ELECTROPURE™ EDI MODULE INSTALLATION CHECKLIST

1. Safety
2. Bolt Torque
3. Handling the Module
4. Mounting Options
5. Module Orientation
6. Pipe and Tubing Connections
7. Power Connection & Wire Conventions
8. Grounding
9. Module Startup

1. Safety

Please read and understand the Safety Section of the Electropure™ EDI Technical Manual before
installation. Please train your colleagues regarding the safe design and operation of EDI
modules. Key safety topics are the use of electricity around water and the handling of the gases
produced at the electrodes.

2. Bolt Torque

Bolt torque is important to maintain high product resistivity and to prevent leakage. Plate-and-
frame devices require torqueing for proper sealing. If the modules become loose, water from
the concentrate can leak and form crystals. It is the customers’ responsibility to prevent leakage
and crystal formation.

The bolts should be torqued at the following times:

1) when the module arrives after shipping,

2) after it has been mounted to the skid,
3) after the skid has been shipped,
4) before operation at the customers' site,
5) after water pressure has been applied,
6) periodically (weekly) for the first month until all of the internal plastic parts have fully
compressed, and
7) whenever the product quality declines a little.
The module is torqued at proper levels at the factory before shipping. After the module is
installed and before the module is operated, the torque should be reset per the procedure in the
technical manual. It is important to use the torque sequence in order to prevent distortion of the
hardware and to assure an even internal pressure level.

Too much torque will result in deformation of the stack. Too little torque will result in internal
and external leaks. The normal torque is 20 ft-lbs (27 N-m). Failure to follow maximum torque
recommendation can result in severe damage to the module hardware.

Failure to keep the torque at the minimum can results in irreversable leakage and the formation
of corrosive crystals formed from leaking concentrate.

3. Handling the Module

The module is designed to be compact and lightweight. However, do not lift by the plumbing
or electrical connections. Do not lift by the end covers. There are 8 lifting and mounting points
on the aluminum frames.

4. Mounting Options

Mount the modules so that the 19 face bolts are accessible for torqueing with a torque wrench.

The module can be mounted in different ways. The most popular way is to install L-or U-
brackets on the skid, which provide a secure track for module to sit in. The module may be
mounted on a single, central rectangular rail. The module is then secured at the top via either
two of the mounting holes on the top. The module may also be suspended by 3/8” rods through
the same four holes on the top. See the “Mounting Methods” drawing in Chapter 10 of the
Electropure™ EDI Technical Manual.

Do not bolt both the front and rear of the module to fixed points as this can constrain and stress
the module hardware during torqueing. One of the endplates needs to be able to move to allow
unrestricted torqueing.

5. Module Orientation

Electropure EDI modules are designed to be installed in an upright, or vertical position. In a

horizontal position, gas can become trapped in the chambers and interfere with ion removal.
6. Pipe and Tubing Connections

The standard modules are provided with 1” (US Standard) female pipe thread (FNPT) fittings for
the main feed and the product. Sanitary Quick-Disconnect connections are a product option (this
option comes with two 1” Sanitary Sani-techtm flange fittings, complete with Buna-N seals,
endcaps for sealing and protection, and True Union Clamps.)

Use Teflon® tape or pure TFE paste for sealing the threads. Do not use pipe dope made for
metal threads as it often contains solvents that will weaken the plastic. Even “FDA-
approved” pipe dopes contain these solvents. The use of pipe dopes with solvents will void the
Electropure limited warranty.

It is very important that the threads are protected before installation to prevent damage and
subsequent leaks. Secure the fittings with a tool to prevent twisting them during threading. If
the fittings are not “backed up” during tightening, they may crack and need to be returned to the
factory for repair.

Do not over-tighten the threads. Starting with the second full thread and continuing over the
length, wrap Teflon thread tape in the direction of the threads. Overlap each wrap by one-half
the width of the tape. Screw the male fitting into the 1" female port (be sure to backup this
fitting) on the module and tighten by hand. Using a strap wench only, further tighten the
connection an additional one to two threads past hand tightness. Avoid excess torque as this
may cause manifold or fitting damage. Read the full threading instructions accompanying the
module.

The tubing connections for the concentrate and electrolyte are 3/8” and 1/4” (see module
drawing), and are push-in-type, self-sealing (John Guesttm) connections. The electrolyte outlet
tubing is colored “yellow.”

There is a metric conversion kit available which converts the 3/8 inch and ¼ inch to metric tubing
sizes (8 mm). Contact Electropure.

7. Power Connection & Wire Conventions

The connection between the module and the power supply is a water-tight gold-plated, three-
connector fitting. The module is provided with a keyed male fitting at the bottom of one face of
the module. A 12 foot (4 meter) power cord, with female connections, is provided with each
module. The GREEN (o), BLACK (-), and WHITE (+) wires at the end of the power cord should be
connected to the appropriate terminals and ground of the DC supply.

The (DC -) cathode is always BLACK.

The (DC +) anode is always WHITE.
The (o) Ground is always GREEN.

8. Grounding

The module itself is grounded through the main DC electrical connection. All conductive parts of
the module are grounded together to the green wire of the connection. This should be grounded
to a suitable ground by a qualified electrician.

Since the water streams are also conductive, current can flow through the water stream to
ground. It is good design to provide a “T” connection in the various feed and outlet streams,
through which a conductive piece can be connected directly to ground (e.g., stainless steel rod
with wire attached).

Note that electrical measuring devices, like conductivity and resistivity probes, can give
erroneous readings if their streams either measure stray current/voltage or measure resistance
to ground via the conductive piece.

9. Module Startup

The key to proper startup is to run as little water through the modules as possible during the
plumbing checkout before applying power. The more water and ions that enter the modules the
longer the initial regeneration procedure will be.

Make all mechanical, plumbing, and electrical connections.

Ensure that there is a Y-trap or filter just before the EDI system. This will prevent construction
debris from entering the EDI modules.

If the EDI is fed from a separate tank, the prefilter should be very fine (5 micron or 20 micron) to
prevent silt from entering and fouling the modules.
Have data sheets and startup notebook on hand. Record initial data and any observations. Call
Technical Service at Electropure with any questions.

Bleed all air out of plumbing system by first filling the manifold(s) and modules slowly with
water, then pulsing water to all three streams to knock bubbles loose. The manifold(s) should be
designed to have no dead legs that can trap air. Removing the air at startup is important because
airlocks in only some of the modules will prevent all modules from getting the same flow of
water. There may be bacteria in the modules after shipment and storage, which can be
dislodged at this point. (Initial sanitization to come later.)

Check all plumbing connections for leaks and repair.

Apply DC power after as little time as possible. If too much water (with ions) is sent through the
module(s) before power is supplied the excess ions will need to be removed with a longer
regeneration procedure.

Check to be sure all three (3) streams for all modules are flowing at the recommended, design
flows.

Check that the pressure drops of all three (3) streams are approximately correct.

Check all modules for startup current. The amperage may be higher than normal on startup and
should drop to a nominal level within 1 hour. All modules should have similar currents to one
another.

Check that the ion concentrations in the concentrate streams are all high. If the module(s) are
running at 90% recovery, then the concentrate should have about 10-11 times the concentration
of the feed. Perform a mass balance on the inlet and outlet ions to determine if the module(s)
are regenerating (excess ions in outlet) or underpowered (too few ions in outlet).

Check all system permissions and interrupts. Check all flow sensors to ensure that minimum
flows are set properly and the correct signals are presented to the control system.

If not immediately, then after about one (1) hour, the product resistivity should rise to the proper
level. If excess ions were introduced during the startup procedure, then a regeneration cycle
may be required before quality is achieved.
Check torque in the unpressurized state (with no pressure) and re-adjust. Follow up with the
recommended periodic torque procedure.

Perform a sanitization, especially if the site is for USP Purified Water.

Leave a maintenance manual at the site with the customer.