Look for shipping damage

Take a careful look at the sides of each crate or shipping skid and look for damage caused by a fork truck or rough handling during shipment. Report this damage to your carrier immediately.

Uncrating & Placement

Carefully move the crates and shipping skids as close to the final resting place as possible. Begin to take the wood crates by removing the plywood skirt that surrounds the lower portion of the assembly. Next you can remove the plastic sheeting that covered the upper portion of the assembly. Use a scissors to cut the beige, clear or white colored nylon tie wraps. Take care not to cut anything else when performing this step. Set aside any PVC piping that may be have been attached to protect it during shipment in a clean safe environment. Use a 9/16” socket to remove the lag screws that secure the metal skids to the 4” x 4” wood skids. Note there is a rubber isolator between the mounting point on the skid and the wood skid. Throw these away as the UF machine is not meant to be mounted on rubber isolators. Do not remove any protective tape covering the of pipe opening until the opening is too used in order to keep dust and dirt from entering the piping. Take care when removing any protective tape to not lose any O-ring that is located in the gland cavity.

Match marks

Match marks were used to identify to pieces that need to be reassembled. These are typically black letters or numbers printed on a yellow label.

Two pieces with the same match mark should be brought together.

Groove Clamp Gaskets Must be already in place

Groove clamps require a gasket to cover the pipe joint. It is important to make sure the appropriate gasket is already in place before two skids or pipe sections are moved together. If you do not place the gasket in first you will have to move the skids apart in order to place the gasket in its proper location.

Pointer shows groove clamp gasket in place.

Placement of Skids to form UF Machine

If your UF machine was large enough are required that it be split into for shipment or movement in your plant, or if you ordered a CIP system or other option, then you will have locate the individual skids as required. The ideal location has adequate space, 150 cm (60 in), on each of the long sides of the UF machine for maintenance. Check to make sure there is adequate headroom of 1.5 m (~5 ft) above the Top Cap for removal of the UF Elements from the UF Module. Place the ‘A’ UF Rack (usually with E-coat paint connection flanges) in its proper location. Next, if your UF Rack was made in two parts (otherwise skip to the next paragraph), place ‘B’ UF Rack next to Unit ‘A’ and insure the appropriate Match Marks are lined up & and each pipe joint that requires a Groove Clamp already has the Groove clamp gasket that can be slid into place. If you order included a CIP system, locate the 2 wooden spacers located in a cardboard box as these were used to factory assemble the interconnecting piping.

A1 is the spacer block.

Floor Drip Pans

If you ordered this option, then locate these parts and place as shown in the product drawing.

Stainless steel drip pan located under groove clamps.

Leveling the UF Machine

This is an important step and do not proceed with the assembly of loose items until the unit(s) have been put into place and leveled. Start the leveling process at the highest corner by running a long bubble level completely around the perimeter of the UF machine.

Note steel shims under the frame to level the frame on the floor. Add a shim(s) as required at one of the adjacent corners to the high corner. Move to the next corner and shim as required. Continue until you are back at the high corner again. Double check completely around on the top flange of the ~8 cm (3” C Channel) with the bubble level – adjust the shims as required.

Typical use of bubble level used to confirm a manifold is still level after shipping Use large C clamps where UF Rack Unit ‘A’ and UF Rack Unit ‘B’ are joined and also where UF Rack Unit ‘B’ and the CIP Unit are spaced apart by the width of the two spacers. Secure Skids to Floor For each of the Units that have a metal skid, there is a gusset with a 12.7 mm (½”) in the center. Use a concrete drill bit to drill a ~7 cm (3”) deep at each of the corners of each skid.

Note: Mounting hole in corner of the frame. Make sure the shims are still in place and the skids are all leveled. Secure the shims permanently so they will not come lose or can be removed. Insert a 12.7 mm (1/2”) diameter concrete floor anchor (provided with shipment) into each drilled hole. Place the washer over the top threaded portion of the anchor, then attach the nut. Use an appropriate socket to tighten as required to secure the skids to the concrete floor. Or if the floor is steel, create a weld bead every 2 feet or so or as required once all the shims are in place. Also weld the shims so they cannot move out or be removed.

Take care to protect fragile equipment during installation

Do not step or lean against PVC piping, gages, or other equipment attached to the UF System. Remove any wood or cardboard bracing or other temporary supports or blocking as required. Remove any bolts, screws or exposed nails that are holding down the metal frame of the UF rack to the wooden skid.

Summary of Loose or Kitted Components & Sub-Assemblies

Here is a list of all the items that have been shipped loose or kitted. These parts will vary according to the Model you ordered. See below for the Model ordered

Single Sided Basic & Double Sided Basic

Integral E-coat paint bypass that goes between the Supply & Return E-coat TruFlow E-coat Paint Manifolds (if ordered). Permeate purge interconnection piping 2 x?” BF valves, wheels + bolt hardware (other side hardware by customer) 1 x?” BF valve, lever + bolt hardware (other side hardware by customer) 1 UF Element for each TruFlow UF Housing Misc. goods: PVC primer & cement, Teflon pipe tape & Teflon paste, touchup paint, extra valve tags, etc. 1 permeate flow meter assembly for each UF Module Valve ID tags for valves provided by customer (as requested)

Single Sided Basic + BF (integral)

Same as Basic plus below - V31 valve Box of Bag Filters, PN 205028

Single Sided Basic + CIP and Double Sided + CIP

Same as Basic plus below - Inside CIP tank: 5 x PN 205028; stainless steel cooling coil, chilled water solenoid valve assembly CIP Clean return piping Permeate Fast Fill piping for CIP tank piping Flush and Drain Valve piping assembly 1-1/2” Groove Clamp for CIP clean Supply piping connection Spare CIP Pump Mechanical Seal & O-ring Kit Spare CIP Panel components (lights, fuses, etc) Clean permeate return piping 2 x Placement spacers (typically wood blocks marked as such)

UF Rack Shipped In Multiple Units

2 x?” Groove Clamps for joining the TruVelocity E-coat Paint Manifolds 2 x 1-1/2” Groove Clamps for joining the CIP Clean Supply & CIP Return manifolds 1 x 2” Groove Clamp for joining the Permeate Manifold

Butterfly Valves Shipped Dry

Do not open or close the butterfly valves too many times before they are wetted with water because they are manufactured ‘dry’ without any lubrication. The valves can be damaged if they are opened and closed excessively in this dry state.

Making Threaded Pipe Connections

To seal threaded PVC pipe connections, use Teflon tape and Teflon paste, which has been provided. For stainless pipe, use a liquid thread compound recommended or approved by your E-coat paint supplier or Teflon tape and Teflon paste.

Adjustment of components & Alignment of Piping Connections

In most cases, some movement of the piping, pre-filter vessels, UF Housings, etc. may occur. It is necessary to review this matter and make adjustments as required. Refer to the appropriate drawing of your system. You can find your Part Number on your invoice. This should be included with this document. Contact UFS if you do not have your appropriate drawing. Measure the distance of the centerline of the E-coat paint manifolds (E-coat Supply, E-coat Return, E-coat balancing if PF option is included) from the floor or bottom of the metal frame, location of the PF vessels, etc. are as shown on the drawing. Use a tape measure to ascertain how close your dimensions are to the ideal. GOAL – make sure all the inlet and outlet piping is square and level with the connection points of the UF Modules and PF Vessels. Each of the E-coat paint manifolds needs to be level & square as well. A good way to start checking is to place a 15 cm (6”) bubble level on the E-coat paint Supply Manifold at each of the major diameters.

Bubble level on major diameter. Next place the bubble level (always keep the bubble level pointing in the direction of E-coat paint flow) on each of the 1-1/2” input isolation valves to the BF Vessels (skip ahead if the BF option was not ordered).

Check to make sure input piping is level.

Next place the bubble level on the vertical sidewall at several points around the diameter of the BF vessel to confirm it is vertical and true. Next place the bubble level on the 1-1/2” PVC valves on the discharge of the BF. Each of the input and output piping needs to be level., If these piping sections are not level, there could be a leak at one of the joints. Make a note of which piping sections and/or BF vessels are not level and/or square & true. These will have to be corrected after all the other items have been checked in a similar fashion.

Next, place the bubble level on the balancing manifold between the BF vessels and the input of the UF Modules, or the 1-1/2” PVC input isolation valves to the UF Modules (if BF are not included). Each of these input pipe needs to be level. The vertical position of the UF Module cannot be adjusted so if these isolation valves are not level the input piping is not level and there could be a leak at one of the joints. If some are not level, make a note of those that are not. Try loosening the 8” clamps around the UF Housing and see if it will set level on its C Channel support. Look at the inlet and outlet End Caps and make sure these are square and true. Retighten the 8” clamps. Then, place the bubble level on the vertical sidewall of the TruFlow UF Housing at several points around its diameter to confirm it is vertical and true. If some are not level, make a note of those that are not. Next, move the bubble level to the 1-1/2” output isolation valves from the UF Modules and check each one of these. Note any that are out of level. Repeat the level test of each of the major diameters of the E-coat paint Return manifold. Note those portions that are not level. Place a bubble level on the Permeate Discharge Manifold at several points and note any spots that are not level. Place a bubble level on the Permeate Clean Return Manifold at several points and note any spots that are not level. If all the tests show a level and square inlet and outlet piping to the UF Modules and the E-coat Paint Supply & Return Manifold, the check is finished by inspecting all the bolted joints to insure that the joints are tight.

Proper tightening of Groove Clamp hardware.

Tighten bolts alternately and equally maintaining metal to metal contact at the bolt pads and tighten securely. Excessive tightening is not necessary. Uneven tightening may cause a gasket to pinch. It is a good idea to lubricate the gasket with glycerin to avoid pinching.

What if something is not Level?

If some checks show Corrective Action is needed. Generally, this is so if one of the horizontal manifolds has shifted in a downward direction. Start with the lowest manifold. Loosen those clamps and/or cantilever supports as required and bring it up so it is level across its entire length. Then move to the next higher manifold and repeat the process. If some of the inlet and outlets piping to the UF Modules, BF Vessels are not level, or the BF or UF Housing are not vertical or true, adjustments need to be made. Start with loosening all the 1-1/2”groove clamps on the inlet side and/or the outlet side (if all the piping, for example on the outlet or the Return side is level, there is no need to adjust them. Next, loosen the E-coat paint manifold that is connected to the groove fittings loosened earlier. You must make several moves at the same time in order to make sure that the inlet and/or outlet piping is made level – also the appropriate E-coat paint manifolds must be made level as well. Correct any problems with the Permeate Manifolds as required The goal is to have the inlet piping to the UF Module, outlet piping from the UF manifold, and the E-coat Paint Manifold level and square to each other. If not done properly, it is likely that a leak may occur.

You DO Not want Paint Leaks

Do not attempt to connect E-coat paint to the UF System until the unit has been leak checked and flushed with DI water. Failure to do so may void the warranty on the UF Elements. If a paint leak occurs and the UF Elements are installed, the UF System will have to be shut down while the repairs are made. There will be E-coat paint solids trapped in the UF Modules and these solids will foul the membrane and reduce the service life of the UF Elements.

Installation of Loose & Kitted Components

Note – Each true union valve has one O-ring for each of the unions – you must confirm that the O-ring is in place and has not fallen off or been lost. Replace any O-rings that are missing. Some items have to be installed once the UF System has been set in place and secured to the floor. Remove any packaging or tape used to keep a connection point free of dust or dirt. Start with the section entitled Basic and then proceed as required according to the Model you purchased

Basic Model (Single and Double Sided)

1. Locate the integral TruVelocity Manifold Bypass assembly and secure with 2 x 1-1/2” groove clamps. (if needed/included) 2. Locate the Butterfly valves for both of the E-coat Paint Manifolds. Install one of these on each of the manifolds. Position the valve indicator arrow so that it can be read without the use of a step ladder or getting on your knees. Follow proper bolt tightening procedures to make sure the bolts are all tightened evenly at the same time. 3. Locate the lever operated permeate discharge manifold butterfly valve. Install it so the lever can be opened and closed without interference. Follow proper bolt tightening procedures to make sure the bolts are all tightened evenly at the same time. 4. Locate the permeate discharge flow meter piping assembly for UF Module A. Make sure the O-rings are installed as required. Use your hand (See photo below) to tighten the union on the bottom side of the flow meter assembly. If you use a tool you can break this flow meter.

4. Repeat Step 4 for each other UF Module.

Basic + BF Model

Same as for Basic plus below - 1. Locate V31 valve and install it into the open end of the Balancing manifold as required.

Basic + CIP Model

Same as for Basic plus below - 1. Remove all the items from inside the CIP tank and set aside. Replace the lid on the CIP tank. Make sure the Match marks on the Lid and Tank agree. 2. Locate all the Groove clamps required to interconnect the CIP piping between the UF Rack and the CIP system. Make sure each groove connection first has the groove gasket over the joint and then install the groove clamp as described earlier. 3. Usually the 3/4” interconnect permeate piping uses PVC unions, so locate all these piping portions and install making sure the Match Marks are correct. 4. Position the CIP cooling coil to it enters the top of the CIP tank away from the CIP Panel so chilled water will not be leaking on the top of the CIP Panel.

Support E-coat Paint & Permeate Pipe

Support the E-coat paint inlet piping, E-coat paint outlet piping, and Permeate outlet piping all within 30 cm (12”) of the Butterfly valve. The weight of the butterfly valves is significant and they need to be supported by pipe support or equal as near to the butterfly valve as possible. Otherwise support these pipes at least every 1.5 m (5 ft).

CIP Panel Completion=

The CIP Panel does not include a motor or panel disconnect switch. The size of the breaker or fuse for the CIP System should be about 20 amps for 460 V AC operation or 30 amps for 230 VAC operation.

CIP Motor Electrical Connection

1. The CIP pump has 5 Hp, 3 phase, 460V AC (or 230 V AC). Customer must provide an appropriate motor disconnect switch, conduit, wiring, etc to bring power to the motor. Do this in accordance with appropriate local and national electrical codes. 2. Do not bump the motor until the pump can be filled and properly primed with DI water. Bump the motor for 1/2 second by pressing the green On switch or less and observe the direction of the fan on the opposite end of the pump. Looking at the end of the motor with the fan, the rotation should be clockwise. If the fan turns counter-clockwise, the motor is wired incorrectly. Rewire the motor and bump the motor again. You will damage the mechanical seal if the motor is bumped and the impeller is dry. This will void the warranty. 3. Confirm that the Reset Dial Adjustment on the Motor Starter is set to M for manual reset of the motor once the starter is turned off for an overload condition and the FLA set point dial is as follows: Motor Voltage = 220V then FLA is set to 14 or if Motor Voltage = 460V then FLA is set to 6.

Make Paint Drain connections

This connection will be send to send paint, permeate, RO water, or DI water back to the E-coat bath. 1. Use 1-1/2” (minimum) PVC piping to connect V31 valve back to the E-coat bath in a spot approved by the E-coat paint vendor. Slope this paint drain pipe at a 2%, or greater, negative slope towards the E-coat tank. 2. Connect V21 valve to the same pipe as Step 1 and maintain a 2% negative slope (for Models with CIP Option only). 3. Connect V27-* valves (for Models with BF Option only)

Does Drain Plug need to be permanently connected?

Each paint manifold has a 3/4” drain plug on the bottom of the major diameter. This is meant to be used as a clean-out plug. If you attach a ¾” ball valve, then make sure to keep the ball wet by adding a weekly step to the Operator Checklist to crack open this valve to 30 seconds once a week.

Make Paint Drain/Waste connections

This connection will be send to send paint, permeate, RO water, or DI water back to the E-coat bath, OR to the waste if there is a chemical not compatible with the E-coat paint. This can be a 1” PVC pipe. Slope this waste pipe at a 2%, or greater, negative slope towards the pit or waste stream. Fabricate a manifold that can accept all the inputs and then direct it either to the Paint Drain or the Waste Drain. 1. Connect V23 valve (for Models with CIP Option only). 2. Connect V15 valve (for Models with CIP Option only).

Make Waste Drain connections

This connection will be send to send permeate, contaminated RO water, or contaminated DI water back ONLY to waste. 1. Connect V12 valve to a ¾” or 1” pipe sloped to drain at a 1-2% slope.

CIP Tank Low Level Switch

1. Remove packing tape from float switch. 2. Attach sensor assembly (1/2” PVC Pipe) to top of CIP tank with ½” Pipe clamps to strut channel so it is 6” above bottom of the CIP Tank.

Clean Return Piping to CIP Tank

1. Attach the permeate discharge piping sections to the permeate purge valve & permeate clean return and support this piping assembly to suit. 2. Connect the 1-1/2” PVC pipe that is the Clean Return to the CIP tank.

Cooling Water Connection

1. Make sure the stainless steel cooling coil is installed in the CIP tank. 2. Rotate the PVC Elbow to suit the direction from which the chilled water will be provided. It does not matter which one is selected as the inlet. 3. Attach the other cooling coil connection to the chilled water return (or waste if city water is used as the chilled water source).

CIP Control Panel Check Out Procedure

1. Close the Panel and secure it. Fill CIP tank with DI water. 2. Turn on the Motor disconnect switch. (by customer) 3. The amber light should be illuminated, indicating power is supplied to the CIP control panel. If not, check the connections at the transformer and the bulb. 4. The pump motor was previously bumped to check rotation. If not, refer to the section above. DO NOT RUN PUMP DRY. Turn on the pump and allow the water to recirculate back through to the CIP tank going through only one UF Housing. This will reduce the water volume. 5. With the pump turned on you should begin to observe that the liquid temperature is being to rise as the pump is adding heat as it operates. Place a thermometer in the CIP tank. Record the temperature when the blue lamp is turned on _____________°C or °F. The factory default is ~38 °C (100 ° F). This indicates that cooling water is being called for (note the cooling water does not have to be connected and the V16 valve should be turned off so the liquid temperature will rise a quickly as possible for this testing. Record the temperature when Red lamp is turned on & the pump stops operating _________°C or °F. The factory default is ~49 °C (120 ° F). Do not change the high temperature set point. If the temperature of the CIP liquid exceeds 49 C (120 F) then irreversible damage can occur to the UF Element. If you want to lower the set point for the cooling water (to prolong the cleaning cycle), then please refer to the manual for the Watlow brand temperature controller in the back of this manual. 6. Turn on the motor, open the Panel Door (only by a qualified plan electrician, who is knowledgeable about electrical safety matters.) and manually trip (with a small screw driver) the motor starter to simulate a high current event. Check to make sure the motor turns off. Reset the motor starter and confirm that the pump can operate normally 7. Use piece of pvc pipe to gently push low level float sensor down. This should trip and illuminate the white panel lamp and also the pump should turn off. 8. If there is trouble refer to the Service Reference on the CIP Panel which is located in the Appendix if there is trouble with any of these steps.

Inside CIP Panel component placement Front view CIP Panel

The photo above is typical of the Inside of a CIP Panel (Door). 8. If there is trouble refer to the Service Reference on the CIP Panel which is located in the Appendix if there is trouble with any of these steps.

Inside CIP Panel component placement

Water flush & leak Check

1. Place a glazed filter bag over the Clean Return piping that enters the CIP tank. This will collect any dirt, or PVC shavings that may be inside the piping sections. 2. Close off the E-coat paint Supply Manifold (V10) and the E-coat paint Return Manifold (V9) butterfly valves. 3. Make sure all the E-coat Paint isolation valves (V3-*, V4-*, V5-* and V6-*) are opened to and from the UF Modules. Note – the UF Elements cannot be installed yet for the initial leak testing 4. Open V1-* and V2-*) and v18 and V12 valves. 5. Also close off all drain valves (V31, V21 V15, V23, V27-*) 6. Fill the CIP tank with water. Be prepared to turn this source back on quickly as the CIP pump will be used to fill up all the piping prior to the start of the leak check. 7. Open the Clean Permeate Return (V13) valve. 8. Throttle back the Permeate Supply Valve (V11) so it is partially open. 9. Turn on the CIP Pump and be prepared to keep the CIP tank full of DI water. 10. The purpose here is two-fold. First, the inside of the piping needs to be flushed and cleaned out. The second purpose is to perform a leak check. 11. Let all the air out of the piping by performing the following steps in the following order. 12. Close the Permeate Purge Valve (V12). 13. Close (V18) once all air has been ejected. 14. Close the Permeate Return Valve (V20) once there is evidence that all the air has been ejected. 15. Close V13 to begin leak check. 16. Deadhead the CIP pump only until the pressure gage on the E-coat Paint Supply Manifold reaches a maximum. Close the CIP pump discharge valve (V7) and turn OFF the CIP pump. 17. Record the pressure shown on the E-coat Paint Supply Manifold below and recheck every 15 minutes for 1 hour. Time Pressure Start ________ 15 min ________ 30 min ________ 45 min _________ 60 min _________ 18. If there is an obvious leak, work to adjust and stop the leak as required. 19. If the pressure gage shows a significant leak, but no leak is found –repeat the test and make sure the CIP Discharge Valve is fully closed.

Leak Repair Tips & Tricks

If a PVC True Union Ball Valve is still leaking, try an alternate O-ring with the same diameter, but the next larger cross section diameter. Order the appropriate O-ring as required. Size & Item Original O-Ring PN Alternate O-Ring PN ½” Ball Valve 565029 565040 ¾” Ball Valve 565030 565041 1-1/2” Ball Valve 565031 565042 2” Ball Valve 565032 565043 2-1/2” Ball Valve 565033 565044 In addition, the unions have an O-ring that may be missing, replaced, or select the next cross section larger to fix a persistent leak. Size & Item Original O-Ring PN Alternate O-Ring PN I½” Union 565034 565038 1-1/2” Union 565035 NA† † You can try to fabricate one from another O-ring using Super Glue to join the two ends together. For threaded joints, use a joint compound approved by your E-coat paint supplier or Teflon thread tape.

Chemical cleaning of the inside of the UF Machine

At this point, especially if the UF Machine is being installed in a new E-coat Paint System, the typical procedure is to perform a cleaning with a strong caustic (high pH) cleaner. If caustic cleaner is used – read the safety label and wear the appropriate protective clothing, eye wear, etc. Be prepared to rinse out the eyes of a person who is splashed. Ask that person if they wear contacts and these too must be removed as part of the effort to rinse away the caustic. Contact your Safety Department for more detailed instructions. You must rinse UF Machine 2 times after chemical cleaning. You must then take a sample of the water used to flush out the UF Machine and submit it to your E-coat paint supplier to insure that there are no contaminates still inside the UF Machine.

Make E-coat Paint Connections

Note - Do not proceed until the unit has passed the water leak check and you are assured that there will be no E-coat paint leaks. Once the E-coat paint is connected, it is much more difficult to fix leaks and other piping problems. Also soft start E-coat paint pump to ensure that there is no pressure surge to system. Also please note that paint MUST circulate for 36 hrs before a UF Element is brought on line. Do NOT operate elements if paint is not at proper temperature. 1. Make the connection from the discharge of the UF Paint Supply Pump using an appropriate size Van Stone Type Flange. Customer must supply stainless steel bolt hardware for the flange. 2. Repeat the above for the E-coat Paint Return Manifold. 3. If there is an E-coat Paint By-pass around, it should NOT tee into piping downstream of the UF System. The pressure inside the By-pass piping is greater than that in the Return coming from the UF System. Flow uncertainties and other problems can occur. The discharge of any E-coat paint by-pass needs to go back directly to the E-coat tank. 4. Test these new E-coat paint Supply and Return piping segments with DI water and confirm there are no leaks. Fix any leaks now as required.

Install UF Elements

Now it is time to install the UF Elements into the UF Housing before the UF System is started up on E-coat paint for the first time. 1. Refer the section below in the Appendix Operator Checklist entitled: ‘UF Element Installation & Removal’.

Normal Start-Up Checklist

See the Checklist entitled ‘Normal Startup’ located in the Operators Checklist. Never operate the UF Module with both the permeate valves closed. Permeate must never be dead-headed. To do so risks blistering the UF membrane or blowing a glue seam or delaminating the UF membrane. If this happens, the UF Element is ruined and the warranty is voided. Remember: Always open valves that are under pressure SLOWLY.

Never operate the system with both of the permeate valves closed.

Typical Start Up Conditions

Observe some paint in permeate flow meters.

It is common with a new UF Element to observe some cloudiness in the permeate discharge line at start up. This is because the pore size distribution includes a small number of large pores. Initially some paint solids can pass through these large pores, but very quickly these large pores become blocked off. Generally this process could take several minutes.

Initial permeate flux decline.

Even though the typical rating for a typical module on typical E-coat paint can be as high as 2.5 gpm +/- 10% for an 8” size, the initial flux can be as much as 4 gpm. To help get a baseline for your system please record the permeate flow rate for each individual UF Module. Please use Bulletin # 999301 (attached later in the document).

Record First Day Baseline Data

After all the UF Modules have been operating successfully for at least 4 hours, it is time to record the permeate flux rate for each UF Module. Use the Baseline Data Sheet for this task. You can make a copy of the form at the back of this manual.

Posting of Operator Checklist Notebook

Place in a prominent place the Operator Checklist Notebook. In addition, you should have a written Emergency Operation Plan. A back up copy of the Operator Checklist is included in the Appendix D l.

Operation of the UF System

Recommended UF Process parameters

E-coat Paint Flow

Maintain a flow rate of at least 70 gpm +15%/- 5% per 8 inch UF Element. Use an E-coat paint flow meter to verify. If you do not have a TigerMag paint flow meter or a portable unit, then you must use the pump curve provided by your pump manufacturer. The pressure gage must be located BEFORE the first valve on the discharge of the UF Supply pump. For a dedicated UF Supply pump, calculate the required flow rate based upon the number of 8” UF Elements and then add 20%. On the pump curve locate this flow rate and then follow up to the pump curve and then go over to your left to read what the supply pressure should be at this flow rate. The pump will only produce the required flow rate if the correct pressure value is shown on this discharge pressure gage. If the pressure gage is not reading the correct value (i.e. too low), then you have to ask yourself if the paint flow rate to the UF machine is also too low. In many cases, poor UF performance is due to low or incorrect flow.

E-coat Paint Pressure

Normal Pressure at inlet to UF System is to be –Low, 3.8 bar (55 psi) –High, 4.5 bar (65 psi) Absolute minimum is 3.5 bar (50 psi)Minimum Pressure Reading of P2, which is the pressure gage on the discharge manifold must be 10-15 psi. This assures at least some positive working pressure over the entire height of the UF Element. Normal Pressure differential across the E-coat paint feed and return manifolds -Low, 1.4 bar (20 psi) -high, 2 bar (30 psi)

When to change Prefilter bags

In the past prefilter bags were generally changed when the delta pressure (delta P) across the filter vessel is0.3- 0.5 bar (5-7 psi). If the delta P is allowed to become more, then that means the inlet pressure to the UF system will be less and could fall below what is recommended. The delta P can be greater only if the E-coat feed pump has plenty of pressure so that the minimum E-coat paint pressure at the inlet to the UF is never below the Low ‘Normal’ recommendation. If you have a TigerMag flow meter then a better method is to watch the flow and when the flow has been reduced by say 5% or 10%, then you can change the bag filters. You should notice an increase in the flow rate (you do not have to change any of the valve positions) after you change the bags. If you did not then the flow reduction is a result of: 1) fouling layer on the surface of the UF membrane, 2) someone has closed a valve restricting the flow of E-coat paint, or 3) pump performance has declined for some reason.

Permeate Flux rate decline

The UF Modules must be cleaned when the permeate flux rate has declined by 20% from the baseline figure, which was reached after about 4 hours of use on the very first day of operation.

Operator Training

A basic UF training Program is included in the Appendix. If you want a PowerPoint version of this, please contact UFS Customer Service for a free copy. UFS offered a 4-hour Onsite training program that costs $1250 and included all expenses (Domestic US Locations). Later in 2003 UFS will offer a 30 minute video tape at no charge to clients.

Operation of the CIP System

In normal operation the CIP pump may run for an hour or so until the Low Temperature Set Point of ~43 deg C (~110 degrees F) is reached at this point. If the temperature of the cooling water is 18 deg C (65 degrees F) then the CIP should be able to run for up to another hour, or so. At this point the cooling system will not be able to keep up and the CIP pump will shut down due to tripping the high temperature level. In most cases, this amount of time is sufficient to properly clean the UF Module. If necessary, the low temperature set point can be lowered so the cooling is initiated sooner so the cleaning cycle can be lengthened. Do not leave the paint solids in the CIP Tank. An accumulation of paint solids can harm the mechanical seal on the CIP pump. Therefore, after use of the CIP System it is important to rinse all paint solids back to the E-Coat tank and make sure the pump is free of paint solids.

General Maintenance and Cleaning

UF Module Storage:

All UF Modules will be shipped in a sealed bag with a preservative solution applied to the membrane surface. This preservative typically has glycerin base with either water or water and propionic acid added. Normally this solution allows for storage for up to one year at between 40 and 100 degrees F. Under No Circumstances Should The UF Element Ever Be Allowed To Freeze or to Dry Out, this will void the warranty. Upon receipt of the UF Elements, the shipping container should be checked for leaks to insure its integrity. If there is a leaking bag, it should be sealed immediately with a hot iron or tape to guarantee that it will remain airtight. The preservative that leaks out is excess material and will not affect the membrane. Under no circumstances should you replace the preservative with water. This will encourage the growth of bacteria and mold that are detrimental to the membrane. The UF Module should then be stored in your normal manner. Do not store above ovens or heat tunnels!!

UF Element Installation and Removal

The installation of the UF Element into the UF Housing is a simple procedure that requires only a few minutes and can usually be done with removing the UF Housing. When handling the UF Elements, it is best to wear gloves as they can be slippery and also to avoid fiberglass slivers that maybe on the hard over wrap. Note - it is easy to break the permeate flow meter when removing the Top Cap. Take care not to damage the delicate flow meter. Note - it is easy to lose the O-rings of Valves V1* and V2* when performing this step. Take special care not to lose these small O-rings. Keep a watch out for these as they can fall out of place very easily. 1) Refer to the SEPRO SPIRAL ELEMENT INSTALLATION INSTRUCTIONS in the APPENDIX.

General Maintenance

Because of the number of variables, it is important that a detailed log of the performance and variables be kept and maintained on a regular basis. This will insure that potential problems can be avoided and the causes of permeate decline can be pinpointed and eliminated as a potential or reoccurring problem. UF maintenance ultimately refers to decline of permeate rate and recovery procedure. Several factors in the normal operation of the UF System can affect the permeate output from the membranes: feed concentration, oil, temperature, flow, pressure differential, pH, and inlet pressure. Preventive Maintenance – daily checks 1) Confirm the proper E-coat paint flow is going to the UF Machine. 2) Check pressure drop across prefilter vessels is nominal3) Record individual permeate flux rates for each UF Module 4) Confirm that the outlet pressure is at least 10-15 psi and the differential across the E-coat feed and return manifolds is nominal.

Preventive Maintenance – weekly checks

1) Flush one UF Module with permeate on Friday & hold in permeate till following Monday. Next Friday continue with a different Module. Each UF Module is to be flushed once per month. 2) Flush a UF Module when its permeate rate is 90% of Baseline 3) Consider a chemical clean when the permeate rate is 80% of Baseline.

Preventive Maintenance – as required

Chemical clean UF Modules as required for any UF Modules when its permeate rate is 80% of Baseline

Preventive Maintenance – semiannual checks

Verify proper E-coat paint flow is being delivered to the UF System by using an indirect E-coat paint flow meter. Verify the proper set points for the Low Temperature and High Temperature levels by testing with hot water and a thermometer. Grease the electric motor as required by standard practice. Clean out the CIP strainer as required. Check for loose connections and persistent drips. Clean the drip pan underneath the UF System. Inspect the UF Feed pump and related subsystems for proper operation. Test the Power backup standby generator that powers the UF E-coat paint pump(s). Check the permeate supply pump/motor(s) to the rinse stages and perform required maintenance. Check the condition/on of each lamp in the CIP panel and replace as required.

E-coat Paint seal on the UF Element

If the UF Element has a Lip seal for blocking the flow of E-coat paint from bypassing the UF Element, then only one of these seals is required. This lip seal should be in the upper most gland (groove for the round seal). The seal should be oriented so the flow of E-coat paint from the bottom of the UF Housing forces the lip or skirt of the seal outward, so it properly seals. Use a thin tool as the UF Element is being replaced to properly position this thin seal in the downward facing position. If your UF Element has a solid or O-ring type seal, then you need to use the proper Seal PN based upon whether the ID of the UF Housing bas been bored out or not – Description UFS PN Bored out UF Housing 565027 Non bored out UF Housing 565028 Once again the appropriate O-ring needs to be placed into the uppermost gland. Some UF Elements only have one gland why others have 2 glands built into the anti-telescoping device.

Changing the CIP pre filter bag

This bag should be changed with a heat treated or glazed bag every several weeks or whenever there are sufficient paint solids in the bag to impede the flow of flushing solution (i.e. permeate) through it. Refer the Operator Checklist for specific instructions.

Changing Low Temperature Set Point

If the Low Temperature Set Point is too high for your situation, it can be lowered. Please refer to the Watlow brand temperature controller section in the back of this manual. Important – Do not change the high temperature set point. After making the change to the Low Temperature Set point – perform the checkout of the CIP Panel Checkout Procedure section earlier in this manual.

Standard Cathodic E-coat Paint Cleaning Formulations

Do not clean at temperatures above 50 deg C (~120 deg F). Always contact your E-coat paint Supplier FIRST before purchasing any UF Cleaner or UF Charge solutions and make sure these solutions are approved for use with the specific E-coat paint you are using.

Standard Flushing

See Operators Checklist for more information.

ormal E-coat Paint Fouling,

Typical cleaning time is up to 2 hours 94% DI water + 3: Butyl Cellosolve + 3% Latic or Formic Acid

Biological Fouling

Look at latest Sepro instructions

Severe Paint Fouling

Same as above + 0.5% Triton X-100 surfactant for the last ½ hour of planned cleaning time.

Lead & Phosphate Fouling

Limit cleaning time to 30 minutes or less 99.5 % DI water + 0.5% nitric acid

Iron Fouling

Limit cleaning time to 30 minutes or less 96 % DI water + 4% citric acid made by mixing citric acid powder with equal amount of DI water.

Permeate Flushing & Chemical Cleaning Procedure

The procedure to either flush a UF Element with permeate or use a chemical cleaner is the basically the same, except for the fluid used. Place a glazed filter bag over the Clean Return piping that enters the CIP tank. This will collect any dirt, or other fouling that was inside the UF Modules. Change this each time the System is cleaned. Note – Use the TruFlux UF System valve locations drawing in the back of this guide shown below to identify the appropriate valve location. 1) Refer the Operator checklist entitled, ‘Monthly Permeate Flushing’ located in the appendix.

CIP Control Panel

Refer to wiring layout of Drawing 221033 for details in the wiring of the CIP panel and the factory default settings. This drawing is located INSIDE the CIP PANEL. Safety Note - disconnect line power to the CIP panel before performing any maintenance on the CIP panel. This disconnect switch is to be provided by the client. The relay contacts that open and close to control the cooling water solenoid valve need to be inspected every 6 months as these contacts do suffer wear and tear as they are operated. Make sure the cooling fan openings on the CIP pump are not obstructed and are free and clear. If the motor started has shut down the motor due to high current conditions then check the operating conditions of the three ‘heaters’ that perform the shutdown operation if the current is high or unusual for some reason.

UF Restart after a Power Outage

It is critical that this be addressed as quickly as possible. Follow the Checklist in the Operator Checklist Notebook entitled ‘Abnormal Shutdown. After power has been restored, flush each UF Element with permeate as presented earlier in the manual. Once all the UF Elements have been flushed, restart the UF Elements with E-coat paint using the procedure presented earlier in this manual.

Warranty Statement

Any items purchased to produce the UF System will carry the original manufacturer’s warranty. UFS will assist the client with any such requests for warranty consideration. Please see the Appendix for the warranty statement on the TruFlux UF System. UFS does not offer a performance warranty on the UF Element because so many of the process, operational, power outages, operator training levels are variables that are far outside the scope of control for UFS Corporation. UFS Corporation will endeavor to assist, trouble shoot and stand beside clients in difficult situations.

FAQ'S

FAQ - Ultrafiltration

Spare Parts

Please refer the recommended Spare parts list at the end of this document.

Replacement Parts

Prefilter Bags

Always make sure to use a prefilter bag that has been heat treated on the exterior surface so there are no loose fibers that can fall off and block the inlet of the spiral wound UF Element.

Warranty

We warrant all equipment manufactured by UFS Corporation to be free from defects in material and manufacture at the time of shipment for a period of one (1) year from the date of shipment. We will furnish without charge, but not install, replacements for such parts as we find to have been defective. This warranty shall not apply to any equipment which has been subjected to misuse, neglect or accident, or has been altered or tampered with, or if corrective work has been done thereon without our specific written consent. No allowances will be made for such corrective work done without such consent. Improper maintenance, deterioration by chemical action, and wear, do not constitute defects. Equipment manufactured by others, and included in our offering, is not warranted in any way by us but carries only the manufacturer’s warranty, if any and will be passed on without modification. All warranty claims must be submitted within ten (10) days of discovery of defects or shall be deemed waived. All parts returned for inspection must be sent prepaid. No representative of our company has any authority to waive, alter, vary or add to the terms hereof without prior approval in writing. The foregoing is in lieu of all other warranties (including that of merchantability), whether express or implied.

Liability

It is expressly understood that our liability, including that for breach of contract, negligence, strict liability in term, or otherwise for our products is limited to the furnishing of such replacement parts, and that UFS Corporation will not be liable for any expense, injury, loss or damage, whether direct or consequential, including but not limited to loss of profits, production, increased cost of operation, or spoilage of material, arising in connection with the sale or use of, or inability to use, our equipment or products for any purpose, except as herein provided.

External Manufacture Links

If you desire more information, please click on the links below:

http://www.ufsc.com

http://www.spearsmfg.com

http://www.cutlerhammer.com

http://www.watlow.com

http://www.selectaswitch.com

http://www.nteinc.com

http://www.haywardindustrial.com

http://www.valvate.com/ASCOSolVal.htm

http://www.pumpsebara.com

http://www.nibco.com

http://www.bluwhite.com

http://www.unistrut.com

http://www.b-line.com

http://www.specialtymfgco.com

http://www.automationdirect.com

http://http://www.krystilklear.com

Appendix

Installation Reference

Ultrafiltration Installation Checklist

UF Element Cleaning Log sheet

UF Element Cleaning Log sheet

Flow Schematic TruFlux UF System Drawing 997303

997303

CIP Panel Wiring Diagram, Drawing 221033

221033

CIP Checkout Procedure, Bulletin 998303

CIP Checkout Procedure, Bulletin 998303

Operators Checklist

TruFlux UF Operator Checklist

UF System Startup Baseline Recording Form

UF Machine Baseline Start UP Record.pdf

BULLETIN 994312