamp permanently affixed to the pressure vessels.
Specify Y in the Vessel
Seismic zone 2A skid. This option provides a structural steel, open frame skid
Support placeholder.
underneath the cation and anion vessels designed in accordance to seismic zone 2A,
for ease of shipment and installation. The piping between the cation and anion
vessels is shipped intact.
Specify Z in the Vessel
Seismic zone 4 skid. This option provides a structural steel, open frame skid
Support placeholder.
underneath the cation and anion vessels designed in accordance to seismic zone 4,
for ease of shipment and installation. The piping between the cation and anion
vessels is shipped intact.
* Refer to the Standard Product Ordering Information for building the part number based on the options you
have chosen.
Standard Accessories Available:

Ordering Information:
Size Code
Specify LFR in the

Accessory placeholder.
Specify TRP in the

Accessory placeholder.
Specify PRV in the

Accessory placeholder
Description of Accessory:
Enter the vessel diameter for the low flow recirculation (LFR) accessory, e.g., a 60
diameter unit would have a size code of 060.
Enter the pipe size for the resin trap (TRP) and inlet pressure reducing regulator
(PRV). The pipe size code is listed in the Accessories Ordering Information for
each diameter unit, e.g., a 60 diameter unit has 3 piping and the pipe size code is
300.
Automatic low flow recirculation pump. This accessory provides a recirculation
pump that automatically takes the effluent service water and directs it to the inlet
(bypassing the inlet flow meter) when the flow rate drops below the minimum
specified flow rate. The pump assembly is pre-wired to a junction box and shipped
loose. Customer will be required to provide the wiring between the control
enclosure and the junction box as well as piping from the pump assembly to the
deionizer.
Effluent resin trap. This option provides a PVC slotted strainer in the effluent
piping of the anion vessel to prevent a catastrophic loss of resin to downstream
processes. The strainer is housed in a clear PVC sight glass to permit visual
inspection. The resin trap is the same size as the service effluent piping on the
deionizer.
Pressure reducing regulator. This option provides a self-contained pressurereducing regulator on the inlet of the cation vessel to control fluctuations in
feedwater pressure +/- 5 psig. The pressure-reducing regulator is the same or
smaller size than the inlet piping of the deionizer and will require the customer to
provide reducing fittings if required.
* Refer to the Accessories Ordering Information for specifying the accessories. Each accessory item must be
ordered as a separate line item.
INTRODUCTION
1.3
Page 1-15
Rev. 0
GLOSSARY OF TERMINOLOGY
NOTE:
1.3.1
The following terms are defined as they relate to the liquid-treatment industry. Many
terms refer to processes, items or equipment not part of this order.
Terminology Common to All Systems
This section contains terms and definitions that are common to all liquid-treatment
systems.
Alkalinity:
An expression of the total basic anions (hydroxyl groups) present in a solution. It

also represents, particularly in water analysis, the bicarbonate, carbonate, and
occasionally, the borate, silicate, and phosphate salts which will react with water
to produce the hydroxyl groups.
Anion:
A negatively-charged particle or ion.
Bicarbonate
Alkalinity:
Calcium Carbonate
Equivalent:
The presence in a solution of hydroxyl (OH-) ions resulting from the hydrolysis of
carbonates or bicarbonates. When these salts react with water, a strong base and a
weak acid are produced, and the solution is alkaline.
This is the value obtained when salts are calculated in terms of equivalent
quantities of calcium carbonate; a convenient method of reducing all salts to a
common basis for comparison.
PPM as CaC03=ION (PPM as such) X Equivalent WT of CaCO3
Equivalent WT of Ion
Carbonate Hardness: That hardness in a water caused by bicarbonates and carbonates of calcium and
magnesium. If alkalinity exceeds total hardness, all hardness is carbonate
hardness; if hardness exceeds alkalinity, the carbonate hardness equals the
alkalinity.
Cation:
A positively-charged particle or ion.
Cavitation:
The phenomenon which occurs in a pump where there is insufficient NPSH (Net
Positive Suction Head) available. The pressure of the liquid is reduced to a value
equal to or below its vapor pressure and small vapor bubbles or pockets begin to
form. As these vapor bubbles move along the impeller vanes to a higher pressure
area, they rapidly collapse. The collapse, or "implosion" is so rapid that it may be
heard as a rumbling noise, as if pumping gravel. May result in reduced capacity,
erratic power consumption, vibration, and mechanical damage.
Colloids:
Matter of very fine particle size, usually in the range of 10-5 to 10-7 cm. in
INTRODUCTION
Page 1-16
Rev. 0
diameter.
Composite Sample:
A sample made up of many small samples taken at regimented intervals.
Concentration:
The amount of substance in weight, moles, or equivalents contained in a unit

volume.
Condensate:
Water obtained by evaporation and subsequent condensation.
Conductivity:
The ability of a substance to conduct heat or electricity. Commonly, used as an

expression of electrical conductivity in micromhos/cm.
Contaminant:
Any foreign component present in another substance; e.g., anything in water that
is not H20 is a contaminant.
Degasifier:
A vessel or device that removes gasses from a liquid by increasing their surface
area and/or subjecting them to a vacuum.
Density:
The weight of a given volume of exchange material, backwashed and in place in

the column.
Dissociation:
Ionization.
Effluent:
The solution which emerges from a system unit.
Electrolyte:
A chemical compound which dissociates or ionizes in water to produce a solution

which will conduct an electric current; an acid, base or salt.
Elements:
Substances which cannot be decomposed by the ordinary types of chemical

change, or made by chemical union.
Equivalent Weight:
The molecular weight of any element or radical expressed as grams, pounds, etc.,
divided by the valence.
Feed:
Any type of influent or process liquid that is to be treated in a filter, ion-exchange

vessel, etc.
Flow Rate:
The volume of solution which passes through a system within a given time. Flow
rate is usually expressed in terms of gallons per minute per cubic foot of resin, or
as milliliters per minute per milliliter of resin.
Formula, Chemical:
A combination of symbols with their subscripts representing the constituents of a

substance and their proportions of atoms.
Grab Sample:
Any sample not collected over a given period of time.
Grain:
A unit of weight; 0.0648 grams; 0.000143 pounds.
INTRODUCTION
Grain per Gallon:

Gram-Milli
-equivalents:
Hardness:
Page 1-17
Rev. 0
An expression of concentration of material in solution. One grain per gallon is

equivalent to 17.12 parts per million.
The equivalent weight in grams, divided by 1000.
The scale-forming and lather-inhibiting qualities which water, high in calcium
and magnesium ions, possesses. Temporary hardness, caused by the presence of
magnesium of calcium bicarbonate, is so called because it may be removed by
boiling the water to convert the bicarbonates to the insoluble carbonates. Calcium
sulfate, magnesium sulfate, and the chlorides of these two metals cause permanent
hardness.
Hardness as
Calcium Carbonate: The expression ascribed to the value obtained when the hardness forming salts are
calculated in terms of equivalent quantities of calcium carbonate; a convenient
method of reducing all salts to a common basis for comparison.
Header:
A main or common piping line.
Headloss:
The reduction in liquid pressure associated with the passage of a solution through
a system; a measure of the resistance of a system or component to the flow of the
liquid passing through it.
Hydroxyl:
The term used to describe the anionic radical (OH-) which is responsible for the
alkalinity of a solution.
Indicators:
Substances which change from one color to another when the hydrogen-ion
concentration reaches a certain value, different for each indicator.
Influent:
The solution which enters a system unit.
Ion
Any particle of less than colloidal size possessing either positive or negative
electric charge.
Ionization:
The dissociation of molecules into charged particles.
Ionization
Constant:
An expression in absolute units of the extent of dissociation into ions of a

chemical compound in solution.
Kilograin:
A unit of weight; one thousand grains. There are seven kilograins per pound.
Mineral:
A natural inorganic substance having a definite chemical composition and

structure.
INTRODUCTION
Page 1-18
Rev. 0
Mole:
Mass numerically equal to the molecular weight. It is most frequently expressed

as the gram molecular weight, i.e., as the weight of one mole expressed in grams.
Molecule:
The smallest unit quantity of matter which can exist by itself and retain all the
properties of the original substance.
Negative Charge:
The electrical potential which an atom acquires when it gains one or more
electrons; a characteristic of an anion.
Noncarbonate
Hardness:
Hardness in water caused by chlorides, sulfates, and nitrates of calcium and

magnesium.
Orifice:
An opening through which a fluid can pass; a restriction placed in a pipe to

provide a means to measure flow.
pK:
An expression of the extent of dissociation of an electrolyte; the negative

logarithm of the ionization constant of a compound.
pOH:
An expression of the alkalinity of a solution; the negative logarithm of the

hydroxyl ion concentration.
Positive Charge:
The electrical potential acquired by an atom which has lost one or more electrons;
a characteristic of a cation.
Precipitate:
The amount of a substance dissolved in a solution that exceeds the solubility of

that substance and, therefore, comes out of solution.
Prefilter:
A filter placed before and in series with some other type of liquid-treatment
equipment.
Productivity:
The measurement of rated output, expressed in gallons/24 hour day under a given
temperature, pressure and salinity (Product Flow).
Purity:
The percentage of desirable vs. undesirable components on a weight basis per unit
volume of sample.
Raw Water:
Untreated water from wells or from surface sources.
Recovery:
The quantity of a given component by weight in the product stream vs. the
amount of that specific component in the feed.
Salinity:
The presence of soluble minerals in water.
Scale:
The precipitate that forms on surfaces in contact with water as the result of a
physical or chemical change.
INTRODUCTION
Page 1-19
Rev. 0
TDS:
Total Dissolved Solids, expressed as parts per million (ppm).
Turbidity:
A suspension of fine particles that obscure light rays but require many days for
sedimentation because of small particle size.
1.3.2
Terminology Specific to Ion-Exchangers (including softeners and iron filters)

This subsection contains terms and definitions for all ion-exchanger systems, such as
softeners, two-beds, mixed-beds, decolorizers, dealkalizers, iron filters, chelators, and
layered-bed exchangers. The terms related to the chemical delivery portions of the
exchangers are covered in the subsection on Chemical Systems Terminology.
Anion Exchange:
The displacement of one negatively-charged particle by another on an anionexchange material.
Attrition:
The rubbing of one particle against another in a resin bed; frictional wear that will
affect the size and life span of resin particles.
Backwash:
The counter-current flow of water through a resin bed (i.e. in at the bottom of the
exchange unit, out at the top) to clean and reclassify the bed after exhaustion. In
mixed bed deionizers, this will separate the heavier cation resin from the lighter
anion resin so that each can be regenerated separately.
Bed:
A mass of ion-exchange resin particles contained in a column.
Blocking Flow:
A flow of water used during regeneration of a mixed bed that prevents caustic
from entering the cation resin layer (See "Mixed-bed").
Carboxylic:
A term describing a specific acidic group (COOH) that contributes cationexchange ability to some resins.
Cleavage and furrowing of a resin bed due to faulty operational procedures. The
solution being treated follows the path of least resistance, runs through these
furrows, and fails to contact active groups in other parts of the bed.
Channeling:
Color Throw:
Discoloration of a liquid passing through ion-exchange resin due to flushing of

excessive color bodies from the resin beads.
Cross-Regeneration: Regeneration of a resin with a base and then an acid (or vice-versa) that is
intended to shrink and swell the resin to loosen color bodies and other materials.
De-Ashing:
The removal of inorganic salts from solution by means of adsorption by ionexchange resins of both the cations and the anions that comprise the salts. See
deionization.
Deionization:
See de-Ashing. Deionization, a more general term than de-ashing, embraces the
INTRODUCTION
Page 1-20
Rev. 0
removal of all charged constituents or ionizable salts (both inorganic and organic)
from solution.
Demineralization:
See de-ashing.
Distribution:
The internal piping (liquid inlets and outlets) of an ion-exchange vessel.
Double DishBottom: A concave plate inside a vessel that blocks off the bottom head (shell). Used to
eliminate problems with gravel or quartz support beds (see "support media").
Downflow:
Conventional direction of solutions to be processed in ion- exchange column

operation, i.e., in at the top, out at the bottom of the column.
Exchange Velocity:
The rate with which an ion is displaced from an exchanger in favor of another.
False Bottom:
A flat plate inside a vessel that blocks off the bottom head (shell). Used to
eliminate problems with gravel or quartz support beds (see "support media").
Fines:
Extremely small particles of ion-exchange materials.
Freeboard:
The space provided above the resin bed in an ion-exchange column to allow for
expansion of the bed during backwashing.
Greensand:
Naturally-occurring materials, composed primarily of complex silicates, which

possess ion-exchange properties.
Hydraulic
Classification:
The rearrangement of resin particles in an ion-exchange unit. As the backwash

water flows up through the resin bed, the particles are placed in a mobile
condition wherein the larger particles settle and the smaller particles rise to the
top of the bed.
Hydrogen Cycle:
A complete course of cation-exchange operation in which the adsorbent is

employed in the hydrogen or free-acid form.
InterfaceCollector:
The lower intermediate distribution of a mixed-bed vessel. Used as a drain during

regeneration.
INTRODUCTION
Page 1-21
Rev. 0
Lateral:
One of the individual drilled pipes that branch out from the internal vessel
distribution headers. Used as an entry or exit point for process fluids.
Media:
The material (resin, carbon, quartz) that is used in a fluid-treatment vessel.
Mixed-Bed:
An ion-exchange vessel containing a mixture of cation and anion resin (in a single
bed).
Physical
Stability
The quality which an ion-exchange resin must possess to resist changes that might
be caused by attrition, high temperatures, and other physical conditions.
Polisher:
An ion-exchange vessel, especially a mixed bed, placed after a primary exchange

unit to remove any remaining unwanted ions.
Quartz:
A hard mineral. Graded quartz is used as a support media in some liquidtreatment applications.
Regenerant:
The solution used to restore the activity of an ion exchanger. Acids are employed
to restore a cation exchanger to its hydrogen form. Brine solutions may be used
to convert the cation exchanger to the sodium form. The anion exchanger may be
rejuvenated by treatment with an alkaline solution.
Regeneration:
The process by which a system is conditioned to ready it for another service

cycle.
Reverse
Deionization:
The use of an anion-exchange unit and a cation-exchange unit (in that order) to
remove all ions from solution.
Rinse:
The final step in a unit regeneration, in which water is flushed through the unit
until the effluent quality is proper.
Riser:
The distribution (internal piping) pipe that carries a process liquid to or away
from the distribution headers.
Salt Splitting:
The act of separating cations from anions in a process feed stream. Usually done
with ion-exchange resin.
Softening:
The removal of hardness - calcium and magnesium - from water.
INTRODUCTION
Page 1-22
Rev. 0
Support Media:
Any type of media that is used to support the bottom distribution laterals and a
media material above it.
Sweeten-On/Off:
Terms used mostly in the sugar industry which describe the process of either
filling a vessel with syrup while displacing water from the vessel or displacing
syrup from a vessel while filling it with water.
Two-Bed:
An ion-exchange unit with a cation vessel and an anion vessel operating in series.
Usually referred to as a "deionizer".
Upflow:
The operation of an ion-exchange unit in which solutions are directed in at the

bottom and out at the top of the container.
Zeolite:
Naturally-occurring hydrous silicates exhibiting limited base exchange.
1.3.3
Terminology Specific to Chemical Systems

This subsection contains terms and definitions for all chemical systems, such as
pretreatment feed systems, regenerant makeup stations, chemical day tanks, membrane
cleanup skids and bulk storage tanks.
Acid:
A substance which dissociates in solution to produce hydrogen ions (H+).
Acidity:
An expression of the concentration of hydrogen ions present in a solution.
Base:
A substance which dissociates in solution to produce hydroxyl ions (OH-).
Brine:
Water saturated or strongly impregnated with salt.
Caustic Soda:
A common water treatment chemical - sodium hydroxide, lye.
Chelating Agents:
Organic compounds having the ability to withdraw ions from their water solutions
into soluble complexes. Used in clean-up of R.O. membranes.
Coagulation:
The neutralization of the charges of colloidal matter; sometimes also considered

to be flocculation.
Elution:
The stripping of adsorbed ions from an ion-exchange material by the use of

solutions containing other ions in concentrations higher than those of the ions to
be stripped.
INTRODUCTION
Page 1-23
Rev. 0
Flocculation:
The process of agglomerating coagulated particles into precipitating flocs, usually

of a gelatinous nature.
Neutralization:
The act of adding acid to an alkaline effluent or alkali to an acidic effluent

to make the effluent pH neutral (7.0 pH).
pH:
An expression of the acidity of a solution; the negative logarithm of the hydrogen

ion concentration (pH 1 very acidic; pH 14, very basic; pH 7, neutral).
Polyelectrolyte:
Water soluble polymers containing ionizable groups as part of their structure;

often useful in causing agglomeration of fine suspended solids.
Regenerant:
The solution used to restore the activity of an ion exchanger. Acids are employed
to restore a cation exchanger to its hydrogen form. Brine solutions may be used
to convert the cation exchanger to the sodium form. The anion exchanger may be
rejuvenated by treatment with an alkaline solution.
Sedimentation:
Gravitational settling of solid particles in a liquid system.
Specific Gravity:
The ratio of the mass of a body to the mass of an equal volume of water at 4o C or
other specified temperature. Dimension - unity.
SAFETY PRECAUTIONS
Page 2-1
Rev. 0
2.0 SAFETY PRECAUTIONS

This section contains general safety guidelines that workers must follow when installing, operating, and
maintaining U.S. Filter equipment.
This section must be read and understood prior to system startup. The guidelines listed here must be
followed at all times to prevent worker injury and equipment damage.
2.1
GENERAL SAFETY GUIDELINES

This subsection contains the safety precautions that are common to all U.S. Filter equipment.
2.1.1
Operator Training
Equipment operators must be trained in the operation of the equipment and in the proper
handling of any hazardous materials or chemicals. Only experienced operators who have
studied this entire manual should be allowed to operate the equipment.
2.1.2
First-Aid Equipment
First-aid equipment must be available in all areas. This equipment must consist of items
needed to treat most common injuries and the items required by the Material Safety Data
Sheets (MSDS's) for the hazardous chemicals and materials used by your system (see
section 2.3).
2.1.3
Equipment Access
Workers must use caution when accessing the equipment. All measures must be taken to
prevent falls and other accidents when equipment is being installed or serviced.
Use extreme caution when working around liquid-treatment equipment. Valve handles,
sample pipes, and other protruding components can cause severe injury to body parts that
strike them. Workers should wear hard hats and safety glasses and should move
cautiously when working under piping and around the equipment.
Climbing on piping can cause worker injury or equipment damage due to falls and equipment
WARNING
tipping.
Never climb on piping to reach equipment or components.
If equipment to be installed or serviced is above an operator's normal reach, use safe,

approved ladders or lifting devices to reach the required area.
SAFETY PRECAUTIONS
Page 2-2
Rev. 0
Avoid using "extension" type or single-run ladders to access equipment, especially if

there are no flat and stable surfaces for a single-run ladder to rest against.
Whenever possible, use a wide, stable folding (free-standing) ladder and tie it to the
equipment or piping.
2.1.4
Protective Personal Equipment (PPE)
Maintain the necessary clothing and equipment to protect operating personnel. For
protection when handling hazardous chemicals or materials, refer to the MSDS's in
section 2.3.
2.1.5
Pressures
WARNING
The sudden release of pressure from pressurized components can cause

severe injury to workers.
Relieve all pressure from piping and components before performing service.
2.1.6
Extreme caution must be used when working with high air or liquid pressures. Pressure
monitoring devices must always be installed and working properly. The liquid-treatment
system must be operated within the pressure limits given in section 1.0 of this manual.
Servicing System Components and Equipment
Before performing maintenance on system components and equipment, and especially

when disassembling individual components, workers must be certain that the components
are isolated from pressure, fluids, and electricity. Spring-loaded devices, such as valves,
must be in their "relaxed" state--that is, with no compression on the loading spring--to
avoid the sudden and accidental motion of individual parts.
An accidental and sudden release of pressure or fluid, accidental contact with energized
electrical components, or the sudden movement of equipment parts during maintenance
procedures can result in severe injury to workers.
Refer to the individual component literature in the Vendor Literature Manual for specific
maintenance guidelines.
SAFETY PRECAUTIONS
2.1.7
WARNING
Page 2-3
Rev. 0
Electricity
Electricity can shock, injure, or cause death.
Always disconnect and lock out electrical power for panels or components
before performing repairs or service.
Operators and workers must use caution when working with motors, control panels, and
other electrical components. These components must be properly wired and grounded,
and should not be allowed to come in contact with process fluids or other liquids.
Electrical control panels and instruments must be properly grounded.
2.1.8
Temperatures
WARNING
High temperatures can cause severe burns to exposed skin.

Wear gloves and protective clothing when handling components that
generate high temperatures.
2.1.9
Operators and workers must use caution when working with processes (steam cleaning)
or components (heat exchangers, motors, pumps etc.) that involve high temperatures.
Automatic System Testing
WARNING
Improper flows of corrosive chemicals or other liquids during a system test

run can cause worker injury or equipment damage.
During a test run of a system, all hand valves must remain closed to prevent
the accidental entry of process fluids.
CAUTION
The water in concentrated chemical piping must be purged completely with

air. Any water remaining in the piping could cause overheating when
chemicals are introduced.
An automatically-controlled system, including the regenerant system, must be test-run
with water prior to the initial operation of the equipment. Operators must be sure that the
entire system operates properly (without leaks) before using regenerants or process
liquids.
SAFETY PRECAUTIONS
Page 2-4
Rev. 0
2.1.10 Servicing Automatically-Controlled Components

WARNING
Accidental and unexpected operation of remote components can cause

personal injury or death.
If controller programming or program modification is performed while
system components are being serviced, disconnect the controller output
devices or the individual component tubing or wiring to avoid accidental
operation.
Workers must use extreme caution when servicing automatically-controlled components.

Sudden and unexpected operation of components being serviced can cause severe injury
to the workers involved.
Before working on automatically-controlled components, make sure that the automatic

controller is disabled to the point that it can not be used to operate remote components.
Close, lock, and tag valves and lockout and tag electrical motor starters and other
electrical devices.
Finally, inform other operators and control room workers of repairs or servicing in
progress.
SAFETY PRECAUTIONS
2.2
Page 2-5
Rev. 0
SPECIFIC SAFETY PRECAUTIONS

This subsection contains the safety precautions for the specific types of equipment that are part
of your U.S. Filter system.
2.2.1
Ion-Exchange Vessels and Storage Tanks

This subsection contains safety precautions specific to storage tanks and to vessels
containing ion exchange resin.
WARNING
Empty tanks and vessels may tip forward suddenly and without warning,
causing equipment damage or injury to workers.
Always brace tanks and vessels securely until they are loaded or are bolted to
the plant floor.
WARNING
Tanks and vessels that are empty (contain no liquids or media bed) may not balance when
stood upright. Workers must use extreme caution when working with empty tanks and
vessels and must brace them securely or mount them permanently to the plant floor.
Heavy manhole covers can cause equipment damage or severe personal
injury or death if dropped from any height.
Do not stand under workers who are removing manhole covers. Use extreme
caution when removing or moving heavy manhole covers.
Use extreme caution when removing heavy manhole covers from vessels being loaded. If
lifting davits (arms) are not provided for the covers, use a sling or chain and some type of
lifting device to remove and hold the cover. Do not remove all of the cover bolts until it
is certain that the cover is securely slung and supported and will not fall.
Falls from the top of a vessel can cause severe injury or death to workers.
WARNING
Always load vessels from a platform or lifting device. Platforms and lifting
devices must be equipped with side rails and slip-resistant surfaces where
workers will stand.
Do not stand of top of a vessel while loading it. The curved top surface does
not provide adequate footing, and the lack of hand holds and the small
surface area can lead to falls.
When a vessel is being loaded, workers must stand on a safe platform or lifting device
and must take all necessary measures to avoid falls.
If a vessel must be loaded using a ladder, use a stable, free-standing ladder that is tall
SAFETY PRECAUTIONS
Page 2-6
Rev. 0
enough to allow workers to easily reach the vessel opening. If possible, tie the ladder to
the vessel with a rope.
WARNING
Confined spaces may contain insufficient oxygen or hazardous chemicals,

materials, or vapors, which could result in serious injury or death.
Do not enter a confined space without proper personal protective equipment.
Before and during entry, follow the proper OSHA procedures.
WARNING
If the vessel must be entered, adhere to the OSHA permit-required confined space
procedures in standard #29 CFR Part 1910.
Process fluids - especially chemicals - entering a vessel while workers are
inside can cause severe injury or death.
Make sure all of the vessel's process entry and exit points have been blinded
off.
WARNING
Before entering a vessel, verify that all connections to the vessel have been isolated and
tagged out. Also assign a person (called a "spotter") to stay outside the vessel near the
manhole. The spotter should be prepared to give assistance to those inside the vessel or
call for help in the event of an emergency.
Spilled ion exchange resin makes standing and walking extremely hazardous
and can lead to falls and worker injury.
If ion exchange resin is spilled on the surfaces where workers must stand and
walk, clean up the media immediately.
When handling vessel media (especially ion-exchange resins), avoid stepping on any of
the media that is spilled. Sweep up and dispose of the spilled media as soon as possible refer to the media MSDS in section 2.3 for cleanup details.
SAFETY PRECAUTIONS
2.2.2
Page 2-7
Rev. 0
Chemical Systems
This subsection covers safety precautions for those systems that use corrosive chemicals,
such as ion exchange systems, chemical day tanks and regenerant dilution stations.
Chemical systems often use highly corrosive chemicals that can cause severe
burns or blindness upon contact.
WARNING
Wear the proper personal protective equipment (PPE) when handling these
chemicals - refer to the chemical MSDS from the chemical supplier.
Equipment operators must be trained in the safe use and handling of hazardous
chemicals.
Fixed (hard-piped) eye washes and emergency showers should be installed at locations
where hazardous chemicals are stored or used.
NOTE:
Facilities such as eye washes and showers must conform to national and local
safety codes and laws.
In areas where large quantities of hazardous chemicals are stored, emergency ("escape")
respirators should provided.
Workers must wear safety glasses, face shields, respirators, and protective clothing when
working with corrosive chemicals.
Refer to the material safety data sheets from the chemical suppliers for information on
recommended safety wear, handling procedures, and storage practices for specific
chemicals.
Operators must use extreme caution when working with corrosive chemicals.
Workers must read the chemical safety information in section 2.3 carefully and must be
familiar with basic first-aid procedures for the chemicals used with this system.
SAFETY PRECAUTIONS
WARNING
Page 2-8
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Chemical sprays from pressurized piping can cause severe injury to workers.
Relieve all pressure from piping before performing service.
Wear protective clothing and face protection when disassembling chemical
piping.
WARNING
Before servicing components that handle hazardous chemicals, make sure all internal
pressure is relieved and that all chemicals have been drained.
Regenerant chemicals entering a vessel while workers are inside can cause
severe injury or death.
Make sure all of the vessel's process entry and exit points have been closed.
Before entering a vessel connected to chemical systems, follow the guidelines given
earlier in this chapter.
Post warning signs in areas and on components containing hazardous chemicals.
Provide adequate water supply to flood areas of spills - refer to the chemical MSDS's
from the chemical supplier for details on handling chemical spills.
Do not breathe chemical vapors or mists. Protect nose, mouth and lungs from damage by
wearing a NIOSH-approved breathing mask.
If chemicals are mixed manually, add chemicals slowly to the full amount of water and
stir the solution. Never add water to a chemical because boiling and spattering can result.
Do not smoke, weld, or operate electrical equipment that may arc in the vicinity where
hydrochloric acid or volatile chemicals are stored or used.
WARNING
Corrosive chemical leaks at bolted flanges and other connections can cause
worker injury and equipment damage.
Chemical-resistant safety shields are recommended for all connections in
piping that carries concentrated corrosive chemicals.
The chemical storage, pumping, and mixing systems must be properly piped, valved, and
wired, and must be leak-free. Piping carrying concentrated corrosive chemicals must be
installed properly using the proper chemically-resistant materials, and all flanged
connections should be covered with shields to prevent chemical sprays in the event of
leaks.
SAFETY PRECAUTIONS
2.2.3
Page 2-9
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Fans, Blowers, and Pumps (if applicable)
WARNING
Contact with rotating drive mechanisms can cause severe personal injury.
Never operate fans, blowers, or pumps without safety shields around the
motor drive mechanisms.
Any fans, blowers, and pumps that are supplied loose (unmounted) must be properly
mounted to avoid movement and excessive vibration.
Also, all motor drive safety shields and belt guards must be properly installed, and all
supplied WARNING and CAUTION signs and labels must be maintained at the device.
Fans and blowers must be covered with shrouds and guard screens before being started.
Inlet screens for fans and blowers must have a small enough grating to keep large
particles and debris from entering the intake.
WARNING
Contact with rotating fans and blower wheels can cause severe injury to
workers.
Do not service filters, guards, or other components until the fan or blower is
stopped and locked out of operation.
2.2.4
WARNING
Glass-Tube Type Flow Meters and Level Gages (if applicable)

Thermal expansion of liquids trapped in glass-tube flowmeters or level
gauges can cause explosive rupture of the tube and injury to workers.
If isolation valves adjacent to a glass-tube flowmeter or level gauge must be
closed, the tube must first be drained completely.
If glass-tube type flow meters or level gauges are used with the system, the clear safety
shields must be undamaged and must be installed properly.
SAFETY PRECAUTIONS
2.3
Page 2-10
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MATERIAL SAFETY DATA SHEETS (MSDS's)

This section contains Material Safety Data Sheets (MSDS's) for hazardous chemicals and
materials supplieded with this equipment. These sheets contain important information about
specific hazards and first aid procedures and must be reviewed by all operating personnel.
Refer also to the MSDs for the chemicals used to regenerate the deionizers. These should be
supplied by the chemical supplier.
Page 3-1
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3.0 PREPARATION AND STARTUP

3.1
EQUIPMENT STORAGE AND INSTALLATION
The purpose of this section is to provide general information on receipt and installation of new
equipment. Procedures for the installation of specific components can be found in the Vendor Literature
Manual.
All equipment must be installed as shown on the piping, wiring and layout drawings for this job. Refer
to the drawings supplied with this equipment when reading and performing the procedures in this
section.
3.1.1
Equipment Handling Procedures
The following guidelines should be observed.

1.
All lifting and moving procedures must be performed by experienced construction

workers using standard rigging methods.
2.
Before beginning any equipment handling procedures, refer to the following

sections in the Occupational Health and Safety Administration (OSHA) manual
#2206: "General Industry Standards." Also, refer to any other applicable
literature and information for cranes, lift trucks, and other equipment used for
lifting and moving.
Subpart N: "Materials Handling and Storage"
Section 1910.176: "Handling Materials - General"
Section 1910.178: "Powered Industrial Trucks"
Section 1910.179: "Overhead and Gantry Cranes:
Section 1919.180: "Locomotive and Truck Cranes"
Section 1919.181: "Slings"
3.2
INITIAL EQUIPMENT RECEIPT AND INSPECTION
3.2.1
Equipment Inspection upon Receipt
Page 3-2
Rev. 0
Follow equipment handling guidelines when moving equipment and

components and when opening crates.
CAUTION
1.
When the job shipment is received, it must be inspected immediately for

completeness and for shipping damage.
NOTE:
Unless otherwise specified U.S. Filter equipment is guaranteed against defective

design, materials, and workmanship for eighteen (18) months from the date of
shipment, or for one (1) year from the time of startup. The warranty on individual
component parts not manufactured by U.S. Filter is limited to that of the
manufacturers of those components.
2.
Record the item and crate numbers of all received pieces. Some crates will
contain several different tagged items; these crates should be opened temporarily
to check the different items.
Compare the item and crate numbers recorded to those shown on the shipping list
supplied with the equipment, and check off each item that has been located. If
items appear to be missing, contact the carrier and U.S. Filter immediately.
NOTE:
Small components that were removed from major components during preparation
for shipping may not have item numbers. These untagged components can be
identified by referring to the piping drawings and the part lists for this job.
3.
Perform a close inspection of all major components, piping and sub-components.

Damage can be easily missed during a quick inspection.
Make sure that gauges, sample piping, and tubes have not been damaged or
broken off. Also look for broken, pinched, or bent piping.
4.
Perform a close inspection of all shipping crates, boxes and loose components.
Verify that no damage has occurred to these pieces.
Page 3-3
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Check for visible damage to crates, piping, and piping ends. If a crate or box appears damaged, open the
crate or box and investigate further.
3.2.2
NOTE:
Shipping damage should be promptly reported to both U.S. Filter and the carrier
to ensure repair or replacement. Avoid releasing equipment for assembly until
all damage claims and/or shortage problems have been resolved.
5.
If the equipment will be stored before being assembled, reseal any crates that
were opened for inspection. Refer to the storage procedures given in subsection
1.3.
Inspection of Lined Vessels

1.
Remove the manhole covers on lined vessels to allow the inspection of the linings
and distribution piping.
NOTE:
If the vessel(s) were loaded at U.S. Filter, use caution when opening to avoid
spilling or losing resin.
2.
Spark testing of vessel lining is recommended to detect pinhole leaks. If

spark-testing equipment is not available, perform a close visual inspection for
scratches, tears, seam separation, and bubbles. For vessels with plastic or rubber
linings look for areas that may have separated from the vessel's side sheet.
3.
If damage to the lining is found, notify U.S. Filter immediately so that repairs can
be made. If the lining is not repaired before the vessels are stored, the areas of
damage must be thoroughly documented with U.S. Filter.
3.3
STORAGE OF UNASSEMBLED COMPONENTS
3.3.1
General Storage Guidelines
Page 3-4
Rev. 0
Use the following instructions if the equipment will be stored before it is assembled.
NOTE:
To store individual system components (such as instruments, valves, controls etc.) refer
to the manufacturer's storage instructions in the Vendor Literature Manual.
Complete inspection of the equipment.
Place a copy of the marked-up shipping list and the written list of received item numbers
together and store them in a safe place. If necessary, make copies of these lists and distribute
them to the individuals who will be involved in the assembly of the equipment.
Select a storage location where all U.S. Filter equipment can be stored in one area. Avoid
separating equipment, components, and crates.
On large job sites, it is easy for small or separated components to become misplaced or lost.
If the equipment must be separated, note the exact locations of all pieces on the shipping list
or the written list of received pieces.
Set the skids and other components on wooden blocks to keep them out of any standing
water and to protect their painted surfaces.
If possible, store the equipment indoors where it will be protected from sunlight and adverse
weather conditions.
If the equipment will be stored for an extended length of time (inside or outside), cover it
with plastic or canvas tarps to protect it from water, dust, paint over-spray, etc.
If the equipment must be stored outside, special precautions must be taken.
Items that can be damaged by water must be securely wrapped with plastic and covered with
tarps.
CAUTION
Storing equipment in direct sunlight may result in the deterioration of

equipment finishes and glued or epoxied parts. The heat from direct
sunlight can weaken or distort plastic and melt the glue used to adhere these
components together.
Page 3-5
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Store the equipment in a shaded area or cover it with light-colored tarps.
If outdoor temperatures are warm, remove all vessel manhole covers to allow air circulation.
When the outdoor temperature is below 32F (0C), it is important to verify that the piping,
pumps, valves, and any other components where liquid may have accumulated are
completely drained.
CAUTION
Always drain all liquids from components that must be stored in freezing
temperatures. Expanding ice can damage components.
Open all hand valves on the equipment to allow trapped water and moisture to escape.
To store electrical panels, make sure all of the openings in the panels are sealed with tape and
that the panel doors are securely closed.
When equipment has been stored in extremely hot or cold temperatures and then is moved to
an assembly area, always allow the equipment temperature to stabilize before beginning
assembly. This is especially important if the equipment is very cold.
When equipment is brought out of storage, compare the component quantities with the
original shipping list. Any pieces that are not found at this time must be located quickly to
avoid delays in assembly and startup of the equipment.
Prior to assembly of the equipment, perform a quick recheck for possible equipment damage.
3.3.2
Page 3-6
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Storage Instructions For Lined Vessels

Storing equipment in direct sunlight may result in damage to vessel linings.
CAUTION
If lined vessels are stored outside in warm weather, the vessels must be
ventilated and protected from direct sunlight.
1.
If a vessel is lined with a hard epoxy material, use extreme caution when
moving the vessel when it is cold. Epoxy linings will crack easily when cold.
CAUTION
2.
3.3.3
If a vessel lining has been damaged, it must be repaired before the vessel is
loaded with resin or other media.
Whenever lined vessels are brought out of storage, the linings must be inspected
for possible damage.
Storage Instructions For Systems Using Ion-Exchange Resins
CAUTION
Storing equipment in direct sunlight may result in damage to ion exchange

resins.
If loaded vessels are stored outside in warm weather, the vessels must be
ventilated and protected from direct sunlight.
All ion-exchange resins must be stored in temperatures above 35F (2 C). For anion
resins the maximum storage temperature is 95 F (35 C). Cation resins can be stored at
any ambient air temperature above 35F (2 C). Temperatures outside these ranges could
damage the resin.
If vessels are to be stored in temperatures outside acceptable ranges, make sure that the
resin has been removed (refer to the vessel's subsystem operating manual in subsection
5.3). Store resin in a rigid plastic lined container(s) capable of handling the weight of the
resin. Cover resin container(s) and place in a storage area that will be kept within the
specified temperature ranges.
3.4
Page 3-7
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EQUIPMENT INSTALLATION GUIDELINES

All equipment and mechanical components listed on the shipping list must be installed according
to the piping, wiring, and layout drawings for this job. These lists and drawings were supplied
with the equipment.
The installation should be performed by qualified maintenance or construction workers in
accordance with applicable plumbing, wiring, and construction codes and procedures.
For information on installing and inspecting specific components, refer to the Vendor Literature
Manual.
3.4.1
General Installation Procedure
NOTE:
Below is a suggested sequence for installing the components for this system. This
sequence may be altered depending on the conditions at the jobsite. Some of the
procedures may be performed simultaneously depending on the availability of workers
and operators.
NOTE:
Before proceeding with the steps in this subsection read the installation procedures
specific to each piece of equipment provided in the Vendor Literature Manual.
1.
CAUTION
Position and level all major components as shown on the layout and piping
drawings, paying special attention to elevations and center-to-center dimensions.
If components do not attach easily or line up exactly, apply only a moderate
amount of force to install them. Excessive force will put an unnecessarily
high stress on the components, which could damage them or cause process
stream leaks.
This equipment was originally assembled at U.S. Filter using the dimensions
given on the design drawings. The components that were shipped loose or
disassembled for shipping will fit back together more easily if the original design
dimensions are adhered to during installation.
NOTE:
When installing an assembly or instrument, do not tighten the bolts and other
fasteners until all of the adjacent assemblies and instruments have been attached
to it. Then evenly tighten all of the assemblies and instruments at the same time.
Page 3-8
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Vibration-induced movement of equipment can result in misalignment and damage to piping

CAUTION
components.
2.
NOTE:
Equipment which requires anchoring to the floor will be equipped with anchor
bolt holes. After positioning, aligning, and leveling each piece of equipment,
anchor it to the plant floor.
Vibrations may cause equipment to "walk" if not properly anchored to the floor.
3.
Mount all loose instruments to their proper locations. Connect the valve/piping
assemblies. Each valve/piping assembly and instrument is labeled with an item
number, which corresponds to the same item number on the shipping list and on
the piping drawings.
4.
Be sure that all of the installed equipment is braced properly so that only a
minimum amount of stress is put on the components and fasteners.
5.
Fabricate and/or install the interconnecting piping between the major components
and their subassemblies, as required. Brace as needed. Always use piping
materials that are compatible with the process stream(s) that the pipe will carry.
6.
Install electrical controls, instruments and any loose field enclosures next to the
equipment or instruments they will control, and connect the necessary tubing
and/or wiring from the enclosures to the equipment valves and instruments. The
tubing connections on the side of each solenoid enclosure or stager valve
(automatic systems only) should be labeled with the tag numbers of the valves
they connect to.
If possible, panels that rest directly on the floor (no support legs) should be
mounted on a slightly raised floor or pad. This will help reduce the chance of
moisture or water getting in the panel.
NOTE:
7.
When mounting a control panel on a raised pad or other structure, be sure that
the height of the controls (switches, etc.) does not exceed the normal reach of
operators.
Install the main control panel (if applicable), and connect the tubing and/or wiring
from the panel to the field enclosures and equipment.
8.
Page 3-9
Rev. 0
Connect the required process streams and utilities to the U.S. Filter equipment as indicated on
the piping drawings. Refer to section 1.0 of this manual for the types of process
streams and utilities used with your system.
9.
3.4.2
Install any remaining wiring and tubing.
Installation Procedures Specific to Lined Vessels
CAUTION
In extremely cold weather, lined tanks should not be bumped or have

excessive stress applied to them.
CAUTION
Never weld on a lined vessel. High temperatures will damage the vessel
lining.
Some of the vessels for this system may be lined with sheet PVC. Sheet PVC
is a thermoplastic and must not be exposed to temperatures above 150F.
Do not weld on lined vessels. The high temperatures necessary for welding may
damage the lining. If welding must be performed on the vessel legs, do not weld
within 12 inches of the actual vessel.
3.4.3
Chemical System Installation

Highly corrosive chemicals are often used during system operation. Bodily
contact with these chemicals can cause severe burns or blindness. Material
safety data sheets have been provided in section 2.0 for all harmful materials
and chemicals provided with this equipment.
WARNING
Failure to install, pre-test, and operate the chemical systems properly can
result in serious injury to workers due to leaks and mechanical malfunctions.
Because of the hazardous chemicals used with regenerant and chemical-feed systems,
special attention must be paid to the installation of their components.
1.
Position any chemical piping assemblies as indicated on the layout prints.
2.
Page 3-10
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Always use chemically resistant materials for the chemical system components.
3.4.4
3.
All supplied caution and warning labels must be installed and maintained at
chemical storage tanks and other components. If labels are lost or damaged, new
labels are available from U.S. Filter or the component manufacturer.
4.
If check valves or chemical ejectors are used, verify that they were installed for
the proper flow direction.
5.
When installation is complete, the entire chemical system must be pressure tested
before actual chemicals are introduced.
Pump Installation Procedures
Once single-phase pumps and pump skids have been installed, the alignment
of the pump-drive couplings must be checked and corrected as necessary to
prevent shattering or distortion of the coupling.
CAUTION
1.
NOTE:
If pumps are shipped loose (not skid-mounted), they must be positioned and then
mounted and grouted to the floor using approved construction procedures. On
single-phase pumps coupled to motors, align the coupling using the pump
manufacturer's instructions in the Vendor Literature Manual.
Do not couple 3-phase pump motors until proper rotational direction has been
achieved (refer to subsection 5.0).
2.
Mount the pump motor starters (if applicable) next to the pump or in a common
motor control center. Wire the motor starters to the pump motors and to the main
control panel.
3.
Many pump manufacturers ship their pumps without lubricants installed; these
lubricants are often shipped in separate containers.
After pumps are mounted and aligned, the proper types and quantities of pump
and gear lubricants should be located and installed.
3.5
Page 3-11
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INSTALLATION OF UTILITIES AND OTHER PERIPHERAL EQUIPMENT

This subsection covers utilities and equipment that are required to operate this system but have
not been provided by U.S. Filter.
The equipment and utilities listed here must be connected and operational before the U.S. Filter
equipment can be operated.
3.5.1
Process Feed
The quality of the feed stream must be maintained as described in section 1.0.
3.5.2
Drain Piping (For Waste, Etc.)
CAUTION
Pipe elbows, tees, and other fittings combined with long pipe runs can
increase backpressure to the point that proper drain flows cannot be
achieved.
Drain piping should be as straight and as short as possible. Drain pipes
should be one size larger than the manifold piping.
The drain piping can be piped into headers to drain, but it is best to pipe the individual
component to a sump, drain trench, or other open drain. Open drains make it easier to
take samples and allow for visual observation by the operating personnel.
If the drain flow will contain hazardous or corrosive chemicals, be sure to use piping
materials that will resist these chemicals.
3.5.3
Interconnecting Piping
CAUTION
Liquid pipe-thread sealers and lubricants can contaminate filter elements

and other components. Teflon tape should be used for assembling threaded
piping for high-purity applications.
All customer-supplied piping must be installed at this time. This piping must be flushed
and cleaned before it is connected to the equipment.
3.5.4
Page 3-12
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Tubing and Wiring

All customer-performed tubing of control valves and wiring of instruments must be
completed.
3.5.5
Electrical
Proper power connections are required for controllers, pumps, etc. Refer to the U.S.
Filter wiring diagrams for specific power requirements.
3.5.6
Air
Dry, oil-free plant air is required for pneumatic valve operation and other functions. Air
must be filtered to remove moisture, oil, and particulates. Refer to section 1.0 or the job
drawings for specific pressure requirements.
NOTE:
3.5.7
All air sources must be filtered to remove moisture, oil, and particulates.
Pumps
All customer-supplied pumps must be leveled, aligned, piped, wired, lubricated and
checked for proper rotation.
NOTE:
3.5.8
The same procedures can be followed as those described for U.S. Filter equipment. Also
refer to the vendor literature supplied with the components.
Storage Tanks
Any storage tanks used with this system must be piped and ready to hold liquids. If
possible, these tanks should be filled with water and checked for leaks prior to beginning
operation.
Be sure storage tanks are clean before introducing any liquids.
3.5.9
Cartridge Filters
Any cartridge filters used with U.S. Filter equipment should be installed, inspected, and
cleaned at this time.
3.5.10 Heaters and Heat Exchangers

Any heaters or heat exchangers needed to supply process liquids at the proper
temperatures must be piped or wired and made operational. Refer to the information
supplied by the equipment manufacturer.
3.6
Page 3-13
Rev. 0
SYSTEM PREPARATION CHECKLIST
Piping And Vessels
All equipment installed, leveled, piped anchored, and grounded.

All piping installation completed; inlet, interconnecting and outlet.
Inlet water supply available at required flows and pressure.
All interconnecting piping, air lines, and vessels pressure tested as required, and free of leaks.
Adequate supports and braces provided for all piping
Air Supply
Air supply available at required flows are pressure.

Air lines, including tubing, complete to all enclosures and valves etc.
Air is of instrument quality; free of water or particulate.
Electrical And Instrumentation
Installation of all instruments and devices which were shipped loose.

All electrical tie-ins completed, all circuits rung out; including all 120 VAC, 480 VAC, neutrals,
grounds and 4-20 mA current loops to and from field devices.
Instrument calibration checked by qualified technician and documented by log sheet or sticker on
each device.
Pumps And Motors
All pumps utilized by the system grouted in and aligned by a certified millwright.
Motor wiring and MCC complete with proper wire size, fuses, heaters, etc.
Pump motors checked for rotation and vibration prior to coupling.
All pumps coupled and lubricated as per manufacturers specifications.
Drain Connections
All drain connections meet unit backpressure requirements.

All drain piping installation complete (at least one pipe size larger than connection at units).
Drain piping tested for leaks where applicable.
Note: Drain piping materials must be compatible with chemical waste streams.
Media
Media inventoried and record made of amount and condition.

Media storage to prevent damage by elements, et., direct sun exposure, rain freezing, etc.
Media loaded as indicated by the instructions.
3.7
INSPECTION OF FACTORY-INSTALLED DISTRIBUTION LATERALS
Page 3-14
Rev. 0
If distribution piping has already been installed in the vessel, inspect it using the procedures given
below. If damage is found, call U.S. Filter immediately.
1. Internal vessel cleanliness is critical. Particulates and/or debris will plug distribution
screen. Any plugged screens will adversely affect system operation. All precautions
must be exercised. For example, all uniforms and shoes must be clean; all manholes
protected so as not to allow debris to enter a vessel or section; and no flushing of pipes
into the vessel.
2. Extreme care must be exercised such that any tools or movement in a vessel does not
puncture a screen or the vessel lining. If a screen or piece of lining is damaged
accidentally, it is critical that workers report it so repairs can be made.
3. Prior to entering an empty vessel, read and follow the Vessel Entry Procedures given in
section 2.0.
4. Remove the vessel manhole cover.
5. Inspect the internal distribution for the following. Refer to the drawing on the next page
for an illustration of the proper lateral orientation.
6.
7.
The locations and dimensions of all distribution components are as shown

on the U.S. Filter distribution installation prints supplied with the
equipment.
All threaded and bolted distribution components are installed tightly.
All distribution screens are free from rips or tears, are clean, and are free
from bacterial growth and other foreign materials.
In vessels with dished bottoms and tops (not with a flat false top or
bottom), vertical riser pipes are drilled with 1/4" holes right at the point
where they exit the vessel. The holes on bottom risers are wrapped with
screen to prevent media loss.
Vessel is clean and lining is undamaged.
Use a long vacuum hose to clean any dirt or contaminants out of the vessel.
Replace the manhole cover.
Page 3-15
Rev. 0
Figure 3-1: Lateral Orientation
Gasket
Tank
VP Deionizer Top Distributor
VP Deionizer Bottom Distributor
3.8
Page 3-16
Rev. 0
EQUIPMENT FLUSH PROCEDURES

The piping and other components must be flushed thoroughly prior to system startup. The
flushing procedures are critical to the proper startup and operation of the equipment.
3.8.1
Customer-Supplied Inlet Piping Flushes
1.
All system inlet piping must be flushed thoroughly before it is connected to the
U.S. Filter system.
Newly-installed piping usually contains welding slag, dirt, and other debris that
will plug filters and can damage pumps.
2.
If the inlet piping runs have already been connected to the skid, the piping must
be disconnected at this time.
3.
Each inlet piping run must be flushed with clean, clear water at the maximum
possible velocity.
The piping runs should be flushed one at a time while workers observe the
effluent flow of water.
3.8.2
4.
Each piping run must be flushed until the effluent is clear and clean.
5.
When a piping run has been flushed thoroughly, it can be connected to the U.S.
Filter system.
Chemical Feed/Storage Tank Flush

Inspect the interiors of all liquid storage tanks. If dirt or other material is present, use
clean water to rinse out the tanks. Dry tanks completely then replace the tank covers to
keep contaminants out. Keep the tank covers in place except when manually adding to
the tank or mixing the tank contents.
3.8.3
Page 3-17
Rev. 0
Piping Flush
Do not flush into a vessel; always flush away from a vessel to protect the
vessel distribution piping (if applicable) and keep the vessel clean.
CAUTION
1.
Open the various process valves needed to allow water to flow through and flush
the system piping.
To open a solenoid-controlled automatic valve, override its solenoid in the panel
closest to the valve. Refer to the vendor literature for the procedure for the
specific solenoids used.
2.
Start the flow of water to the system. If necessary, start a pump to move the flush
water forward.
3.
The flush water should now flow through the piping and to drain through the
various effluent outlets.
As the flush continues, close or throttle hand valves as required to direct the water
through all areas of the piping.
While the piping is flushing, open each sample valve in the piping momentarily to
flush all dead legs.
4.
When the flush effluent is clear and clean, stop the water flow.
If applicable, turn off the pump, reconnect the valve tubing, and remove the
solenoid overrides.
3.8.4
Vessel Cleaning and Flushing

Inspect the interiors of all pressure vessels.
Remove any large debris or particulates by vacuuming or wiping. Be sure to follow the
Vessel Entry procedures in section 2.0 if entering a vessel to clean it.
Remove smaller particles and dirt by opening any low-point drain valve on the vessel
face-piping, or remove the caps or plugs at the bottom of the piping manifold. Use clean
water to rinse out any remaining dirt.
3.9
Page 3-18
Rev. 0
PRESSURE TESTING
Mechanical failure during pressure testing can result in serious injury to
workers. Do not exceed the pressure rating of components when performing
pressure tests.
WARNING
Wear eye and face protection when performing pressure tests.

When all equipment and components have been installed, the system must be pressure tested
with water using the following procedures.
3.9.1 General Pressure Test Guidelines
1.
Vent the vessel or piping, and fill it with water using the normal inlet valves.
For systems with stainless steel piping or fittings, you may want to use water with
a low chloride content (<50 ppm), such as deionized water, to minimize the
corrosion of the piping during extended pressure-testing.
Do not pressure-test the system with compressed air. If a mechanical failure
occurs while the system is pressurized with air, the released air can propel
fragments of piping or other components at high speeds, resulting in worker
injury.
WARNING
Always fill and pressurize the system with water. Water is basically
incompressible and will not "store" energy as will compressed air.
2.
Be sure that the piping and vessels to be tested are filled with water. This
minimizes the possibility of injuries should a mechanical failure occur during the
pressure testing.
3.
Pressurize each portion of the system to its maximum operating pressure, but not
any higher. To do this, deadhead the pump(s) that supplies process feed to that
portion of the system.
4.
During pressure testing, stand away from vessel windows, in-line sight glasses,
glass-tube flowmeters, and plastic piping. These are the components that are
most likely to fail during pressure testing.
5.
Page 3-19
Rev. 0
When the vessels and piping are completely filled with water, close any vent
valves and allow the pressure to reach the maximum pressure of the inlet pump
(dead-head the pump) or the maximum pressure rating on the system, whichever
is lower. Refer to section 1.0 for vessel pressure ratings.
When the pressure stabilizes, close the inlet valves and turn off the pump to keep
the system at the desired pressure.
6.
If possible, allow the system to remain pressurized for several hours, then perform
a close inspection.
7.
Tighten any fittings or other bolted components that are leaking. If components
must be disassembled for repairs, be sure to relieve all pressure from the system
first.
NOTE:
3.9.2
After the system has been operated at normal temperatures for some time, the
fasteners may require retightening.
Internal Leak Tests for Valves

These tests are intended to insure that the control valves are closing and sealing properly.
1.
To check for inward leaks, close all valves and pressurize all inlet and outlet
headers with water. Open all manifold sample valves and allow the manifold to
drain.
If water continues to flow from a sample valve after the manifold is drained, a
leaking valve is indicated.
2.
To check for outward leaks, pressurize the vessel and manifold piping with water.
Close all valves and drain any accessible inlet and outlet headers. If water
continues to flow from the inlet and outlet headers after they are drained, a
leaking valve is indicated.
3.
Valves must be able to hold pressure for a minimum of one hour. Any leaking
valves must be adjusted, repaired, or replaced and then retested before the system
is operated.
NOTE:
3.9.3
Page 3-20
Rev. 0
If an automatic control valve leaks when closed, check to see if it uses

"bottoming" stops. If these stops are present, adjust the stops according to the
valve manufacturer's instructions.
External Leak Tests for Vessels with Windows

This subsection describes the procedures for pressure-testing vessels with windows, to
check for external (visible) leaks.
1.
Make sure that all of the nuts are too tight to spin by hand. If not, loosen all of
the nuts to hand-tight, and tighten them to 12 ft-lbs in 2 ft-lb increments. Tighten
them in the order shown on the next page.
2.
If a leak occurs at a vessel window, tighten the window nuts in 2 ft-lb increments
until the leak stops or until the maximum torque is reached, as shown in the table
below. Tighten in the sequence shown on the drawings that follow the table.
After repairs are made, pressurize the system again to double-check these repairs.
Table 3-1: Window Tightening Pressures/Torques
Maximum Pressure (psig)
Maximum Bolt Torque (ft-lbs)
75
12
100
14
150
18
200
22
Figure 3-2: Tightening Rectangular Windows
Page 3-21
Rev. 0
Figure 3-3: Tightening Round Windows
3.10
Page 3-22
Rev. 0
VESSEL LOADING
2.10.1 General Guidelines for Loading Ion-Exchange Vessels

The following are guidelines for loading two-beds and mixed-bed exchangers.
1.
Remove the manhole cover on the top or upper sidesheet of the vessel (refer to
section 2.0 for safety precautions). On small vessels with no manhole, disconnect
the piping going into the top of the vessel, remove the bolts holding the flanged
top piece to the spool body of the vessel, and lift off the entire top piece.
2.
Prior to loading any media into a vessel, all internal distribution must be inspected
using the procedures given earlier in this section, and the vessel must be cleaned
to remove foreign material.
If the distribution laterals are wrapped with steel or plastic screen, check the
wrappings carefully for tears or breaks. Use extreme care when working with
wrapped laterals.
3.
The vessel to be loaded must be properly leveled and braced before loading
begins.
4.
Refer to Section 1.0 of the main manual for the sizes, types, and quantities of
media to be loaded into each vessel or tank.
To find the relationship between media weight and volume, use the table in
Section 1.2.10 of the main manual.
While loading each two-bed, be sure to fill out the data form at the end of this
Section of the main manual.
CAUTION
Page 3-23
Rev. 0
If the vessel has bottom distribution laterals wrapped with screen, use
extreme care when loading the vessel. If the screens are torn or broken
during loading the media can be lost to drain.
Figure 3-4: Single-Layer Cation or Anion Bed (typical)
MEDIA
vp2bedmedia.wmf
Page 3-24
Rev. 0
3.10.4 Loading Ion-Exchange Vessels (except Mixed-Beds)

The following are general guidelines for loading resin in an ion-exchange or chelation
vessel, with the exception of mixed-bed deionizers. Examples of these vessels are
softeners, dealkalizers, and the cation and anion vessels in a two-bed deionizer.
NOTE:
1.
When loading anion resin, use soft or deionized water to fill the vessel.
Before loading any resins, always verify that the proper resins are being used.
Cation and anion resins must not be mixed or placed in the wrong vessels.
Prior to loading resins into process vessels, record the lot or batch number(s) of
the resin. When loading the resins, record the installed location (vessel number or
name) of each lot or batch of resin.
If resin container labels are missing or if there is doubt about the identity of a
resin, contact U.S. Filter or the resin manufacturer.
4.
Larger quantities of resin are most conveniently loaded using a large eductor.
The eductor draw line is inserted directly into a shipping drum and the eductor
outlet line is placed in the vessel manhole or is connected to a resin sluice nozzle
near the top of the vessel (where applicable). Once the eductor motive flow is
started, a separate sluice (fluidization) line must be inserted into the drum to keep
the resin fluidized.
When transferring resin with an eductor, some of the water in the vessel may have
to be drained out as the transfer progresses.
5.
If the resin is new, it must receive an initial regeneration before being placed in
Service. Perform all startup procedures given later in this section.
3.11
Page 3-25
Rev. 0
STARTUP PROCEDURES
To start up the VP Series two-bed deionizer, use the following procedures.
3.11.1 Regeneration System Setup

Use caution when handling regeneration chemicals. Refer to the safety
information in section 2.2 of the main manual before handling.
WARNING
1.
The customer is to supply acid (technical grade or better) at the specified

concentration (30% HCl) to the acid eductor. The customer is to supply the acid
tank.
2.
The customer is to supply caustic (rayon-grade or better) at the specified

concentration (50% NaOH) to the caustic eductor. The customer is to supply the
caustic tank.
3.
Set the air pressure regulators for the valve solenoids to 55 psi.
3.11.2 Two-Bed Deionizer Startup
1.
Open all customer supplied manual valves. In addition, close all sample valves
and vent valves, and open all of the instrument isolation valves.
2.
Make sure that the customer's waste system is ready to handle the chemical
wastes that will be generated by the two-bed system.
Contact with electricity can cause burns, cardiovascular failure, or death.
Follow the precautions given in section 2.0 of the main manual.
WARNING
3.
Start up the controller using the applicable vendor literature provided for that
controller (see section 9.1 of the main manual). Verify that the values in the Data
Access tool (DAT) on the control monitor contain the initial control setpoints
listed in the Control Write-Up document in section 4.2.
Page 3-26
Rev. 0
4.
Calibrate all of the instrumentation on the system using the manufacturers'

instructions in the Vendor Literature Manual.
5.
Verify that the vessels have been properly loaded using the instructions given
earlier in this chapter.
6.
Regenerate the two-bed unit using normal start-up procedures with the following
exceptions:
8.
A.
Extend the backwash steps so that each step lasts until the backwash
effluent is clear and clean.
B.
Extend all of the chemical-in steps so that each step lasts twice as long as
indicated in the Regeneration Sequence in section 1.2.13. New resins
require twice the normal amount of chemicals for the first regeneration.
Following the initial regeneration of the unit, put the system into Service. This
completes the startup of the two-bed system.
3.12
Page 3-27
Rev. 0
VP SERIES TWO-BED DEIONIZER DATA FORM

The following page explains the VP Series two-bed deionizer data form. The purpose of this
form is to consistently record data and system performance.
3.12.1 Cation/Anion Two Bed Data Form Instructions

The numbers below refer to the sample data form that follows the next page. An unmarked
data form is located after the chart. Make copies of the data form for future use.
GENERAL DATA
1.
Record both the site and customer name.

eg. Smith Const
2.
Record the original manufacturer.

eg. USF/Rockford
3.
Record the manufacturers model number off of the component.

eg. VPTS060AXBPD
4.
Record the serial number off of the component, if not available record the
system serial number.
eg. 56034
5.
Record the component tag number.

eg. TB-1A, Unit A
REGENERATION DATA
6.
Sequence number that is actually used in the regeneration.

eg. If Backwash anion is the first step, put a number 1 at Backwash anion.
If Acid In II is not used, leave blank.
7.
Record the minutes for each step.
8.
Record the flow rate for each step.
9.
Record the test method used to determine the flow rate.

eg. flow indicator FI-1, flow restrictor, orifice plate, bucket test
10. Record the pressure (feed) during each step.

11. Record the test method used to determine the pressure.
eg. pressure indicator PI-1
NOTE: The test method may not be located on the actual piece of equipment. eg. The
backwash anion flow rate may be located on the pretreatment equipment.
Page 3-28
Rev. 0
SERVICE DATA
12. Record the minutes used during the leak test.
13. Record the pressure during the leak test.
14. Record the feed temperature during service.
15. Are the chemical tanks full, empty, clean, etc?
16. Record the flow rate during service.
17. Record the test method used to determine the flow rate.
eg. Flow indicator FI-1
18. Record the feed pressure during service.
eg. Pressure indicator PI-1
19. Record the test method used to determine the pressure.
20. Record the ph during service. This should be taken as soon after a regeneration as
possible.
21. Record the test method used to determine the ph.
eg. paper, handheld meter, meter ph-1
PERFORMANCE DATA
22. Record the conductivity during service
23. Record the test method used to determine conductivity
eg. Thornton L, CE-1
REFERENCE DATA
24 Record the resin loaded into the vessel, use the marking on the drum or bag
eg. C-211, A-264
P/N XYZ
25. Record the lot number of the resin, use the markings on the bag or drum.
26. Record the cubic feet of resin loaded.
27. This area is used for systems that require subfill. This system does not use subfill
underneath the resin.
28. Quantity in pounds or cubic feed of each layer of subfill.
29. Record the type and grade of chemicals used for regeneration.
eg. HCl-Technical, NaOH Rayon
30. Record the concentrated chemical concentration.
eg. 20%, 50%
31. Record the dilute chemical concentration (to the bed).
eg. 4%
32. Record the gallons of concentrated chemical used per regeneration.

eg. 50 gallons
33. Indicated that these items have been checked.
34. Record the voltage the main panel is operating at.
eg. 120V
35. Any comment the US Filter service person deems to be reportable.
GENERAL
36. Name of US Filter service person who performed the work. Must
include printed last name.
37. Date the actual work was completed.
Page 3-29
Rev. 0
Page 3-30
Rev. 0
OPERATION
Page 4-1
Rev. 0
4.0 OPERATION
This section gives the procedures needed to operate the VP Series two-bed deionizer system for units
that consist of a cation exchanger, an anion exchanger, a customer-supplied acid day tank, and a
customer-supplied caustic tank.
WARNING
Acid and caustic are very hazardous materials. Use extreme caution when
working with these chemicals. Operators must read and understand section
2.0 of the main manual before attempting to work with regenerants.
4.1
THEORY OF OPERATION
When in service, water from the customers source flows through both the cation and anion (two-bed)
vessels supplied with this system. The two-beds are controlled automatically with an Allen-Bradley
MicroLogix programmable logic controller (PLC). Operators may interface with the system - to change
presets, modify setpoints using the A-B Data Access Tool (DAT).
Water from the customers source flows to the distribution piping in the top of the cation vessel then
down through the resin bed to the outlet line. The cation exchanger removes the majority of the
dissolved cations (sodium, calcium, magnesium, etc.). After exiting the cation vessel, the water flows to
the top distribution of the anion vessel. The water passes down through the anion resin bed where
dissolved anions (chloride, sulfate, nitrate) are removed. The effluent from the anion vessel flows to the
customers application.
When the two-bed resins are full of dissolved cations and anions, the vessels are removed from service
and regenerated. The volume of water treated, or the waters conductivity is used to determine when
regeneration is needed. When the volume or conductivity of the effluent water surpasses the setpoint,
regeneration can be automatically or manually initiated. During regeneration, the hydrochloric acid
(HCl) flows down through the cation resin and sodium hydroxide (NaOH-caustic) flows down through
the anion resin. The regenerant waste water flows to drain for disposal. After completion of the
chemical-in steps, the vessels are rinsed and returned to service.
4.2
PROCESS CONTROL DOCUMENT
The document starting on the next page is the Process Control Document (Control Write-Up), which
describes the automatic controls, system alarms, interlocks between the different units in the total
system (if applicable), and how each of the subsystem units sequence between the service modes and
regeneration steps. This document has its own table of contents. This section of the manual continues
after page 14 of the Control Write-Up.
OPERATION
4.3
Page 4-2
Rev. 0
REGENERANT MAKE-UP PROCEDURES

Before each regeneration, make sure that adequate supplies of acid (HCl) and caustic (NaOH)
are available. Each regenerant container/tank must contain at least the amount of chemical used
during one regeneration - refer to the Regeneration Volume Specifications in section 1.2.12 for
regenerant concentrations and volumes. If not, replace the container or refill the tank.
4.3.1 Recommended Chemicals for Regeneration
The quality of the regenerant chemical used for regeneration is one of the most important
factors in maintaining exchange capacity. Although chemically pure (CP) chemicals are not
required for regeneration of ion-exchange equipment, certain contaminants must be avoided.
Technical grade chemicals, free of oils and other organic materials are adequate for
regeneration of cation resins.
Hydrochloric or muriatic acid should be technical grade, of a minimum of 30% HCl by weight.
The hydrochloric acid should not contain excessive iron or organic materials. Iron levels
should be less than 5 ppm (as Fe) for semiconductor or other high purity applications. US Filter
does not recommend the use of the so-called by-product hydrochloric acid obtained from the
hydrolysis of chlorinated organic chemicals. This is especially true if the solution passing
through the deionizer is to be used for human consumption. Hydrochloric acid obtained by the
either the salt-acid or hydrogen-chlorine process is satisfactory.
Hydrochloric acid containing inhibitors should never be used. When buying chemicals for use
in the regeneration of ion-exchange resins, it is a good idea to request an analysis of these
materials from the supplier.
Anion exchange resins are generally regenerated with sodium hydroxide. Strong base anion
exchangers are best regenerated with nylon or rayon grade sodium hydroxide, 76% Na2O. This
grade of caustic is low in iron, silica and chlorides which eliminates fouling of the strong base
anion exchangers.
If caustic is purchased in the liquid form as a 50% solution, the same grades should be
purchased as mentioned above. Mercury-cell grade caustic (NaOH) should be used in mixedbed polishers, condensate polishers, and other high-purity applications. Make certain that the
caustic is low in chlorates.
Actual regenerant qualities are specified on the following page.
OPERATION
Page 4-3
Rev. 0
Chemicals for Cation Resins (such as C-211)

HYDROCHLORIC (MURIATIC) ACID
Grade - Muriatic Acid, Technical (HCl)
Color - White to light yellow
Concentration - Minimum (18o Be') - 28% HCl
Sulfuric Acid, as SO3 = 4,000 ppm max
Iron (Fe)
= 100 ppm max (5 ppm for high purity application)
Freezing point
= -40oF
Organic contaminants = 100 ppm O2 consumed
Weight per gallon
= 9.5 lbs.
Acid should be free of turbidity, inhibitors and oxidants.
Chemicals for Strong-Base Anion Resins (such as A-244)
SODIUM HYDROXIDE (CAUSTIC SODA)
MERCURY CELL GRADE LIQUID
Typical Analysis
NaOH
Na2CO3
NaCl
NaClO3
Na2SO4
SiO2
Al2O3
CaO
MgO
Fe
Ni
Cu
Mn
Hg
Freezing point
Average
50.6%
200 ppm
20 ppm
Less than 1 ppm
10 ppm
10 ppm
3 ppm
3 ppm
0.6 ppm
2 ppm
0.6 ppm
0.2 ppm
Less than 0.2 ppm
1.0 ppm
54o F
SODIUM HYDROXIDE (CAUSTIC SODA)

RAYON GRADE FLAKE
Typical Analysis
NaOH
Na2O
Na2CO3
NaCl
NaClO3
Fe2O3
SiO2
Al2O3
CaO
MgO
Cu
Mn
Pb
Ni
Na2SO4
As
Average
98.25%
76.61%
7,600 ppm
5,700 ppm
Less than 2 ppm
10 ppm
39 ppm
10 ppm
27 ppm
38 ppm
0.2 ppm
0.5 ppm
0.5 ppm
0.9 ppm
2,000 ppm
0.01 ppm
OPERATION
4.4
Page 4-4
Rev. 0
BACKWASH FLOW TEMPERATURE CORRECTION

Figure 4-1: Backwash Flow Chart
Note: Refer to section 1.2.9 in the manual for flow and temperature specifications.
Carbon and
Multimedia Filters
Resin Beds
+40
(+22)
Degrees F
(Degrees C)
Above Design
Temperature
+30
(+17)
+20
(+11)
+10
(+5)
Design
Temperature
-10
(-5)
Degrees F
(Degrees C)
Below Design
Temperature
-20
(-11)
-30
(-17)
-40
(-23)
0.4
0.5
0.6
0.7
0.8
0.9
1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
Water Temperature Correction Factor
To Determine the proper backwash flow:

1. Look up the design backwash flow and temperature
2. Measure the actual backwash temperature
3.Calculate the difference between the design and actual temperatures
4.Look up the Water Temperature Correction Factor on the graph above
the design backwsh flow by this factor
5.Multipy the design backwash flow by this factor.
BACKWASH.WMF
OPERATION
4.5
Page 4-5
Rev. 0
SPECIAL OPERATING PROCEDURES

1. To operate the two-bed system, use the Process Parameters information, the Process and
Instrumentation Diagram (P & ID) which follows this section. Refer also to the Control
Write-Up Document contained in Section 4.2 of the manual.
2.
During the Service mode, periodically sample the effluent at the anion vessel's lower
sample valve and make sure that the product quality is acceptable. Refer to Section 5 of
the main manual for typical sampling procedures.
If a backwash flow rate is too high, resin can be lost to the drain. If resin is
seen in the backwash effluent, throttle the setting device immediately.
CAUTION
3.
During each Backwash step, make sure that whole resin beads do not go above the upper
vessel window (if applicable) or into the flow glass (FG) on the backwash drain line. If
so, check the backwash flow against the table in section 1.2.12.
Acid and caustic are very hazardous materials. Use extreme caution when
working with these chemicals. Operators must read and understand section
2.0 of the main manual before attempting to work with regenerant chemicals.
WARNING
4.
5.
4.6
During the chemical-in steps, periodically sample the dilute chemical and determine its
specific gravity. Use the testing procedures given in section 5 of the main manual.
Near the end of the Cation Final Rinse step, take two samples of the rinse effluent one
minute apart, and check their pH. If the pH is stable, let the step time-out normally. If
the pH is still changing, extend the step until the pH is stable, and adjust the step time
accordingly.
P&ID DRAWINGS
The VP Series two-bed P & ID drawing follows this page. This drawing shows system
components and their relationship to each other. The P&ID covers all the various sized units.
NOTE:
The P&ID is not drawn to scale.
Page 5-1
Rev. 0
5.0 SAMPLING AND TESTING

This section contains procedures for sampling and testing the VP Series two-bed deionizer system.
Selected sampling and testing procedures should be performed regularly during the operation of this
system. A well-kept logbook of test dates and results and of operator observations is an invaluable tool
for troubleshooting future performance problems. Any tests used with this system must be performed
on a regular basis and must be accurately recorded in a logbook.
The frequency of sampling and testing is normally at the discretion of the customer. In some cases,
specific tests and data collection are required to maintain the process and equipment guarantee.
For further information on sampling and testing procedures, refer to the ASTM book of standards for
water.
5.1
Page 5-2
Rev. 0
TAKING SAMPLES FOR ANALYSIS

This section covers sampling and testing procedures specific to deionizer systems.
5.1.1
Resin Sampling by Core Sample

Prior to taking resin samples, be sure to have on hand an adequate supply of clean plastic
bottles. Plastic sample bottles and bottle labels are available from the U.S. Filter area
representative .
1.
Resin samples should be taken following a complete regeneration of the

ion-exchange vessel.
If the deionizer will not attain the proper conductivity or resistivity during its final
rinse, allow the vessel to rinse for the normal amount of time and then stop the
regeneration.
When water is gravity-drained from a vessel, a vent valve must be opened
near the top of the vessel. Draining a vessel without an air vent open can
cause the vessel to collapse due to the vacuum produced by the draining
water.
CAUTION
2.
At the end of the regeneration, open a manual vent valve at the top of the vessel
and a manual drain valve at the bottom of the piping manifold and drain the water
in the vessel down to the top of the resin bed. If desired, compressed air can be
used to "blowdown" the water in the vessel.
3.
When the water in the vessel has been drained down to the top of the resin bed,
close the drain valve. Leave the vent valve open.
If compressed air was used to blowdown the water, relieve all pressure from the
vessel. Open a vent valve before proceeding further.
4.
Remove the upper manhole cover in the sidesheet or the head shell.
5.
To provide the most accurate information on resin condition, a resin sample must
be representative of the entire resin bed. Use a "grain thief" or related device to
take a core sample of the resin bed. Figure 5-1 demonstrates the use of a grain
thief to take a resin sample.
Page 5-3
Rev. 0
Do not take a resin sample by taking resin from only the top of the bed. The
particulates and resin fines that normally collect at the top of the resin bed will
not accurately represent the entire bed.
6.
Take enough resin from the bed to fill a quart jar. Seal the jar tightly, label the jar
with the date, type of deionizer (cation, anion, mixed bed, etc.), and the original
U.S. Filter/Rockford job number, and then send the sample to U.S. Filter or to any
lab with resin testing facilities.
Contact U.S. Filter/Rockford for current prices for resin testing services.
Figure 5-1: Media Sampling
Grain
Thief
Grain
Thief
Manhole
Manhole
Top of Media
Acceptable
sample.wpg, 7/26/95
Top of Media
Best
5.1.2
Page 5-4
Rev. 0
Resin Sampling by Eductor
1.
The following items are required when sampling resin with an eductor.
(1)
eductor with 1-2 gpm motive flow
(1)
flexible hose to supply motive water to eductor
(1)
flexible hose to carry water and educted resin from the eductor to a
dewatering device
(1)
flexible hose or pipe wand connected to draw port of eductor. Must be

long enough to reach to the bottom of the vessel.
(1)
resin dewatering device (screened box, filter bag, etc.)

Source of softened or deionized water with a minimum of 2 gpm @ 50
psig.
2.
Resin samples should be taken following a complete regeneration of the

ion-exchange vessel.
3.
If the deionizer will not attain the proper conductivity or resistivity during its final
rinse, allow the vessel to rinse for the normal amount of time and then stop the
regeneration.
Draining a vessel without an air vent open can cause the vessel to collapse
due to the vacuum produced by the draining water. When water is
gravity-drained from a vessel, a vent valve must be opened near the top of
the vessel.
CAUTION
4.
At the end of the regeneration, open a manual vent valve at the top of the vessel
and a manual drain valve at the bottom of the piping manifold and drain the water
in the vessel down to the top of the resin bed. If desired, compressed air can be
used to blowdown the water in the vessel.
5.
When the water in the vessel has been drained down to the top of the resin bed,
close the drain valve. Leave the vent valve open.
If compressed air was used to blowdown the water, relieve all pressure from the
vessel. Open a vent valve before proceeding further.
Page 5-5
Rev. 0
6.
Remove the upper manhole cover from the vessel.
7.
Open all manifold valves normally used to backwash the vessel. Throttle a hand
valve to provide a slow upward flow of water to fluidize the resin bed.
8.
Start the motive flow of water to the eductor. Direct the eductor outlet hose into
the resin dewatering device.
9.
Insert the draw hose or wand into the resin bed and slowly push it to the bottom
of the vessel. When the hose or probe touches the bottom of the vessel, pull it
back out slowly.
NOTE:
Do not take a resin sample by taking resin from only the top of the bed. The
particulates and resin fines that normally collect at the top of the resin bed will
not accurately represent the entire bed.
10.
Continue to push the draw hose or wand into the resin bed until the desired
amount of resin has collected in the dewatering device.
11.
When the desired amount of resin has been collected, stop all water flows, close
all valves in the vessel manifold, and reinstall the manhole cover.
12.
Place the collected resin in a glass or plastic sample bottle.
13.
Seal the bottle tightly, label it with the date, type of deionizer (cation, anion,
mixed bed, etc.), and the original U.S. Filter/Rockford project number, and then
send it to Rockford or to any lab with resin testing facilities.
5.2
Page 5-6
Rev. 0
PROCEDURE FOR CHECKING SPECIFIC GRAVITY
1.
Rinse Hydrometer with fresh water and dry with clean cloth.
2.
Fill glass cylinder about 3/4 full with solution to be tested.
3.
Gently float hydrometer in solution and spin the hydrometer stem so that it does not hang
up on the side of the cylinder.
4.
Read the scale at the point where the liquid surface touches.
5.
Pour out solution, rinse cylinder and hydrometer.

Table 5-1: Specific Gravities of the Most Common Regenerants at 68F (20C)
SOLUTION
PERCENT
CAUSTIC
SODA
(X=.021%)
HYDROCHLORIC
(X=.019%)
1.010
1.003
1.021
1.008
1.032
1.013
1.043
1.018
1.054
1.023
1.065
1.028
1.076
1.033
1.087
1.038
10
1.110
1.047
12
1.131
1.057
15
1.164
1.073
20
1.219
1.098
26
1.285
1.129
30
1.328
1.149
50
1.525
-------
93
-------
-------
The value of the specific gravity at 68 F (S68) will change (x)% for each F above or below 68F. The specific
gravity (St) at (t)F can be calculated using the formula below. The expansion factor (x) is given in the chart for
each regenerant.
St = S68 [ 1 - x(t - 68)/100 ]
MAINTENANCE
Page 6-1
Rev. 0
6.0 MAINTENANCE AND TROUBLESHOOTING

This section provides periodic maintenance procedures needed to avoid problems with the two-bed
deionizer system. While this liquid-treatment system does not require a great deal of routine or periodic
servicing, certain maintenance procedures are required to guarantee continued satisfactory operation.
Troubleshooting information is included to help solve problems that may occur.
6.1
MAINTENANCE
Because of the complexity of many of the instruments and mechanical components used with this
system, no attempt is made here to give specific instructions for maintenance or repairs of these
components. The purpose of this section is to alert operators and maintenance workers of general
areas where maintenance is required.
CAUTION
To avoid equipment damage, all plant-maintenance schedules and

procedures must equal or exceed those recommended by the individual
component manufacturers.
For specific and detailed maintenance procedures for vendor components, refer to Section 9.1
Vendor Literature.
NOTE:
If an approved plant-maintenance schedule exists and is followed regularly, such a

schedule may be used as a substitute for many of the maintenance procedures given in
the vendor literature.
Unless an approved plant-maintenance schedule exists, be certain to follow the
maintenance schedules recommended by the individual component manufacturers.
Most maintenance procedures for this equipment can be performed using common hand tools and
plumbing equipment; any special tools required for individual components must be obtained from the
component manufacturers.
6.1.1 General Maintenance Guidelines
Maintenance personnel should have a thorough understanding of the safety procedures given
in section 2.0 before attempting repairs or maintenance to this equipment.
Before working on any of the components and equipment used with this system, workers must
read and understand the safety-related material given in section 2.0 of this manual. Of special
importance are the areas of equipment access, pressures, and servicing system components,
and the precautions specific to the types of equipment in your system.
Maintenance procedures should be performed only by experienced technicians or maintenance

workers who are familiar with the types of components and equipment used with this system.
MAINTENANCE
Page 6-2
Rev. 0
Workers who perform maintenance on the components and equipment used with this system
should read and follow all instructions and procedures given in section 8.4 Vendor Literature.
Before attempting to perform maintenance on system components and equipment, and

especially when attempting to disassemble individual components, workers must be certain
that the components are isolated from pressure, fluids, and electricity.
Spring-loaded devices, such as valves, should be in their "relaxed" state - that is, with no
compression on the loading spring - to avoid the sudden and accidental motion of individual
parts.
The table on the next page contains typical schedules for maintenance of the most commonlyused system components. This should be used as a guide only. For actual maintenance
frequencies, refer to the component instructions in the Vendor Literature.
MAINTENANCE
Page 6-3
Rev. 0
6.1.2 Scheduled Maintenance Chart
MAINTENANCE PROCEDURE
RECOMMENDED INTERVAL
Influent and effluent liquid samples
Every 6 months or as required for diagnostic

purposes
Vessel and component painting
As required
Vessel and piping leak inspection
Weekly
Valve operation and leak checking
As required
Valve diaphragm replacement
Annually
Instrumentation independent lab

check
Every 6 months
Control panel & component

maintenance (automatic unit only)
Weekly
Liquid contamination of pump and

gear lubricants (if applicable)
Weekly
Media sampling
Once a year or as required for

purposes
Media level check
Weekly if vessel has windows, otherwise

whenever media is sampled
Sight strainers (if applicable)
Weekly
Silica probe inspection (if

applicable)
Annually with resin check
diagnostic
6.1.3 Chemical Systems

Analyze bulk regenerant chemicals
Get assay for each truck load or chemical

container/bag
Inspect and clean chemical tanks

regenerant day tanks
As required
MAINTENANCE
6.2
Page 6-4
Rev. 0
COMPONENT MAINTENANCE
This subsection contains general maintenance procedures for the component types that are most
often used on U.S. Filter systems but not included in the Vendor Literature.
The maintenance procedures for all other components on your system are covered by the
component manufacturer's instructions in the Vendor Literature.
6.2.1 Piping
The main piping on the system vessels is PVC pipe. Any fasteners used on this piping may
need periodic tightening to prevent leaks. If the system is operated within the temperature
and pressure limitations given in this manual, little or no maintenance is required.
6.2.2 Feed Source and Product Storage

The feed supply and product storage area must be available for use and in good repair
before attempting to operate the U.S. Filter system.
6.2.3 Existing (Customer-Supplied) Equipment
Any existing (customer-supplied) equipment used in conjunction with the U.S. Filter
equipment must be properly maintained and operated. Optimum performance of the U.S.
Filter equipment cannot be attained unless all other system components are operating
properly.
6.2.4 Electrical Enclosures
WARNING
Sparks from components in control enclosures can cause explosions in

hazardous atmospheres. If explosion-proof enclosures are used with this
system, extra caution must be used when working with the enclosures.
Be certain that all power is removed from an explosion-proof enclosure
before opening it. If the enclosure is equipped with a power/door interlock,
check the interlock occasionally to be sure it functions properly.
Check solenoid or other electrical enclosures occasionally to be sure that the doors are
closed tightly and are latched or fastened properly. Water and other fluids must not enter
the enclosures.
MAINTENANCE
Page 6-5
Rev. 0
6.2.5 Control Panels
Very little maintenance is required for control panels and their components. The following is
a list of general guidelines for operators to use while operating and maintaining control panels.
Operators must be certain the operating conditions for microprocessor controllers are within
the ranges listed in the component instructions in the Vendor Literature.
Check any air inlet and outlet grilles at least once a week and clean them when necessary.
The controller must be properly grounded and protected from the possibility of
static-electricity discharges.
Operators must monitor the condition of any controller backup battery and must replace it
when necessary. An audible alarm and/or an alarm light are often activated when the backup
battery is low.
Control panel doors must be kept closed at all times to prevent excessive dirt or dust from
collecting inside the panel.
If the control panel is located in a corrosive or damp atmosphere, the panel should be
inspected, cleaned, and painted regularly.
6.2.6 Contact Switches
Externally-mounted switches (on valves, pumps, etc.) should be checked periodically for
corrosion, debris, and loose or broken wires.
Switches that are used to initiate step, modes, or alarms (flow or pressure switches, for
example) should be checked for calibration occasionally. Also, any limit switches used on the
control valves may have to be adjusted periodically.
6.2.7 All Vessels
The vessels should provide many years of service with only minimal exterior maintenance
(painting), provided the system is operated within the design pressure and temperature
limitations.
If vessels are installed outside and are exposed to freezing temperatures, the vessels and their
piping must be insulated and heated or else must be shutdown and drained.
If vessels are stored outside and are exposed to freezing temperatures, they must be
completely drained and must be handled carefully when moved.
MAINTENANCE
Page 6-6
Rev. 0
6.2.8 Lined Vessels

CAUTION
Welding on a lined vessel will damage the lining.

Never weld on a lined vessel or within 12 inches of the vessel.
CAUTION
Vessels in this system are lined with PVC. PVC is a thermoplastic and must
not be exposed to temperatures > 150F.
PVC linings are not recommended for use with organic chemicals containing
chlorine or nitrogen groups, glacial acetic acid or acetic anhydride, ketones,
lacquer solvents and thinners and petroleum fractions lighter than No. 1 fuel
oil.
U.S. Filter guarantees all vessel linings against defective materials and workmanship for a
limited period of time. Improper handling or storage procedures may void the lining
guarantee. Follow all instructions given in this manual when handling or storing lined
vessels.
6.2.9 Resins
CAUTION
Regeneration backwash flowrates must be monitored closely to prevent the

loss of resin through the backwash outlet.
If, at any time, resin is seen in the backwash sight glass or in the drain itself,
the backwash flowrate must be reduced immediately.
The resins are the most important part of the system, as they are responsible for the actual
treatment process. They are also one of the most expensive components of the system.
Their maintenance is a continual process through proper operation and regeneration.
Strict attention to the operating conditions and the regeneration procedures is the best
safeguard against premature resin failure.
6.2.10 Strainer Screens (vessel outlets)

Many systems have protective devices on the vessel outlets designed to guard against resin
loss should the regenerant, interface, or bottom distributors fail. Barring this unlikely
circumstance, the strainer screens require no maintenance other than an occasional
cleaning.
CAUTION
If sight strainers are removed from the pipe lines, be certain to reinstall them
in the correct positions.
As shown on the blueprints for this job, strainer elements must point "upstream" when
installed in the piping runs. If strainers are installed backwards, they will still trap resin,
but operators will not be able to observe this resin.
MAINTENANCE
Page 6-7
Rev. 0
6.3 TROUBLESHOOTING
This section provides the procedures needed to avoid and troubleshoot problems with the two-bed
deionizer system. While this deionizer does not require a great deal of routine or periodic servicing,
certain maintenance procedures are required to guarantee continued satisfactory operation.
6.3.1 General Troubleshooting Tips
This section describes some of the common problems that can occur during operation of this
system and the steps an operator can take in finding their causes. The best troubleshooting tool
an operator can have is his knowledge of the normal system operation. Operators should read and
be familiar with the rest of this manual prior to using this section. During the first few months of
system operation, operators should carefully observe and note normal operation characteristics for
future reference.
1.
The most helpful tool in troubleshooting problems is the operator's knowledge of the
normal operating conditions. Then, if the system develops a problem, the operator may
notice a change in operating conditions that could help him identify the cause of the
problem. Many problems occur because the system is no longer operating under the
conditions stated in this manual, particularly chapter 3.0 (Operation.)
Selected sampling and testing procedures should be performed regularly during the
operation of this system. While the actual frequency of sampling and testing is at the
discretion of the customer, any tests used with this system must be preformed on a regular
basis and must be accurately recorded in a logbook.
A well-kept logbook of test dates and results and of operator observations is an invaluable
tool for troubleshooting future performance problems.
2.
Double-check for problem symptoms to be sure that a problem really exists. An

inaccurate instrument or a temporary change in feed quality, pressure, or flow can indicate
a problem where none exists.
3.
Don't overlook these simple problems.
4.
A hand valve that is closed

The power turned off to a control panel
The power turned off to a pump
Wires cut or disconnected
Equipment damaged or missing
Valve solenoids manually overridden
Incorrect control setpoints in the process controller
To troubleshoot flow blockage, locate any large pressure drop and investigate all the
MAINTENANCE
Page 6-8
Rev. 0
equipment in that area until the source of the blockage is found.

5.
To troubleshoot electrical problems, first identify the control flow pattern, which is the
pathway that the signal takes from an input device to the controller, through the
controller, then from the controller to the output device. Second, investigate all the
components of this control flow pattern until the cause of the problem is discovered. Start
with the easiest and most probable components, such as the input and output modules
(where applicable).
6.
To troubleshoot an instrumentation problem, refer to the instrument manufacture's service

literature in the Vendor Literature Manual.
7.
To troubleshoot problems with other pieces to equipment, refer to the information

available in the component manufacturer's service literature in the Vendor Literature
Manual.
6.3.2 Deionizer Troubleshooting

This section provides operators with a quick reference source to use while troubleshooting a problem
with a deionizer system. Because it is impractical to attempt to provide an exhaustive troubleshooting
chart for a large deionization system, only those problems most likely to occur are dealt with here. None
of the charts presented here should be considered to be exhaustive; these charts are intended to point out
the most likely causes of the listed problems.
6.3.3 Deionizer Troubleshooting Charts

Listed on the following pages are possible problems that can occur during deionizer operation,
along possible causes and solutions can be found.
If there is a valve or pump malfunction: first inspect the valve or pump in the field to for proper
operation. Then, make sure air pressure to the solenoid or power to the motor starter is proper turn on the valve or pump manually for a brief moment. Finally, make sure the proper output is
energized.
If there is a pressure drop across an in-line strainer element, shutdown the system, remove the
strainer element, and clean it using the instructions provided in the Vendor Literature Manual.
If the pressure drop is across a vessel's resin bed, remove the vessel from service and backwash it
thoroughly. Make sure the resin expands at least 50% and stays expanded for at least a half-hour.
For troubleshooting alarms, refer to section 3 of the Control Write-Up in chapter 3 of the main
manual.
MAINTENANCE
Page 6-9
Rev. 0
6.3.4 High Conductivity/Improper pH

CAUSE
COMMENTS
1. Normal exhaustion
Regenerate the unit.
2. Inaccurate conductivity - faulty

sensor, transmitter, or meter
Calibrate all instruments involved.
3. The previous regeneration was

ineffective
Check flow rates independently.
Broken resin beads (fines) stay in the resin bed and cause
large pressure drop.
Low chemical volumes or

concentrations
May not have been enough chemical to recharge the

resin.
High chemical flows and low contact

times
The resin was not exposed long enough to recharge the

resin.
Resin not rinsed of chemicals prior to

service rinse
Fast rinse steps are too slow or too short.
Mg will precipitate, and leak hardness into product.
Hardness in chemicals or rinse water
Poor flow distribution, chemicals or

rinse
Will occur if flow is too low, resin is fouled, or

distribution is not installed properly.
Low or no backwash flow
4. Feed is leaking into the product

stream.
Check for debris caught in valves.
5. Increase in feed salt content - not

following feed specs in Section #1.0
of the main manual.
Resin may require more regenerant to keep achieving low

conductivity.
6. Resin is fouled hardness or organic

material on resin
Do not use hard water in the presence of the OH ion.
7. Damaged resin - exposed to high

temperature or chemical
concentrations
Temperature not to exceed 95 F. Chemical concentrations

to be per Sections 1 and 3.
8. Poor feed flow distribution

(channeling)
Feed flow too low
Must observe the minimum flow rate.
Resin fouled
Hardness or organic growth.
Distribution improper
Inspect distribution.
MAINTENANCE
Page 6-10
Rev. 0
CAUSE
9. Feed flow too high - improper feed
setpoint
COMMENTS
Once the flow exceeds the maximum the resins can't remove
as many ions.
6.3.5 Low Capacity

CAUSE
1. Inaccurate volume throughput
indication - faulty flow sensor,
transmitter, or totalizer
COMMENTS
Calibrate all instruments involved. Check flow rates
independently. Check controller setpoints.
2. Previous regeneration was improper:
Low chemical volumes or

concentrations
May not have been enough chemical to recharge the

resin completely.
High chemical flows and low contact

times
The resin may not have been exposed long enough to

chemicals.
Resins not rinsed of chemicals prior to

service rinse
Poor flow distribution of chemicals or

rinse water
Fast rinse steps are too slow or too short.

Will occur if flow is too low, resin is fouled, or
distribution not aligned.
3. Increase in feed salt or color content Bring the feed in line with normal specs or add more resin.
not following feed specs provided in
Section 1 of the main manual
4. Low resin volumes
Distribution leaking resin, backwash
flow too high
Resin will be collected in effluent or drain strainers.
5. Too much air in the resin bed - liquid

level went below resin
Check for leaking drain valve and low back pressure on

vessel.
6. Resin is fouled - hardness or organic

material on the resin
Do not let hardness be in the presence of the OH ion.
7. Resin is damaged - exposed to high

temperature or chemical
concentrations
Temperature not to exceed 95 F. Resin may have exceeded

its life span.
8. Poor feed flow distribution

(channeling):
Must observe the minimum flow rate
Feed flow too low
Hardness or organic growth
Resin fouled
Inspect distribution
Distribution improper
MAINTENANCE
Page 6-11
Rev. 0
CAUSE
9. Previous service run was

too long - resin overexhausted and normal regen
was ineffective
COMMENTS
End service runs after recommended volume of feed has
been treated or when effluent has high conductivity, or
low pH
6.3.6 Low or No Flow

CAUSE
COMMENTS
1. Improper flow setpoint - operator

error
Set flow using Section 1 as a guide.
2. Inaccurate flow indication faulty

sensor, transmitter, or indicator
Calibrate all instruments involved.
3. High pressure drop across resin bed
Check backwash flow rate and time; may have resin leak.
Hardness or organic growth
Increasing temperature will decrease feed viscosity
Too many resin fines, clogged effluent

strainer
Resin is fouled
Temperature too low
Check flow rates independently.
4. Low level in supply tank improper

level controls
May want to put in auto shutdown on low level
5. Valve or pump malfunction
Check for faulty valve, improper air pressure, tripped motor

starter, jammed pump, no pump prime, electrical control
problem
6. Malfunctioning pressure control valve

(PRV)
Check and adjust PRV.
7. Obstruction in line
Check for pressure drops
8. Improperly positioned hand valve
Open or close appropriate valves.
6.3.7 High Flow

CAUSE
COMMENTS
1. Improper setpoint - operator error
Set flow per Section 1.
2. Inaccurate flow indication - faulty

instrument or controller
Calibrate all instruments involved. Check flow rates

independently.
MAINTENANCE
Page 6-12
Rev. 0
6.3.8 Loss of Resin

CAUSE
COMMENTS
1. Backwash flow rate too high
Reduce flow rate. Inspect and repair.
2. Broken internal distributor
Inspect and repair.
Page 7-1
Rev. 0
7.0
7.1
SHUTDOWN ON POWER LOSS

Bacterial growth can occur in stagnant water inside a water-treatment vessel.
CAUTION
If a vessel must shutdown for more than a month, perform the storage
procedures given at the end of this chapter.
7.1.1
Procedures Following Power Loss

If electrical power to the system is lost for more than a few minutes, perform the
following procedures.
1.
If power to the equipment is lost, all valves at the equipment will close and
all pumps will stop.
Turn off all pumps upstream and downstream of the system. This will prevent
deadheading and starvation of customer-supplied pumps.
2.
Place all HAND/OFF/AUTO selector switches at the control panel in the OFF
position.
Place all MAN/AUTO selector switches at the control panel in the MAN position.
3.
Try to determine what the operating status (Regeneration, Service, etc.) of the
equipment was when the power was lost. This information will be helpful when
the system is restarted.
4.
During a power loss, do not allow any type of maintenance or repairs to be

performed at the equipment unless the proper vessel and system entry procedures
have been performed - see section 2 of the main manual.
All equipment being worked on during a power loss must be isolated and disconnected
from power and air supplies to prevent injury to workers if the power is restored without
notice.
5.
7.1.2
If it is necessary to continue to operate the equipment during a total plant power

loss, portable generators and air compressors can be used to keep the equipment
in service.
Restart From Power Loss
Page 7-2
Rev. 0
When electrical power is restored to the system, perform the following procedures.
1.
Check the control panel for indications of normal operation.

If there is no activity at the panel controls and instruments, refer to the
controller troubleshooting information in the Vendor Literature Manual.
2.
Observe, note, and acknowledge any alarm conditions at the control panel.
3.
Check the operating status of the equipment and verify that the individual
units have returned to the positions they were in when the power was lost.
4.
Return all selector switches at the control panel to their normal positions.
5.
Restart all customer-supplied pumps.
6.
Restart the individual units in the system as required.
7.
Verify proper operation of all equipment.
Page 7-3
Rev. 0
7.1.3 Temporary Shutdown for Maintenance or Emergencies

Bacterial growth can occur in stagnant water inside a water-treatment vessel.
CAUTION
If a vessel must shutdown for more than a month, perform the storage
procedures given at the end of this chapter.
A.
Procedures for Temporary Shutdowns

1.
During a normal service run, a unit can be shutdown by pressing the

service pushbutton on the control panel.
2.
To shutdown the entire system quickly, turn off the power to the control
panel. All air open / spring to close valves will close and all pumps will
stop.
If the power to the panel is disconnected, perform the power-loss procedures given
earlier.
3.
During a regeneration sequence, the quickest method of stopping the

process is to press the regeneration pushbutton while the lamp is lit to place
the unit in Lockout. During lockout the sequence timer is stopped and all
related valves will close.
B.
Restart from Temporary Shutdowns
1.
If a unit was shutdown with the by the pushbutton, place it back in Service
by pressing the SERVICE pushbutton.
2.
If the system was shutdown by disconnecting power from the panel,

reconnect the power and then perform the restart procedures given earlier
in this chapter.
7.2
Page 7-4
Rev. 0
UNLOADING VP SERIES TWO-BED DEIONIZERS

If the VP Series two-bed media must be removed for replacement or to allow the vessel to be
inspected, replaced, or repaired, unload the media using the following procedures. For all resin
unloading procedures, some type of dewatering device will be required for receiving the resin.
A large wooden box with a fine screen bottom or a tank with a wrapped lateral drain will work
best.
1.
The recommended procedure is to unload the resin using the resin removal opening in the
vessel side sheet.
2.
Drain all water from the vessel and then place the dewatering device under the resin
removal opening and remove the blind flange from the opening. If there is not enough
room to fit a dewatering device near the vessel, install a hose and flange at the removal
opening and direct the hose to the dewatering device.
3.
Allow enough water to flow into the vessel through the bottom distribution. The water
stream with resin should begin to flow out of the vessel.
If difficulties are encountered in transferring the resin out of the vessel, it may be
necessary to introduce a fast flow of water into the vessel through the top distribution
while the fluidization flow continues from the bottom distributor. The fast downward
flow of water should push the fluidized resin out of the removal opening.
4.
If desired, the resin can be unloaded using an eductor to reverse the procedure used when
loading with an eductor.
Drain the water in the vessel down to the top of the resin bed, insert the eductor suction
line into the vessel, and then direct the eductor outlet line to the dewatering device.
Control a flow of water a into the vessel through the bottom distribution and then start the
eductor motive flow. Maintain a minimum fluidization flow to avoid dilution and
excessive water use.
5.
If the unloaded resin is to reinstalled later, it must be sealed in drums or other containers
and stored carefully. The resin must not be allowed to dry out and must not be exposed
to extremes of temperature.
7.3
Page 7-5
Rev. 0
STORAGE
The following procedures apply to all of the ion-exchange vessels for this system.
NOTE:
The following procedures must be performed manually using the air solenoid
overrides at the unit solenoid panels.
1.
Run the vessel to service or to drain until it is exhausted.
2.
Place the vessel in the Offline mode.
3.
Backwash the resins in the normal manner.
4.
To completely exhaust the resins, remove the deionizer tank covers and pour into each
tank 8 lbs. of evaporated salt for each cubic foot of resin. After the salt is in, replace the
covers and rinse the beds to drain until the salt is completely washed out.
5.
Rinse the salt through the beds until a sample taken at the drain tests at approximately
1.005 specific gravity.
6.
Close the inlet water valve and open the vent valve momentarily to relieve the internal
pressure. With the vessel filled and all valves securely closed, the deionizer shutdown is
complete.
7.
If the vessel is to be stored for over one month, it must be rinsed with 2-3 bed volumes of
water every 2 weeks to avoid bacterial growth.
8.
When returning the vessel to Service, perform the startup procedures given in chapter 2
of the Subsystem Operating Manual in Section 3.2. New or completely exhausted cation
resin must be regenerated with double the normal acid dose.
NOTE:
If a lined vessel has been in storage for more than three months, the lining must be
inspected before the vessel is returned to Service.
7.3.1
Page 7-6
Rev. 0
Storage of Tanks
7.3.2
1.
Drain the tank completely.
2.
Cover all tank openings and the drain nozzles to prevent dust and dirt from
entering the tank.
3.
Before placing the tank in service, rinse thoroughly with clean water and dry with
oil-free compressed air.
Storage of Miscellaneous Equipment

Refer to the Vendor Literature Manual for information on storing individual components.
PARTS LIST
Page 8-1
Rev. 0
8.0 PARTS LISTS AND DRAWINGS

This section contains all available U.S. Filter parts lists for this job.
The U.S. Filter parts lists do not list individual components for vendor supplied equipment. For
information on vendor components, refer to the component literature in the separate Vendor Literature
Manual supplied with this equipment.
When contacting U.S. Filter about equipment and parts, be prepared to supply the equipment project
number, part number and other information supplied on the parts lists.
Refer to the literature in Vendor Literature for component installation, operation, and maintenance
instructions.
8.1
EQUIPMENT LIST
The equipment list for the systems described in this manual follows this page. The purpose of
the equipment list is to convey the part number, quantity and description of all tagged items
shown on the process and instrumentation drawing(s).
Refer to the data included with your equipment.
PARTS LIST
8.2
Page 8-2
Rev. 0
RECOMMENDED SPARE PARTS LIST

The document starting on the following page lists the recommended replacement parts or
components to be kept on site. The items included in the spare parts list are for those parts that
require replacement on a regular basis, such as gaskets, seals etc. The list also includes rebuild
kits and parts that are not readily available in the event of a component failure. This list conveys
the part number and description of the parts.
VP SERIES
TWO BED SPARE PARTS LIST
Page 1 of 3
Rev. 0
VP-DI ELECTRICAL SPARE PARTS LIST

USF PART #
DESCRIPTION
Complete Control Panels

42/S41AX-06XJX
42/S41BX-06XJX
Two Bed LT Main Control Panel (MCP) w/UL

Mixed Bed LT Main Control Panel (MCP) w/UL
MAIN CONTROL PANELS

PLC
03/30890-04
03/30890-03
03/30890-23
03/30890-35
03/30890-06
PLC Base with (12) 24VDC Digital Inputs and (12) ac/dc Relay Outputs
PLC Processor
Add On 8pt AC/DC Relay Output Module
PLC Rack Assembly Right End Cap
Data Access Tool
Power Distribution
03/03714-01
03/02938-14
03/02938-20
Circuit Breaker, 10A 120/240V UL

Fuse, 4A 250V
Fuse, 10A 250V
Terminal Track Mounted Devices

03/31617-01
24VDC, 1FC Contact Relay
03/30556-04
Power Supply, 24VDC 100W UL
03/30556-05
Power Supply, 24VDC 240W UL
Horn
03/10181-01
120VAC Horn, Nema 4
VP SERIES
TWO BED SPARE PARTS LIST
USF PART #
Page 2 of 3
Rev. 0
DESCRIPTION
Enclosure Face Mounted Components

Conductivity Instrument
18/02840-02
Conductivity/Resistivity Monitor, 120VAC
Flow Indicating Totalizer
18/32304-01
6 Digit Meter,Dual Alarms, 120/230VAC
18/32320-01
Mdl, 2 RLY Card for Pax1000
Auto Operation Off-On Selector Switch
03/02976-12
2 Position Selector Switch Operator, Nema 4X
03/02976-10
Normally Open Contact Block
Alarm Silence Pushbutton
03/02976-08
Black Pushbutton Operator, Nema 4X
03/02976-10
Regeneration Pushbutton Light
03/02976-06
Pushbutton Light Operator, Nema 4X
03/02976-09
Full Voltage 120vac Light Module with Latch
03/02976-10
Service Pushbutton Light
03/02976-06
Pushbutton Light Operator, Nema 4X
03/02976-09
Full Voltage 120vac Light Module with Latch
03/02976-10
Solenoid Air Supply
05/85019-33
Filter/Regulator w/0-160psi Gauge
Solenoid Manifold / Fittings
05/31780-01
Solenoid Valve Only
13/02149-02
Nickel Plated Brass 1/4"T to 1/8"P Male Straight Tube Fitting
13/02693-04
1/4" Tubing Plug
VP SERIES
MIXED BED SPARE PARTS LIST
Page 3 of 3
Rev. 0
VP-DI MECHANICAL SPARE PARTS LIST MATRIX

TTank Size

16
20
24
30
36
42
05/31114-18
05/31114-18
05/31114-20
05/32284-16
05/32284-17
48
54
60
05/31717-22
05/31717-24
66
72
PART
Valves 101,
103, 201,
202, 203
05/31114-16
Valve 104
05/32284-08
Valves 105
205
05/32284-12
Valve 106,
204, 207
05/32284-08
Valve 108
05/31114-08
Valve 209
Valve 114,
214
Valve 131
05/31114-08
Valve 247
05/11134-08
Valve 132
Valve 233
Valves 135,
137, 235,
Valves 134,
136, 138,
236, 239
Ejector 101,
201
Gage 101,
102, 201
Flow
Element 101
Lower Hub
Lower
Lateral
AE-201
conductivity
element
05/85626-31
05/85626-31
05/32284-12
05/32284-16
05/32284-18
05/32284-17
05/32284-20
05/32284-12
05/32284-16
05/3171
7-28
05/32284-20
05/3228
4-24
05/14335-24DA
05/32284-17
05/1433
5-28DA
05/3228
4-18
05/31114-12
05/01463-08
05/14304-01
05/11134-12
05/85626-32
05/02461-04
05/14426-04
05/85505-08, -08A, -08B & -08H
05/85505-12
05/85505-16
14/86552-37
14/86552-38
05/85505-17
15/02332-04
21/31623-01N
14/86552-32
14/86552-32
14/86552-32
14/86552-52
14/31827-07
14/31827-09
14/31827-11
14/31827-12
18/02839-01
18/02839-02
14/86552-53
49/32360-01
N/A
N/A
N/A
N/A
VP SERIES
MIXED BED SPARE PARTS LIST
Page 4 of 3
Rev. 0
VP-DI MECHANICAL SPARE PARTS LIST MATRIX

Pipe Size
1.25
1.5
2.5
PARTS LIST
8.3
Page 8-3
Rev. 0
DRAWINGS
The VP Series two-bed drawings follow this page. The electrical drawings show the control
panel layout and line wiring. The piping drawings show the piping arrangement and components
as assembled. The drawings for all the various sized units are included. Use the drawing for the
specific unit you have.
VP SERIES
TWO BED CONTROL WRITE-UP
Page 1 of 14
Rev. 5
RECORD OF REVISIONS
Electrical
Engineer
REV
DATE
DESCRIPTION
04-29-00
Original issue, 14 pages.
RGW
12-26-00
Revised input interlock descriptions, 14 pages.
RGW
01-23-01
Revised Red Lion Config Chart, 14 pages.
RGW_
03-02-01
Revised Red Lion SCLFAC Time Base, 14 pages.
RGW_
03-22-01
Revised Red Lion Pro5 tbASE, 14 pages.
_ RGW _
04-04-03
Revised 6.1 Red Lion Config. Chart, 14 pages.
_ ADN _
VP SERIES
Page 2 of 14
Rev. 5
TABLE OF CONTENTS
for
TWO BED VP SERIES
SECTION
DESCRIPTION
1.0
CONTROL OVERVIEW.....................................................................................3
2.0
TWO BED OPERATION ....................................................................................3

2.1
2.2
2.3
2.4
2.5
2.6
3.0
PAGE
Regeneration ...........................................................................................................3
Regeneration Complete...........................................................................................4
Service Rinse / Service ...........................................................................................4
Exhaustion Rinse ....................................................................................................4
Off Line...................................................................................................................5
Status Lamp Reference Chart .................................................................................5
ALARMS ...............................................................................................................6
3.1
3.2
3.3
3.4
3.5
4.0
Alarm Silence..........................................................................................................6
Total Throughput ....................................................................................................6
Exhausted................................................................................................................6
Excessive Service Rinse ..........................................................................................6
Excessive Final Rinse ..............................................................................................6
DATA ACCESS TOOL.........................................................................................7
4.1
4.2
4.3
How To Use .............................................................................................................7

Regeneration Data...................................................................................................8
Service Data ............................................................................................................8
5.0
VALVE SEQUENCE..........................................................................................10
6.0
INSTRUMENTATION ......................................................................................10
6.1
6.2
7.0
EXTERNAL INTERLOCKS..............................................................................13
7.1
7.2
8.0
Red Lion Flow Rate Indicator / Totalizing Indicator ...........................................10

Thornton Conductivity Monitor.............................................................................12
Input Interlocks ......................................................................................................13

Output Interlock Configuration .............................................................................13
DUPLEX OPERATION......................................................................................14
VP SERIES
Page 3 of 14
Rev. 5
1.0 CONTROL OVERVIEW

The system provided consists of controls for a simplex two bed hereafter referred to as the "unit".
The PLC control system consists of an Allen Bradley MicroLogix 1500 controller, with discrete
pushbuttons, lights; data access tool; and conductivity and flow instruments as the operator interface.
All controls are housed in a 30"H x 24"W x 12"D Nema 4/12 painted steel enclosure mounted on the
unit face piping.
2.0 TWO BED OPERATION

Operation is slightly different for duplex alternating operation. (see section 8.0 for additional
information)
2.1
REGENERATION
1.
Regeneration Initiation
With the unit in off line, the "Regeneration" pushbutton may be pressed to place the unit
into the regeneration sequence. The REGENERATION lamp will light.
Automatic Operation Selector Switch in "On".
With the unit in exhaustion rinse and exhausted; or totalized, the unit will enter the
regeneration sequence automatically. The REGENERATION lamp will light.
2.
Sequence
The regeneration sequence consists of sequential timed steps of Backwash Cation, Acid
In Cation, Slow Rinse Cation, Fast Rinse Cation, Backwash Anion, Caustic In Anion,
Slow Rinse Anion, and Final Rinse The presets for these steps are entered into the PLC at
the factory. The presets can be changed in the field with the Data Access Tool (See
Section 4.0). Final Rinse is terminated by reaching the proper conductivity set point
entered on the Thornton conductivity monitor so the preset time entered for this step is
for excessive final rinse. If proper conductivity is not reached within this time the
"Excessive Final Rinse" alarm will sound.
3.
Sequence Control Features

PB Lockout
During regeneration the "Regeneration" pushbutton can be toggled to place the unit in
and out of lockout. During lockout the sequence timer is stopped, and all regeneration
associated valves are de-energized. Pressing the pushbutton a second time will deactivate
the lockout function. The REGENERATION lamp will blink off.
Auto Lockout
Auto lockout occurs when there is an Excessive Final Rinse alarm. The sequence timer is
stopped, and all regeneration associated valves are de-energized. The REGENERATION
lamp will fast alternate flash. The excessive final rinse auto lockout can be reset by
pressing the Regeneration pushbutton.
Restart
When the "Regeneration pushbutton is pressed and held for (4) four seconds the
Regeneration sequence is reset back to the first step, Backwash Cation.
VP SERIES
2.2
Page 4 of 14
Rev. 5
REGENERATION COMPLETE
Automatic Operation Selector Switch in "Off".
When the regeneration sequence is complete the regeneration lamp will blink on to
indicate the regeneration is complete.
When the regeneration sequence is complete the unit will enter service rinse.
2.3
SERVICE RINSE / SERVICE

Automatic Operation Selector Switch in "Off".
With the unit off line or at regeneration complete, the "Service" pushbutton may be
pressed to place the unit into service rinse.
The unit will enter service rinse automatically upon entering regeneration complete.
While in service rinse the SERVICE lamp will blink on. Once the conductivity is proper
and the minimum service rinse preset is reached, the unit will advance to service.
Should the unit stay in service rinse longer than the excessive service rinse preset, the
"Excessive Service Rinse" alarm will sound. For proper operation, the preset value for
the minimum service rinse must be less than the preset for excessive service rinse.
During service, the SERVICE lamp will not flash and remain at a steady on state. Once
the unit has gone to service, it will not return to service rinse. The presets can be changed
in the field with the Data Access Tool (See Section 4.0).
OPTIONAL AUTOMATIC LOW FLOW RECIRCULATION
A recirculation pump is provided to maintain flow through the unit during low flow and
no flow conditions. The low flow / no flow condition is determined by the paddle wheel
flow sensor and Red Lion display. The recirculation pump is enabled and disabled
automatically during the service mode based on the flow rate of the unit. The flow set
point is set on the Red Lion Alarm #2. (see section 6.1 for set point).
2.4
EXHAUSTION RINSE
While in service, should the conductivity rise above the set point (typically at the end of
the service run), the unit will go into exhaustion rinse. The SERVICE lamp will blink off.
If the conductivity stays bad for the duration set on the exhaustion rinse preset,
the exhaustion rinse timer will time out activating the "Exhausted" alarm. If the
conductivity drops below the set point before the preset time, the unit will return to
service and the exhaustion rinse timer will reset. The preset can be changed in the field
with the Data Access Tool (See Section 4.0).
VP SERIES
2.5
Page 5 of 14
Rev. 5
OFF LINE
With the unit in service rinse, service, or exhaustion rinse, the "Service" pushbutton may
be pressed to take the unit off line. The lack of a REGENERATION lamp or SERVICE
lamp represents the off line mode.
The unit will go into regeneration automatically when the unit is "Exhausted (high
conductivity) or the totalizer exceeds the preset volume set on the Red Lion flow
indicator.
2.6
STATUS LAMP REFERENCE CHART

Flash Indications:
Blink Off Lamp is on and goes off for 0.1 seconds.
Blink On Lamp is off and goes on for 0.1 seconds.
Fast Alternating Lamp is on for 0.2 seconds and off for 0.2 seconds.
Slow Alternating Lamp is on for 0.8 seconds and off for 0.8 seconds.
REGENERATION Lamp
SERVICE Lamp
Off Line
Off
Off
Regeneration normal
Steady On
Off
Regeneration in pushbutton lockout
Blink Off
Off
Regeneration in auto lockout

because of excessive final rinse
Fast Alternating
Off
Regeneration in auto lockout

because of loss of supply water
Slow Alternating
Off
Regeneration Complete
Blink On
Off
Service Rinse
Off
Blink On
Service
Off
Steady On
Exhaustion Rinse
Off
Blink Off
Service Standby
because of loss of supply water
Off
Slow Alternating
Lamp Test (see section 3.1)
Steady On
Steady On
VP SERIES
Page 6 of 14
Rev. 5
3.0 ALARMS
3.1
ALARM SILENCE
Press the Alarm Silence pushbutton to silence the audible alarm. By holding the Alarm
Silence pushbutton for 3 seconds it becomes a Lamp Test pushbutton for the
REGENERATION and SERVICE lamps.
3.2
TOTAL THROUGHPUT
The Totalized alarm is active at all times and is indicated when the totalizer total throughput
value has exceeded the preset on the Red Lion flow instrument. The alarm is reset at the end of
regeneration. (see section 6.1 for setting preset).
3.3
reset
EXHAUSTED
The Exhausted alarm is active during the exhaustion rinse mode and is indicated by the
conductivity reading on the Thornton conductivity monitor above the set point. The alarm is
at the end of regeneration. (see section 6.2 for set point)
NOTE:
If the " Automatic Operation Selector Switch is in "On" the unit
will enter regeneration automatically upon "Exhaustion" or "Total Throughput".
The appropriate alarm will register but will be automatically silenced.
3.4
EXCESSIVE SERVICE RINSE

The Excessive Service Rinse alarm is active during the service rinse mode and is indicated by
conductivity reading on the Thornton conductivity monitor above the set point. The alarm clears
when the unit is no longer in the service rinse mode.
3.5
by
EXCESSIVE FINAL RINSE

The Excessive Final Rinse alarm is active during the final rinse step of regeneration and is
indicated by the conductivity reading on the Thornton conductivity monitor above the set point.
The unit will go into auto lockout so as not to waste rinse water. This auto lockout is indicated
the REGENERATION lamp fast alternating. The auto lockout can be unlocked and the excessive
final rinse timer reset by pressing the Regeneration pushbutton. This will allow the unit to
rinse again. Should the unit not rinse to quality the operator should investigate the cause (ie. No
chemicals) and restart the sequence.
VP SERIES
Page 7 of 14
Rev. 5
4.0 DATA ACCESS TOOL

4.1
HOW TO USE
The Data Access Tool mounted on the front of the MicroLogix PLC can be used to monitor the
regeneration sequence and modify the step presets. The only keys used are the INT (integer) key,
ENTER key, ESC (escape) key, and the UP/DOWN arrow key.
Monitoring and editing:
1.
Press the INT key. The element (left two digit display) flashes if not protected.
2.
Use the UP/DOWN arrow key to scroll through the list of elements 0-47. Check the
listing on the next page for the specific function.
3.
Press ENTER to select the element you want to edit. The element number becomes
steady and the data (right four digit display flashes if it is not protected.
4.
Use the UP/DOWN arrow key to increment or decrement the value. Holding down the
UP/DOWN arrow key causes the integer value to increment or decrement quickly.
5.
Press ENTER to accept the new data. Press ESC to discard the new data.
4.2
REGENERATION DATA
Minutes
Entry Value
DAT Element Protected
Current Regen Step Number
N/A
N/A
Yes
Current Regen Step Preset Time
N/A
N/A
Yes
Current Regen Step Accum Time
N/A
N/A
Yes
Output Interlock (See Section 7.2)
N/A
0 or 1
No
Backwash Cation Preset Time
15.0
150
11
No
Acid In Cation Preset Time
25.0
250
12
No
Slow Rinse Cation Preset Time
21.0
210
13
No
Fast Rinse Cation Preset Time
15.0
150
14
No
Backwash Anion Preset Time
15.0
150
15
No
Caustic In Anion Preset Time
45.0
450
16
No
Slow Rinse Anion Preset Time
18.0
180
17
No
Excessive Final Rinse Preset Time
25.0
250
18
No
VP SERIES
4.3
SERVICE DATA
Page 8 of 14
Rev. 5
Minutes
Entry Value
DAT Element Protected
Minimum Service Rinse Preset Time 2.0
20
31
No
Excessive Service Rinse Preset Time 10.0
100
32
No
Exhaustion Rinse Preset Time
100
33
No
10.0
VP SERIES
Page 9 of 14
Rev. 5
5.0 VALVE SEQUENCE

Mode / Step
Valves Open
Off Line
-----------------
Service Rinse
10101, 10201, 10205
Service
10101, 10201, 10202
Exhaustion Rinse
10101, 10201, 10205
Regeneration
Step 1
Backwash Cation
10103, 10104
Step 2
Acid In Cation
10106, 10108, 10105
Step 3
Slow Rinse Cation
10106, 10105
Step 4
Fast Rinse Cation
10101, 10105
Step 5
Backwash Anion
10101, 10203, 10204
Step 6
Caustic In Anion
10101, 10207, 10209, 10205
Step 7
Slow Rinse Anion
10101, 10207, 10205
Step 8
Final Rinse
10101, 10201, 10205
Regeneration Complete
-------------------------
VP SERIES
Page 10 of 14
Rev. 5
6.0 INSTRUMENTATION
6.1
RED LION FLOW RATE INDICATOR / TOTALIZING INDICATOR

The Red Lion indicator can be toggled between flow rate (down arrow button) and totalizing
counter (up arrow button). The preset for total throughput is set on the Red Lion indicator alarm
#1. When the indicator has totalized it sends a signal to the PLC. The totalizer accumulates
whenever there is flow going past the paddle wheel flow element located in the influent pipe.
The totalizer is reset at the end of the regeneration sequence by a two second pulse from the
PLC. Refer to the Red Lion operation manual for instrument specifics.
( ) = Red Lion Entry
rINP1
ASCFAC
Lo-cut
HyS-2
*SP-1
((k Factor) * (rdSP 1 / 60))

10 * (1 / k Factor)
Low Flow StPt / 2
25% of AL-2
Set @ 500 (will be adjusted in field)
Unit
Dia
Pipe
Dia
Fitting
K
Factor
PV8T010
PV8T010
PV8T010
Service
Flow
GPM
10
16
24
(rINP1)
352.44
352.44
352.44
Range
GPM
(rdSP1)
15
25
35
88.1
146.9
205.6
(ASCFAC
)
10.215
10.215
10.215
16
20
24
1
1
1
30
36
42
1-1/4
1-1/2
2
PV8T012
PV8T015
PV8S020
48
54
60
2
2-1/2
3
66
72
3
4
(Lo-cut) Low Flow

Setpoint
(SP-2)
1
2
1.5
3
2
4
(HyS-2)
38
54
74
177.18
117.85
66.74
55
80
100
162.4
157.1
111.2
20.318
30.547
53.941
3.5
5
6.5
7
10
13
1.8
2.5
3.3
PV8S020
PV8S025
PV8S030
97
123
153
66.74
42.99
26.65
120
160
200
133.5
114.6
88.8
53.941
83.740
2.251
8.5
11
13.5
17
22
27
4.3
5.5
6.8
PV8S030
PV8S040
182
220
26.65
15.01
250
300
111.0
75.1
2.251
3.997
16
19
32
38
8
9.5
0.5
0.8
1
The Red Lion DIP switch settings and programming for a unit using a Signet #2536 flow sensor.
N/A denotes programming locations that may not even appear or can be left at the factory
default. Bold Print requires setting other than default.
Dip Sw Settings:
Left Sw (Mag Pickup)

Middle Sw (Logic)
Right Sw (NPN O.C.)
DOWN
UP
UP
VP SERIES
1-INP
1-INP
1-INP
1-INP
1-INP
1-INP
1-INP
1-INP
A CNt
ArESEt
AdECPt
ASCFAC
ASCALr
ACNtLd
A P-UP
PrSEN
2-FNC
2-FNC
2-FNC
2-FNC
2-FNC
2-FNC
2-FNC
2-FNC
USr-1
USr-2
Usr-3
F1
F2
rSt
Sc-F1
Sc-F2
3-LOC
3-LOC
3-LOC
3-LOC
3-LOC
3-LOC
3-LOC
3-LOC
3-LOC
3-LOC
3-LOC
3-LOC
3-LOC
3-LOC
3-LOC
A CNt
b CNt
C CNt
rAtt
HI
LO
SP-1
SP-2
ACNtLd
bCNtLd
CCNtLd
ASCFAC
bSCFAC
CSCFAC
COdE
cnt
2Er0
0
(See Chart)
1
(0)
NO
NO
(dsPrSt)
NO
NO
NO
NO
dsPrSt
NO
NO
rEd
LOC
LOC
rEd
LOC
LOC
LOC
LOC
LOC
LOC
LOC
Ent
LOC
LOC
0
Page 11 of 14
Rev. 5
4-rtt
4-rtt
4-rtt
4-rtE
4-rtE
4-rtE
4-rtE
4-rtE
4-rtE
4-rtE
4-rtE
4-rtE
4-rtE
rAteeN
LO-Udt
HI-Udt
rtE dP
SEG5
rdSP 0
r INP 0
rdSP 1
r INP 1
rOUNd
LOCUt
HI-t
LO-t
rAtE-A
1.0
2.0
0
0
0
0.0
(See Chart)
(See Chart)
1
(See Chart)
2.0
2.0
5-CtrC
C CNt
NONE
6-SPt
6-SPt
6-SPt
6-SPt
6-SPt
6-SPt
6-SPt
6-SPt
6-SPt
6-SPt
6-SPt
6-SPt
6-SPt
6-SPt
6-SPt
6-SPt
6-SPt
Lit-n
Out-1
SUP-n
Act-n
ASN-n
SP-n
trC-n
tyP-n
Stb-n
HyS-n
tOFF-n
tON-n
tOUt-n
AUtO-n
rSd-n
rSAS-n
rSAE-n
SP-1
NOr
NOr
(Save)
(LAtCH)
(A CnE)
(*500)
NO
N/A
N/A
N/A
N/A
N/A
N/A
N/A
NO
NO
NO
SP-2
NOr
NOr
(Save)
(bOUNd)
(ratE)
(See Chart)
NO
(LO)
(yES)
(See Chart)
0.00
0.00
1.00
NO
NO
NO
NO
VP SERIES
6.2
Page 12 of 14
Rev. 5
THORNTON CONDUCTIVITY MONITOR

The Thornton conductivity monitor is used to indicate the quality of effluent water and
determine when the unit has rinsed to quality or exhausted. The PLC receives a signal from the
monitor alarm set point. The set point is the same for final rinse, service rinse, and exhaustion
rinse. The PLC has a five second "change" delay on the set point to prevent nuisance switching.
Refer to the Thornton operation manual for instrument specifics.
Thornton Conductivity Monitor Setup (Channel A):
Display:
Setpoint
Relay
Left
- A primary
- Fixed range - (u)S / cm
Right
- A secondary (a)
- Deg F
Auto Scroll
- Off
Number/Signal
Value/State
Assigned relay
Overrange
- 1 / A primary
- 10.00 (factory default) / (u) High
-1
- Yes
- 1, delay = 0
- Hyster = 00%
- Inverted
- Wired to C1 and NO1
VP SERIES
Page 13 of 14
Rev. 5
7.0 EXTERNAL INTERLOCKS

7.1
INPUT INTERLOCKS
Input interlock #1:
The input must be a dry isolated contact. This input is non configurable. Water Supply
Available is assumed when the input is energized. The panel is shipped with a jumper
(JMP1) installed between terminals H1 and 217. To use, remove the jumper and replace with the
dry isolated contact which is closed when there is a water supply available.
If the unit is in service rinse, service, or exhaustion rinse; and the dry contact opens the unit will
go to service standby indicated by the SERVICE lamp at slow alternating. When the contact
closes the unit will go back to service via service rinse.
If the unit is in regeneration and the dry contact opens the unit will go to auto lockout indicated
by the REGENERATION lamp at slow alternating. The sequence timer is stopped, and all
regeneration associated valves are de-energized. When the contact closes the unit will continue
the regeneration.
See electrical drawings for connection.
Input interlock #2:
The Service pushbutton is wired to terminals H1 and 207 so it can be paralleled by a remote
signal for start/stop of the service mode. This signal must be a dry contact closure. It must also
be momentary in nature as the same signal is used to start the mode sequence of service
rinse/service/exhaustion rinse and stop that mode sequence.
7.2
OUTPUT INTERLOCK CONFIGURATION

One output interlock, an isolated dry form C (one normally open and one normally closed)
contact is provided. This output is configurable for two scenarios by entering a 0 or 1 in DAT
element 06. The factory default is 0.
Enter a 0 to:
Send a signal (energized output relay) that the unit is in regeneration. This
interlock could be used to prevent equipment upstream from shutting off
the water supply during regeneration.
Enter a 1 to:
Send a signal (energized output relay) that there is flow forward. This
could be used to tell equipment downstream when water is available.
VP SERIES
Page 14 of 14
Rev. 5
8.0 DUPLEX OPERATION

Both units can operate (as a system) either dependently or independently.
While operating independently (parallel operation) each unit cycles though the unit modes
independently of what the other unit is doing. Therefore, it is possible to have both units in
Service or Regeneration at the same time.
While operating dependently (alternating service mode), the mode of one unit is limited based
on the mode of the other unit. In dependant operation, one unit is in Service Rinse
or Service while the other is in Regeneration or Regeneration Complete. The unit in
Regeneration Complete will not index automatically to Service Rinse while the other unit is on
line. When the unit in Service becomes "Exhausted" or "Totalized", the unit in Regeneration
Complete will index to Service Rinse (if the Auto Operation switch is in On). Once this new
unit indexes to Service, the exhausted or totalized unit will index to Regeneration (if the Auto
Operation switch is in On). When operating in the dependent mode both unit Auto Operation
selector switches should be in the On position.
No interlocks are required for parallel (independent) operation. Each unit has its own
regeneration system and low flow reciculation if that option was included.
For alternating (dependent) operation connect the two relay interlocks CR-263 In Service and
CR-283 Exhausted or Totalized to their respective inputs on the opposite unit. Also the
Alternating Service (JMP2) must be removed in each panel.
See electrical drawings for connections.

VENDOR LITERATURE
Page 9-1
Rev. 0
9.0 VENDOR LITERATURE

This subsection contains the manufacturers instructions for all of the major components on your
U.S. Filter system. These instructions are arranged alphabetically by manufacturer.
Refer to the chart on the following page to locate the specific literature for your equipment.

Manual de Lecho Mixto

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Manual de Lecho Mixto

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VPT Series

Two Bed Deionizer

General System Description ................................................................... 1-1

General Safety Guidelines ...................................................................... 2-1

PREPARATION AND STARTUP

Theory of Operation................................................................................. 4-1

Taking Samples for Analysis .................................................................. 5-2

Maintenance General ............................................................................... 6-1

Shutdown on Power Loss........................................................................ 7-1

Equipment List......................................................................................... 8-1

Vendor Literature Section........................................................................ 9-1

PROPRIETARY RIGHTS STATEMENT

MANUAL USERS GUIDE

Warnings indicate condition, practices, or procedures that must be observed

Cautions indicate a situation that may cause damage or destruction of

GENERAL SYSTEM DESCRIPTION

Product Flow Rate (in gpm)

The following chart details the design parameters.

Simplex (duplex optional)

Maximum Inlet Turbidity:

Maximum Inlet TDS:

500 ppm as CaCO3 (29.2 grains/gallons)

8 gpm/ft (2.5 gpm/ft )

8 gpm/ft2 (2.2 gpm/ft3)

4.5 lbs (100%) HCl/ft3

6.0 lbs (100%) HCl/ft3

1.56 gallons 30% HCl/ft3

0.90 gallons 50% NaOH / ft3

SYSTEM DESIGN SPECIFICATIONS

Carbon steel, butt welded seams

100 psig non-code (optional: ASME code & stamp)

Structural steel legs, seismic zone 4 (optional: zone 2A and 4 skids)

Non-code: removable head w/ (2) 4 x 6 hand holes

(1) 11 x 15 crab style

5 to 7 mil DFT epoxy (optional: 20 to 40 mil DFT baked PVC)

35 to 45 mil DFT vinyl ester (optional 60 to 80 mil DFT baked

PVC radial flow point distributor

PVC hub with PVC slotted laterals

Schedule 80 PVC, socket-welded and flanged

Schedule 80 PVC, socket-welded

Schedule 80 PVC, socket-welded & flanged with clear sight glass

Automatic Process Valves:

PVC bodied, EPDM diaphragm

2-1/2 and larger

Cast iron butterfly, EPDM seats, Nylon-coated disk, SS trim

Air-to-open, spring-to-close, except backwash, rinse outlet and

(1) PVC ball

Product Water Sample

(2) PVC ball, one on each vessel

(2) PVC ball, on for each regenerant chemical

(3) PVC ball, one for each pressure gauges

(1) 2 dial, 316 stainless steel

(1) 2 dial, 316 stainless steel

Service Outlet Gauge

(1) 2 dial, 316 stainless steel

Signet paddlewheel flow element on inlet to cation vessel

Thornton 240-XXX cell in the effluent piping of the anion vessel

Product Conductivity Monitor

Thornton 200 CR Digital meter mounted in panel

NEMA 4 enamel painted steel

Programmable Logic Controller

Allen-Bradley MicroLogix 1500, 24 VDC, fixed I/O type

Allen-Bradley discrete 32 point (12 inputs, 20 outputs)

Pushbuttons and lights