Serv-A-Pure 1447 DI System Operation & Maintenance Manual · 1447 DI System Operation & Maintenance...

1447 DI System Operation & Maintenance Manual Serv-A-Pure Company • 1101 Columbus Ave. Bay City, MI 48708

Phone: (800) 338-4905 • Fax: (989) 892-1092 • www.servapure.com Rev. C

Serv-A-Pure 1447 DI System

Operation & Maintenance Manual


of 19 Phone: (800) 338-4905 • Fax: (989) 892-1092 • www.servapure.com

Table of Contents Section Description 1.0 Glossary of Terms 2.0 General Description

2.1 Principles of Purifying Water 2.2 Laboratory Grade Water System Specifications 2.3 pH In Ultra Pure Water

3.0 Product Specification 3.1 System Drawings and Layout 4.0 Installing the System 5.0 Maintenance 6.0 Consumable and Spare Parts 7.0 Requesting Service 8.0 Troubleshooting Guide 9.0 Tank Sizes and Capacities 10.0 Warranty



1.0 Glossary of Terms

The following terms are used throughout this text. Please take a few moments to familiarize yourself with them so that the information and instructions within are clear. TERM DESCRIPTION DI “Deionization” is the process used in this system to purify the water.

Deionization removes almost all minerals from the water GPM “Gallons Per Minute” tells the flow rate of the system. TDS “Total Dissolved Solids” is a measure of the combined content of all inorganic

and organic substances. Typically measured in PPM or Microsiemens. TOC “Total Organic Carbon” is the amount of carbon bound in an organic compound

and is often used as a measure of water quality or cleanliness. RO “Reverse Osmosis” is a water purification technology that may be used to greatly

extend the life of DI cartridges.



2.0 General Description • This deionized water system has been engineered to consistently produce Type II ultrapure water. This system is user-‐friendly, does not require any pretreatment options, and lowers the cost per gallon to purify the water • Adding a pre-‐treatment reverse osmosis system will greatly increase the lifespan of each deionizer tank. However one is not required and this system can run directly off of city water. The feed water quality will determine the necessary pretreatment, if any. Optional pretreatment systems are available to operate from tap water that does not meet feed water specifications. • Serv-‐A-‐Pure’s 1447 DI water system does not use any reservoir which allows bacteria to build up. All water produced is purified as it is drawn off to reduce any possibility of bacteria contamination. The 1447 DI system can provide you with up to 8.0 gallons per minute (depending on tank size) of deionized water. Whether you use 1 gallon per day or 1000 gallons per day, the 1447 DI system is a perfect fit for nearly every application. • The 1447 DI system is designed to provide water that has high resistivity and low TOC (> 1.0 MΩ*cm and ≤ 500 ppb). The 1447 DI system is ideally suited for higher water use applications such as, closed loop systems, industrial applications and solar panel rinsing. • Every 1447 DI system comes with free technical phone support. Your 1447 DI cartridges can be changed out by a member of Serv-‐A-‐Pure’s courteous and friendly staff. Alternatively, all cartridges can be sent to you via common carrier to allow for more economical change outs. • All filters on the 1447 DI system are recommended to be changed at a minimum of every 6 months, depending on feed water quality. This allows maintenance to take place as little as two times per year.



2.1 Principles of Purifying Water

The Serv-‐A-‐Pure 1447 DI system uses deionization as the process to purify water. The deionization process removes all ions from a solution. The 1447 DI system uses mixed bed resins combined with both cation and anion resins. Cation resins remove all cations (positively charged ions such as Sodium, Calcium, and Magnesium) and anion resins remove all anions (negatively charged ions such as sulfate, bicarbonate and chlorides).

Deionization systems can be either continuous or batch mode operations. In a continuous system, the water is purified as quickly as it is used, whereas in batch operations the water will be purified slower than the end usage and stored in a tank so it may be used at faster flow rates.

Sizing a system is based upon your water usage. There are three basic requirements used to determine the design of a water purification system:

1. Maximum demand (gpm peak) 2. Average demand (gpm average per day) 3 Water purity level required.

The first governs the amount of flow rate and the second sizes the storage required (if any). 1447 Deionization Operation Water enters the 1447 DI system and passes first through a 5.0 micron pre filter. This filter removes particulate and sediment from the raw water. Next it passes through a carbon absorption cartridge, which removes chlorine and other organics from the feed water. The water then passes through one or more deionization tanks that exchange the ions in the water stream for hydrogen ion and the hydroxyl ion, which leaves us with only H2O left in the water. Finally, the water passes though a 1.0 micron post filter to ensure no resin fines are passed into the purified water stream. Red/Green purity lights monitor the quality of the water to ensure you are still receiving Type II lab water.



2.2 Laboratory Grade Water System Specifications

Different published norms define the quality required for specific laboratory water applications: ASTM and ISO 3696 for laboratory applications, CLSI guidelines for clinical laboratories. The table below outlines the different water specifications based on different water type per ASTM guidelines:

Contaminant Parameter and Unit Type 1 Type 2 Type 3 Ions Resistivity (MΩ*cm @ 25 C) > 18.0 > 1.0 > 0.05 Organics TOC (ppb) < 10 < 50 < 200 Pyrogens (Eu/ML) < 0.03 NA NA

Particulates Particulates > 0.2 μm (units/mL) < 1 NA NA

Colloids Silica (ppb) < 10 < 100 < 1000 Bacteria Bacteria (cfu/mL) < 1 < 100 < 1000

These values are only guidelines, as some specific laboratory applications may require a quality superior to the quality indicated by the norms. TYPE 1 Type 1 water is the grade required for critical laboratory applications such as HPLC

mobile phase preparation, blanks and sample dilution in GC, HPLC, AA, ICP-‐MS and other advanced analytical techniques; preparation of buffers and culture media for mammalian cell culture and IVF; production of reagents for molecular biology applications (DNA sequencing, PCR); and preparation of solutions for electrophoresis and blotting.

TYPE 2 Type 2 water is the grade used in general laboratory applications such as buffers, pH solutions and microbiological culture media preparation, as feed to Type 1 water systems, clinical analyzers, cell culture incubators and weatherometers; and for the preparation of reagents for chemical analysis or synthesis.

TYPE 3 Type 3 water is the lowest laboratory water grade, recommended for glassware rinsing, heating baths and filling autoclaves, or to feed Type 1 lab water systems.

These standards can be used in conjunction with the Type of water.

Measurement (Unit) A B C Heterotrophic Bacteria Count (CFU/ml) 10/1000 10/100 1000/10

Endotoxin (units per ml) 0.03 0.25 n/a



2.3 pH In Ultra Pure Water

In discussing pH and pH as applied to corrosion most people forget that the total salt content is also important in corrosion. The pH measurement of Ultra Pure water is practically meaningless. The classic story is the technician who drew a sample of 18 MegOhm water, carried it 40 feet to the pH meter and found he had a pH of 6.5. He knew this could not be correct so he swirled the water to get a better reading. To his amazement, the pH dropped to 4.5. He, of course, felt the water was not pure, however, what he did not realize until later was that he had added CO2 to the water. He had formed carbonic acid during his swirling and this had lowered the pH. The question is, was the pH of 4.5 on Ultra Pure water more corrosive than pH 7.0 Ultra Pure water? The answer is no, because one mg/l of Sodium Bicarbonate would immediately raise the pH to over 7.0. A pH of 4.5 in water of 500 mg/L Total Dissolved Solids (TDS) would be quite corrosive and would require well over 500 mg/L of Sodium Bicarbonate to raise the pH over 7.0. What this tells you is that pH alone without knowledge of the other components in the water is not sufficient to base a decision on. It should be remembered that Ultra Pure water will always tend to be slightly acidic, i.e. pH less than 7.0, because of the tendency for CO2 to dissolve in water. Without other salts to buffer the weak carbonic acid the pH value will be reduced. The pH of water with less than 10 mg/l TDS has questionable validity. The pH of water with between 10 and 50 mg/L TDS becomes more important, but not the major indicator of corrosion. The pH is the major indicator of corrosion with water with over 50 mg/l TDS.



3.0 Product Specification Specifications 1447-‐2-‐3BB Feed Water Potable tap water with conductivity < 2000µS/cm @ 25°C,

At a pressure of 15-‐90* psi Flow Rate Up to 8.0 GPM Resistivity > 1.0 MΩ•cm @ 25°C (Type II) Typically Operating Temperature Range 35 – 100°F (2-‐38°C) TOC < 500 ppb Wall Plate Weight, Approx: 65 pounds Floor Space Dimensions (H x W x D) 72” x 48” x 24” *Pressures exceeding 90 psi may require an optional inlet pressure regulator



Legend

Valve! N/O = Normally Open! N/C = Normally Closed

Install Dr / 1447 DI 2 Tank Install

Typical Two Tank Mixed Bed Deionization Installation To Provide ≥ 1.0 MegOhm Water

Raw Water IN

Note:!Water Enters The D. I. Tanks Thru!The Female Fitting & Exits Out The !Male Fitting.

Connect Inlet!Plumbing Here

WP5-BB!WP5-BB20P!

5.0 Micron Filter!20” BB Cartridge!

#355223

Pure Water Out !Connect to outlet with !only Plastic or Stainless!Steel Pipe

!When Light on Tank #2 Goes Out!If Light on DI-2 goes Out With Water Flowing Change DI-1 and DI-2 with New Full DI Tanks.!!When Light on Tank #1 Goes Out!Remove DI-1 and return for reprocessing!Move DI-2 to the DI-1 position and install New Full tank in DI-2 position.

Purity Light!

TANKS

(989) 892-7745 (800) 338-4905

LOCATION

DATE

SCALE

DRAWN

DRG NONA

2 Tank Deionization Exchange System - AH2

RCH

For 5.0 gpm Maximum Flow Rate

11-30-09

091020

Serv-A-Pure Company !1101 Columbus. Ave. Bay City, MI. 48708

#1447 DI Tanks, 3.75 cu. ft.

Note:!Water is good while lights!remain lit. When light on #2!tank goes Out, exchange tanks.

RFC-1!RFC20-BB!

Carbon Cartridge!20” BB Cartridge!

#155247

WP1-BB!WP1-BB20P!

1.0 Micron Filter!20” BB Cartridge!

#355222

DI-1!Mixed Bed DI Tank!

14" x 47"!3.75 cu. ft. Resin

DI-2!Mixed Bed DI Tank!

14" x 47"!3.75 cu. ft. Resin



4.0 Installing the System

This section includes instructions for initial installation and start-‐up of the unit. Described herein are selection of unit location, unit unpackaging, and connection of the unit to the water and electrical supplies. Also described are cartridge installation and the purging of trapped air. 5.1 Setup

• Select a location for the unit, which is in close proximity to the water supply and electrical supply connection. Select a wall that will support a 70-‐pound load on 16-‐inch stud centers or provide wall-‐backing material. • Carefully remove all of the packaging material and tape used for shipping purposes, and position the unit in its operating location. The top of the wall plate should be mounted 72” off of the ground.

• Connect the inlet plumbing to the supplied MPT ball valve. Inlet plumbing can be made from any material such as copper, cast iron, pvc etc. • Connect the outlet plumbing to the supplied MPT ball valve. Outlet plumbing needs to be constructed from PVC, CPVC, SS or some other inert material to reduce leaching of contaminants into the DI water.

5.2 Installing the Cartridges

• Install the pre-‐sediment, pre-‐carbon and post-‐sediment filters. These may come installed in the housings for shipping purposes. If so, open the housings and remove the packaging material from the filters and re-‐install. Hand tight is ok, no need to tighten down with the provided spanner wrench. Only use the wrench if you have a small leak and for help in removing the housings.

• Arrange the DI cylinders below the wall plate. Make all connections from the wall plate to the DI cylinders by following the attached labels. Such as connect “DI Tank #1 Inlet to DI Tank #1 Inlet”.

5.3 Start Up Procedure

• Plug in the 2 supplied resistivity lights. The electrical outlet should be properly grounded and fused. The lights will be red with no water flowing through them. • Open Test Valve #1 and place an open container underneath valve. • Slowly turn on the water supply to the unit and correct any leaks at the supply



connections. •Allow the air to bleed from the system through the outlet valve into the open container. When all air has been purged from the first 2 filter housings close valve. • Open Test Valve #2 and placed open container underneath the valve. • Allow all of the air to bleed from the deionization tanks. Verify that the purity lights turn “Green” with the water flowing. Once the purity lights turn “Green” and the air is completely purged, close the outlet valve. • The system is now ready to be used.



5.0 Maintenance

The 1447 DI system was designed and manufactured to have the ability to produce Type II lab water for many uses. It purifies water that meets or exceeds the specifications recommended by ASTM and CAP for Type II Lab Water when it is operated and maintained according to these instructions.

• The pre-‐sediment, pre-‐carbon and post-‐sediment filters should be changed every 6 months, or more often if necessary. • The DI resin cylinders must be replaced when the purity light indicates the water purity is below your requirements or every 6 months. • The exterior surfaces may be cleaned with a mild detergent and a soft cloth to keep the unit looking new and clean.

Replacing the Cartridges The pre-‐sediment, pre-‐carbon and post-‐sediment cartridges are expendable items that have a limited capacity to filter the water. Monitor the pressure using the installed pressure gauges and change if the pressure drop becomes too great (15-‐20 PSI drop). The cartridges should be replaced every 6 months as a matter of routine maintenance or every time the DI cylinders are replaced. • Turn off the inlet and outlet ball valves.

• Place an open container under one of the blue handled test valves. Open the valve and bleed the pressure off of the system. Verify both pressure gauges read 0 psi before continuing. • Using the supplied spanner wrench, remove the filter housing sumps from the wall plate. Remove the installed cartridges and dispose properly, according to local codes. • Install new cartridges and screw the sumps back onto the wall plate. •If needed, exchange the DI cylinders at this time (see below). • Ensure open container is still under test valve and slowly open the inlet ball valve. Bleed all air out of system. Close the test valve and open the outlet valve. • Inspect the housings for leaks at this time.



Replacing the DI Cylinders The DI cylinders can only remove a certain amount of contaminants from the water before they need to be replaced. When the purity light turns red, with water flowing, it is time to change out the DI cylinders.

• Turn off the inlet and outlet ball valves.

• Place an open container under one of the blue handled test valves. Open the valve and bleed the pressure off of the system. Verify both pressure gauges read 0 psi before continuing.

• Unscrew the connections on top of the DI tanks

• Install new DI cylinders and firmly cam down each connection.

• Reconnect the connection on top of the DI tanks. Ensure open container is still under test valve and slowly open the inlet ball valve. Bleed all air out of system. Confirm purity lights turn green (make take a few gallons). • Inspect each fitting for leaks.



6.0 Consumables and Spare Parts

Pre-‐sediment 5.0 Micron Filter Part Number: 5M-‐WP-‐20BB Pre-‐sediment 20” Carbon Filter: Part Number: 155247-‐43 Post-‐Sediment 1.0 Micron Filter Part Number: 1M-‐WP-‐20BB 14” x 47” DI Tank Part Number: SAP-‐1447-‐MB O-‐Ring for Filter Housings Part Number: 151122 Spanner Wrench for Filter Housings Part Number: 144368



7.0 Requesting Service

Before calling the factory to request service, search the troubleshooting guide on the next page for symptoms, which your unit exhibits, and verify the cause and possible remedies listed. If your symptom is not listed, or the remedy does not provide a cure, contact:

1101 Columbus Ave Bay City, MI 48611

Phone: (989) 892-‐7745 Fax: (989) 989-‐1092 www.ServAPure.com

Email: [email protected]



8.0 Troubleshooting Guide

Symptom Cause Remedy No Water Flow Inlet/Outlet Valve Is

Closed No Feed Water Pressure

Open the inlet/outlet valve and check for flow Check feed line and correct condition

Slow Water Flow Feed Pressure Low Plugged pre/post filters

Feed Pressure needs to be between 30-‐80 psi Change filter that is plugged. Use pressure gauges to determine which on is plugged.

Purity Light Red No Flow Tanks Exhausted

Water needs to be flowing for light to read properly If water is flowing and light is red, change DI Tanks

Tanks Exhaust Quickly

High Feed Water TDS High Water Usage

Install pretreatment option such as RO system Upgrade to larger DI tanks

DI Tank Leaking Resin under o-‐ring on fitting

Remove seal and ensure no resin beads or other debris are there

Filter Housing Leaking

Sump Not Tight O-‐Ring damaged

Tighten the sump with spanner wrench (Do not over tighten) Replace o-‐ring



9.0 Tank Sizes and DI Capacities

The following chart shows the estimated amount of gallons each DI tank will produce. For example, if you have a 635 DI tank and your feed water is 200 ppm, you can expect your DI tank to produce 504 gallons.

Feed Water TDS (ppm or

mg/l)

618 (0.27 ft3)

818 (0.44 ft3)

635 (0.57 ft3)

835 (0.92 ft3)

844 (1.25 ft3)

1447 (3.75 ft3)

10 4,934 8,041 10,417 16,814 21,017 67,255 50 954 1,555 2,014 3,251 4,063 13,003 100 477 777 1,007 1,625 2,032 6,501 200 239 389 504 813 1,016 3,251 300 159 259 336 542 677 2,164 400 119 194 252 406 508 1,625 500 95 155 201 325 406 1,300



10.0 Warranty

Serv-‐A-‐Pure’s 1447 DI system has a one-‐year warranty from the date of purchase. If any component fails to function normally within the first year, return the unit to the factory prepaid. If in the opinion of the factory, failure was due to defects in materials or workmanship, repair or replacement will be made without charge. A reasonable service charge will be made for diagnosis or repairs not covered by this warranty. Serv-‐A-‐Pure Company assumes no other responsibility or liability. This warranty does not cover filters or DI cylinders, as their lifespan is completely dependent on the feed water quality. Also any products which has been subject to misuse, neglect, accident or used in violation of operating instructions nor does it extend to any units altered or repaired by anyone other than Serv-‐A-‐Pure Company or Serv-‐A-‐Pure authorized technicians. In no event shall Serv-‐A-‐Pure Company be liable for any incidental, consequential, special, indirect, punitive or exemplary damages or lost profits from any breach of this warranty or otherwise. Serv-‐A-‐Pure Company reserves the right to make changes in design, specifications and prices without notice.


Phone: (800) 338-4905 • Fax: (989) 892-1092 • www.servapure.com Rev. C

Serv-A-Pure 1447 DI System Operation & Maintenance Manual · 1447 DI System Operation & Maintenance...

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